Toyota - 4Runner - Wiring Diagram - 2007 - 2007

2007 4RUNNER ELECTRICAL WIRING DIAGRAM Section Code Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . A . . . . 2 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . B . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . C . . . . 12 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . D . . . . 17 GLOSSARY OF TERMS AND SYMBOLS . . . . . E . . . . 18 RELAY LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . F . . . . 20 ELECTRICAL WIRING ROUTING . . . . . . . . . . . G . . . . 32 SYSTEM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . H . . . . 52 GROUND POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . 368 POWER SOURCE (Current Flow Chart) . . . . . J . . . . 376 CONNECTOR LIST . . . . . . . . . . . . . . . . . . . . . . . . K . . . . 386 PART NUMBER OF CONNECTORS . . . . . . . . . L . . . . 406 OVERALL ELECTRICAL WIRING DIAGRAM . M . . . . 412 1 4RUNNER (EM03M0U) A INTRODUCTION This manual consists of the following 13 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. (Only wiring information for complete circuits is included.) I GROUND POINT Shows ground positions of all parts described in this manual. J POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. K CONNECTOR LIST Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. M OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. (Only wiring information for complete circuits is included.) A H 2 4RUNNER (EM03M0U) FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2007 4RUNNER. Applicable models: UZN210, 215 Series GRN210, 215 Series Refer to the following manuals for additional service specifications and repair procedures for these models: Manual Name D 2007 4RUNNER Repair Manual D 2007 TOYOTA New Car Features Pub. No. RM03M0U NM04J0U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. NOTICE Always follow the directions given in the above repair manuals when handling supplemental restraint system components (such as removal, installation, inspection, etc.) in order to prevent accidents and supplemental restraint system malfunction. E2006 All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing : Jul. 06, 2006 01–060706–00 HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. 3 4RUNNER (EM03M0U) B HOW TO USE THIS MANUAL * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] Stop Light (BAT) [N] (IG) 15A STOP 7.5A GAUGE 2 [B] 3 IB 4 IB L (S/D) W–R R–L 1 7 3C 2 [G] [C] S6 Stop Light SW 15 3C 14 IE1 8 L4 Light Failure Sensor 4 11 1 (Shielded) Stop 3 R6 Rear Combination Light LH R7 Rear Combination Light RH W–B [J] G–B [I] G–R G–R G–R 2 H17 High Mounted Stop Light [K] 1 6 W–B W–B 1 BV1 W–B W–B W–B 3 BO 50 Rear Lights [F] G–R [H] 1 BV1 13 Y–G L G–W (S/D) G–W 2 Stop [E] [L] BL [M] 4 4RUNNER (EM03M0U) C7 Combination Meter 4 15 IE1 7 4 R–L L (S/D) R G–W Skid Control ECU with Actuator [D] (W/G) 1 B [A] : System Title [H] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: Indicates Relay Block No.1 B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. P Y GR = Gray [D] : Indicates related system. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. = Pink = Yellow O = Orange [E] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Example: L–Y L (Blue) [I] Female Male ( ) Y (Yellow) : Indicates a wiring Splice Point Example: The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. [J] : Indicates a shielded cable. [K] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order from upper left to lower right Numbered in order from upper right to lower left Example: 3C indicates that it is inside Junction Block No.3 Female Male [L] : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. [M] : Page No. [N] : Indicates the ignition key position(s) when the power is supplied to the fuse(s). 5 4RUNNER (EM03M0U) B HOW TO USE THIS MANUAL [O] System Outline Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. Stop Light Disconnection Warning When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] : Parts Location Code See Page Code See Page Code See Page C7 34 L4 36 R7 37 H17 36 R6 37 S6 35 [Q] : Relay Blocks Code 1 [R] See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Brace LH) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Brace LH) IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) [S] : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel) BV1 50 Luggage Room Wire and Floor Wire (Luggage Room Left) [T] : Ground Points Code See Page Ground Points Location BL 50 Under the Left Center Pillar BO 50 Back Panel Center 6 4RUNNER (EM03M0U) B [O] : Explains the system outline. [P] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual. ∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example : L 4 Á Á Parts is 4th in order Light Failure Sensor [Q] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [R] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [S] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [T] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center. 7 4RUNNER (EM03M0U) B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( EA , IB and IC shown below) can also be checked this way. I GROUND POINT W–B W–B FAN MAIN Relay 5 FAN MAIN Relay 5 A/C Control Assembly W–B 5 A/C Relay No.3 5 W–B A W–B A W–B Blower Motor O/D Main SW W–B A/C Relay No.2 W–B A Cigarette Lighter A W–B W–B Clock Blower SW A W–B W–B A Parking Brake SW J1 Junction Connector W–B Radiator Fan Motor 7 3B W–B Headlight Cleaner Relay W–B Combination Meter W–B W–B Headlight LH W–B W–B W–B W–B Front Fog Light LH 3 3F 13 3G W–B W–B W–B W–B Front Turn Signal Light LH Brake Fluid Level SW W–B W–B 5 3E W–B 6 3E Front Clearance Light LH W–B W–B Door Lock Control SW 2 IA1 W–B 1 3D W–B W–B Front Clearance Light RH W–B Front Fog Light RH W–B Front Turn Signal Light RH W–B Combination SW 7 3C W–B Headlight RH Cruise Control ECU Remote Control Mirror SW Turn Signal Flasher W–B W–B Defogger SW W–B Combination SW W–B W–B W–B W–B Door Lock Motor RH W–B W–B W–B Door Courtesy SW RH W–B Unlock Warning SW 10 EA2 15 W–B ID1 W–B W–B W–B Door Lock Control Relay W–B Power Window Master SW W–B EA W–B Idle–Up SW Door Courtesy SW LH 8 W–B IB1 Door Lock Control SW W–B W–B W–B A/C Amplifier W–B W–B W–B W–B W–B W–B Blower Resistor Power Window Control Relay Door Lock Motor LH W–B (4A–GZE) 4 Fuel Control SW 4 4 3 IC3 W–B W–B BR Radio and Player 4 W–B Woofer Speaker Amplifier BR W–B BR BR BR Combination Meter 4 BR Fuel Sender W–B 4 BR 5 BA1 W–B BR Auto Antenna Motor Combination Meter 4 HEATER Relay IB * IC The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 8 4RUNNER (EM03M0U) B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fues, etc.) and other parts 10A ECU–B 2 2 Short Pin 7.5A DOME 15A EFI Battery 2 30A AM2 6 Fusible Link Block 10A HAZARD 2 20A RADIO NO.1 S2 Starter 10A HORN 6 100A ALT 5 60A ABS Engine Room R/B (See Page 20) 20A 10A Fuse System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off System Theft Deterrent and Door Lock Control 214 230 112 122 Power Source B 1 BA1 W 1.25B FL MAIN Battery 50A MAIN B 2 1 7.5A DOME 2 2 W 7 EB1 W W 1 1 2 R 1 7.5A AM1 2 1 2 2 W–R 6 EB1 W–R W B 15A HAZ–RADIO 2 W 8 4 AM2 2 AM1 1 ST2 IG2 ST1 IG1 ACC I8 Ignition SW 2 20A DEFOG B–Y ∗ 1 1 2 1 W–R The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 9 4RUNNER (EM03M0U) B HOW TO USE THIS MANUAL K CONNECTOR LIST [A] I14 I15 I16 Dark Gray Gray 1 2 3 4 J1 [C] 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 [D] [B] J4 K1 Black K2 L1 1 2 1 2 Dark Gray A A A A A A A A A B B DD A A B CC CDD 1 K CONNECTOR LIST BA1 1 2 3 4 5 6 7 8 9 10 11 12 13 Black BD2 [E] 1 2 3 4 5 6 7 8 9 10 11 5 4 3 2 1 13 12 11 10 9 8 7 6 Gray [F] 4 3 2 1 11 10 9 8 7 6 5 [A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector Indicates a connector which is connected to a short terminal. Junction Connector Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. Same Color Short Terminal [C] : Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. [D] : Connector Color Connectors not indicated are milky white in color. [E] : Indicates the connector shapes which are used to join wire harnesses. On Left : Female connector shapes On Right : Male connector shapes Numbers indicate pin numbers. [F] : Indicates connector colors. (Connectors with not indicated colors are white) 10 4RUNNER (EM03M0U) B L PART NUMBER OF CONNECTORS Part Name Code Part Number Code Part Name Part Number A1 A/C Ambient Temp. Sensor 90980–11070 D4 Diode (Courtesy) 90980–11608 A2 A/C Condenser Fan Motor 90980–11237 D5 Diode (Interior Light) 90980–10962 A3 A/C Condenser Fan Relay 90980–10940 D6 Diode (Moon Roof) 90980–11608 90980–10848 A4 A/C Condenser Fan Resistor 90980–10928 D7 Door Lock Control Relay A5 A/C Magnetic Clutch 90980–11271 D8 Door Lock Control SW LH A6 A/T Oil Temp. Sensor 90980–11413 D9 Door Lock Control SW RH A7 [A] ABS Actuator [B] 90980–11151 [C] D10 Door Courtesy SW LH A8 ABS Actuator 90980–11009 D11 Door Courtesy SW RH 90980–11148 90980–11097 A9 ABS Speed Sensor Front LH 90980–10941 D12 Door Courtesy SW Front LH A10 ABS Speed Sensor Front RH 90980–11002 D13 Door Courtesy SW Front RH A11 Airbag Sensor Front LH D14 Door Courtesy SW Rear LH A12 Airbag Sensor Front RH A13 Airbag Squib 90980–11156 90980–11856 D15 Door Courtesy SW Rear RH 90980–11194 D16 Door Key Lock and Unlock SW LH 90980–11070 D17 Door Key Lock and Unlock SW RH 90980–11170 [A] : Part Code [B] : Part Name [C] : Part Number Toyota Part Number are indicated. Not all of the above part numbers of the connector are established for the supply. 11 4RUNNER (EM03M0U) C TROUBLESHOOTING VOLTAGE CHECK To Ignition SW IG Terminal (a) Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) Fuse [A] SW 1 Voltmeter [B] (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. Ohmmeter (b) Contact the two leads of an ohmmeter to each of the check points. SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode Digital Type Analog Type (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. 12 4RUNNER (EM03M0U) C FINDING A SHORT CIRCUIT To Ignition SW IG Terminal (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Test Light Fuse Case Short [A] SW 1 Short [B] Disconnect Disconnect Light Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. Relay CAUTION: Short [C] Disconnect SW 2 Solenoid (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Pull Up Press Down Press Down 13 4RUNNER (EM03M0U) C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 Example: (Case 1) 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 0.2 (mm) Up 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR Tool TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer For Non–Waterproof Type Connector HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. ”Case 1” Raise the terminal retainer up to the temporary lock [Retainer at Full Lock Position] position. Stopper Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) Secondary Locking Device ”Case 2” Open the secondary locking device. 14 4RUNNER (EM03M0U) C Tool Tab Tab Example: (Case 1) [B] Terminal Retainer Tool [Male] Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black [Female] ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (YMark) and pull the terminal retainer up to the temporary lock position. Retainer at Full Lock Position HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Temporary Lock Position [Male] Example: (Case 2) [Female] ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] 15 4RUNNER (EM03M0U) C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR 16 4RUNNER (EM03M0U) ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. 2WD 4WD A/C A/T ABS ACIS ADD BEAN CAN CD DIFF. EC ECU ESA ETCS–i IC INT J/B LH LSD R/B RH SFI SPEC. SRS SW TEMP. TRAC TVIP VSC VSV VVT VVT–i w/ w/o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = Two Wheel Drive Vehicles Four Wheel Drive Vehicles Air Conditioning Automatic Transmission Anti–Lock Brake System Acoustic Control Induction System Automatic Disconnecting Differential Body Electronics Area Network Controller Area Network Compact Disc Differential Electrochromic Electronic Control Unit Electronic Spark Advance Electronic Throttle Control System–intelligent Integrated Circuit Intermittent Junction Block Left–Hand Limited Slip Differential Relay Block Right–Hand Sequential Multiport Fuel Injection Specification Supplemental Restraint System Switch Temperature Traction Control TOYOTA Vehicle Intrusion Protection Vehicle Stability Control Vacuum Switching Valve Variable Valve Timing Variable Valve Timing–intelligent With Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. 17 4RUNNER (EM03M0U) E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE FILAMENT filament to heat up and emit light. A headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M 18 4RUNNER (EM03M0U) MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E SPEAKER An electromechanical device which creates sound waves from current flow. RELAY Basically, an electrically operated 1. NORMALLYswitch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. 2. NORMALLY OPEN SWITCH, MANUAL Opens and closes circuits, thereby 1. NORMALLY stopping (1) or OPEN allowing (2) current flow. RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. (Reed Switch Type) SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are not joined; crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. 19 4RUNNER (EM03M0U) F RELAY LOCATIONS [Engine Compartment] Skid Control ECU with Actuator Engine Room R/B No.3 Engine Room R/B Air Injection Control Driver Engine Room R/B No.4 [Body] Moon Roof Control ECU Rear Seat Audio Controller Tire Pressure Warning Antenna and Receiver Stereo Component Amplifier Towing Converter Relay Door Control Receiver 20 4RUNNER (EM03M0U) Back Door ECU F [Instrument Panel] Transponder Key Amplifier Center J/B Theft Deterrent ECU Transponder Key Computer Engine Control Module 4WD Control ECU Suspension Control ECU Tire Pressure Warning ECU A/C Control Assembly Turn Signal Flasher Relay Daytime Running Light Relay Driver Side J/B Body ECU Airbag Sensor Assembly Shift Lock Control ECU [Seat] Position Control ECU and SW Occupant Classification ECU 21 4RUNNER (EM03M0U) F RELAY LOCATIONS 2 : Engine Room R/B Engine Compartment Left (See Page 20) * 1:ACC CUT Relay * 2:FR FOG Relay * 3:STA Relay * 4:HEATER Relay * 5:MG CLT Relay * 6:RADIO NO.1 * 7:C/OPN Relay * 8:DOME Relay * 9:EFI Relay * 10:A/F HEATER Relay * 11:HEAD (LO LH) * 12:HEAD (HI LH) FUEL PUMP Relay AC115V INV Relay IG Relay DEFOG Relay 60A HEATER (for High Current) 5 1 7.5A 2 OBD 2 3 1 15A 2 FR FOG 1 15A 2 AC115V INV 1 10A 2 STOP *3 3 5 3 5 1 4 2 1 4 2 1 3 5 1 1 2 2 3 5 3 5 *5 2 1 1 2 RADIO NO.2 2 20A 1 TOWING 2 30A 1 DR/LCK 2 20A 1 2 2 30A BATT CHG (for High Current) *2 1 2 1 *4 4 *10 3 5 *9 3 5 *8 3 5 1 5 2 1 1 3 50A J/B (for High Current) 1 2 30A TOWING BRK (for High Current) 1 2 50A AM1 (for High Current) 1 2 50A AIR SUS (for High Current) 1 2 1 2 EFI 2 20A 1 ETCS 2 10A 1 1 2 *1 50A A/PUMP (for High Current) 3 1 4 2 HEATER NO.2 2 7.5A 1 AIRSUS NO.2 2 10A 1 SEAT HEATER 2 25A 1 DEFOG 2 30A MIR HEATER 1 2 10A 40A TOWING (for High Current) 3 5 2 TRN-HAZ 2 15A 1 A/F HEATER 2 15A 1 HORN 2 10A 1 1 ECU-B 10A 2 *6 1 20A 2 DOME 10A 2 3 5 *7 2 1 1 ALT-S 2 7.5A 1 Short Pin 2 1 1 2 1 30A AM2 (for High Current) 2 1 40A ABS MTR (for High Current) 5 HEAD Relay 2 3 5 2 30A ABS SOL (for High Current) 2 1 4 2 HEAD (LO RH) 10A 2 1 *11 10A 2 HEAD (HI RH) 10A 2 1 *12 10A 2 EFI NO.2 1 10A 2 140A ALT (for High Current) 2 3 STOP LP CTRL Relay 22 4RUNNER (EM03M0U) 1 F 3 : Engine Room R/B No.3 Engine Compartment Left (See Page 20) 3 1 4 3 2 1 2 5 5 BATT CHG Relay TOWING TAIL Relay : Engine Room R/B No.4 Engine Compartment Left (See Page 20) 3 1 2 5 AIR SUS Relay 23 4RUNNER (EM03M0U) F RELAY LOCATIONS : Driver Side J/B Lower Finish Panel (See Page 21) 201918 17 16 1514 1312 11 10 9 8 7 6 5 4 3 2 1 (from Roof Wire) 1A 10 9 8 7 20 19 18 17 6 5 4 3 2 1 16 15 14 13 12 11 5 4 3 2 1 13 12 1110 9 8 7 6 1B 1 2 3 4 5 6 7 8 9 10111213 (from Engine Room Main Wire) 4WD 20A IG1 15A ECU-IG 10A CIG 10A ACC 7.5A RR WSH 15A TAIL 10A 30A POWER (for Medium Current) 1 1C 2 FR WIP-WSH 30A STA NO.2 7.5A GAUGE 7.5A SRS 10A 1 PWR OUTLET 15A P P/SEAT 30A D P/SEAT SECU/HORN 30A 10A 2 1 6 2 5 4 3 1 2 (from Engine Room Main Wire) 1D IGN 10A 2 6 5 4 1 3 (from Engine Room Main Wire) 12 11 10 9 24 23 22 21 8 7 16 15 6 5 4 3 2 1 18 17 16 15 14 13 6 5 4 3 2 1 14 13 12 11 10 9 1F 16 15 8 7 8 7 20 19 1E 14 13 12 11 10 9 6 5 4 3 2 1 (from Floor No.2 Wire) 24 2322 21 12 1110 9 2019 8 7 181716151413 6 5 4 3 2 1 (from Engine Room Main Wire) 24 4RUNNER (EM03M0U) F Body ECU 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 POWER Relay DC SKT Relay TAIL Relay 2 HORN Relay 2 3 5 2 3 5 1 2 3 5 1 3 5 1 1 4 3 2 1 1G 4 3 2 1 (from Instrument Panel Wire) 1H 1 2 3 4 2 1 4 3 17 18 19 20 21 22 1 2 3 4 5 6 23 24 25 26 7 8 9 10 27 28 29 30 31 32 11 12 13 14 15 16 (from Instrument Panel Wire) 9 10 11 12 13 14 1 2 3 4 5 6 1K 16 15 8 7 13 14 15 16 17 18 1 2 3 4 5 6 15 16 7 8 19 20 7 8 2122 23 24 9 10 11 12 1L 14 13 1211 10 9 6 5 4 3 2 1 (from Instrument Panel Wire) 1 2 3 4 5 6 13 14 15 16 17 18 1J 7 8 19 20 9 10 1112 21 22 23 24 (from Instrument Panel Wire) 32 31 30 29 28 27 16 15 14 13 12 11 26 25 24 23 10 9 8 7 22 21 20 19 18 17 6 5 4 3 2 1 (from Instrument Panel Wire) 25 4RUNNER (EM03M0U) F RELAY LOCATIONS [Driver Side J/B Inner Circuit] 7.5A STA NO.2 3 1D 2 1K 13 1L 4 1K 4 1D 21 1E 15 1L 10 1J 10A IGN 6 1D 2 1L 23 1E 11 1J 7.5A GAUGE 4 1G 1 1J 2 1J 10A SRS 20 1L 3 1H 10 1F 4 1H 10A SECU/HORN 1 1C 10 1K 23 1J 12 1K 7 1E 14 1K 30A P P/SEAT 32 1J 8 1E 30A D P/SEAT 29 1J 24 1J 2 1G 1 1L 30A POWER 1 2 9 1F POWER Relay 5 3 2 1 1A 1 1H 1 5 1J 25 1J 17 1E 2 1F 18 1E 11 1A 6 1J 3 1G 4 1J TAIL Relay 5 3 1 10A TAIL 21 1J 9 1B 11 1B 2 15 1F 5 1L 6 1E 13 1F 22 1J 15A PWR OUTLET 9 1A 4 1A 19 1A DC SKT Relay 3 5 1 2 10 1A 10 1E 30 1J 31 1J 7.5A ACC 8 1K 5 1D 3 1E 16 1E 10A CIG 17 1L HORN Relay 5 3 1 2 (Cont. Next Page) 26 4RUNNER (EM03M0U) 1 1D 13 1K F (Cont'd) 15A IG1 2 1C 20 1E 1 1E 8 1J 2 1E 2 1A 17 1J 7 1K 10A ECU-IG 18 1J 12 1E 20 1J 28 1J 15 1K 8 1F 16 1L 3 1A 30A FR WIP-WSH 16 1K 22 1E 4 1F 9 1J 4 1B 3 1L 5 1B 11 1F 15A RR WSH 4 1L 12 1B 12 1F 13 1B 14 1J 6 1K 20A 4WD 15 1J 13 1J 16 1J 2 1H 6 1B 7 8 11 5 BZR2 BECU HAZ LSR 18 1L 1 10 18 22 4 21 WIG TRLY GND1 SIG ACC PWS 12 1A 15 1A 21 1L 13 1A 22 1L 7 1A 23 1L 6 1A 24 1L 6 1F 8 1B 14 1A 24 17 ACT- GND2 HRLY L1 1 1G L2 11 1K 5 1A UL1 14 SPD 16 19 20 15 Body ECU 1 1K 10 1L 13 11 1L ILE 24 1E 12 1L 12 1J ACT+ 3 STPI WMTR 9 1E 26 1J 3 1K 9 1L 8 1A 16 1F 5 1K 6 1L 9 1K 16 1A 18 1A RDEF 12 BDR1 BZR 23 2 6 9 14 1F 1 1B 3 1B 10 1B 27 4RUNNER (EM03M0U) F RELAY LOCATIONS : Center J/B Instrument Panel Brace RH (See Page 21) Black A A A B B B B B (from Instrument Panel Wire) 3A 3B A A A A A B B B B B A A A A B B B B A A B B B B B B B B (from Instrument Panel Wire) Gray 3C C C C B B G G G F F F E B B A A A A A A B B E E D D D D D D E E E F B B C C C F F G G G (from Instrument Panel Wire) Black 3D B B B B D D D D D D A A A A A A A A A A D D C C C C C C D D D D B B B B D D D D (from Instrument Panel Wire) Dark Gray B B B F F B B F E E B B E D D A A A D C 3E A C C A A C C C B B D D D E B B B B B E E F F F (from Instrument Panel Wire) 3F A A B A A B B B A A B B B B A A A B B B A A A A A B B B B B B B A A A A B B B B (from Instrument Panel Wire) 28 4RUNNER (EM03M0U) Memo 29 4RUNNER (EM03M0U) F RELAY LOCATIONS [Center J/B Inner Circuit] A 3A E 3C A 3A E 3C A 3A E 3C B 3A D 3C B 3A D 3C B 3A D 3C B 3A B 3D B 3A B 3D A 3B B 3D A 3B B 3D A 3B A 3D A 3B A 3D B 3B A 3D B 3B A 3D B 3B A 3D B 3B D 3D B 3B D 3D B 3B D 3D C 3C D 3D C 3C D 3D C 3C D 3D B 3C D 3D B 3C D 3D B 3C C 3D B 3C C 3D A 3C C 3D A 3C B 3E A 3C B 3E F 3C B 3E F 3C B 3E F 3C B 3E G 3C B 3E G 3C B 3E G 3C A 3E A 3E A 3E (Cont. Next Page) 30 4RUNNER (EM03M0U) F (Cont'd) F 3E F 3E F 3E E 3E E 3E E 3E D 3E D 3E D 3E C 3E C 3E C 3E A 3F A 3F A 3F A 3F A 3F A 3F A 3F A 3F A 3F B 3F B 3F B 3F B 3F B 3F B 3F B 3F B 3F B 3F B 3F B 3F 31 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [2UZ–FE] G2 G1 A46 A13 H8 E1 H6 A45 A47 F7 A12 B14 A44 A43 F8 A9 A10 C2 F6 A2 H4 F5 H3 H2 H1 F2 A15 C3 A 1 A/C Ambient Temp. Sensor A 2 A/C Lock Sensor A/C Magnetic Clutch A 9 ABS Speed Sensor Front LH A 10 ABS Speed Sensor Front RH A 12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A 13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) A 14 Airbag Sensor Front LH A 15 Airbag Sensor Front RH A 43 Air Injection Control Driver A 44 Air Injection Control Driver A 45 Air Pressure Sensor A 46 Air Pump A 47 Air Switching Valve E2 E3 A1 C1 H9 C4 A14 H10 F1 E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp. Sensor E 3 Engine Hood Courtesy SW F 1 Front Fog Light LH F 2 Front Fog Light RH F 5 Front Parking Light LH Front Turn Signal Light LH F 6 Front Parking Light RH Front Turn Signal Light RH F 7 Front Wiper Motor F 8 Fuel Pump Resistor G 1 Generator G 2 Generator B 14 Brake Fluid Level Warning SW C C C C 1 2 3 4 Camshaft Position Sensor Camshaft Timing Oil Control Valve LH Camshaft Timing Oil Control Valve RH Crankshaft Position Sensor H 1 H 2 H 3 H 4 H 6 H 8 H 9 H10 Headlight LH (High) Headlight LH (Low) Headlight RH (High) Headlight RH (Low) Heated Oxygen Sensor (Bank 1 Sensor 2) Heated Oxygen Sensor (Bank 2 Sensor 2) Horn (High) Horn (Low) 32 4RUNNER (EM03M0U) G Position of Parts in Engine Compartment [2UZ–FE] I8 V13 I16 K2 P1 V11 S2 T3 T4 I15 V1 I13 V2 N1 I7 S28 W3 M1 S29 I14 I5 T1 V3 I6 I3 N2 J3 V4 J2 I4 J1 V12 I11 I12 I1 I2 W2 I I I I I I I I I I I I I I I I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Ignition Coil and Igniter No.1 Ignition Coil and Igniter No.2 Ignition Coil and Igniter No.3 Ignition Coil and Igniter No.4 Ignition Coil and Igniter No.5 Ignition Coil and Igniter No.6 Ignition Coil and Igniter No.7 Ignition Coil and Igniter No.8 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Injector No.5 Injector No.6 Injector No.7 Injector No.8 J 1 Junction Connector J 2 Junction Connector J 3 Junction Connector K 1 Knock Sensor (Bank 1) K 2 Knock Sensor (Bank 2) W1 I10 P3 S3 K1 T2 I9 O1 O 1 Oil Pressure SW P 1 Park/Neutral Position SW P 3 Pressure SW S 2 S 3 S 28 S 29 Starter Starter Skid Control ECU with Actuator Skid Control ECU with Actuator T 1 Theft Deterrent Horn T 2 Throttle Control Motor Throttle Position Sensor T 3 Transfer Shift Actuator T 4 Turbine Speed Sensor V 1 V 2 V 3 V 4 V 11 VSV (ACIS) VSV (Purge) VVT Sensor (Bank 1) VVT Sensor (Bank 2) Vehicle Speed Sensor (Electronically Controlled Transmission) V 12 VSV (Air Switching Valve Bank 1) V 13 VSV (Air Switching Valve Bank 2) M 1 Mass Air Flow Meter N 1 Noise Filter (Ignition No.1) N 2 Noise Filter (Ignition No.2) W 1 Washer Level Sensor W 2 Washer Motor W 3 Wireless Door Lock Buzzer 33 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [1GR–FE] H6 E1 H8 E2 A13 C4 F7 B14 F8 A12 G2 A10 G1 A11 A9 F6 F5 H4 H2 H3 H1 F2 A15 C3 E3 A 1 A/C Ambient Temp. Sensor A 2 A/C Lock Sensor A/C Magnetic Clutch A 9 ABS Speed Sensor Front LH A 10 ABS Speed Sensor Front RH A 11 ADD Actuator A 12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A 13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) A 14 Airbag Sensor Front LH A 15 Airbag Sensor Front RH A1 C2 H9 A2 H10 A14 F1 F 1 Front Fog Light LH F 2 Front Fog Light RH F 5 Front Parking Light LH Front Turn Signal Light LH F 6 Front Parking Light RH Front Turn Signal Light RH F 7 Front Wiper Motor F 8 Fuel Pump Resistor G 1 Generator G 2 Generator B 14 Brake Fluid Level Warning SW C 2 Camshaft Timing Oil Control Valve LH C 3 Camshaft Timing Oil Control Valve RH C 4 Crankshaft Position Sensor E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp. Sensor E 3 Engine Hood Courtesy SW H 1 H 2 H 3 H 4 H 6 H 8 H 9 H10 Headlight LH (High) Headlight LH (Low) Headlight RH (High) Headlight RH (Low) Heated Oxygen Sensor (Bank 1 Sensor 2) Heated Oxygen Sensor (Bank 2 Sensor 2) Horn (High) Horn (Low) 34 4RUNNER (EM03M0U) G Position of Parts in Engine Compartment [1GR–FE] I13 P1 V11 N1 T3 V1 T4 I14 K1 I6 I12 I4 V2 S28 I5 W3 I3 S29 I11 S3 T1 S2 I1 I2 M1 J3 I9 J2 J1 K2 I10 W2 I I I I I I I I I I I I 1 2 3 4 5 6 9 10 11 12 13 14 Ignition Coil and Igniter No.1 Ignition Coil and Igniter No.2 Ignition Coil and Igniter No.3 Ignition Coil and Igniter No.4 Ignition Coil and Igniter No.5 Ignition Coil and Igniter No.6 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Injector No.5 Injector No.6 J 1 Junction Connector J 2 Junction Connector J 3 Junction Connector K 1 Knock Sensor (Bank 1) K 2 Knock Sensor (Bank 2) M 1 Mass Air Flow Meter N 1 Noise Filter (Ignition No.1) O 1 Oil Pressure SW W1 P2 P3 V4 T2 V3 O1 P 1 Park/Neutral Position SW P 2 Power Steering Oil Pressure SW P 3 Pressure SW S 2 S 3 S 28 S 29 Starter Starter Skid Control ECU with Actuator Skid Control ECU with Actuator T 1 Theft Deterrent Horn T 2 Throttle Control Motor Throttle Position Sensor T 3 Transfer Shift Actuator T 4 Turbine Speed Sensor V 1 V 2 V 3 V 4 V 11 VSV (ACIS) VSV (Purge) VVT Sensor (Bank 2) VVT Sensor (Bank 1) Vehicle Speed Sensor (Electronically Controlled Transmission) W 1 Washer Level Sensor W 2 Washer Motor W 3 Wireless Door Lock Buzzer 35 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel (*4) (*3) A20 A21 A39 A27 A36 B1 A37 A29 (*4) (*3) A26 A28 A48 A49 * 1:w/ Side Airbag * 2:w/o Side Airbag * 3:Limited * 4:Except Limited A25 A18 A24 B2 A42 B3 A17 A16 B4 B5 B6 A19 A 16 A 17 A 18 A 19 A 20 A 21 A 22 A 24 A 25 A 26 A 27 A 28 A 29 A 30 A 31 A 32 A 33 A 34 A 36 A 37 A 38 A 39 A 42 A 48 A 49 A30 A31 (*1) (*2) A/C Control Assembly A/C Control Assembly A/C Evaporator Temp. Sensor A/C Room Temp. Sensor A/C Solar Sensor A/C Solar Sensor A/T Shift Lever Illumination Accel Position Sensor Air Inlet Control Servo Motor Air Mix Control Servo Motor Air Mix Control Servo Motor LH Air Mix Control Servo Motor RH Air Vent Mode Control Servo Motor Airbag Sensor Assembly Airbag Sensor Assembly Airbag Sensor Assembly Airbag Sensor Assembly Airbag Sensor Assembly Airbag Squib (Steering Wheel Pad) Antenna Amplifier Ashtray Illumination Automatic Light Control Sensor Auto LSD SW Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Front Passenger Airbag Assembly) A32 A33 A34 (*1) (*2) B B B B B B 1 2 3 4 5 6 A38 A22 Back Door Power Window Control SW Blower Motor Blower Motor Controller Body ECU Body ECU Body ECU 36 4RUNNER (EM03M0U) G Position of Parts in Instrument Panel D2 D24 C8 C9 C12 C10 C11 C13 C14 C5 D3 H11 G3 E4 E5 E6 E7 E8 F10 F9 D4 C 5 C 6 C 7 C 8 C 9 C10 C 11 C12 C13 C14 C15 D1 Center Speaker Cigarette Lighter Cigarette Lighter Illumination Combination Meter Combination Meter Combination Meter Combination Meter Combination SW Combination SW Combination SW Cup Holder Illumination D 1 Data Link Connector 3 D 2 Daytime Running Light Relay Turn Signal Flasher Relay D 3 Defogger SW Heater Control Panel Passenger Seat Belt Warning Light Security Indicator Light D 4 Diff. Lock SW D 5 Downhill Assist Control SW D24 Diode (Rear Wiper) I18 I17 F11 C7 C6 C15 E E E E E 4 5 6 7 8 D5 H12 H19 Engine Control Module Engine Control Module Engine Control Module Engine Control Module Engine Control Module F 9 4WD Control ECU F 10 4WD Control ECU F 11 4WD Control SW G 3 Glove Box Light H 11 Hazard SW H12 Height Control SW H19 Height Control Mode Select SW I 17 Ignition Key Cylinder Light Transponder Key Amplifier I 18 Ignition SW 37 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel J10 J20 J8 J9 J18 J16 J17 J19 J21 J52 J51 J50 J49 (*6) (*5) J26 J27 J28 J29 J30 J31 J32 J11 J33 J12 J34 J13 J35 J4 J36 J14 J48 J6 J47 J7 J37 J15 J25 J5 * 5:1GR-FE * 6:2UZ-FE J22 J 4 J 5 J 6 J 7 J 8 J 9 J 10 J 11 J 12 J 13 J 14 J 15 J 16 J 17 J 18 J 19 J 20 J 21 J 22 J 23 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector J23 J24 J 24 J 25 J 26 J 27 J 28 J 29 J 30 J 31 J 32 J 33 J 34 J 35 J 36 J 37 J 47 J 48 J 49 J 50 J 51 J 52 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector 38 4RUNNER (EM03M0U) G Position of Parts in Instrument Panel V5 R13 S30 (*7) (*7) (*9) (*7) (*10) (*9) (*7) (*8) (*8) (*7) (*7) R27 R10 R2 R9 R11 R4 R5 R12 R26 R1 R3 * 7:w/ Navigation System * 8:w/o Navigation System * 9:6 Speaker * 10:10 Speaker w/o Navigation System T8 T5 Z1 P4 T16 S13 V14 S14 S31 S15 T6 S12 M2 T9 K 3 Key Interlock Solenoid Unlock Warning SW M 2 Main SW P 4 Parking Brake SW P 5 Power Outlet (115V) P 6 Power Outlet (Front) R 1 R 2 R 3 R 4 R 5 R 9 R10 R 11 R12 R13 R25 R26 R27 Radio and Player Radio and Player Radio and Player Radio and Player Radio and Player Radio and Player with Display Radio and Player with Display Radio and Player with Display Radio and Player with Display Rheostat Roll Sensing of Curtain Shield Airbag Cutoff SW Radio and Player with Display Radio and Player with Display R25 K3 S11 Y1 S6 P6 S4 S5 P5 S 4 Seat Heater SW LH S 5 Seat Heater SW RH S 6 Shift Lock Control ECU Transmission Control SW S 11 Steering Sensor S 12 Stop Light SW S 13 Suspension Control ECU S 14 Suspension Control ECU S 15 Suspension Control ECU S 30 Seat Memory SW S 31 Stereo Jack Adapter T 5 T 6 T 8 T 9 T 16 Theft Deterrent ECU Towing Brake Controller Transponder Key Computer Turn Signal Flasher Relay Tire Pressure Warning ECU V 5 VSC Warning Buzzer V 14 Video Terminal Y 1 Yaw Rate Sensor Z 1 Option Connector (TVIP ECU) 39 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Body (*2) I19 D23 D18 D13 I20 D9 D19 C16 H18 (*1) L2 H18 * 1:w/ Rear Spoiler * 2:w/o Rear Spoiler C17 D11 D16 D21 D17 D15 J38 J42 D8 D7 D22 H16 D12 B10 A41 B11 D10 D20 D14 J39 F14 H15 A 40 ABS Speed Sensor Rear LH A 41 ABS Speed Sensor Rear RH A40 H17 H13 L1 H14 J40 L4 B8 B9 D19 Door Lock Detection SW Front RH Door Lock Motor Front RH D20 Door Lock Detection SW Rear LH Door Lock Motor Rear LH D21 Door Lock Detection SW Rear RH Door Lock Motor Rear RH D22 Door Speaker Front LH No.1 D23 Door Speaker Front RH No.1 B 7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW Back Door Lock Motor B 8 Back Door ECU B 9 Back Door ECU B 10 Back Door Opener SW License Plate Light B 11 Back Door Power Window Motor F 14 Fuel Pump Fuel Sender C16 Curtain Shield Airbag Squib LH C17 Curtain Shield Airbag Squib RH D 7 D 8 D 9 D10 D 11 D12 D13 D14 D15 D16 J41 Door Control Receiver Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy Light Rear LH Door Courtesy Light Rear RH Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH Door Lock Motor Front LH D17 Door Lock Control SW Front LH Power Window Master SW D18 Door Lock Control SW Front RH H13 H14 H15 H16 H17 H18 Height Control Compressor Height Control Motor Height Control Sensor Rear LH Height Control Sensor Rear RH Height Control Valve High Mounted Stop Light I 19 Inner Mirror I 20 Interior Light J 38 J 39 J 40 J 41 J 42 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector L 1 Low Pressure Tank Valve L 2 Luggage Compartment Light L 4 Canister Pump Module 40 4RUNNER (EM03M0U) B7 G Position of Parts in Body P17 V6 M4 P7 T18 M5 S21 V7 P13 R18 P9 T13 P11 P15 T17 S19 W4 S20 M3 R20 P12 S23 R24 S22 P10 P8 P14 R15 S32 R22 T12 R21 P16 T10 S16 T11 R16 S33 S34 S18 V9 M 3 Mirror Heater LH Remote Control Mirror LH M 4 Mirror Heater RH Remote Control Mirror RH M 5 Moon Roof Control ECU P 7 Moon Roof Control SW Personal Light P 8 Power Outlet (Rear) P 9 Power Window Control SW Front RH P 10 Power Window Control SW Rear LH P 11 Power Window Control SW Rear RH P 12 Power Window Motor Front LH P 13 Power Window Motor Front RH P 14 Power Window Motor Rear LH P 15 Power Window Motor Rear RH P 16 Pretensioner LH P 17 Pretensioner RH R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 Rear Combination Light LH Rear Combination Light RH Rear Door Speaker LH Rear Door Speaker RH Rear Seat Audio Controller Rear Speaker LH Rear Speaker RH Rear Window Defogger Rear Window Defogger Rear Wiper Motor Rear Wiper Position SW R24 Remote Control Mirror SW S17 T14 R17 R19 R14 S35 T15 R23 S 16 S 17 S 18 S 19 S 20 S 21 S 22 S 23 S 32 S 33 S 34 S 35 Side Airbag Sensor Front LH Side Airbag Sensor Front RH Side Airbag Sensor Rear LH Side Airbag Sensor Rear RH Door Speaker Front LH No.2 Door Speaker Front RH No.2 Stereo Component Amplifier Stereo Component Amplifier Step Light Front LH Step Light Front RH Step Light Rear LH Step Light Rear RH T 10 T 11 T 12 T 13 T 14 T 15 T 17 T 18 Tailgate Control SW Television Camera Tension Reducer Solenoid LH Tension Reducer Solenoid RH Towing Converter Relay Trailer Socket Tire Pressure Warning Antenna and Receiver Telephone Microphone V 6 Vanity Light LH V 7 Vanity Light RH V 9 Voltage Inverter W 4 Woofer 41 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING Position of Parts in Seat [Power Seat] J53 P24 S24 P26 O3 J45 J46 O4 S27 P19 B15 P21 L5 O5 S25 O7 B17 B16 O6 * 1:w/ Driving Position Memory * 2:w/o Driving Position Memory J43 J44 (*2) (*2) B12 P20 S26 P28 P27 P18 (*1) (*2) L3 P23 P 18 P 19 P 20 P 21 P 23 P 24 P 25 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector L 3 Lumbar Support Control SW (Driver’s Seat) L 5 Lumbar Support Control Motor (Driver’s Seat) O O O O O O 3 4 5 6 7 8 P25 Power Seat Control SW (Driver’s Seat) Power Seat Control SW (Front Passenger’s Seat) Power Seat Motor (Driver’s Seat Front Vertical Control) Power Seat Motor (Driver’s Seat Lifter Control) Power Seat Motor (Driver’s Seat Reclining Control) Power Seat Motor (Driver’s Seat Slide Control) Power Seat Motor (Front Passenger’s Seat Reclining Control) P 26 Power Seat Motor (Front Passenger’s Seat Slide Control) P 27 Position Control ECU and SW P 28 Position Control ECU and SW B 12 Buckle SW LH Seat Position Airbag Sensor B 15 Buckle SW LH B 16 Buckle SW RH B 17 Buckle SW RH J 43 J 44 J 45 J 46 J 53 O8 Occupant Classification ECU Occupant Classification ECU Occupant Classification Sensor Front LH Occupant Classification Sensor Front RH Occupant Classification Sensor Rear LH Occupant Classification Sensor Rear RH S 24 S 25 S 26 S 27 Seat Heater LH Seat Heater RH Side Airbag Squib LH Side Airbag Squib RH 42 4RUNNER (EM03M0U) G Position of Parts in Seat [Manual Seat] B16 B17 J45 J46 S27 J43 J44 B12 S26 L3 B15 L5 O5 O3 O4 O6 O O O O O O B 12 Buckle SW LH Seat Position Airbag Sensor B 15 Buckle SW LH B 16 Buckle SW RH B 17 Buckle SW RH J 43 J 44 J 45 J 46 O7 Junction Connector Junction Connector Junction Connector Junction Connector 3 4 5 6 7 8 O8 Occupant Classification ECU Occupant Classification ECU Occupant Classification Sensor Front LH Occupant Classification Sensor Front RH Occupant Classification Sensor Rear LH Occupant Classification Sensor Rear RH S 26 Side Airbag Squib LH S 27 Side Airbag Squib RH L 3 Lumbar Support Control SW (Driver’s Seat) L 5 Lumbar Support Control Motor (Driver’s Seat) 43 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [2UZ–FE] Engine Wire EB2 EB1 EE EQ ER ED EC EB EA EA1 Engine Room Main Wire Engine No.2 Wire 44 4RUNNER (EM03M0U) G : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [1GR–FE] Engine Wire EE Sensor Wire EF ED1 EC1 EB Differential Wire EA EA2 Engine Room Main Wire Engine No.2 Wire 45 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness Relay Wire Instrument Panel No.2 Wire IG1 IH1 II1 Engine Wire Engine Room Main Wire Roof Wire Instrument Panel Wire Assembly Instrument Panel Wire Engine Room Main Wire IB2 IB1 IC1 Front Door RH Wire IC3 Cigarette Lighter Wiring Assembly IC4 Floor Wire IA1 IA2 IV1 IC5 Front Door LH Wire Console Box Wire (No.1) ID1 IE1 Radio Installation Wiring Sub Assembly IC2 Floor No.2 Wire IF1 : Location of Ground Points II IK IG IH 46 4RUNNER (EM03M0U) IJ G : Location of Connector Joining Wire Harness and Wire Harness Instrument Panel Instrument No.2 Wire Panel Wire IJ1 Engine Wire Instrument Panel Wire Assembly Engine Room Main Wire IL1 IU1 IM1 IM2 Engine Room Main Wire IN2 IN1 Roof Wire IP1 Radio Installation Wiring Sub Assembly Front Door RH Wire IP2 Front Door LH Wire IO3 Floor No.1 Wire IT1 IO2 Floor No.2 Wire Relay Wire IK1 Cigarette Lighter Wiring Assembly IR1 IS1 Console Box Wire 47 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points Roof Wire Radio Installation Wiring Sub Assembly BJ1 Front Door RH Wire BD1 BD2 Instrument Panel Wire BB1 BM Rear Door No.1 Wire Floor Wire Back Door No.1 Wire Front Door LH Wire BA1 BP BL BL1 Step Rear Floor RH Wire BO Step Rear Floor LH Wire Back Door No.2 Wire BE1 Rear Door No.2 Wire BH1 Floor No.2 Wire BG1 BC1 BC2 BM1 BN Skid Control Frame Wire Sensor Wire BF1 48 4RUNNER (EM03M0U) Frame No.3 Wire Memo 49 4RUNNER (EM03M0U) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Power Seat] Floor Wire BI1 * 1:w/ Driving Position Memory Floor No.2 Wire BK1 (*1) Seat No.2 Wire 50 4RUNNER (EM03M0U) Seat No.1 Wire G : Location of Connector Joining Wire Harness and Wire Harness [Manual Seat] Floor Wire BI1 Floor No.2 Wire Seat No.2 Wire Seat No.1 Wire 51 4RUNNER (EM03M0U) Power Source 10A MIR HEATER B–R 1 2 2 B–L 2 30A DEFOG 1 2 Y–G 2 DEFOG Relay B–R W–B 2 2 2 1 3 5 R 2 2 L–Y Y–R 4 2 50A AIR SUS 30A TOWING BRK B 2 2 2 2 2 2 BR–Y 4 5 3 1 2 4 4 1 1 1 1 2 2 W–L 2 2 1 1C L–W 10A SECU/HORN 30A P P/SEAT 2 2 L 30A D P/SEAT 10A STOP 1 1 2 2 G–W 1 2 2 5 3 1 2 10A TAIL V 15A FR FOG 1 2 30A POWER 15A AC115V INV TAIL Relay 2 2 LG 15A PWR OUTLET 140A ALT 7. 5A OBD 2 1 2 2 O B 2 25A SEAT HEATER IG Relay 5 3 1 2 2 2 2 B–Y 2 1 W–B Y–R Battery B 2 W–B 50A J/B 1 2 L–B 50A AM1 40A TOWING 1 GR AIR SUS Relay 50A A/PUMP R 4 1 2 30A BATT CHG B–Y L–Y 2 2 10A AIRSUS NO. 2 2 1 1 54 4RUNNER (EM03M0U) 2 2 LG Y–R R 2 2 HEATER Relay 1 2 5 3 L 2 7. 5A HEATER NO. 2 B–Y 2 4 1 2 2 2 G–Y W–B 2 I18 Ignition SW W–L ACC 3 W–G W–L 2 AM1 IG1 4 L–Y R 7 AM2 IG2 6 B–R ST2 8 G–B 30A AM2 2 1 2 40A ABS MTR 2 1 60A HEATER R 2 Y–B 30A ABS SOL 1 2 2 2 1 2 Y Short Pin 1 2 2 W W L L 20A EFI 1 2 1 1 10A HORN W–G 2 2 1 2 2 1 15A TRN–HAZ B–Y 2 2 2 GR 20A DR/LCK 1 15A A/F HEATER B–R 2 10A HEAD(HI RH) 2 2 G–W 1 GR 1 30A TOWING 1 2 20A RADIO NO. 2 1 1 2 2 R–W 10A HEAD(HI LH) 2 2 2 R–B 2 2 10A ETCS 7. 5A ALT–S W 2 2 2 2 R–L 10A HEAD(LO RH) W–L 1 2 2 R–B 10A HEAD(LO LH) HEAD Relay 5 3 1 2 R–B 2 2 2 1 2 2 R–Y W 55 4RUNNER (EM03M0U) Power Source 7. 5A ACC W–G 5 1D 10A CIG 15A IG1 10A ECU–IG 15A RR WSH 20A 4WD W–G 2 1C L–Y 30A FR WIP–WSH 10A IGN 6 1D B–R 7. 5A GAUGE 10A SRS G–B 3 1D 7. 5A STA NO. 2 10A DOME 1 2 R 2 20A RADIO NO. 1 W 1 2 2 L–Y 2 10A ECU–B L 1 2 W–R 2 EFI Relay W–G L 2 2 1 5 2 3 2 2 W–B 10A EFI NO. 2 B 2 56 4RUNNER (EM03M0U) 1 2 2 L–W : Parts Location Code See Page I18 Code See Page Code See Page 37 : Relay Blocks Code See Page Relay Blocks (Relay Block Location) 2 22 Engine Room R/B (Engine Compartment Left) 4 23 Engine Room R/B No.4 (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1C 1D See Page 24 Junction Block and Wire Harness (Connector Location) Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 57 4RUNNER (EM03M0U) Starting ∗ ∗ ∗ ∗ 7 AM2 1 2 3 4 : 2UZ–FE : 1GR–FE : 1GR–FE Cold Area Spec. : 1GR–FE Except Cold Area Spec. IG2 G–B G–B ST2 8 I18 Ignition SW R 3 1D 7. 5A STA NO. 2 B–Y G G B–Y A A (∗1) B B (∗2) A A B B 2 2 2 L–Y J35 Junction Connector 3 G J27(B), J28(A) Junction Connector 1 11 IM1 B–Y 2 IC4 STA Relay 5 Combination Meter B–Y 2 B–Y 2 5 P1 Park/Neutral Position SW 1 6 EA1 (∗1) 4 EA2 (∗2) B–Y L–Y (∗2) Y B 8 B 11 C 12 C B (∗1) 6 IM2 (∗1) 4 IM2 (∗2) 4 B Y–G N J3 Junction Connector 2 P P Y–G W–B B–Y 2 30A AM2 A A (∗1) B B (∗2) B–Y R 2 2 1K B–Y R B–Y R 1 C B–L W (∗4) M (∗2) (∗1) (∗1) 1 1 A B W–B (∗3) B–R S 2(A), (B), S 3(C) Starter STAR/ NSW STA Battery E 5(B), E 6(C) Engine Control Module EB 58 4RUNNER (EM03M0U) STSW : Parts Location Code See Page Code See Page E5 B 37 J27 B 38 E6 C 37 J28 A 38 I18 37 J35 33 (2UZ–FE) J3 P1 35 (1GR–FE) 38 33 (2UZ–FE) Code S2 S3 See Page A 35 (1GR–FE) B 33 (2UZ–FE) C 33 (2UZ–FE) 35 (1GR–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1D 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1K 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) EA2 45 (1GR–FE) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IM1 IM2 Joining Wire Harness and Wire Harness (Connector Location) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) : Ground Points Code EB See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender 59 4RUNNER (EM03M0U) H SYSTEM CIRCUITS 2007 4RUNNER ELECTRICAL WIRING DIAGRAM SYSTEM CIRCUITS ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Active Height Control Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System (w/ Navigation System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System (10 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto LSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Glare–Resistant EC Mirror with Compass . . . . . . . . . . . . . . . . . . . Automatic Light Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downhill Assist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Modulated Air Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Tension Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronically Controlled Transmission and A/T Indicator (1GR–FE) . . . . Electronically Controlled Transmission and A/T Indicator (2UZ–FE) . . . . . Engine Control (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Control (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Immobiliser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hill–Start Assist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Auto Turn Off System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirror Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moon Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi Mode 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiplex Communication System (BEAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiplex Communication System (BEAN Bus) . . . . . . . . . . . . . . . . . . . . . . . . Multiplex Communication System (CAN Bus) . . . . . . . . . . . . . . . . . . . . . . . . . Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Assist (Rear View Monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Outlet (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Outlet (12V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat (Driver’s Seat w/ Driving Position Memory) . . . . . . . . . . . . . . . . 52 4RUNNER (EM03M0U) Page 258 268 358 334 342 348 258 302 140 174 68 296 352 252 246 202 258 268 306 238 230 84 70 98 136 184 182 130 258 304 64 60 162 154 176 142 330 288 274 104 100 102 334 334 300 298 308 H Power Seat (Driver’s Seat w/o Driving Position Memory) . . . . . . . . . . . . . . . Power Seat (Front Passenger’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Deterrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Pressure Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal and Hazard Warning Light (w/ Daytime Running Light) . . . . . Turn Signal and Hazard Warning Light (w/o Daytime Running Light) . . . . VSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 312 316 54 192 330 186 294 178 318 292 281 58 170 162 222 326 258 322 146 150 258 212 53 4RUNNER (EM03M0U) Ignition for 2UZ–FE 7 AM2 B–R IG2 6 ST2 I18 Ignition SW B–Y R 7 EA1 1 EB1 B–R W–B B–R 4 1 3 2 L–W R–W 4 1 4 3 2 I4 Ignition Coil and Igniter No. 4 I3 Ignition Coil and Igniter No. 3 2 I2 Ignition Coil and Igniter No. 2 I1 Ignition Coil and Igniter No. 1 R 2 R–Y 2 B–R 3 3 LG 1 W–B W–B R–Y W–B B–R W–B L–Y B–R 4 1 B–R W–B B–R R–W B–R B–R B–R LG–B B–R W–B B–R 2 30A AM2 R–Y R–Y R–Y R–Y R–W R–W R–W 1 LG R–Y LG–B R–W L–W L–Y B 2 8 24 15 25 11 10 IGT1 IGF1 IGT2 IGF2 IGT3 Battery E4 Engine Control Module 60 4RUNNER (EM03M0U) IGT4 G G–W IGT5 1 4 1 4 1 4 R–W R–W R–W IGT6 2 3 2 13 12 14 IGT7 ED 4RUNNER (EM03M0U) 2 N1 Noise Filter (Ignition No. 1) W–B 4 B–R B–R W–B B–R 1 W–B R–Y N2 Noise Filter (Ignition No. 2) W–B W–B W–B R–Y I8 Ignition Coil and Igniter No. 8 B–R B–R W–B R–Y 3 R–W 2 G–B 3 R–Y W–B W–B G–W B–R W–B I7 Ignition Coil and Igniter No. 7 I6 Ignition Coil and Igniter No. 6 W–B B–R R–Y 2 R–W B–R B–R G 3 B–L B–R G–B B–L I5 Ignition Coil and Igniter No. 5 B–R B–R B–R W–B 1 E4 Engine Control Module ER 2 1 IGT8 9 B EC 61 Ignition for 2UZ–FE : Parts Location Code See Page Code See Page Code See Page E4 37 I4 33 (2UZ–FE) I8 33 (2UZ–FE) I1 33 (2UZ–FE) I5 33 (2UZ–FE) I18 37 I2 33 (2UZ–FE) I6 33 (2UZ–FE) N1 33 (2UZ–FE) I3 33 (2UZ–FE) I7 33 (2UZ–FE) N2 33 (2UZ–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) EB1 44 (2UZ–FE) Engine No.2 Wire and Engine Wire (Near the Starter) : Ground Points Code See Page Ground Points Location EC 44 (2UZ–FE) Right Bank Cylinder Head ED 44 (2UZ–FE) Left Bank Cylinder Head ER 44 (2UZ–FE) Rear Side of Front Right Fender 62 4RUNNER (EM03M0U) Memo 63 4RUNNER (EM03M0U) Headlight B 4(A), B 5(B), B 6(C) Body ECU (BAT) (ACC) 10A ECU–B (IG) 7. 5A ACC 10A ECU–IG SIG 10 ACC 22 BECU HRLY 11 17 HF2 20 C 2 R–B 2 R–B 4 1B 8 1B W W W–R 19 IC4 2 2 R–B R–B W W ∗ 1 : w/ Daytime Running Light ∗ 2 : 2UZ–FE ∗ 3 : 1GR–FE 2 3 HEAD Relay 1 5 B 2 Battery 130 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU R–B R–B R–B 2 1 10A HEAD (LO LH) 2 10A HEAD (LO RH) 10A HEAD (HI LH) 2 10A HEAD (HI RH) 2 2 23 IC4 1 1 R–G W–B W–B 1 R–W 2 H1 Headlight LH (High) 2 H4 Headlight RH (Low) R–W 2 R–L 2 R–B 2 2 R–Y 2 2 1 12 D 10 IN1 R–G 7 IM1 R–G Beam 13 D C10(C), C11(D) Combination Meter Head (USA) 13 C BR R–G 22 IC4 R–G R–G R–G W–B W–B(∗1) (∗1) W–B W–B(∗1) EA EB ED (∗3) BR BR (∗2) W–B (∗1) W–B H2 Headlight LH (Low) 1 R–W 1 R–G 1 H3 Headlight RH (High) 2 EE 131 4RUNNER (EM03M0U) Headlight B 4(A), B 5(B), B 6(C) Body ECU HEAD GND1 HF 7 C R–W 1 IH1 9 IH1 GND2 4 PKB 2 B 16 L 14 A 2 1H J18(A), J19(B) Junction Connector LG GR R 1 C E B GR 8 W–B A Head W–B 1 EA1 (∗2) 3 EA2 (∗3) High Flash LH RH L (∗1) G–Y 3 (∗1) 1 G–B 4 7 R–G Turn GR Dimmer SW Auto Low 6 IC4 1 GR A P4 Parking Brake SW J15 Junction Connector Tail LG 2 OFF Light Control SW 1 1E W–B 16 (∗1) R–W 13 A A W–B W–B C12 Combination SW R 17 1J E A E A E A R–G J10(A), J11(B) Junction Connector R–G D B R–G G2 Generator J12(A), J13(B) Junction Connector B A R–G G–Y(∗1) B B G–B(∗1) R–G R–G W–B(∗1) W–B(∗1) W–B(∗1) W–B(∗1) A A ∗ 1 : w/ Daytime Running Light ∗ 2 : 2UZ–FE ∗ 3 : 1GR–FE IG 132 4RUNNER (EM03M0U) J5 Junction Connector W–B A W–B (∗1) (∗1) W–B (∗1) J37 Junction Connector 4RUNNER (EM03M0U) TFR 8 7 4 2 (∗1) W–B 20 IC4 H11 Hazard SW A 1 IN1 3 2 B 3F B 3F A IK (∗1) TFL W–B TSL (∗1) TSR W–B (∗1) W (∗1) W (∗1) 14 1J J24 Junction Connector 2 R–Y (∗1) R–B 12 (∗1) 42 IC4 R–Y (∗1) R–B (∗1) G–B DRL (∗1) 3 F6 Front Turn Signal Light RH 2 IH1 (∗1) (∗1) LG–R 7 A W–B E A 3 IH1 F5 Front Turn Signal Light LH D B G–B 9 (∗1) E G–Y IG (∗1) DRL G–Y 1 (∗1) B 3F B (∗1) H A W–B 6 (∗1) (∗1) B–Y 2 W–B F B J22(A), J23(B) Junction Connector J7 Junction Connector (∗1) B–Y 8 1J (∗1) Y–R 15A IG1 (∗1) Y–R J20(A), J21(B) Junction Connector D2 Daytime Running Light Relay Turn Signal Flasher Relay (∗1) Y–R (IG) W–B G–Y(∗1) (∗1) Y–R B 4(A), B 5(B), B 6(C) Body ECU 8 HAZ (BAT) 15A TRN–HAZ 15 1J 2 2 A 3 10 HAZ G–B(∗1) W–B(∗1) W–B(∗1) A II 133 Headlight System Outline (w/ daytime running light) ∗ This system is designed to automatically activate the turn signal lights during the daytime to keep the car highly visible to other vehicles. This system is controlled by the body ECU. This system makes use of the turn signal lights as daytime running lights. For this reason, when the turn signal lights are operated, the daytime running lights function is interrupted momentarily, which, however, will be brought back into operation as soon as the interposed operation is over. ∗ This system is enabled when the conditions given below are met. A) Ignition switch ON condition B) Turn signal light switch OFF condition C) Hazard light switch OFF condition D) Light control switch OFF condition E) Parking brake switch OFF condition (Parking brake out of operating condition)** **: This system does not become active when the parking brake switch is ON. However, once the OFF signal of the parking brake switch is input into the body ECU, this system will become active thereafter, regardless of whether the parking brake switch is ON or OFF. : Parts Location Code See Page B4 A 36 B5 B 36 B6 C 36 C10 C 37 C11 D 37 C12 37 D2 37 Code H1 F6 G2 Code J12 34 (1GR–FE) J13 32 (2UZ–FE) H2 H3 H4 32 (2UZ–FE) F5 See Page 32 (2UZ–FE) See Page A 38 B 38 J15 38 34 (1GR–FE) J18 A 38 32 (2UZ–FE) J19 B 38 34 (1GR–FE) J20 A 38 32 (2UZ–FE) J21 B 38 34 (1GR–FE) J22 A 38 J23 B 38 34 (1GR–FE) H11 37 32 (2UZ–FE) J5 38 J24 38 34 (1GR–FE) J7 38 J37 38 P4 39 32 (2UZ–FE) J10 A 38 34 (1GR–FE) J11 B 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1E 1H 1J 3F See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) Joining Wire Harness and Wire Harness (Connector Location) EA2 45 (1GR–FE) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) 134 4RUNNER (EM03M0U) : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel EE 135 4RUNNER (EM03M0U) Front Fog Light R R–B R R–L 2 G–R 1 B 6(C) Body ECU 1 C HEAD G–R R HF2 HRLY 17 10A HEAD (HI LH) 2 IC3 1 IH1 2 20 C W–B G–R R W–B R–L 2 10 13 16 8 1B C12 Combination SW Light Control SW W W OFF 19 IC4 Tail Head R–B W Fog Light SW W Dimmer SW Auto 2 2 2 3 1 5 Low High Flash OFF ON 11 17 HEAD Relay R–G B 2 Battery 136 4RUNNER (EM03M0U) (BAT) 15A FR FOG 2 R–L LG R–L 2 G–R 2 2 2 5 FR FOG Relay W–B 1 3 2 2 G G–R G W–B G 1 A G F2 Front Fog Light RH G 1 2 10 D C10(C), C11(D) Combination Meter Front Fog 2 13 C BR W–B W–B A 7 IM1 BR (1GR–FE) (2UZ–FE) A BR W–B W–B J15 Junction Connector F1 Front Fog Light LH G 12 IC3 J5 Junction Connector IG EA ED EE 137 4RUNNER (EM03M0U) Front Fog Light : Parts Location Code See Page B6 C 36 C10 C 37 C11 D 37 C12 Code F1 F2 37 See Page Code J5 38 34 (1GR–FE) J15 38 32 (2UZ–FE) 34 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B See Page 24 Junction Block and Wire Harness (Connector Location) Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IC3 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC4 : Ground Points Code EA ED EE IG See Page 44 (2UZ–FE) 45 (1GR–FE) See Page 32 (2UZ–FE) Ground Points Location Front Right Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block 46 Left Kick Panel 138 4RUNNER (EM03M0U) Memo 139 4RUNNER (EM03M0U) Automatic Light Control (BAT) (BAT) 50A J/B (IG) 10A ECU–B 2 (ACC) 7. 5A ACC 10A ECU–IG 2 2 L–W W–R 2 1 1C 4 1B 5 1 TAIL Relay 3 2 18 11 TRLY BECU GND1 HRLY 4 GND2 16 22 ACC SIG A 3 C B 5(B), B 6(C) Body ECU CLTB 6 C CLTE 21 C CLTS 4 C G–W Y 3 IG1 2 IG1 1 IG1 G–W Y G–O 10 IH1 L–Y 2 1H 8 1B L–Y G–O 17 10 W C12 Combination SW 12 R–B Light Control SW OFF 16 HEAD Relay 1 3 4 CLTB CLTE CLTS 5 A 2 J15 Junction Connector 1 Head Auto 3 W–B 2 2 W–B 2 Tail W–B B A Battery A A J5 Junction Connector IG 140 4RUNNER (EM03M0U) A39 Automatic Light Control Sensor System Outline The automatic light control system works when the light control SW is turned to AUTO. The automatic light control sensor detects the brightness around the vehicle. By this function, the system automatically turns the taillight and headlight on if the brightness is below the regular level and turns the taillight and headlight off when the surroundings become brighter than the regular level. : Parts Location Code See Page A39 Code See Page 36 C12 37 Code See Page J15 38 B5 B 36 D12 40 J18 A 38 B6 C 36 J5 38 J19 B 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1C 1H See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IG1 46 Instrument Panel No.2 Wire and Instrument Panel Wire (Behind the Combination Meter) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) : Ground Points Code IG See Page 46 Ground Points Location Left Kick Panel 141 4RUNNER (EM03M0U) Light Auto Turn Off System (BAT) (ACC) 7. 5A ACC 50A J/B 2 L–W 2 1 1C 5 1 TAIL Relay 2 18 ACC G–O 1 IH1 8 IH1 10 IH1 R–B G–O H B 14 12 W 13 F A 6 IO3 A 2 W–B B A Battery A J5 Junction Connector IG 142 4RUNNER (EM03M0U) 1 D15 Door Courtesy SW Rear RH 1 P–L P–B 1 D14 Door Courtesy SW Rear LH W–B 1 5 A RRCY 12 B 37 IE1 D13 Door Courtesy SW Front RH 16 J15 Junction Connector 1 Head C12 Combination SW HEAD Relay RLCY 11 B Tail Auto 3 W–B 2 2 PCTY 24 B R–B R–B Light Control SW OFF 2 DCTY 23 B P–L A 3 C G 2 1H 8 1B TAIL 8 C P–B HEAD 1 C J18(A), J19(B) Junction Connector R–Y GND2 16 G 4 R GND1 HRLY D12 Door Courtesy SW Front LH TRLY 17 B 4(A), B 5(B), B 6(C) Body ECU 22 R 3 (IG) (BAT) (BAT) 10A ECU–B 10A ECU–IG 10A DOME 2 2 2 R 2 W–R 8 1F 4 1B 12 1F 10 IC4 R B–R W–R D J7 Junction Connector D B 4(A), B 5(B), B 6(C) Body ECU 11 R 10 BECU MPX2 23 A BR–R F J39 Junction Connector 3 5 PRG +B B7 Back Door Courtesy SW Back Door Half Latch SW W–R 2 RDA E 40 IE1 BR–R R 41 IE1 G–O 39 IE1 L–R F 38 IE1 E B–R G–O PRG 3 B L–R RDA 4 B R SIG E D7 Door Control Receiver 5 9 BD1 10 BD1 7 BD1 6 3 5 BD1 B R–G G–Y B–R A B L–R A A R A A W–B A A J40(A), J41(B) Junction Connector W–B W–B W–B 1 3 A 1 A 5 A 6 A 6 B 7 B 21 B MPX2 BECU SIG HALF FULL LSE W–B GND B 8(A), B 9(B) Back Door ECU BO BL 143 4RUNNER (EM03M0U) Light Auto Turn Off System System Outline When all doors are closed after opening some or all of them after the Ignition SW is turned from ON to OFF with the head and tail lamps ON, these lamps will remain ON for 30 seconds after the doors are closed and then go OUT automatically. Pressing the lock SW on a wireless controller twice in succession turns OFF the lamps instantly. : Parts Location Code B4 See Page Code See Page Code See Page A 36 D7 40 B5 B 36 D12 40 J18 A 38 B6 C 36 D13 40 J19 B 38 40 D14 40 B7 J15 38 J39 40 B8 A 40 D15 40 J40 A 40 B9 B 40 J5 38 J41 B 40 37 J7 38 C12 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1F 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1C : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 144 4RUNNER (EM03M0U) Memo 145 4RUNNER (EM03M0U) Turn Signal and Hazard Warning Light with DRL (IG) (BAT) 15A IG1 15A TRN–HAZ 2 8 1J A B–Y Y–R 2 J7 Junction Connector A Y–R 20 IC4 H A L–Y J20(A), J21(B) Junction Connector L–B 5 1J TRR L–B 3 TRL L–Y 5 L–B B L–Y 6 IG L–Y B–Y 1 L–B Y–R F B 23 1J 15 1F 9 1F 3 1G 2 1G D2 Turn Signal Flasher Relay 14 1J L–B 3 IH1 L–Y 2 IH1 HAZ 10 W TSR 8 G–Y 1 IN1 TSL 7 G–B 42 IC4 E 9 W–B R–Y TFR 2 R–B TFL 4 6 10 LH 2 C12 Combination SW 3 2 BR W–B 13 D B B 3F W–B A W–B Turn LH Turn Turn RH H11 Hazard SW RH 2 C10 Combination Meter G–Y 3 W G–B R–Y 1 W–B 2 3 W–B 3 F6 Front Turn Signal Light RH F5 Front Turn Signal Light LH R–B 15 1J J22(A), J23(B) Junction Connector B 3F J15 Junction Connector E A 7 IM1 A EB A EA IG A W–B J37 Junction Connector A IK 146 4RUNNER (EM03M0U) A J24 Junction Connector II ED BR(1GR–FE) W–B J5 Junction Connector W–B A BR(2UZ–FE) A W–B W–B W–B B 3F EE W–B W–B 2 6 BL 3 A A A A L–Y A L–B L–Y L–B L–B L–Y D T14 Towing Converter Relay Turn R15 Rear Combination Light RH Turn J39 Junction Connector A W–B W–B J40(A), J41(B) Junction Connector R14 Rear Combination Light LH L–Y L–B D A D 9 3 LTIN RTIN 6 A A A B BO 147 4RUNNER (EM03M0U) Turn Signal and Hazard Warning Light with DRL : Parts Location Code See Page C10 37 C12 D2 F5 F6 H11 Code See Page Code See Page J5 38 J37 38 37 J7 38 37 J15 38 J40 A 40 J41 B 40 J39 40 32 (2UZ–FE) J20 A 38 34 (1GR–FE) J21 B 38 R14 41 32 (2UZ–FE) J22 A 38 R15 41 34 (1GR–FE) J23 B 38 T14 41 37 J24 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1F 1G 1J 3F See Page Junction Block and Wire Harness (Connector Location) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH EE 148 4RUNNER (EM03M0U) Memo 149 4RUNNER (EM03M0U) Turn Signal and Hazard Warning Light without DRL (IG) (BAT) 15A IG1 15A TRN–HAZ 2 A L–Y L–Y L–B L–B L–Y B–Y A B–Y H A 3 IF1 5 L–Y IF1 EL L–Y L–B 15 1F 9 1F 8 IF1 3 1G 2 1G 14 1J L–B IF1 G–B 7 23 1J 6 G–B W–B IF1 5 1J ER 5 7 8 EHW G–Y T9 Turn Signal Flasher Relay GND LL L–B 3 LR L–Y 2 +B W 4 W L–B 1 IG 9 10 IF1 IF1 L–Y 6 B–Y F B IF1 Y–R Y–R L–B 1 6 10 G–Y J20(A), J21(B) Junction Connector Y–R 20 IC4 L–Y J7 Junction Connector Y–R 2 L–B 8 1J LH 13 3 C12 Combination SW BR W–B 2 W–B D B Turn LH RH Turn H11 Hazard SW 2 Turn RH 3 C10 Combination Meter G–Y 1 W 3 IH1 W–B 2 IH1 G–B 15 1J B 3F J22(A), J23(B) Junction Connector A B 3F J15 Junction Connector E A 7 IM1 A IG A W–B J37 Junction Connector A IK 150 4RUNNER (EM03M0U) A J24 Junction Connector II ED BR(1GR–FE) A J5 Junction Connector W–B A BR(2UZ–FE) A W–B W–B W–B B 3F EE W–B 2 6 BL 3 A A A A 9 3 LTIN RTIN BO 3 2 EB 4RUNNER (EM03M0U) R–Y L–Y R–Y D R–B L–B 4 F6 Front Turn Signal Light RH R–B A F5 Front Turn Signal Light LH 6 L–Y A L–B L–Y L–B D T14 Towing Converter Relay Turn R15 Rear Combination Light RH Turn L–Y W–B W–B W–B J39 Junction Connector A W–B W–B J40(A), J41(B) Junction Connector R14 Rear Combination Light LH L–Y L–B IF1 2 IF1 L–B 42 IC4 1 IN1 D 3 2 A A A B W–B EA 151 Turn Signal and Hazard Warning Light without DRL : Parts Location Code See Page C10 37 C12 37 F5 F6 Code See Page J7 Code 38 J15 See Page J39 40 38 J40 A 40 32 (2UZ–FE) J20 A 38 J41 B 40 34 (1GR–FE) J21 B 38 R14 41 32 (2UZ–FE) J22 A 38 R15 41 34 (1GR–FE) J23 B 38 T9 39 T14 41 H11 37 J24 38 J5 38 J37 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1F 1G 1J 3F See Page Junction Block and Wire Harness (Connector Location) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH EE 152 4RUNNER (EM03M0U) Memo 153 4RUNNER (EM03M0U) Interior Light B 4(A), B 5(B), B 6(C) Body ECU (ACC) 7. 5A ACC GND2 ACC 4 13 7 1A 8 1A 12 1A 18 1A W (∗1) W–B W (∗3) W (∗3) W–B 2 1H ILE GND1 16 22 W (∗3) W (∗3) 1 W(∗4) 3 2 A (∗3) 2 B (∗4) 1 2 B 5 V6 Vanity Light LH P7 Personal Light W(∗4) 3 A 3 B 1 E V7 Vanity Light RH W (∗3) W(∗4) W (∗3) W(∗4) W (∗1) 2 2 W (∗1) DOOR (∗1) R 1 A (∗3) 1 B (∗4) ON OFF L2 Luggage Compartment Light DOOR ON OFF I20(A), (B) Interior Light W 4 1A 19 1A 9 1A 6 1E 1 22 1J (∗3) W (∗3) W W(∗4) W (∗3) W(∗4) R R–W A J5 Junction Connector IG 154 4RUNNER (EM03M0U) R H H H E ∗ ∗ ∗ ∗ 1 2 3 4 2 2 J35 Junction Connector 9 BB1 (∗2) (∗2) 2 1 (∗2) S35 Step Light Rear RH W–R 2 BM1 4 IO3 R(∗2) E R–W 4RUNNER (EM03M0U) 2 1 1 H 2 BL1 R 3 IE1 R 1 13 IA1 9 BA1 R 4 IE1 P–G (∗2) W–R 26 A DCYL 1 2 D10 Door Courtesy Light Rear LH P–G (∗2) W–R C A W–G 8 BB1 D8 Door Courtesy Light Front LH Y–G (∗2) (∗2) W–R LP R W–R (∗2) W–R 6 B R E (∗2) (∗2) 2 R 5 IO3 (∗2) (∗2) (∗2) W–R C A S34 Step Light Rear LH W–R R (∗2) 1 BL1 (∗2) 1 BM1 W–R C B S32 Step Light Front LH W–R R R R (∗2) S33 Step Light Front RH W–R R L–R Y RCYL R A A 22 B (∗2) 2 (∗2) 1 D11 Door Courtesy Light Rear RH L–R 9 IP1 R C B R 1 1 IP2 R 2 R 9 1K R R–G PCYL (∗2) R A A I17 Ignition Key Cylinder Light 6 D9 Door Courtesy Light Front RH Y R 25 A (∗2) R J12(A), J13(B) Junction Connector B 4(A), B 5(B), B 6(C) Body ECU 21 B LCYL J20(A), J21(B) Junction Connector 9 IA1 8 BA1 1 2 E E J6 Junction Connector : w/ Vanity Light : Limited : w/ Rear Seat Entertainment System : w/o Rear Seat Entertainment System R–W 155 Interior Light B 4(A), B 5(B), B 6(C) Body ECU PRG LMRY 3 B DCTY 23 B PCTY 24 B R–B R 41 IE1 10 IC4 1 IC3 R 39 IE1 D R R 38 IE1 J7 Junction Connector R G–O D L–R D R 3 A R–Y RDA 4 B 3 5 PRG +B 10A DOME 2 H B 2 R E 1 D7 Door Control Receiver R F A 2 W–B 2 J18(A), J19(B) Junction Connector R 2 RDA L–R G–O (BAT) DOME Relay 1 3 1 2 R W–B W–B W–B R–W 2 1 D13 Door Courtesy SW Front RH A B A A D12 Door Courtesy SW Front LH A A J40(A), J41(B) Junction Connector A A 2 R–B 5 R W–B BO W–B W–B R–W BL 156 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU RLCY 11 B RRCY DRLP 12 B 12 C DCY2 SIG 11 C 10 W–L V–Y (IG) P–L P–B (IG) 10A ECU–IG 7. 5A GAUGE 17 A 8 C 4 1G 16 C 13 C BR R–L R 1 D15 Door Courtesy SW Rear RH D14 Door Courtesy SW Rear LH P–L P–B 15 C 1 B–R C 8(A), C10(C) Combination Meter 6 IO3 F B H A J 8(A), J 9(B) Junction Connector 37 IE1 Door R–L 8 1F (1GR–FE) BR BR (2UZ–FE) R 7 IM1 R B–R W–B W–B ED EE 157 4RUNNER (EM03M0U) Interior Light B 8(A), B 9(B) Back Door ECU MPX2 23 A BECU 1 A 5 A SIG 6 A GND 3 A FULL LSE 7 B 21 B B–R MPX2 BECU 11 G–Y B 4(A), B 5(B), B 6(C) Body ECU 6 3 B W–B 40 IE1 9 BD1 7 BD1 5 BD1 10 BD1 W–R B–R W–B W–R 2 W–R 2 L–R 12 1F R 4 1B 10A ECU–B BR–R (BAT) BR–R F E F J39 Junction Connector E B–R B7 Back Door Courtesy SW B–R W–B 158 4RUNNER (EM03M0U) System Outline The interior light is controlled by the body ECU. This system has following features. 1. Normal Operation ∗ When one of the doors opened, the interior light, luggage compartment light and open door warning light is turned on. When the all doors are closed, the interior light, luggage compartment light and open door warning light is turned off. 2. Illuminated Entry System ∗ When a door is unlocked through a key operation or transmitter operation, or if a door is opened or closed, the illuminated entry system turns ON the interior light and the ignition key illumination. ∗ If the ignition switch is turned to the ACC or ON position or if all doors are locked during the 15 seconds in which these lights are ON, they will immediately turn OFF. : Parts Location Code B4 See Page Code See Page Code A 36 D14 40 B5 B 36 D15 40 J35 B6 C 36 I17 37 J39 B7 40 B8 A 40 I20 J21 See Page B 38 38 40 A 40 J40 A 40 B 40 J41 B 40 B9 B 40 J5 38 L2 40 C8 A 37 J6 38 P7 41 C10 C 37 J7 38 S32 41 D7 40 J8 A 38 S33 41 D8 40 J9 B 38 S34 41 D9 40 J12 A 38 S35 41 D10 40 J13 B 38 V6 41 V7 41 D11 40 J18 A 38 D12 40 J19 B 38 D13 40 J20 A 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A 1B 1E 1F See Page Junction Block and Wire Harness (Connector Location) 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1G 1H 1J 1K 159 4RUNNER (EM03M0U) Interior Light : Connector Joining Wire Harness and Wire Harness Code IA1 IC3 IC4 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BL1 48 Floor No.2 Wire and Step Rear Floor LH Wire (Near the Side Step LH) BM1 48 Floor Wire and Step Rear Floor RH Wire (Near the Side Step RH) IP1 IP2 : Ground Points Code ED See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH EE 160 4RUNNER (EM03M0U) Memo 161 4RUNNER (EM03M0U) 2 IG A B 8 C TAIL 8 IH1 OFF 14 1 Tail Head A B A A 2 EB 1 2 A J5 Junction Connector EA 162 4RUNNER (EM03M0U) R14 Rear Combination Light LH 9 1B G TRLY Stop/Tail 13 1F W–B 2 Stop Light SW STOP LP CTRL Relay G 5 1L G–Y G L–W L–W G 1 1C F6 Front Parking Light RH 18 G 3 10A TAIL 2 W–B 1 5 F5 Front Parking Light LH 140A ALT G TAIL Relay 50A J/B 1 W–B G 1 C12 Combination SW G B 2 J14(A), J15(B) Junction Connector W–B Light Control SW 2 W–B W–B Battery B Taillight and Illumination G G 2 B 6(C) Body ECU 11 1B 2 1 4 6 16 W–B W–B G G G J39 Junction Connector G ∗ 1 : w/ Navigation System ∗ 2 : w/o Navigation System B B B G B G G B A B A B B B B B B B B G G G 1 1 1 1 G G Stop Light SW STOP LP CTRL Relay 2 BD1 B B J16(A), J17(B) Junction Connector G B A G G 2 2 C13 Combination SW 2 A42 Auto LSD SW RH LH 1 3 3 BH1 W–R W–G W–G W–B W–G 10 W–B 6 2 W–B Stop/Tail R15 Rear Combination Light RH B10 License Plate Light 4 M2 Main SW 4 W–G 1 D4 Diff. Lock SW R25 Roll Sensing of Curtain Shield Airbag Cutoff SW G G G–Y 2 BH1 10 BD1 W–B II1 W–B 1 A A A A A B A B W–B J40(A), J41(B) Junction Connector A A A B A A A B J16(A), J17(B) Junction Connector W–B A A A B A A W–R(∗1) W–R(∗2) W–G W–G W–B W–B BL BO 163 4RUNNER (EM03M0U) Taillight and Illumination G G G G G G D 3D D 3D D 3D D 3D D 3D D 3D G D 3D C15 Cup Holder Illumination G G G W–G W–G W–G W–G A 3F A 3F A 3F A 3F A 3F A 3F W–G W–G W–G (∗2) 2 A 3F C 3E (∗2) 2 1 A 3F A 3F W–R 2 1 10 C 3E (∗1) 1 1 D5 Downhill Assist Control SW G ILL– 2 H19 Height Control Mode Select SW ILL+ H12 Height Control SW 9 W–G D3 Defogger SW Heater Control Panel ILL– 12 A (∗5) 5 C (∗6) G (∗2) G W–G SWG 6 D 6 D W–G ILL– 12 B R 1(A), R 2(B), R 3(C), R 5(D) Radio and Player G (∗1) SWG 6 A 2 A (∗5) 10 B (∗6) ILL+ (∗7) ILL+B(∗8) W–G 13 D (∗3) 12 D (∗4) ILL+ (∗1) G I B 2 B W–R D A R10(A), R12(B) Radio and Player with Display J31(A), J32(B) Junction Connector G G D 3D G ELS1(∗3) ELS2(∗4) W–G E 7(D) Engine Control Module W–R(∗1) W–G W–R(∗2) W–G W–G W–G W–G W–G W–B W–B W–G 164 4RUNNER (EM03M0U) G G G G G 1 IR1 3 IR1 W–G 2 2 IR1 4 IR1 F11 4WD Control SW C7 Cigarette Lighter Illumination A38 Ashtray Illumination 2 3 W–G 1 W–B 4 1 W–G 5 1 W–B 5 W–G 5 1 G G G G G G A22 A/T Shift Lever Illumination 2 W–G 2 : w/ Navigation System : w/o Navigation System : 2UZ–FE : 1GR–FE : Except 6 Speaker : 6 Speaker : w/ CD Changer : w/o CD Changer G W–G H11 Hazard SW G G G S5 Seat Heater SW RH 4 G W–G 6 G W–G S4 Seat Heater SW LH 6 G B1 Back Door Power Window Control SW G G 1 2 3 4 5 6 7 8 G ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ W–G W–G W–G W–G W–G W–G W–G W–G W–G W–B W–B W–G W–G 165 4RUNNER (EM03M0U) Taillight and Illumination G (IG) (IG) (BAT) 7. 5A GAUGE ∗ 3 : 2UZ–FE ∗ 4 : 1GR–FE 10A DOME 15A IG1 2 4 1G R 2 8 1J G R G A A B D J7 Junction Connector C A D R C A J7 Junction Connector J10(A), J11(B) Junction Connector A J 8(A), J 9(B) Junction Connector Y–R 10 IC4 R–L F B 9 15 16 7 13 R G G Y–R H A J20(A) Junction Connector Illumination H A C10 Combination Meter 4 Tail (Except USA) G 1 G3 Glove Box Light Y–R 1 Illumination H A W–B 2 T A A BR BR A A BR W–B W–B W–G W–B W–G 7 IM1 (∗4) B 3F B 3F E B (∗3) 3 W–G 5 – W–G 6 E W–G B 3F ILL– J 8(A), J 9(B) Junction Connector R13 Rheostat IG W–G W–B A A J24 Junction Connector W–G II J37 Junction Connector IK 166 4RUNNER (EM03M0U) ED EE : Parts Location Code See Page A22 36 A38 A42 B1 Code See Page Code See Page F11 37 36 G3 37 36 H11 37 J40 A 40 36 H12 37 J41 B 40 36 H19 37 B10 40 J5 38 R1 A 39 C7 37 J7 38 R2 B 39 C10 37 J8 A 38 R3 C 39 C12 37 J9 B 38 R5 D 39 C13 37 J10 A 38 R10 A 39 C15 37 J11 B 38 R12 B 39 D3 37 J14 A 38 R13 39 D4 37 J15 B 38 R14 41 D5 37 J16 A 38 R15 41 37 J17 B 38 R25 39 32 (2UZ–FE) J20 A 38 S4 39 38 S5 39 B6 C E7 D F5 34 (1GR–FE) F6 J24 32 (2UZ–FE) J31 A 38 34 (1GR–FE) J32 B 38 J37 38 J39 40 M2 39 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1C 1F See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1L 3D 3E 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) II1 46 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace LH) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IR1 47 Instrument Panel Wire and Cigarette Lighter Wiring Assembly (Rear Console) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BH1 48 Back Door No.1 Wire and Back Door No.2 Wire (Left Side of Back Door) 167 4RUNNER (EM03M0U) Taillight and Illumination : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH EE 168 4RUNNER (EM03M0U) Memo 169 4RUNNER (EM03M0U) Stop Light (BAT) (IG) 15A IG1 10A STOP 2 20 1E Y–R 2 G–W E J1 Junction Connector E D D Y–R Y–R 2 2 S12 Stop Light SW 5 1 3 2 4 2 G–B G–Y G–Y 2 2 LG 1 B 2 STOP LP CTRL Relay G–W B J4 Junction Connector 16 STPO J4 Junction Connector E E 170 4RUNNER (EM03M0U) S28 Skid Control ECU with Actuator G–B G–B W–B W–B W–B 6 BL 4RUNNER (EM03M0U) 4 A A A A A A (∗1) 2 B W–B 1 B H18(A) High Mounted Stop Light 1 (∗1) G–Y (∗2) G–Y TAIL Fuse G–Y TAIL Fuse G–Y B A (∗2) 4 W–B H18(B) High Mounted Stop Light G G G–Y J40(A), J41(B) Junction Connector B A Stop/Tail R15 Rear Combination Light RH Stop/Tail R14 Rear Combination Light LH 1 W–B W–B G–B J40(A), J41(B) Junction Connector ∗ 1 : w/ Rear Spoiler ∗ 2 : w/o Rear Spoiler G–Y C B B A 3 BD1 16 1F 24 1E 1 A 2 A 6 10 BD1 A A A B BO 171 Stop Light : Parts Location Code H18 See Page Code A 40 B 40 J40 33 (2UZ–FE) J41 J1 See Page J4 35 (1GR–FE) 2 See Page 22 41 A 40 S12 39 B 40 R14 41 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1F 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code BD1 See Page 48 Joining Wire Harness and Wire Harness (Connector Location) Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) : Ground Points Code See Page See Page R15 : Relay Blocks Code Code 38 Ground Points Location BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 172 4RUNNER (EM03M0U) S28 33 (2UZ–FE) 35 (1GR–FE) Memo 173 4RUNNER (EM03M0U) Back–Up Light (IG) 15A IG1 Y–R 8 1J R–Y A J7 Junction Connector B A Y–R 1 IM1 J20 Junction Connector R–Y B R–Y H J33 Junction Connector H Y–R 2 1L A 1 R J25 Junction Connector P1 Park/Neutral Position SW 10 1F 2 Y–R R–Y A J40(A), J41(B) Junction Connector B B 2 IM1 W–B A A A A A A R–Y 1 BG1 Y 6 W–B 6 C A R15 Rear Combination Light RH R–Y 2 Back–Up 3 R14 Rear Combination Light LH C A Back–Up C A R–Y Y–R 4 J40(A), J41(B) Junction Connector A B W–B W–B B/UP BO 174 4RUNNER (EM03M0U) BL T15 Trailer Socket : Parts Location Code See Page Code See Page Code See Page J7 38 J40 A 40 R14 41 J20 38 J41 B 40 R15 41 J25 38 33 (2UZ–FE) T15 41 J33 38 P1 35 (1GR–FE) : Junction Block and Wire Harness Connector Code 1F 1J 1L See Page Junction Block and Wire Harness (Connector Location) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BG1 48 Floor No.2 Wire and Frame No.3 Wire (Rear Side of Side Frame LH) : Ground Points Code See Page Ground Points Location BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 175 4RUNNER (EM03M0U) IGT1 24 IGF1 LG–B 8 LG 1 3 2 W–R W–R B–R 4 1 3 2 IGT2 LG W–R W–R IGT3 Battery E4 Engine Control Module 64 4RUNNER (EM03M0U) B–R W–B 4 1 4 3 2 LG–B W–R 30A AM2 W–B I4 Ignition Coil and Igniter No. 4 W–B B–R B–R I18 Ignition SW I3 Ignition Coil and Igniter No. 3 B–R 4 P–L 2 W–R I2 Ignition Coil and Igniter No. 2 3 W–B B–R 2 1 Y–R R IG2 6 P–L W–R 2 I1 Ignition Coil and Igniter No. 1 R 7 AM2 Y–R B Ignition for 1GR–FE B–R ST2 6 1D 4 1H 13 IM1 B–R B–R B–R W–B W–B W–B 1 W–R W–R 2 9 10 11 IGT4 W–R IGT5 N1 Noise Filter (Ignition No. 1) I6 Ignition Coil and Igniter No. 6 B–R W–B 1 4 1 4 3 2 12 13 B–R W–B W–B W–B W–R 2 W–R B–R W–B L 3 GR B–R W–B L W–B GR I5 Ignition Coil and Igniter No. 5 B–R 2 1 W–R IGT6 E4 Engine Control Module EF 65 4RUNNER (EM03M0U) Ignition for 1GR–FE : Parts Location Code See Page Code See Page Code See Page E4 37 I3 35 (1GR–FE) I6 35 (1GR–FE) I1 35 (1GR–FE) I4 35 (1GR–FE) I18 37 I2 35 (1GR–FE) I5 35 (1GR–FE) N1 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1D 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IM1 See Page 47 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) : Ground Points Code EF See Page 45 (1GR–FE) Ground Points Location Rear Side of Left Bank Cylinder Block 66 4RUNNER (EM03M0U) Memo 67 4RUNNER (EM03M0U) Key Reminder (BAT) (IG) (ACC) 10A ECU–IG 10A ECU–B (IG) 7. 5A ACC (BAT) 7. 5A GAUGE 2 10A DOME 2 2 2 R–L W–R 4 1G R 4 1B 11 10 BECU 22 ACC SIG B 5(B), B 6(C) Body ECU E A F A GND1 DCY2 KSWO 11 C 10 IC4 15 C 8 C 19 B R 4 2 1H W–B G–Y A B J18(A), J19(B) Junction Connector R–B H B 16 V–G 14 C W–L GND2 KSW DCTY 23 B F B 7 IM1 H A J 8(A), J 9(B) Junction Connector 2 K3 Unlock Warning SW G–Y A W–B BR (1GR–FE) BR W–B A B J15(B) Junction Connector A B (2UZ–FE) W–B R 1 A IG J5 Junction Connector ED EE 176 4RUNNER (EM03M0U) D D R R 15 C C 9(B), C10(C) Combination Meter 16 C BR C B 13 C R–L B A J14(A), J15(B) Junction Connector 1 D12 Door Courtesy SW Front LH R–B G–Y Buzzer J7 Junction Connector System Outline Key Reminder System With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver’s door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 23 of the body ECU, the body ECU operates, current flows from TERMINAL (C) 15 of the ECU to TERMINAL (B) 19 of the combination meter to GROUND and key reminder buzzer sounds. : Parts Location Code See Page B5 B 36 B6 C 36 C9 B 37 C C10 D12 Code See Page J5 J7 Code See Page 38 J15 B 38 38 J18 A 38 J8 A 38 J19 B 38 37 J9 B 38 40 J14 A 38 K3 39 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1G 1H See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) : Ground Points Code ED EE IG See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block 46 Left Kick Panel 177 4RUNNER (EM03M0U) Seat Belt Warning G–Y (BAT) (IG) (ACC) 10A ECU–IG 10A ECU–B 7. 5A ACC (IG) (BAT) 15A IG1 2 (IG) 10A DOME 7. 5A GAUGE 2 2 8 1J 4 1G R R–L Y–R G–Y W–R 2 A J7 Junction Connector R A 10 IC4 4 1B 11 10 BECU 22 SIG 13 A DBKL ACC Y–R D J7 Junction Connector D R–L GND1 R GND2 16 B 4(A) Body ECU 4 H A J20(A) Junction Connector H A Y–R W–B 2 1H 1 2 3 4 5 6 7 8 : 2UZ–FE : 1GR–FE : w/ Side Airbag : w/o Side Airbag : w/ Driving Position Memory : w/o Driving Position Memory : w/ Power Seat (Front Passenger' s Seat) : w/o Power Seat (Front Passenger' s Seat) A J25 Junction Connector A R W–B Y–R ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ Y–R A J5 Junction Connector IG 178 4RUNNER (EM03M0U) EE BR Y–R A 3C ED 4 BI1 8 4 FSR+ FSR– BSW BGND 9 5 2 A 2 B 1 A (∗7) 1 B (∗8) B16(A), (B) Buckle SW RH 4RUNNER (EM03M0U) (∗5) 1 BI1 W–B F B (∗5) FSR– 2 D (∗3) 10 E (∗4) W–B PBEW (∗5) 2 C L (∗5) L (∗6) PBEW K B J43(A), J44(B) Junction Connector 3 W–B A 3C (∗5) G–Y (∗6) G–Y G–Y G–Y Buzzer (∗6) FSR+ W–B 1 D 3 E G–Y J 8(A), J 9(B) Junction Connector D A J43(A), J44(B) Junction Connector IG+ A32(C), A33(D), A34(E) Airbag Sensor Assembly G–Y 13 B B B B (∗6) W–B R L–R BR C 9(B), C10(C) Combination Meter O3 Occupant Classification ECU H A B 2 GR W 7 IM1 W BR (∗1) 13 C L BR (∗2) 18 B (∗1) H A B BR 1 Y–R LG 16 C R R–L D3 Passenger Seat Belt Warning Light R 15 C (∗2) R R J 8(A), J 9(B) Junction Connector Driver' s Seat Belt G–Y G–Y J20(A), J21(B) Junction Connector D A C A 26 IE1 12 B C B D A 10 BK1 3 B15 Buckle SW LH 4 B J53 Junction Connector A B B A A 1 BK1 BL 179 Seat Belt Warning System Outline When the driver has not fastened the seat belt while the ignition SW is ON, the driver seat belt warning light blinks, and a warning buzzer comes on. Also, in the front passenger seat, a sensor recognizes passenger, and when the passenger has not fastened the seat belt, the front passenger seat belt warning light blinks. : Parts Location Code See Page Code See Page A32 C 36 B16 B 43 (*2) A33 D 36 C9 B 37 A34 E 36 C10 C 37 B4 A 36 D3 37 42 (*1) J5 38 43 (*2) J7 38 B15 B16 A B 42 (*1) J8 A 38 43 (*2) J9 B 38 42 (*1) J20 A 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1H 1J 3C : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BI1 BK1 50 (*1) Floor Wire and Seat No.1 Wire (Under the Front RH Seat) 51 (*2) 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) : Ground Points Code ED See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH EE * 1 : Power Seat * 2 : Manual Seat 180 4RUNNER (EM03M0U) Code J21 See Page B J25 38 J43 A J44 B J53 O3 38 42 (*1) 43 (*2) 42 (*1) 43 (*2) 42 (*1) 42 (*1) 43 (*2) Memo 181 4RUNNER (EM03M0U) Garage Door Opener (BAT) 10A DOME 2 R 2 R 2 5 2 2 DOME Relay 3 1 2 R R–W 2 6 1E R 1 IC3 4 1A R 3 LMRY 5 B4 Body ECU P7 Personal Light B Garage Door Opener E W–B 1 12 1A W–B 2 1H A J5 Junction Connector IG 182 4RUNNER (EM03M0U) : Parts Location Code See Page B4 Code 36 J5 See Page 38 Code P7 See Page 41 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IC3 See Page 46 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code IG See Page 46 Ground Points Location Left Kick Panel 183 4RUNNER (EM03M0U) Front Wiper and Washer (IG) 30A FR WIP–WSH C14 Combination SW 22 1E 9 1J 11 6 IN1 L–Y L L INT TIME Washer HI LO INT OFF Wiper Relay L–Y 2 1 M L W2 Washer Motor L–W 16 IC4 L–W 7 L–B 14 IC4 L–B 8 L–R 17 IC4 L–R 17 L–W 16 L L W–B L 2 2 3 L 4 1 W–B Front Wiper and Washer SW A J15 Junction Connector M A A 5 W–B W–B F7 Front Wiper Motor J5 Junction Connector IG 184 4RUNNER (EM03M0U) EB System Outline With the ignition SW turned on, the current flows to TERMINAL 17 of the wiper and washer SW, TERMINAL 1 of the washer motor and TERMINAL 2 of the front wiper motor through the FR WIP–WSH fuse. 1. Low Speed Position With the wiper and washer SW turned to LO position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 1 of the front wiper motor to TERMINAL 5 to GROUND and causes the front wiper motor to run at low speed. 2. High Speed Position With the wiper and washer SW turned to HI position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 8 to TERMINAL 4 of the front wiper motor to TERMINAL 5 to GROUND and causes the front wiper motor to run at high speed. 3. INT Position With the wiper and washer SW turned to INT position, the wiper relay operates and current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 2 to GROUND. This activates the intermittent circuit and the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 1 of the front wiper motor to TERMINAL 5 to GROUND and the wiper operates. Intermittent operation is controlled by a condenser charge and discharge function in the relay. 4. Washer Interlocking Operation With the wiper and washer SW pulled to washer position (Washer SW ON position), the current flows from the FR WIP–WSH fuse to TERMINAL 1 of the washer motor to TERMINAL 2 to TERMINAL 11 of the wiper and washer SW to TERMINAL 2 to GROUND and causes the washer motor to run and the window washer to spray. Simultaneously, current flows from the FR WIP–WSH fuse to TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 1 of the front wiper motor to TERMINAL 5 to GROUND, causing the wiper to function. : Parts Location Code See Page C14 F7 Code See Page 37 J5 38 32 (2UZ–FE) J15 38 34 (1GR–FE) W2 33 (2UZ–FE) Code W2 See Page 35 (1GR–FE) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) : Ground Points Code EB IG See Page 44 (2UZ–FE) 45 (1GR–FE) 46 Ground Points Location Front Left Fender Left Kick Panel 185 4RUNNER (EM03M0U) Rear Wiper and Washer B 4(A), B 5(B), B 6(C) Body ECU 10A ECU–IG (IG) 7. 5A ACC 15A RR WSH WIG 1 ACC 22 BECU GND2 10 11 16 8 1F 4 1B 12 1F W–R 10A ECU–B (ACC) W–R (IG) B–R (BAT) SIG GND1 4 2 W–R 2 W–B W–B 2 1H W–R J5 Junction Connector B–R A A IG 186 4RUNNER (EM03M0U) W–B W–B J15 Junction Connector W–B Rear Wiper and Washer SW 10 C RWON C A B A B A 12 10 C14 Combination SW 2 9 C RWINT 7 IH1 4RUNNER (EM03M0U) BR–R BR–W 2 BR–W C A GR–R 2 GR–R B–O WMTR J12(A), J13(B) Junction Connector A B J12(A), J13(B) Junction Connector 4 D24 Diode (Rear Wiper) 1 GR–R LG–B M LG–B LG–B B B 3 IC3 LG–B W2 Washer Motor B 4(A), B 5(B), B 6(C) Body ECU 23 A MPX2 1 1B 3 40 IE1 BR–R Washer OFF LO HI Washer 13 A A W–R W–R B–R B–R W–B 187 Rear Wiper and Washer B 8(A), B 9(B) Back Door ECU W–B L–R B 5 BD1 W–R B–R 5 6 3 F E 2 SSRB 6 PLS 3 PLS2 5 A SIG 7 BD1 1 BR–R BECU 10 BD1 R 9 BD1 GND 3 A W–B LSE 21 B B–R FULL 7 B G–Y HALF 6 B R–G IC– 23 B L–W IC1 16 B B–O IC2 17 B W–R IC+ 11 B Y–G MPX2 1 A 6 A E B7 Back Door Courtesy SW Back Door Half Latch SW B11 Back Door Power Window Motor A A A A W–B W–B A B W–R B–R BO 188 4RUNNER (EM03M0U) BL J40(A), J41(B) Junction Connector F E W–R B–R J39 Junction Connector B 8(A), B 9(B) Back Door ECU (BAT) BDR 4 A SGND 18 B P W 12 B 3 B WIP+ 30A POWER WIP– 2 B 1 B L 2 BR–B Y–G R–G 1 3 5 4 L–O L–O P–B G–R 6 BD1 2 1F Return Position Furthest Position M Stop 2 R23 Rear Wiper Motor Rear Wiper Position SW 189 4RUNNER (EM03M0U) Rear Wiper and Washer System Outline ∗ Rear wiper operation The back door ECU initiates rear wiper intermittent or continuous operation according to rear wiper SW command from the body ECU. At this point, the position of the back door window is confirmed and, if it is not fully closed, the command will be neglected preventing the rear wiper from starting. If the ignition SW is turned OFF while the rear wiper is operating, it comes to a stop but only after the wiper arm has returned to its initial position. ∗ Rear washer operation Turning the rear washer SW ON, with the ignition SW ON and the back door window fully closed, initiates rear washer operation. : Parts Location Code B4 See Page Code See Page Code A 36 C14 37 J40 B5 B 36 D24 37 J41 B6 C 36 J5 38 B7 40 J12 A 38 J13 B 38 B8 A 40 B9 B 40 J15 38 40 J39 40 B11 See Page A 40 B 40 R23 W2 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1B 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1F 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 190 4RUNNER (EM03M0U) 41 33 (2UZ–FE) 35 (1GR–FE) Memo 191 4RUNNER (EM03M0U) Power Window B 4(A), B 5(B), B 6(C) Body ECU (ACC) 7. 5A ACC ACC 22 BDR1 12 BDN BUP 8 B 10 B Y–R 20A DR/LCK B–L (BAT) 6 3 COM 19 B 2 2 G–W DOWN B–Y 9 1E 1 UP B1 Back Door Power Window Control SW 192 4RUNNER (EM03M0U) E B 4(A), B 5(B), B 6(C) Body ECU KSW GND1 14 C GND2 SIG PWS 16 10 21 G–Y 4 POWER Relay E A J18(A), J19(B) Junction Connector A B (BAT) 1 (IG) 30A POWER 5 10A ECU–IG 2 3 C B 2 1H 1 1H 2 1F 25 1J 8 1F 28 1J W–B W L–O L–O B–R B–R B A J14(A), J15(B) Junction Connector G–Y 2 G B–R 2 K3 Unlock Warning SW G–Y G J20 Junction Connector W–B A B W–B W–B A B J15(B) Junction Connector W–B 1 B–R W–B B–R L–O A J5 Junction Connector L–O A A W IG 193 4RUNNER (EM03M0U) Power Window B 4(A), B 5(B), B 6(C) Body ECU W/L 1 P9 Power Window Control SW Front RH A A B A B B C B B A A A L–R 7 IA2 12 IA2 R 5 IP2 L–Y R 9 IP2 R–B R–B 10 IP2 L–Y 2 B 5 W 4 J22(A), J23(B) Junction Connector 1 L–Y 3 L–R L L–R P13 Power Window Motor Front RH L–B 2 1 M W/L 2 22 C L–Y 24 C L–R R L–Y R–B C W C W C C W W J33 Junction Connector W W C J7 Junction Connector C C W W–B W–B B–R B–R B–R B–R L–O L–O L–O L–O W 194 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU D17 Power Window Master SW RLU 12 RLD R–L L G 11 IA2 10 IA2 9 IA2 6 IA2 6 BA1 L–B L 1 G–R L–B 2 7 BA1 G–R G 5 G–W 6 BB1 2 G–W G 7 BB1 2 L G–B P15 Power Window Motor Rear RH B 10 3 5 2 1 3 M 1 M 1 P14 Power Window Motor Rear LH RRD 16 G–B 2 IA2 RRU 18 L–O 12 IA1 B–R 5 IA2 W R BW 7 B B2 11 B B 6 R–B PU 13 R PD 15 R R–B W W P11 Power Window Control SW Rear RH 5 BB1 P10 Power Window Control SW Rear LH 5 BA1 W W 4 W 4 W W–B W–B B–R B–R B–R L–O L–O L–O 195 4RUNNER (EM03M0U) Power Window B 4(A), B 5(B), B 6(C) Body ECU L2 UL3 12 A 20 D17 Power Window Master SW BZR BZR2 9 7 10 1B 6 1B 3 PLS 14 PLS2 17 GND 2 E 1 W–B 6 IA1 4 5 3 6 D U SSRB PLS PLS2 E M 2 B 9 10 7 J38 Junction Connector B W–B B P12 Power Window Motor Front LH G 2 L 1 8 IA1 D16 Door Key Lock and Unlock SW Front LH BR–B W–G W–R W–L L L–B 1 W3 Wireless Door Lock Buzzer VCC G DU 4 L DD 9 Y–B P–B 3 1K W–B W–B 4 IA2 W–B B–R B–R L–O L–O 196 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU RDA PRG 4 B DCTY 3 B PCTY 23 B RLCY 24 B RRCY 11 B 12 B 2 P–L 37 IE1 6 IO3 R R–B 1 D15 Door Courtesy SW Rear RH 1 41 IE1 R 39 IE1 G–O 38 IE1 L–R R D 1 D14 Door Courtesy SW Rear LH 1 J7 Junction Connector D13 Door Courtesy SW Front RH D D12 Door Courtesy SW Front LH R P–L 10 IC4 P–B L–R G–O F A P–B H B 2 J18(A), J19(B) Junction Connector 10A DOME R–Y R–B (BAT) 2 3 5 RDA PRG +B E 1 D7 Door Control Receiver A A A A W–B W–B A B A A J40(A), J41(B) Junction Connector W–B W–B W–B B–R B–R L–O L–O BO BL 197 4RUNNER (EM03M0U) Power Window B 4(A), B 5(B), B 6(C) Body ECU B 8(A), B 9(B) Back Door ECU BECU MPX2 MPX2 23 A 11 BECU 1 A 5 A GND 3 A SIG BDR 6 A 4 A W–B B L 40 IE1 9 BD1 7 BD1 10 BD1 5 BD1 6 BD1 W–B B–R L–O W–R W–R 2 W–R 2 L–R 12 1F R 4 1B 10A ECU–B BR–R (BAT) BR–R F E J39 Junction Connector F E B–R J39 Junction Connector W–B B–R L–O 198 4RUNNER (EM03M0U) B 8(A), B 9(B) Back Door ECU IC– HALF FULL LSE 7 B 21 B 4 5 1 2 6 3 5 6 3 R G SSRB PLS PLS2 E Y–G B–R 6 B G–Y 23 B R–G 1 IC1 16 B L–W 2 IC2 17 B B–O 3 IC+ 11 B W–R R–B BDDN 25 B Y–B BDUP 13 B V–Y UP 5 B GR–R DOWN 4 B LG–B E 19 B T10 Tailgate Control SW B7 Back Door Courtesy SW Back Door Half Latch SW M B11 Back Door Power Window Motor 199 4RUNNER (EM03M0U) Power Window System Outline ∗ The power window system is controlled by the body ECU. This system has following features. 1. Manual Up and Down Function This function causes the window to open or close while the power window switch is being pulled halfway up or pushed halfway down. The window stops as soon as the switch is released. 2. Front Doors One–Touch Auto Up and Down Function The front doors one–touch auto up and down function enables the window of front doors to be fully opened or closed at a touch of the power window switch. 3. Jam Protection Function A jam protection function automatically stops the power window and moves it downward if a foreign object gets jammed in the window during one–touch auto–up operation. 4. Remote Control Function The up and down operations of the front passenger door window and the rear door windows can be controlled by operating the power window master switch. 5. Ker–Off Operation Function Within about 45 seconds when turn OFF the ignition SW or open and shut the driver’s seat door, this function enables the door window operation with the power window master switch and/or the manual operation at each passenger’s seat door. (The driver’s seat door includes the one–touch auto up and down operation as well) 6. Key–Linked Up and Down Function A key–linked up and down function, which is linked to the driver door key cylinder operation, open or close the window of the all doors. ∗ When the battery terminal or fuse is disconnected, the glass position of all doors have to be reset to the initial positions, door by door, by the power window control switch in accordance with the following procedure: A) Reconnect the battery terminal or fuse. B) Turn ON the ignition switch. C) Lower the window of each door by the power window switch to open it halfway or more. D) Then move the window up by the power window switch to close it fully. Do not release the switch for at least one second after the window is fully closed. 7. Back Window Control When the ignition SW is off, the ignition key is not inserted into the ignition key cylinder, the back window can be opened by pressing the back window open SW of the transmitter for approximately 0.8 seconds. At that time, the wireless door lock buzzer beeps once. : Parts Location Code See Page B1 Code See Page 36 D17 40 A 36 J5 38 B5 B 36 B6 C 36 J14 A 40 J15 B4 B7 Code J41 See Page B 40 K3 39 38 P9 41 38 P10 41 B 38 P11 41 J7 B8 A 40 J18 A 38 P12 41 B9 B 40 J19 B 38 P13 41 38 P14 41 A 38 P15 41 B 38 T10 41 B11 40 J20 D7 40 J22 D12 40 J23 D13 40 J33 38 D14 40 J38 40 D15 40 J39 40 D16 40 J40 A 40 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) 200 4RUNNER (EM03M0U) W3 33 (2UZ–FE) 35 (1GR–FE) : Junction Block and Wire Harness Connector Code 1B 1E 1F See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1H 1J 1K : Connector Joining Wire Harness and Wire Harness Code IA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IP2 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) IA2 : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 201 4RUNNER (EM03M0U) Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU 20A DR/LCK (ACC) 7. 5A ACC (BAT) 7. 5A GAUGE (IG) 10A DOME (BAT) 15A IG1 (IG) ACC 22 DRLP BDR1 12 12 C DCY2 11 C SPD 14 2 2 1 1G V–R R–L 9 1E W–L 2 V–Y 4 1G 2 R 8 1J SP1 12 GR–R Y–R G–W J7 Junction Connector R 10 IC4 A S28 Skid Control ECU with Actuator 7 IC2 GR–R Y–R D J7 Junction Connector A D C 8(A), C 9(B), C10(C) Combination Meter J25 Junction Connector F B J 8(A), J 9(B) Junction Connector Y–R H A A Speedometer H A 4 B 5 B Door H A 8 C R J20(A) Junction Connector 17 A Y–R R A 15 C 16 C R BR 2 IM1 13 C R–L 2 BR (∗1) BR ∗ 1 : 2UZ–FE ∗ 2 : 1GR–FE (∗2) Y–R 7 IM1 P1 Park/Neutral Position SW P 6 G–B EE 202 4RUNNER (EM03M0U) BR (∗1) BR (∗2) G–B ED B 4(A), B 5(B), B 6(C) Body ECU RRCY L1 12 B P–L P–B 1 E A 8 5 1 1K A D A D L–W L–O L–W D L–O R–W 4 IA1 A L–W G–W 5 IA1 L–O L–W B B B W–B J38 Junction Connector W–B G–B 5 1K P–L 1 D15 Door Courtesy SW Rear RH 1 D14 Door Courtesy SW Rear LH D13 Door Courtesy SW Front RH D12 Door Courtesy SW Front LH J 8(A) Junction Connector E A 1 J6 Junction Connector L 15 6 IO3 P–B R–B G–B 1 UL L–O 37 IE1 W–B F A E J18(A), J19(B) Junction Connector H B UL1 19 L–O RLCY 11 B R–Y R–B J18(A), J19(B) Junction Connector C A 24 B D17 Door Lock Control SW Front LH G–B C B PCTY 23 B L–W DCTY P 17 B C J35 Junction Connector W–B C G–B 4 IA2 W–B 8 IM1 G–B 203 4RUNNER (EM03M0U) Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU L2 20 UL3 12 A LSWD 21 A ACTD 10 A LSWP 30 A ACT+ ACT– 23 24 9 1L 18 1L 3 1K B–W G W–R L–B B–W L–B L–R 8 IA1 7 IA1 13 IA2 8 IA2 7 IP1 7 IP2 2 IP2 G W B–R B–W B B–R B–W 9 10 8 1 4 7 1 4 L–R L 6 IA1 L 6 1L W–B 5 IP1 3 W–B W–B L–W 6 IP1 L–O L 6 R 5 Lock Unlock D18 Door Lock Control SW Front RH L–O 4 IP2 M W–B W–B 7 D16 Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH Door Lock Motor Front LH M 8 W–B L–W D19 Door Lock Detection SW Front RH Door Lock Motor Front RH W–B W–B W–B W–B W–B W–B A A J37 Junction Connector IK 204 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU GND2 14 C GND1 4 L DBKL 14 A 13 A GR G–Y 16 G–Y KSW LSR 5 W–B J20(A), J21(B) Junction Connector D A GR E A A A B B G–Y A B E B J18(A), J19(B) Junction Connector 10 1L L–R 22 1L L–B 15 1K W 11 1L L–R 23 1L L–B W 16 1L J18(A), J19(B) Junction Connector 2 1H L–R 6 1 4 C B GR M G–Y M 1 EA1 (∗1) 3 EA2 (∗2) 4 BB1 10 BK1 K B L L 2 K3 Unlock Warning SW W–B 4 BA1 D A 4 D21 Door Lock Detection SW Rear RH Door Lock Motor Rear RH 9 W–B D20 Door Lock Detection SW Rear LH Door Lock Motor Rear LH W–B W–B 9 (∗3) L–B 4 G–Y W 1 G2 Generator L L–R 6 (∗3) G–Y L–B B A 6 IC4 (∗4) 12 BB1 G–Y 11 BB1 (∗4) 10 BB1 J43(A), J44(B) Junction Connector 12 BA1 GR 11 BA1 J14(A), J15(B) Junction Connector 10 BA1 W 26 IE1 3 B15 Buckle SW LH 1 J53 Junction Connector (∗3) (∗4) J43(A), J44(B) Junction Connector W–B B B (∗3) A B W–B A B : 2UZ–FE : 1GR–FE : w/ Driving Position Memory : w/o Driving Position Memory W–B A A A A A (∗3) W–B (∗4) 1 BK1 W–B 1 2 3 4 W–B ∗ ∗ ∗ ∗ W–B A B J15(B) Junction Connector W–B W–B W–B W–B W–B 4 A J5 Junction Connector IG BL 205 4RUNNER (EM03M0U) Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU B 8(A), B 9(B) Back Door ECU 10 2 2 2 1F R B–R 1 A 6 BD1 7 BD1 BR–R 40 IE1 5 BD1 9 BD1 F E BR–R W–R MPX2 SIG 6 A B 8 1F BECU 5 A B–R 4 1B W–R 12 1F W–R BR–R 2 BDR 4 A L–R 11 30A POWER 10A ECU–B 10A ECU–IG SIG W–R BECU (BAT) L–O MPX2 23 A (BAT) L (IG) J39 Junction Connector F W–R B–R 206 4RUNNER (EM03M0U) E B 8(A), B 9(B) Back Door ECU 6 4 3 1 2 1 M 2 W–B 5 GND 3 A B10 Back Door Opener SW LG–R HSW– 22 B V–W HSW+ 10 B L–R ACT– 14 B L–B 10 BD1 W–B B7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW Back Door Lock Motor A A A A J40(A), J41(B) Junction Connector W–B A B BO W–B ACT+ 15 B B–R LSE 21 B BR–W POS 8 B G–Y FULL 7 B R–G HALF 6 B BL 207 4RUNNER (EM03M0U) Door Lock Control System Outline The door lock control is controlled through the various signal input into the body ECU through communication control of the body ECU etc. 1. Manual Unlock Operation When the door lock control SW of the driver’s or passenger’s side door is pushed to UNLOCK, the door will unlock. 2. Manual Lock Operation When the door lock control SW of the driver’s or passenger’s side door is pushed to LOCK, the door will lock. 3. Door Key Unlock Operation ∗ Unlock operation from driver’s side door When the driver’s side door is unlocked once using the ignition key, only the driver’s side door is unlocked. If this operation is repeated within 3 seconds, all the other doors are unlocked. 4. Ignition Key Reminder Operation When the door lock operation is made using the door knob with the ignition key remained inserted in the key cylinder and the door open, unlock operation is automatically made. Additionally, if lock operation is made with the door lock control SW or door key lock and unlock SW, unlock operation is automatically made after the lock operation has been completed. 5. Shift–Lever–Interlocked Auto Lock Control ∗ Auto lock operation The auto lock control automatically locks all the doors when the shift lever is put into other position than parking position with all the doors closed, the ignition switch ON, and the engine running. ∗ Auto unlocking operation The auto lock control automatically unlocks all the doors when the shift lever is put into parking position from other position with the ignition switch ON during traveling at a speed not exceeding 16 km/h. 6. Vehicle–Speed–Interlocked Auto Lock Control ∗ Auto lock operation control If any of the doors is not locked with the ignition switch ON and the engine running, the auto lock control automatically locks all the doors when the vehicle has gathered speed reaching or exceeding 20 km/h. ∗ Unlocking prevention feature When the vehicle is traveling at a speed reaching or exceeding 20 km/h, the unlocking function is disabled. ∗ Auto lock repeat prevention feature Once auto lock is activated, auto lock operation cannot not be repeated until a door is opened or the ignition switch is turned OFF with the vehicle traveling at a speed not exceeding 16 km/h. 7. Door–Open/Close–Interlocked Auto Unlocking When the driver’s side door is opened within 10 seconds after the ignition switch is turned OFF, all the doors are unlocked automatically. ∗ When the battery terminal or fuse is disconnected for some reason, resetting to the initial status is necessary using the door lock control SW front LH (Driver’s seat master SW) in accordance with the following procedure: (1) Reconnect the battery terminal or fuse. (2) With the back door closed, operate the door lock control SW front LH (Driver’s seat master SW) for locking and unlocking. 208 4RUNNER (EM03M0U) : Parts Location Code B4 See Page Code See Page Code See Page A 36 D18 40 J35 38 B5 B 36 D19 40 J37 38 B6 C 36 D20 40 J38 40 40 D21 40 J39 B7 B8 A 40 B9 B 40 B10 B15 G2 40 32 (2UZ–FE) J40 A 40 34 (1GR–FE) J41 B 40 J43 A J44 B 40 J5 38 42 (*1) J6 38 43 (*2) J7 38 42 (*1) 43 (*2) 42 (*1) C8 A 37 J8 A 38 C9 B 37 J9 B 38 J53 42 (*1) C10 C 37 J14 A 38 K3 39 D12 40 J15 B 38 D13 40 J18 A 38 D14 40 J19 B 38 D15 40 J20 A 38 D16 40 J21 B 38 D17 40 J25 P1 S28 43 (*2) 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1E 1F See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1G 1H 1J 1K 1L : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) EA2 45 (1GR–FE) IA1 IA2 IC2 IC4 Joining Wire Harness and Wire Harness (Connector Location) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) IP1 IP2 * 1 : Power Seat * 2 : Manual Seat 209 4RUNNER (EM03M0U) Door Lock Control : Ground Points Code See Page Ground Points Location ED 44 (2UZ–FE) Left Bank Cylinder Head EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 210 4RUNNER (EM03M0U) Memo 211 4RUNNER (EM03M0U) Wireless Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU (BAT) (BAT) 50A J/B (ACC) 20A DR/LCK 7. 5A ACC ACC 22 2 TRLY HRLY HAZ GND2 18 17 8 16 14 1J 2 3 2 5 1 1 1C 8 1B L–W W 2 1H W 10 IF1 W W (∗1) 10 HAZ 8 EHW T9 Turn Signal Flasher Relay W R–B D2 Turn Signal Flasher Relay (∗2) W–B 9 1E G–W G–W TAIL Relay 2 (∗2) 2 L–W BDR1 12 2 2 3 2 5 1 HEAD Relay B 2 Battery 212 4RUNNER (EM03M0U) W–B B 4(A), B 5(B), B 6(C) Body ECU GND1 TOUT ILE 4 6 A 13 DCTY PCTY 23 B RLCY RRCY 11 B 24 B 12 B P–B P–L R–B (BAT) 37 IE1 6 IO3 H B 2 9 1K 2 1 P–L 1 D15 Door Courtesy SW Rear RH 2 1 G–R A A C A C A (Except Limited) 1 1D 13 1K 1 A (∗3) 1 B (∗4) DOOR ON OFF L2 Luggage Compartment Light DOOR ON OFF I20(A), (B) Interior Light R 2 3 1 G–R 3 1 D14 Door Courtesy SW Rear LH R W C B 2 A (∗3) 2 B (∗4) 3 A 3 B J12(A), J13(B) Junction Connector W (∗3) W(∗3) W(∗4) W(∗4) (∗3) 2 W(∗4) 5 GR–B W(∗3) 6 HORN Relay I17 Ignition Key Cylinder Light W (∗3) P–B 10 1E D13 Door Courtesy SW Front RH R–G W (∗3) W (∗3) W–G W (∗4) F A D12 Door Courtesy SW Front LH 8 1A R–B 7 1A J18(A), J19(B) Junction Connector R–Y 10A HORN E J6 Junction Connector J14(A), J15(B) Junction Connector E B B 1 W(∗4) W W(∗4) (∗3) R G–R ∗ ∗ ∗ ∗ W 1 2 3 4 : w/ Daytime Running Light : w/o Daytime Running Light : w/ Rear Seat Entertainment System : w/o Rear Seat Entertainment System (∗3) W(∗3) 9 1A 22 1J 6 1E R–W R–W W–B W–B 213 4RUNNER (EM03M0U) Wireless Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU MPX3 KSW 26 C J18(A), J19(B) Junction Connector B 3E BR–B 2 A 3D B 3E 1 T1 Theft Deterrent Horn W–B B–R W–R 2 A B J12(A) Junction Connector G–R A B G D A D A B–R G 1 W3 Wireless Door Lock Buzzer A 3D J20 Junction Connector Y–B C B 2 2 IN1 1 6 1B P–B +B1 10 W–R W–B IG T5 Theft Deterrent ECU B–R G–R 1 BR–B 29 B A MPX1 SH– E 5 31 J14(A), J15(B) Junction Connector HORN 10 1B E A 12 KSW 7 A B K3 Unlock Warning SW W–L +B2 BZR2 J15(B) Junction Connector B–R 3 A B G–Y 10 1K B B BZR 9 G–Y 28 1J B B BR–Y 8 1F B–R 10A SECU/HORN G–Y 10A ECU–IG BR–Y BR–Y (BAT) G–Y (IG) 14 C G–Y SIG 10 B–R W–B W–B B–R W–R B–R R–W R–W W–B W–B A A J24 Junction Connector II 214 4RUNNER (EM03M0U) A J5 Junction Connector B 4(A), B 5(B), B 6(C) Body ECU LSWD ACTD 10 A LSWP 30 A ACT+ ACT– LSR 23 24 5 9 1L 18 1L B–W 21 A L–B L–R W L–B L–R W L–B L–R 13 IA2 8 IA2 7 IP1 7 IP2 2 IP2 10 BA1 11 BA1 12 BA1 10 BB1 11 BB1 12 BB1 B–W W L–B L–R W L–B L–R 8 1 4 7 1 4 6 1 4 6 1 4 L–R 7 IA1 B–R 10 1L B 22 1L B–W 15 1K L–B 11 1L B–R 23 1L W–R 16 1L W 6 1L J38 Junction Connector 4 IP2 9 D20 Door Lock Detection SW Rear LH Door Lock Motor Rear LH M 9 W–B D19 Door Lock Detection SW Front RH Door Lock Motor Front RH W–B 8 M 4 BA1 4 BB1 W–B B D16 Door Lock Detection SW Front LH Door Lock Motor Front LH W–B W–B 7 M W–B M D21 Door Lock Detection SW Rear RH Door Lock Motor Rear RH W–B W–B B W–B W–B W–B W–B 4 IA2 W–R W–R B–R B–R R–W R–W A A A A J5 Junction Connector IG J37 Junction Connector IK 215 4RUNNER (EM03M0U) Wireless Door Lock Control B 4(A), B 5(B), B 6(C) Body ECU RDA PRG 4 B LMRY 3 B DRLP 12 C 3 A G–O D 38 IE1 39 IE1 41 IE1 J7 Junction Connector R R 10 IC4 1 IC3 R R R D V–Y L–R D G–O R 2 3 5 RDA PRG 10A DOME +B R L–R (BAT) 17 A 2 Door R D7 Door Control Receiver W–B 1 R W–B 2 2 C 8(A), C10(C) Combination Meter 2 E 16 C 5 A A A B DOME Relay 3 1 2 10 BD1 R A A J40(A), J41(B) Junction Connector A A 2 2 R–W W–B W–B W–B R F B J 8(A), J 9(B) Junction Connector H A W–R W–R B–R B–R R–W BO W–B W–B W–B BL 216 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU B 8(A), B 9(B) Back Door ECU (BAT) 23 A 11 BDR 4 A MPX2 BECU 1 A 5 A SIG GND 6 A 3 A W–B 30A POWER MPX2 BECU 2 (BAT) R L–R B 5 BD1 W–R B–R F E W–R W–R W–R BR–R W–R 7 BD1 BR–R 40 IE1 2 2 9 BD1 6 BD1 L–O 10A ECU–B L 12 1F L–O 4 1L BR–R 2 1F 4 1B F E B–R J39 Junction Connector W–R B–R W–B 217 4RUNNER (EM03M0U) Wireless Door Lock Control B 8(A), B 9(B) Back Door ECU B–R LSE 21 B L–R ACT– 14 B L–B ACT+ 15 B BR–W POS 8 B G–Y FULL 7 B R–G HALF 6 B 5 6 4 1 2 3 M B7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW Back Door Lock Motor 218 4RUNNER (EM03M0U) System Outline Door lock control (Lock and unlock), back window control (Back window open) and panic control (Theft alarm and flash) is performed by remote control, without the ignition key inserted in the door key cylinder, using low–power electrical waves emitted by a transmitter. 1. Normal Operation ∗ Lock operation When the lock SW on the transmitter is pressed, all the doors are locked. ∗ Unlock operation When the unlock SW on the transmitter is pressed once, only the driver door is unlocked. When the unlock SW is pressed again within 3 seconds, all the doors are unlocked. 2. Auto Lock Function When the door is not actually opened within 30 seconds after the door has been unlocked by the unlock SW on the transmitter, all the doors are automatically locked. If any of the following conditions are detected, the wireless door lock does not function. ∗ Any door is opened. ∗ The ignition key is inserted into the ignition SW. ∗ When the lock detection SW of all the doors are locked. 3. Wireless Door Lock Stop Function If any of the following conditions are detected, the wireless door lock does not function. Lock operation ∗ When any door is open (Door courtesy SW on) ∗ The ignition key is inserted into the ignition SW (Unlock warning SW on) ∗ Ignition SW is on Unlock operation ∗ Ignition SW is on 4. Buzzer Sound Function During lock operation, when the body ECU receives a lock signal from the door lock detection SW, the wireless door lock buzzer goes on once. During unlock operation, when the body ECU receives an unlock signal from the door lock detection SW, the wireless door lock buzzer goes on twice. With any door open, when the body ECU receives a lock signal from the transmitter, the wireless door lock buzzer goes on for approx. 10 seconds. If the door is closed, or ignition SW is on, or if the unlock signal is received from the transmitter while the buzzer is on, the buzzer stops. 5. Visual Confirmation of Lock or Unlock During lock operation, when the body ECU receives a lock signal from the door lock detection SW, the turn signal light is flashed once. During unlock operation, when the body ECU receives an unlock signal from the door lock detection SW, the turn signal light is flashed twice. 6. Remote Panic Operation Panic will function when doors are locked or unlocked, open or closed. When the panic button (Transmitter) is pushed once, interior lights light up, and theft alarm and horn sounds and turn signal light, headlights and taillight flash. Then, the panic or the unlock button (Transmitter) is pushed once more, interior lights are turned off, sounding and flashing will stop. Panic will not function when ignition key is in ignition key cylinder. 7. Repeat Function If the lock detection signal in response to the output signal is not received after the body ECU has output the lock signal, the lock signal is output again. 8. Buzzer Volume Control The volume of the wireless door lock buzzer can be set among 5 steps by operating the transmitter, when the ignition SW is off, any door open, and the ignition key is not in the ignition key cylinder. 9. Illuminated Entry Function When the body ECU detects the unlock state after the unlock operation has been made, it turns on the lights, such as the ignition key cylinder light and interior light for approx. 15 sec. If all the doors are locked during this operation, lighting is cancelled and the lights immediately fade out. 219 4RUNNER (EM03M0U) Wireless Door Lock Control : Parts Location Code B4 See Page Code See Page Code See Page A 36 D20 40 J20 38 B5 B 36 D21 40 J24 38 B6 C 36 I17 37 J37 38 A 40 J38 40 B 40 J39 B7 40 I20 B8 A 40 B9 B 40 J5 38 J40 A 40 C8 A 37 J6 38 J41 B 40 C 37 C10 J7 40 38 K3 39 D2 37 J8 A 38 L2 40 D7 40 J9 B 38 D12 40 J12 A 38 D13 40 J13 B 38 T5 39 D14 40 J14 A 38 T9 39 D15 40 J15 B 38 D16 40 J18 A 38 D19 40 J19 B 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1B 1C 1D 1E 1F 1H 1J 1K 1L 3D 3E : Connector Joining Wire Harness and Wire Harness Code IA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IA2 IC3 IC4 IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) IP1 IP2 220 4RUNNER (EM03M0U) T1 W3 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 221 4RUNNER (EM03M0U) Theft Deterrent B 4(A), B 5(B), B 6(C) Body ECU (BAT) (BAT) 50A J/B (ACC) 20A DR/LCK 7. 5A ACC ACC 22 BDR1 TRLY HRLY GND2 12 18 17 16 GND1 ILE 4 13 7 1A 8 1A 2 3 2 5 1 1 1C L–W 8 1B 2 1H W–B 9 1E W TAIL Relay 2 G–W L–W 2 G–W 2 W W (∗3) W (∗3) W (∗3) (∗4) W (∗3) W(∗3) W (∗3) W(∗4) DOOR 2 ON OFF 3 L2 Luggage Compartment Light DOOR W(∗3) 2 A (∗3) 2 B (∗4) ON OFF 3 A 3 B 1 A (∗3) 1 B (∗4) W R–B I20(A), (B) Interior Light W(∗4) W(∗4) 1 W W(∗4) 3 2 2 W(∗3) (∗3) W(∗4) 2 W(∗3) HEAD Relay W(∗4) 5 1 B 2 Battery 222 4RUNNER (EM03M0U) W–B B 4(A), B 5(B), B 6(C) Body ECU PCTY RLCY RRCY 24 B 11 B P–L DCTY 23 B P–B LMRY 3 A R–Y HAZ 8 37 IE1 6 IO3 DRLP 12 B 12 C J18(A), J19(B) Junction Connector 10A DOME H B 2 1 IC3 2 14 1J D2 Turn Signal Flasher Relay T9 Turn Signal Flasher Relay 1 R C 8(A), C10(C) Combination Meter P–L P–B R 16 C 2 R R–W 2 1 D15 Door Courtesy SW Rear RH 3 8 1 D14 Door Courtesy SW Rear LH EHW 2 1 D13 Door Courtesy SW Front RH D12 Door Courtesy SW Front LH HAZ 2 DOME Relay 5 W (∗2) 2 Door R 1 10 IF1 10 17 A R–B W R (∗2) W (∗1) R F A V–Y R R–B (BAT) R 6 1E ∗ ∗ ∗ ∗ 1 2 3 4 : w/ Daytime Running Light : w/o Daytime Running Light : w/ Rear Seat Entertainment System : w/o Rear Seat Entertainment System F B H A J 8(A), J 9(B) Junction Connector 10 IC4 9 1A D J7 Junction Connector W(∗3) D R W(∗4) W–B W–B 223 4RUNNER (EM03M0U) Theft Deterrent B 4(A), B 5(B), B 6(C) Body ECU SIG TOUT (BAT) 10 (Except Limited) G–R 6 A (IG) (BAT) 10A SECU/HORN 10A ECU–IG 10A HORN 8 1F 28 1J B–R B–R 2 10 1K G–R W–L W–G 2 5 3 HORN Relay 1 1D 13 1K IND E 25 29 DSWH 34 12 P–G SIND 7 GR–G 2 W–B GND 3 +B2 W–B 1 HORN GR–G 5 D3 Security Indicator Light T5 Theft Deterrent ECU 10 1E G–R E3 Engine Hood Courtesy SW B 3F 4 W–B B 3F W–B B B 1 B 3F W–B C A J14(A), J15(B) Junction Connector C A P–G G–R GR–B 6 IC3 B–R B–R W–B W–B J24 Junction Connector A W–B A II 224 4RUNNER (EM03M0U) W–B W–B W–B EB B 4(A), B 5(B), B 6(C) Body ECU UL3 LSWD ACTD 12 A 21 A 10 A L–B L2 20 W–R KSW 14 C G MPX3 26 C LSWP 30 A B A KSW MPX1 IG T5 Theft Deterrent ECU B–R W–R A 3D B 3E C B G B–W 7 IA1 13 IA2 8 IA2 9 10 8 1 4 B 3E 2 D W–B 7 W–R D 8 IA1 M J12 Junction Connector A 3D G +B1 2 K3 Unlock Warning SW J20 Junction Connector 10 6 IA1 G–Y SH– L–R 31 B–W G–Y 12 B–R BR–Y 1 L–R W G–Y T1 Theft Deterrent Horn BR–B 1 B–W G BR–B E A L A B L A B J18(A), J19(B) Junction Connector G–Y B B 2 IN1 J14(A), J15(B) Junction Connector G–Y BR–B B B BR–Y 3 1K BR–Y D16 Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH Door Lock Motor Front LH B B–R W–B B–R B A B W–B A B J15(B) Junction Connector B–R J38 Junction Connector 4 IA2 W–B B–R W–B 1 W–R B–R B–R W–B W–B W–B W–B W–B W–B W–B W–B A A A A J5 Junction Connector IG 225 4RUNNER (EM03M0U) Theft Deterrent B 4(A), B 5(B), B 6(C) Body ECU BECU 11 9 1L 18 1L 16 1L 23 1L 11 1L 15 1K 22 1L 10 1L 4 1L 12 1F 4 1B L–R 6 1L W–R LSR 5 W–R ACT– 24 W–R ACT+ 23 L–B L–R W L–B L–R W L–B L–R 7 IP1 7 IP2 2 IP2 10 BA1 11 BA1 12 BA1 10 BB1 11 BB1 12 BB1 B B–R B–W W L–B L–R W L–B L–R B–W 7 1 4 6 1 4 6 1 4 B–W L–R W–R W–B 4 IP2 4 BA1 D20 Door Lock Detection SW Rear LH Door Lock Motor Rear LH M 9 W–B 9 W–B D19 Door Lock Detection SW Front RH Door Lock Motor Front RH W–B W–B 8 M D21 Door Lock Detection SW Rear RH Door Lock Motor Rear RH 4 BB1 W–R W–B M W–R B–R B–R W–B W–B W–B A A A J37 Junction Connector IK 226 4RUNNER (EM03M0U) B 8(A), B 9(B) Back Door ECU FULL POS LSE 7 B 8 B 21 B B–R HALF 6 B GND 3 A L L–R B 40 IE1 9 BD1 6 BD1 7 BD1 5 BD1 W–B R 30A POWER 2 2 SIG 6 A (BAT) 10A ECU–B 2 BECU 5 A BR–R (BAT) BDR 4 A BR–W MPX2 1 A G–Y MPX2 23 A R–G B 4(A), B 5(B), B 6(C) Body ECU 10 BD1 2 1F 4 3 W–B 6 B–R W–R L–O L–O 5 W–R BR–R B7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW F E F E W–R B–R J39 Junction Connector B–R W–B W–B W–R A A A A J40(A), J41(B) Junction Connector W–B A B BO BL 227 4RUNNER (EM03M0U) Theft Deterrent : Parts Location Code B4 See Page Code See Page Code 36 D19 40 B5 B 36 D20 40 J20 38 B6 C 36 D21 40 J24 38 32 (2UZ–FE) J37 38 34 (1GR–FE) J38 40 A 40 J39 B 40 J40 J41 B7 40 B8 A 40 B9 B 40 C8 A 37 C C10 E3 I20 J19 See Page A B 38 40 A 40 B 40 37 J5 38 D2 37 J7 38 K3 39 D3 37 J8 A 38 L2 40 D12 40 J9 B 38 D13 40 D14 40 J14 A 38 T5 39 D15 40 J15 B 38 T9 39 D16 40 J18 A 38 J12 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1B 1C 1D 1E 1F 1H 1J 1K 1L 3D 3E 3F : Connector Joining Wire Harness and Wire Harness Code IA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IA2 IC3 IC4 IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) IP1 IP2 228 4RUNNER (EM03M0U) T1 33 (2UZ–FE) 35 (1GR–FE) : Ground Points Code EB See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 229 4RUNNER (EM03M0U) ECT and A/T Indicator for 2UZ–FE D1 Data Link Connector 3 (BAT) (BAT) 10A ETCS 20A EFI CANH 13 14 2 P–L 2 TC CANL 6 2 2 J18 Junction Connector V P H 1 D 2 D J50(D), J51(E), J52(F) Junction Connector ST–Plug L W–G 5 12 IC4 2 E 13 IC4 L W–B 2 E A LG 35 IC4 2 1 E 1 A B 8 E 3 E 7 E P–L GR 2 2 L 3 W–G EFI Relay 2 BATT 34 D 33 D CANH +BM W–B MREL B C 3C P–L 1 F C 3C J29(A), J30(B) Junction Connector L GR P–L H 23 E TC CANL E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module +B 1 E +B2 2 E S1 S2 11 B 10 B SR 9 B SLT+ 13 B SLT– 12 B SLU+ 15 B SLU– 14 B A B R–B L–R P–L R–W B A B LG–B B GR W–L B 2 B B C A 13 SLT– 5 SLU+ SLU– BR SB B 6 SLT+ LG 14 SR GR 7 S2 W J31(A), J32(B) Junction Connector 10A EFI NO. 2 J 2(A), J 3(B) Junction Connector B A 15 S1 G 8 1 B W–B B 2 W–B 2 11 IC4 E1 Electronically Controlled Transmission Solenoid J4 Junction Connector A A L–W EB L–W 17 IC3 L–W 12 IM1 IH 230 4RUNNER (EM03M0U) L–W J28 Junction Connector C C L–W (BAT) 10A STOP 2 2 G–Y A24 Accel Position Sensor G–W 15 IC3 2 S12 Stop Light SW VPA1 VPA2 VCP1 VCP2 EP1 EP2 6 3 4 1 5 2 W–R R–B B–Y W–L LG–B V–W E 3C 1 G–Y G–Y J31(A), J32(B) Junction Connector G–Y E 3C B H A 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 J4 Junction Connector B R–B B–Y W–L LG–B V–W 18 E 19 E 26 E 27 E 20 E 21 E VPA VPA2 VCPA VCP2 EPA G–Y W–R E B 15 E EPA2 STP E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VG 30 A B–W Y–B 3 B 2 B 4 B OT2+ E2 +B 5 B 1 B M 1(B) Mass Air Flow Meter THA L–W OT2– 1 E2G BR L O OT– 2 THA 22 A 9 OT+ VG E1 Electronically Controlled Transmission Solenoid E2G 29 A W–R BR 10 SL2– E2 28 A L Y–G B–R 3 SL2+ THO2 32 B L L R 11 SL1– THO1 24 B O 4 SL1+ SL2– 16 B B–W B–Y G–B 12 SL2+ 17 B V SL1– 18 B Y SL1+ 19 B BR BR BR L–W 231 4RUNNER (EM03M0U) ECT and A/T Indicator for 2UZ–FE (ST) 7. 5A STA NO. 2 2 1K 4 2 L–Y P1 Park/Neutral Position SW N B–Y 5 6 IM2 J28 Junction Connector 1 T4 Turbine Speed Sensor 1 V11 Vehicle Speed Sensor (Electronically Controlled Transmission) P 2 A A B–Y STA Relay Y–R W–R L–Y R–L L–Y P B–Y A 35 B 27 B 34 B 26 B 12 C 8 B 11 C NT+ NT– SP2+ SP2– STSW STAR/ NSW STA E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module E01 E1 4WD E04 E05 1 C 8 C 7 B 6 B G R–L 6 4 2 1 2 VTA1 VTA2 M+ M– 5 VC E2 1 T2 Throttle Control Motor Throttle Position Sensor BR W 3 E2 Engine Coolant Temp. Sensor R R (Shielded) L–R 7 A W–B E03 4 B W–B E02 6 A W–B ME01 3 B W–B THW 21 A W–B GE01 17 A W–B M– 4 A W–B M+ 5 A BR VTA2 19 A R–B VTA1 20 A Y VC 23 A BR ED 232 4RUNNER (EM03M0U) EE EE (IG) G–R ATL AT4 4 3 V 2 G ATD 5 B–L NSSD G 3C D 3C D 3E G 3C D 3C D 3E B A 10 D 9 D 20 D 2 L 4 G B–L 9 E IGSW G B B B V D B G–R B B D A J10(A), J11(B) Junction Connector J35(A), J36(B) Junction Connector A B B–O B B F A V D A J 8(A), J 9(B) Junction Connector G E A G B–L E A B A G G–R D 3C G–R J31(A), J32(B) Junction Connector B–O G 3C B–L B A B–L J 8(A) Junction Connector B–O B A AT2 9 W NSSL 10 G–R 11 1J P–L S6 Transmission Control SW 10A IGN E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module P W–B W–B OILW 29 D SPD 8 D R D 3 11 D 21 D 19 D R–Y EOM 35 D V–R EC 9 C L L V V G B W G W–B G A J29(A), J30(B) Junction Connector A A W–B A A J33(A), J34(B) Junction Connector R–Y A B V–R 1 IM2 P–L B–L J37 Junction Connector A V–R P IK 233 4RUNNER (EM03M0U) L H A G–W G–W H A H A A A A A C A C A L D B 2 1J R–Y V E B 234 4RUNNER (EM03M0U) B A B A C B I A G–B G–B Y–R J20 Junction Connector G–B A J35(A) Junction Connector R–Y J7 Junction Connector Y–R G–R R–Y R–Y G–W Y–R J25 Junction Connector H R–Y V A R–Y V L 2 J33(A), J34(B) Junction Connector L G–R P1 Park/Neutral Position SW Y–R G–W L J29(A), J30(B) Junction Connector L A G–W V J10(A), J11(B) Junction Connector E B F B V L J10(A), J11(B) Junction Connector ECT and A/T Indicator for 2UZ–FE (IG) 15A IG1 H 8 1J 2 IM1 A Y–R RB LL 2L DL NL RL PL 8 3 7 9 1 6 20 IM2 21 IM2 9 IM1 10 IM1 1 IM1 8 IM1 G–R V G–B C A C A 2 1L R–Y R–Y G–W W W G G L P–L P–L B–L B–L V–R V–R P P (IG) (BAT) J7 Junction Connector D 7. 5A GAUGE S28 Skid Control ECU with Actuator 10A DOME 2 SP1 D 2 12 J 8(A), J 9(B) Junction Connector R GR–R R R 4 1G 7 IC2 GR–R F B 16 C 4 B C 8(A), C 9(B), C10(C), C11(D) Combination Meter Speedometer 15 C 10 IC4 R R–L H A E A A/T OIL TEMP J 8(A), J 9(B) Junction Connector G–B G–B 4 3 2 L 18 D 17 D 16 D 15 D 14 D R–Y G–W W G L P–L B–L 5 B 13 C BR D 19 D V–R N 1 C G–B G–B R 20 D P 15 A P A B 1 1G R–Y G–W 7 IM1 11 1K G V–R W L B 3D BR P–L B–L B 3D V–R V–R P ED 235 4RUNNER (EM03M0U) ECT and A/T Indicator for 2UZ–FE System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock–up hydraulic pressure. The electronically controlled transmission, however, electrically controls the line pressure, throttle pressure, lock–up pressure and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls gear shift timing and lock–up timing in response to the vehicle’s driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection for each gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. Gear Shift Operation When driving, the engine warm up condition is input as a signal to TERMINAL THW of the engine control module from the engine coolant temp. sensor and the vehicle speed signal from vehicle speed sensor is input to TERMINAL SP2+ of the engine control module. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA1 and VTA2 of the engine control module as throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. Line Hydraulic Pressure Control The engine control module adjusts the line hydraulic pressure to the optimal level by controlling TERMINAL SLT+ of the module according to the engine torque data. This realizes the smooth gear shifting. 3. High Response Gear Shifting Control The engine control module performs the high response engine torque up control to control the ignition–timing lag as well as opening the electronic throttle when shifting down. By doing this, the gear shifting is performed in a short period of time. Moreover, the engine control module uses the orifice switching control, which optimizes the speed of applying and reducing the hydraulic pressure. And it realizes the fine shifting condition by applying and reducing hydraulic pressure slowly when the gear shifting shock is important and quickly when the high response is required. 4. Clutch Hydraulic Pressure Control The engine control module controls the clutch operation in the optimal timing and with the best hydraulic pressure according to the engine torque data and the number of the clutch revolution 5. Lock–Up and Flexible Lock–Up Control The engine control module carries out the lock–up control by controlling the TERMINAL SLU+ of the module according to the shift position, vehicle speed, throttle opening degree and running conditions. The engine control module also steadily keeps applying the lock–up clutch a delicate slippage to improve the transmission efficiency (Fuel efficiency) of the torque converter. 6. Stop Light SW Circuit If the brake pedal is depressed (Stop light SW on) when driving in lock–up condition, a signal is input to TERMINAL STP of the engine control module. The engine control module operates and cuts the current to the solenoid to release lock–up. 7. AI–Shift Control The engine control module judges whether the road is downslope or upslope by detecting the throttle opening degree or the vehicle’s speed. Moreover it can expect the winding roads by detecting the turning condition of the vehicle. The engine control module keeps unnecessary shifting up from the fourth gear from operating and carries out the automatic shifting down to the third gear in order to control the vehicle running according to the road conditions. The engine control module also reads the driver’s intention during driving from his (her) accelerating operation and the running conditions of the vehicle. As a result of that, ideal shifting patters for each driver are automatically selected without any switching operations. 236 4RUNNER (EM03M0U) : Parts Location Code See Page A24 Code 36 See Page J4 See Page J34 B 38 C8 A 37 38 J35 A 38 C9 B 37 J8 A 38 J36 B 38 C10 C 37 J9 B 38 C11 D 37 J10 A 38 J50 D 38 D1 37 J11 B 38 J51 E 38 E1 32 (2UZ–FE) J18 38 J52 F 38 M1 B 33 (2UZ–FE) E2 J7 Code 38 J37 38 32 (2UZ–FE) J20 38 E4 A 37 J25 38 P1 33 (2UZ–FE) E5 B 37 J28 38 S6 39 E6 C 37 J29 A 38 S12 39 E7 D 37 J30 B 38 S28 33 (2UZ–FE) E8 E 37 J31 A 38 T2 33 (2UZ–FE) J2 A 33 (2UZ–FE) J32 B 38 T4 33 (2UZ–FE) J3 B 33 (2UZ–FE) J33 A 38 V11 33 (2UZ–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1G 1J 1K 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1L 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC4 IM1 IM2 : Ground Points Code See Page Ground Points Location EB 44 (2UZ–FE) Front Left Fender ED 44 (2UZ–FE) Left Bank Cylinder Head EE 44 (2UZ–FE) Rear Side of Cylinder Block IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel 237 4RUNNER (EM03M0U) Charging W–L 2 AM1 IG1 4 L–Y B–R ACC L–Y 2 1C 6 1D 7 AM2 IG2 6 15A IG1 7. 5A GAUGE B–R R 4 1G I18 Ignition SW 2 R–L 2 20 1E B4 Body ECU Y–R W W–L ST2 2 15 C J1 Junction Connector 2 J18(A), J19(B) Junction Connector A A A A GR 1 E 16 A GR 140A ALT E B E Y–R GR 1 Charge C 8(A), C10(C) Combination Meter L 14 J1 Junction Connector 50A AM1 ∗ 1 : 2UZ–FE ∗ 2 : 1GR–FE D D J 8(A), J 9(B) Junction Connector 2 2 2 2 2 2 EA1 (∗1) 2 EA2 (∗2) 1 EA1 (∗1) 3 EA2 (∗2) 5 EA1 1 EA2 Y–R W Y–R 1 1 GR 30A AM2 7. 5A ALT–S 2 G A GR 1 B 4 B 2 B 2 L IG 1 A B B S Battery IC Regulator G 1(A), G 2(B) Generator 68 4RUNNER (EM03M0U) W GR B R W 6 IC4 Y–R G B : Parts Location Code See Page B4 36 C8 A 37 C10 C 37 G1 32 (2UZ–FE) A 34 (1GR–FE) Code G2 See Page B I18 J1 32 (2UZ–FE) Code See Page J8 A 38 34 (1GR–FE) J9 B 38 37 J18 A 38 33 (2UZ–FE) J19 B 38 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1C 1D 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1E 1G : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) EA2 45 (1GR–FE) IC4 46 Joining Wire Harness and Wire Harness (Connector Location) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 69 4RUNNER (EM03M0U) ECT and A/T Indicator for 1GR–FE D1 Data Link Connector 3 (BAT) (BAT) 10A ETCS 20A EFI CANH TC CANL 6 13 14 2 P–L 2 2 2 P V J18 Junction Connector H 2 D ST–Plug L 2 E W–G E A 13 IC4 L 2 8 E 3 E 7 E P–L GR 1 L A B W–G EFI Relay BATT 33 D +BM C A 7 14 SR B W S2 SLT– 12 B 6 SLT+ SLU+ 15 B 13 SLT– SLU– 14 B R–B P–L 15 S1 SLT+ 13 B R–W A B J31(A), J32(B) Junction Connector B B J 2(A), J 3(B) Junction Connector 10A EFI NO. 2 TC 5 SLU+ LG B GR B B A B SR 9 B L–R S2 10 B GR S1 11 B LG–B +B2 2 E SB +B 1 E 8 B A 23 E CANL G 2 2 1 34 D CANH E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module W–B 2 B MREL 2 W–L 3 SLU– BR 5 LG 12 IC4 W–B 35 IC4 2 C 3C P–L 1 E 1 F C 3C J29(A), J30(B) Junction Connector 1 D J50(D), J51(E), J52(F) Junction Connector L GR P–L H B W–B W–B 2 B 2 11 IC4 E1 Electronically Controlled Transmission Solenoid J4 Junction Connector A A L–W EB L–W 17 IC3 L–W 12 IM1 IH 238 4RUNNER (EM03M0U) L–W L–W (BAT) 10A STOP 2 2 G–Y A24 Accel Position Sensor G–W 15 IC3 2 S12 Stop Light SW VPA1 VPA2 VCP1 VCP2 EP1 EP2 6 3 4 1 5 2 W–R R–B B–Y W–L LG–B V–W E 3C 1 G–Y G–Y J31(A), J32(B) Junction Connector G–Y E 3C B H A 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 J4 Junction Connector B R–B B–Y W–L LG–B V–W 18 E 19 E 26 E 27 E 20 E 21 E VPA VPA2 VCPA VCP2 EPA G–Y W–R E B 15 E EPA2 STP E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module BR E2 28 A R–W R–B 3 A 2 A 4 A L OT2– 1 VG E2G THA +B E2 1 A 5 A BR M 1(A) Mass Air Flow Meter L OT2+ L–W 2 THA 22 A 9 OT+ OT– E1 Electronically Controlled Transmission Solenoid E2G 29 A R–Y 10 SL2– 30 A L Y–G B–R 3 SL2+ VG THO2 32 B O L R 11 SL1– THO1 24 B O 4 SL1+ SL2– 16 B B–W B–Y G–B 12 SL2+ 17 B V SL1– 18 B Y SL1+ 19 B BR BR BR L–W 239 4RUNNER (EM03M0U) ECT and A/T Indicator for 1GR–FE (ST) 7. 5A STA NO. 2 2 1K 4 2 L–Y P1 Park/Neutral Position SW N B–Y 5 4 IM2 J27 Junction Connector 1 T4 Turbine Speed Sensor 1 V11 Vehicle Speed Sensor (Electronically Controlled Transmission) P 2 B B B–Y STA Relay R–L L–Y L–Y 27 B 34 B 26 B 12 C NT+ NT– SP2+ SP2– B–Y Y–R 35 B P W–R B 8 B 11 C STAR/NSW STSW STA E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module E03 ME01 E1 E01 E02 3 B 1 C 7 A 6 A L B–L 6 4 2 1 2 VTA1 VTA2 M+ M– VC E2 W 3 1 T2 Throttle Control Motor Throttle Position Sensor BR 5 E2 Engine Coolant Temp. Sensor R P (Shielded) L–R 4 B BR E04 7 B BR E05 6 B BR THW 21 A W–B GE01 17 A W–B M– 4 A W–B M+ 5 A W–B VTA2 19 A G–W VTA1 20 A G–B VC 23 A BR EF 240 4RUNNER (EM03M0U) EE (IG) G–R S6 Transmission Control SW NSSL ATL AT4 AT2 ATD 10 4 3 5 2 W G D 3C D 3E G 3C D 3C D 3E J35(A), J36(B) Junction Connector E A E A G V B A D A F A V G B A B 9 E 10 D 20 D 9 D 2 4 L R D 11 D 21 D IGSW B–L G B–L G–R B B B–O D B E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module D A EOM 3 19 D OILW 29 D SPD 8 D R–Y V–R P V V R–Y G B G A J29(A), J30(B) Junction Connector J33(A), J34(B) Junction Connector A A L W–B B B J 8(A), J 9(B) Junction Connector B B A B V B–L G 3C J10(A), J11(B) Junction Connector B–L G 3C G J31(A), J32(B) Junction Connector G–R D 3C B A 35 D 9 J 8(A) Junction Connector B A B–O B A NSSD B–L G–R B–O 11 1J P–L 10A IGN W V–R W–B G P–L B–L J37 Junction Connector A V–R P IK L 241 4RUNNER (EM03M0U) V V G–W G–W H A A A A A C A C A E B L 242 4RUNNER (EM03M0U) B A B A C B I A D B 2 1J G–B G–B Y–R Y–R J20 Junction Connector G–B R–Y J7 Junction Connector A J35(A) Junction Connector G–W Y–R J25 Junction Connector G–R R–Y R–Y V H R–Y L A R–Y V H A J33(A), J34(B) Junction Connector L G–R P1 Park/Neutral Position SW 2 G–W L J29(A), J30(B) Junction Connector L Y–R R–Y V L H A J10(A), J11(B) Junction Connector E B F B A G–W L J10(A), J11(B) Junction Connector ECT and A/T Indicator for 1GR–FE (IG) 15A IG1 H 8 1J 2 IM1 A Y–R RB LL 2L DL NL RL PL 8 3 7 9 1 6 20 IM2 21 IM2 9 IM1 10 IM1 1 IM1 8 IM1 G–R V G–B C A C A 2 1L R–Y R–Y G–W W W G G L P–L P–L B–L B–L V–R V–R P P (IG) (BAT) J7 Junction Connector D 7. 5A GAUGE S28 Skid Control ECU with Actuator 10A DOME 2 D SP1 2 12 GR–R J 8(A), J 9(B) Junction Connector R R R 4 1G 7 IC2 GR–R F B 16 C 4 B C 8(A), C 9(B), C10(C), C11(D) Combination Meter Speedometer 15 C 10 IC4 R R–L H A E A A/T OIL TEMP J 8(A), J 9(B) Junction Connector G–B G–B 4 3 2 L 18 D 17 D 16 D 15 D 14 D R–Y G–W W G L P–L B–L 5 B 13 C BR D 19 D V–R N 1 C G–B G–B R 20 D P 15 A P A B 1 1G R–Y G–W 7 IM1 11 1K G V–R W L B 3D BR P–L B–L B 3D V–R V–R P EE 243 4RUNNER (EM03M0U) ECT and A/T Indicator for 1GR–FE System Outline Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock–up hydraulic pressure. The electronically controlled transmission, however, electrically controls the line pressure, throttle pressure, lock–up pressure and accumulator pressure etc. through the solenoid valve. The electronically controlled transmission is a system which precisely controls gear shift timing and lock–up timing in response to the vehicle’s driving conditions and the engine condition detected by various sensors. It makes smooth driving possible by shift selection for each gear which is the most appropriate to the driving conditions at that time, and by preventing downing, squat and gear shift shock when starting off. 1. Gear Shift Operation When driving, the engine warm up condition is input as a signal to TERMINAL THW of the engine control module from the engine coolant temp. sensor and the vehicle speed signal from vehicle speed sensor is input to TERMINAL SP2+ of the engine control module. At the same time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA1 and VTA2 of the engine control module as throttle angle signal. Based on these signals, the engine control module selects the best shift position for the driving conditions and sends current to the electronically controlled transmission solenoid. 2. Line Hydraulic Pressure Control The engine control module adjusts the line hydraulic pressure to the optimal level by controlling TERMINAL SLT+ of the module according to the engine torque data. This realizes the smooth gear shifting. 3. High Response Gear Shifting Control The engine control module performs the high response engine torque up control to control the ignition–timing lag as well as opening the electronic throttle when shifting down. By doing this, the gear shifting is performed in a short period of time. Moreover, the engine control module uses the orifice switching control, which optimizes the speed of applying and reducing the hydraulic pressure. And it realizes the fine shifting condition by applying and reducing hydraulic pressure slowly when the gear shifting shock is important and quickly when the high response is required. 4. Clutch Hydraulic Pressure Control The engine control module controls the clutch operation in the optimal timing and with the best hydraulic pressure according to the engine torque data and the number of the clutch revolution 5. Lock–Up and Flexible Lock–Up Control The engine control module carries out the lock–up control by controlling the TERMINAL SLU+ of the module according to the shift position, vehicle speed, throttle opening degree and running conditions. The engine control module also steadily keeps applying the lock–up clutch a delicate slippage to improve the transmission efficiency (Fuel efficiency) of the torque converter. 6. Stop Light SW Circuit If the brake pedal is depressed (Stop light SW on) when driving in lock–up condition, a signal is input to TERMINAL STP of the engine control module. The engine control module operates and cuts the current to the solenoid to release lock–up. 7. AI–Shift Control The engine control module judges whether the road is downslope or upslope by detecting the throttle opening degree or the vehicle’s speed. Moreover it can expect the winding roads by detecting the turning condition of the vehicle. The engine control module keeps unnecessary shifting up from the fourth gear from operating and carries out the automatic shifting down to the third gear in order to control the vehicle running according to the road conditions. The engine control module also reads the driver’s intention during driving from his (her) accelerating operation and the running conditions of the vehicle. As a result of that, ideal shifting patters for each driver are automatically selected without any switching operations. 244 4RUNNER (EM03M0U) : Parts Location Code See Page A24 Code 36 See Page J4 See Page J34 B 38 C8 A 37 38 J35 A 38 C9 B 37 J8 A 38 J36 B 38 C10 C 37 J9 B 38 C11 D 37 J10 A 38 J50 D 38 D1 37 J11 B 38 J51 E 38 E1 34 (1GR–FE) J18 38 J52 F 38 M1 A 35 (1GR–FE) E2 J7 Code 38 J37 38 34 (1GR–FE) J20 38 E4 A 37 J25 38 P1 35 (1GR–FE) E5 B 37 J27 38 S6 39 E6 C 37 J29 A 38 S12 39 E7 D 37 J30 B 38 S28 35 (1GR–FE) E8 E 37 J31 A 38 T2 35 (1GR–FE) J2 A 35 (1GR–FE) J32 B 38 T4 35 (1GR–FE) J3 B 35 (1GR–FE) J33 A 38 V11 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1G 1J 1K 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1L 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC4 IM1 IM2 : Ground Points Code See Page Ground Points Location EB 45 (1GR–FE) Front Left Fender EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block EF 45 (1GR–FE) Rear Side of Left Bank Cylinder Block IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel 245 4RUNNER (EM03M0U) Cruise Control for 2UZ–FE D1 Data Link Connector 3 (BAT) 10A ETCS CANL TC 6 14 13 P–L 2 CANH V 20A EFI P (BAT) 2 2 2 C 3C 2 E LG 13 IC4 L W–B 12 IC4 8 E 3 E 7 E P–L GR 1 L A B EFI Relay 33 D +BM TC SB 6 SLT+ E1 Electronically Controlled Transmission Solenoid IH 246 4RUNNER (EM03M0U) R–W 13 SLT– 5 SLU+ SLU– BR 14 SR SLU– 14 B R–B LG–B P–L W–L B W 7 S2 B C A 15 S1 SLU+ 15 B LG 8 SLT– 12 B L–R A B SLT+ 13 B GR GR A B SR 9 B 11 IC4 EB 23 E CANL G S2 10 B J31(A), J32(B) Junction Connector S1 11 B B +B2 2 E B +B 1 E W–B W–B B B 34 D CANH 2 B A B BATT E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module W–B 2 B MREL 2 J 2(A), J 3(B) Junction Connector 3 J29(A), J30(B) Junction Connector 1 E P–L 1 F 2 W–G 5 C 3C E A 35 IC4 2 2 D W–G W–G L 1 D ST–Plug J50(D), J51(E), J52(F) Junction Connector L GR P–L H J18 Junction Connector H (IG) S6 Transmission Control SW 15A IG1 NSSD 9 V D 3E A D 3E EP1 EP2 6 3 4 1 5 2 W–R R–B B–Y W–L LG–B V–W 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 7 D H V VCP2 2 A A A A Y–R VCP1 Y–R VPA2 J20 Junction Connector VPA1 P1 Park/Neutral Position SW A Y–R H 2 IM1 A Y–R W–R R–B B–Y W–L LG–B V–W A 18 E 19 E 26 E 27 E 20 E 21 E VPA VPA2 VCPA VCP2 EPA E B J29(A), J30(B) Junction Connector J7 Junction Connector A24 Accel Position Sensor V Y–R 9 IM1 V 8 1J V J25 Junction Connector 21 D EPA2 D E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VTA1 M– 4 A GE01 17 A E2 28 A EC EOM 35 D 9 C 1 IM2 G 2 1 M+ M– BR R 4 VTA2 VC A B A A A A W–B 5 J33(A), J34(B) Junction Connector R SL2– (Shielded) R–B 6 3 SL2+ M+ 5 A VTA1 Y L R 11 SL1– V 4 SL1+ Y 12 VTA2 19 A W–B 20 A W–B VC 23 A L–R B–R SL2– 16 B B–W SL2+ 17 B B–Y SL1– 18 B G–B SL1+ 19 B E2 W–B W–B A J37 Junction Connector E1 Electronically Controlled Transmission Solenoid T2 Throttle Control Motor Throttle Position Sensor W 3 IK 247 4RUNNER (EM03M0U) Cruise Control for 2UZ–FE (BAT) (IG) 10A STOP 10A IGN 2 2 23 1E G–Y C B–O J4 Junction Connector 3 S12 Stop Light SW 2 C B–O B–O G–W 15 IC3 11 1J 1 4 R–L J 8(A) Junction Connector G–Y E 3C B A B A B–O G–Y G–Y E 3C J4 Junction Connector J31(A), J32(B) Junction Connector B A H A J31(A), J32(B) Junction Connector B 11 IC3 B B B G–Y R–L B–O E B 15 E 16 E 9 E ST1– STP IGSW E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module E04 7 B E05 6 B E01 7 A E02 6 A E1 1 C CCS ME01 3 B 18 D 3 IK1 L–B V–R 10 IM2 BR L–B 8 D BR BR W–B W–B W–B W–B W–B W–B W–B BR PI SPD 2 D 4 LG E03 4 B 5 CCS ON–OFF ECC G B + RES – SET CANCEL V–R C13 Combination SW G A J29(A), J30(B) Junction Connector 4WD 8 C LG V–R BR EE ED 248 4RUNNER (EM03M0U) BR (IG) (BAT) 10A DOME 7. 5A GAUGE 2 2 R 4 1G J7 Junction Connector D 10 IC4 R R R–L D H A J 8(A), J 9(B) Junction Connector R F B 16 C Speedometer CRUISE LG V–R 5 B 13 C 4 B GR–R 11 A BR C 8(A), C 9(B), C10(C) Combination Meter 15 C 1 1G 7 IM1 V–R 11 1K GR–R 7 IC2 12 SP1 B 3D BR LG S28 Skid Control ECU with Actuator B 3D V–R V–R BR 249 4RUNNER (EM03M0U) Cruise Control for 2UZ–FE System Outline The cruise control system is a constant vehicle speed controller in which control of the switch on the instrument panel makes it possible to automatically adjust the opening of the engine throttle valve without depressing of the accel pedal. 1. Set Operation When the ON–OFF SW is turned on, the system starts preparations necessary for the cruise control and turns on the indicator light in the combination meter. 2. Set Speed Control When the – SET SW is operated with the cruise control main SW turned on during travelling, the constant vehicle speed is controlled. 3. Coast Control When the – SET SW is kept turned on during cruise control travelling, the engine control module controls the throttle valve to decelerate the vehicle. Every time the – SET SW is turned on instantaneously, the vehicle speed is decelerated approximately 1.5 km/h. 4. Accel Control When the + RES SW is kept turned on during cruise control travelling, the engine control module controls the throttle valve to accelerate the vehicle. Every time the + RES SW is turned on instantaneously, the vehicle speed is accelerated approximately 1.5 km/h. 5. Resume Control When the vehicle speed is above the low speed limit (Approximately 40 km/h, 25 mph) if the cruise control is cancelled, use of the + RES SW accelerates the vehicle to the speed level used before canceling the cruise control. 6. Manual Cancel Mechanism If any of the following signals is input during cruise control travelling, the cruise control is cancelled. ∗ The stop light SW is turned on. ∗ The CANCEL SW is turned on. ∗ The ON–OFF SW is turned off. ∗ Gear is shifted from D position to other positions than D. 7. Auto Cancel Operation ∗ If any of the following conditions are detected, the set speed is erased and the control is canceled. (1) Disconnection and/or short in the stop light SW (2) Malfunction in the vehicle speed signal (3) Malfunction in the electronic throttle parts (4) Malfunction in the stop light SW input circuit (5) Malfunction in the cancel circuit (6) The actual vehicle speed becomes –16 km/h slower than the set speed ∗ If the following condition is detected, the set speed is kept and the control is canceled. (1) The actual vehicle speed becomes slower than the minimum speed limit. 8. Overdrive Control Function Overdrive is sometimes cut off on gradients during cruise control driving. When end of climbing gradient is determined by throttle opening degree information after overdrive is canceled, control is reset to overdrive condition after overdrive resetting timer operation. Also, when overdrive is cut off during accelerator resuming control, control is reset to overdrive condition when accelerator resuming control is finished. 250 4RUNNER (EM03M0U) : Parts Location Code See Page A24 Code 36 J2 J3 See Page Code See Page A 33 (2UZ–FE) J32 B 38 B C8 A 37 33 (2UZ–FE) J33 A 38 C9 B 37 J4 38 J34 B 38 C10 C 37 J7 38 J37 38 C13 37 J8 A 38 J50 D 38 D1 37 J9 B 38 J51 E 38 E1 32 (2UZ–FE) J18 38 J52 F 38 E4 A 37 J20 38 P1 33 (2UZ–FE) E5 B 37 J25 38 S6 39 E6 C 37 J29 A 38 S12 39 E7 D 37 J30 B 38 S28 33 (2UZ–FE) E8 E 37 J31 A 38 T2 33 (2UZ–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1K 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Instrument Panel Wire and Instrument Panel Wire (Left Upper Side of the Glove Box) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC4 IK1 IM1 IM2 : Ground Points Code See Page Ground Points Location EB 44 (2UZ–FE) Front Left Fender ED 44 (2UZ–FE) Left Bank Cylinder Head EE 44 (2UZ–FE) Rear Side of Cylinder Block IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel 251 4RUNNER (EM03M0U) Cruise Control for 1GR–FE D1 Data Link Connector 3 (BAT) 10A ETCS CANL TC 6 14 13 P–L 2 CANH V 20A EFI P (BAT) 2 2 2 C 3C 2 E LG 13 IC4 L W–B 12 IC4 8 E 3 E 7 E P–L GR 1 L A B EFI Relay 33 D +BM TC SB 6 SLT+ E1 Electronically Controlled Transmission Solenoid IH 252 4RUNNER (EM03M0U) R–W 13 SLT– 5 SLU+ SLU– BR 14 SR SLU– 14 B R–B LG–B P–L W–L B W 7 S2 B C A 15 S1 SLU+ 15 B LG 8 SLT– 12 B L–R A B SLT+ 13 B GR GR A B SR 9 B 11 IC4 EB 23 E CANL G S2 10 B J31(A), J32(B) Junction Connector S1 11 B B +B2 2 E B +B 1 E W–B W–B B B 34 D CANH 2 B A B BATT E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module W–B 2 B MREL 2 J 2(A), J 3(B) Junction Connector 3 J29(A), J30(B) Junction Connector 1 E P–L 1 F 2 W–G 5 C 3C E A 35 IC4 2 2 D W–G W–G L 1 D ST–Plug J50(D), J51(E), J52(F) Junction Connector L GR P–L H J18 Junction Connector H (IG) S6 Transmission Control SW 15A IG1 NSSD 9 V D 3E A D 3E EP1 EP2 6 3 4 1 5 2 W–R R–B B–Y W–L LG–B V–W 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 7 D H V VCP2 2 A A A A Y–R VCP1 Y–R VPA2 J20 Junction Connector VPA1 P1 Park/Neutral Position SW A Y–R H 2 IM1 A Y–R R–B B–Y W–L LG–B V–W 19 E 26 E 27 E 20 E 21 E VPA VPA2 VCPA VCP2 EPA J25 Junction Connector V W–R A 18 E E B J29(A), J30(B) Junction Connector J7 Junction Connector A24 Accel Position Sensor V Y–R 9 IM1 V 8 1J 21 D EPA2 D E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VC VTA1 VTA2 20 A 19 A M+ M– 5 A 4 A GE01 17 A E2 28 A EOM 35 D SL2– W–B BR (Shielded) A B R 3 SL2+ 5 VC 6 4 2 1 VTA1 VTA2 M+ M– A A J33(A), J34(B) Junction Connector L B–R 11 SL1– V 4 SL1+ Y 12 R B–W B–Y G–B L–R 23 A L SL2– 16 B P SL2+ 17 B G–W SL1– 18 B G–B SL1+ 19 B W T2 Throttle Control Motor Throttle Position Sensor W–B E2 3 E1 Electronically Controlled Transmission Solenoid J37 Junction Connector A IK 253 4RUNNER (EM03M0U) Cruise Control for 1GR–FE (BAT) (IG) 10A STOP 10A IGN 2 2 B–O G–Y G–W 15 IC3 B–O J4 Junction Connector 3 S12 Stop Light SW 2 C C 11 1J B–O 23 1E 1 4 R–L J 8(A) Junction Connector G–Y E 3C B A B A B–O G–Y G–Y E 3C J4 Junction Connector J31(A), J32(B) Junction Connector B A H A B 11 IC3 J31(A), J32(B) Junction Connector B B B G–Y R–L B–O E B 15 E 16 E 9 E ST1– STP IGSW E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module E03 4 B E04 7 B E05 6 B ME01 3 B E01 7 A E02 6 A CCS E1 PI SPD 2 D 1 C 8 D 18 D J28 Junction Connector 10 IM2 3 IK1 BR L–B E 5 ECC CCS EF EE 254 4RUNNER (EM03M0U) + RES G A LG – SET V–R C13 Combination SW ON–OFF G B J29(A), J30(B) Junction Connector 4 LG V–R L–B BR BR BR BR BR W–B W–B W–B W–B E CANCEL V–R (IG) (BAT) 10A DOME 7. 5A GAUGE 2 2 R 4 1G J7 Junction Connector D 10 IC4 R R R–L D H A J 8(A), J 9(B) Junction Connector R F B 16 C Speedometer 13 C 4 B GR–R 5 B BR 7 IC2 1 1G 7 IM1 11 1K GR–R LG 11 A V–R CRUISE C 8(A), C 9(B), C10(C) Combination Meter 15 C V–R 12 SP1 B 3D BR LG B 3D V–R S28 Skid Control ECU with Actuator V–R EE 255 4RUNNER (EM03M0U) Cruise Control for 1GR–FE System Outline The cruise control system is a constant vehicle speed controller in which control of the switch on the instrument panel makes it possible to automatically adjust the opening of the engine throttle valve without depressing of the accel pedal. 1. Set Operation When the ON–OFF SW is turned on, the system starts preparations necessary for the cruise control and turns on the indicator light in the combination meter. 2. Set Speed Control When the – SET SW is operated with the cruise control main SW turned on during travelling, the constant vehicle speed is controlled. 3. Coast Control When the – SET SW is kept turned on during cruise control travelling, the engine control module controls the throttle valve to decelerate the vehicle. Every time the – SET SW is turned on instantaneously, the vehicle speed is decelerated approximately 1.5 km/h. 4. Accel Control When the + RES SW is kept turned on during cruise control travelling, the engine control module controls the throttle valve to accelerate the vehicle. Every time the + RES SW is turned on instantaneously, the vehicle speed is accelerated approximately 1.5 km/h. 5. Resume Control When the vehicle speed is above the low speed limit (Approximately 40 km/h, 25 mph) if the cruise control is cancelled, use of the + RES SW accelerates the vehicle to the speed level used before canceling the cruise control. 6. Manual Cancel Mechanism If any of the following signals is input during cruise control travelling, the cruise control is cancelled. ∗ The stop light SW is turned on. ∗ The CANCEL SW is turned on. ∗ The ON–OFF SW is turned off. ∗ Gear is shifted from D position to other positions than D. 7. Auto Cancel Operation ∗ If any of the following conditions are detected, the set speed is erased and the control is canceled. (1) Disconnection and/or short in the stop light SW (2) Malfunction in the vehicle speed signal (3) Malfunction in the electronic throttle parts (4) Malfunction in the stop light SW input circuit (5) Malfunction in the cancel circuit (6) The actual vehicle speed becomes –16 km/h slower than the set speed ∗ If the following condition is detected, the set speed is kept and the control is canceled. (1) The actual vehicle speed becomes slower than the minimum speed limit. 8. Overdrive Control Function Overdrive is sometimes cut off on gradients during cruise control driving. When end of climbing gradient is determined by throttle opening degree information after overdrive is canceled, control is reset to overdrive condition after overdrive resetting timer operation. Also, when overdrive is cut off during accelerator resuming control, control is reset to overdrive condition when accelerator resuming control is finished. 256 4RUNNER (EM03M0U) : Parts Location Code See Page A24 36 Code J3 See Page B Code 35 (1GR–FE) J33 J34 See Page A 38 B 38 C8 A 37 J4 38 C9 B 37 J7 38 C10 C 37 J8 A 38 J50 D 38 C13 37 J9 B 38 J51 E 38 D1 37 J18 38 J52 F 38 E1 34 (1GR–FE) J20 38 J37 38 P1 35 (1GR–FE) E4 A 37 J25 38 S6 39 E5 B 37 J28 38 S12 39 E6 C 37 J29 A 38 S28 35 (1GR–FE) E7 D 37 J30 B 38 T2 35 (1GR–FE) E8 E 37 J31 A 38 J2 A 35 (1GR–FE) J32 B 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1K 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Instrument Panel Wire and Instrument Panel Wire (Left Upper Side of the Glove Box) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC4 IK1 IM1 IM2 : Ground Points Code See Page Ground Points Location EB 45 (1GR–FE) Front Left Fender EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block EF 45 (1GR–FE) Rear Side of Left Bank Cylinder Block IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel 257 4RUNNER (EM03M0U) ABS, TRAC, VSC, Auto LSD, DAC and HAC (BAT) (BAT) (IG) 30A ABS SOL 40A ABS MTR 2 2 : 2UZ–FE : 1GR–FE 4WD : w/ Electric Modulated Air Suspension : w/o Electric Modulated Air Suspension 1 J4 Junction Connector G R L P B–O L–O 9 Y FRO Y–B FLO 8 Y–B C 2 A 2 B 31 A 18 A 4 A 3 A 17 A 1 B 38 A +BM1 FL+ +BS +BM2 FL– FR+ FR– 37 A FLO IG2 S15 Suspension Control ECU C 2 (∗3) 2 1 2 3 4 L–R 1 ∗ ∗ ∗ ∗ B–O Y–B A10 ABS Speed Sensor Front RH 23 1E A9 ABS Speed Sensor Front LH 2 (∗3) 2 10A IGN FRO S28(A), S29(B) Skid Control ECU with Actuator RL– PKB GND3 LBL 41 A 4 B 28 A GND1 1 A W–B A B A A A A 6 BC2 3 BC2 4 BE1 3 BE1 2 2 B W (∗4) W–B (∗4) B W–B A41 ABS Speed Sensor Rear RH A40 ABS Speed Sensor Rear LH W 1 P4 Parking Brake SW 1 BE1 W–B LG W–B 1 2 BE1 1 1 W–B EA EB BO 258 4RUNNER (EM03M0U) (∗1) LG A B 2 J 2(A), J 3(B) Junction Connector B B W–B W B (∗4) (Shielded) V (∗3) G (∗4) P (∗3) (∗4) R (∗4) (Shielded) B A W–B J 2(A), J 3(B) Junction Connector 1 1E W–B 2 BC2 W–B 1 BC2 2 1E B14 Brake Fluid Level Warning SW 5 BC2 (∗1) 8 IB2 W–B V 4 BC2 7 IB2 W 10 IB2 B 9 IB2 P W–B LG 19 A W RR– 5 A B RR+ 6 A V RL+ 20 A P GND2 32 A ADD H B 24 A L4 G B B 20 A IND2 F 9(A), F10(B) 4WD Control ECU J28 Junction Connector B 3F B 3F B 3F A B W–B A II 4RUNNER (EM03M0U) R–W P 6 2 44 A 17 IC2 A IK W–B Y–R C 8 IM1 A A HDCS 3 4 B 3F A J25 Junction Connector Y–R H A H A J20(A) Junction Connector Y–R Y–R (2WD) A E J7 Junction Connector E D5 Downhill Assist Control SW B A A B A A B J14(A), J15(B) Junction Connector 9 R–W EXI C J35 Junction Connector 2 Y–R 15A IG1 (2WD) 13 IC2 W–B G–B Y–R (2WD) T3 Transfer Shift Actuator G–B G–B G–B E A J 8(A) Junction Connector Y–R P1 Park/Neutral Position SW C A (4WD) 27 A E A (4WD) C A J18(A) Junction Connector E W–B F A 1 IC2 W–G STPO W–G G–B 1 W–B E A J1 Junction Connector (4WD) 3 G–B E W–B 12 IC2 D W–B NEO R–L 2 (4WD) A B R–L 10 A (4WD) 16 A R–L 7 A (4WD) 2 R–L 18 IC3 2 STOP LP CTRL Relay 4 (4WD) 2 IC2 LG D J37 Junction Connector 18 B EXI4 1 J24 Junction Connector C LG 2 R–L 21 A J20(A), J21(B) Junction Connector STP J31(A), J32(B) Junction Connector G–W (4WD) C F A G–R STP2 (4WD) 45 A G–R 3 (4WD) J4 Junction Connector G–R G–B 2 G–B 5 (4WD) A11 ADD Actuator J4 Junction Connector G–W 2 G–R W–L W–B (4WD) S12 Stop Light SW G–W 10A STOP (4WD) W–L EXI3 (4WD) 26 A J29(A), J30(B) Junction Connector 16 IM2 W–L G–Y B (4WD) GR (∗2) G–Y B W–L GR (∗2) G–Y 2 (4WD) C J28 Junction Connector 6 EC1 GR (∗1) (∗2) ADD GR GR (∗2) B (∗2) GR (∗2) (BAT) (IG) 8 1J 20 1E A 2 2 IM1 Y–R 14 A S28(A), S29(B) Skid Control ECU with Actuator P 43 A CSW 6 IC2 CDL 3 A42 Auto LSD SW 11 IM2 4 22 B W–B P1 W–B A J5 Junction Connector IG 259 ABS, TRAC, VSC, Auto LSD, DAC and HAC B–R (IG) R–Y R–B 10A ECU–IG R–Y R–B 15 IC2 4 IC2 R–Y R–B 28 1J B D B–R 12 1E R–W B–R J4 Junction Connector B–R V5 VSC Warning Buzzer 2 B R–W J4 Junction Connector F F J1 Junction Connector F 5 IC2 D IG1 R–W 46 A BZ R–B B–R 30 A R–Y GR–G 1 13 A 24 A 42 A D/G TS WFSE S28(A), S29(B) Skid Control ECU with Actuator R V–W 19 IC2 16 IC2 9 IC2 (∗2) L–W (∗5) (∗7) V–W L–W R 14 IM2 13 IM2 HDCW 33 A (4WD) VSCW 36 A 20 IC2 7 IC3 Y–R LG–R 18 IC2 LG–R B–L 8 IC2 B–L GR–R 7 IC2 GR–R B 11 IC2 B W 22 IC2 W WT 35 A BR–Y 15 A Y–R INFR IND 34 A L–W WA 29 A (4WD) BRL 3 B (∗6) SP1 12 A G–W CANH 11 A (2WD) CANL 25 A BR–Y(4WD) Y–R L–W(∗2) L–W(∗6) L–W(∗5) L–W(∗7) R LG–R B–L GR–R W–B W–B W–B W–B B W 260 4RUNNER (EM03M0U) B–R B–R R–Y R–Y R–B R–B R–W R–W ∗ ∗ ∗ ∗ ∗ ∗ 1 2 5 6 7 8 : 2UZ–FE : 1GR–FE 4WD : 2UZ–FE 2WD : 2UZ–FE 4WD : 1GR–FE 2WD : 1GR–FE (IG) (BAT) 7. 5A GAUGE 10A DOME 2 4 1G C 8(A), C 9(B), C10(C), C11(D) Combination Meter R R–L 2 15 C D J7 Junction Connector BRAKE D H A 17 C 20 C 4 D 19 A 4 B 13 C 16 C BR GR–R B–L LG–R R L–W(∗7) L–W(∗1) L–W(∗2) Y–R BR–Y(4WD) F B J 8(A), J 9(B) Junction Connector R ABS 18 C Slip VSC TRAC 12 A VSC OFF (4WD) AUTO LSD (2WD) DAC Speedometer R 10 IC4 R BR–Y(4WD) Y–R 12 IM2 L–W(∗2) L–W(∗6) 7 IM1 L–W(∗5) L–W(∗7) BR (∗1) (∗8) LG–R BR R B–L GR–R W–B W–B W–B W–B B B W W EE ED 261 4RUNNER (EM03M0U) ABS, TRAC, VSC, Auto LSD, DAC and HAC B–R R–Y R–Y R–B R–B R–W R–W R W (BAT) 10A ECU–B 2 W–R B–R 2 G A 4 1B J20(A) Junction Connector G A D A B 3E E B D A J12(A), J13(B) Junction Connector W–R B–R 4 1L GND CANL 11 3 1 2 CANL W CANH ESS 2 R B–R IG W–B B–R 5 IG1 B 1 BAT Y W–R 9 W–B S11 Steering Sensor B 3E 3 CANH Y1 Yaw Rate Sensor B W–B Y W–B B B W W 262 4RUNNER (EM03M0U) R–Y R–B R–W R R–Y W G A J18(A) Junction Connector R–W R–B R–Y G A 15 12 7 D1 Data Link Connector 3 WFSE TS CANH SIL V L LG CANL 34 P CANH 33 R CANL 14 W 6 E7 Engine Control Module 1 B 2 B 1 D 2 D 1 E 2 E 2 C 1 A 2 A Y B W J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector 1 F W–B 1 C B ST–Plug B Y B W IH 263 4RUNNER (EM03M0U) ABS, TRAC, VSC, Auto LSD, DAC and HAC System Outline 1. Normal Operation The VSC system helps prevent the vehicle from slipping sideways as a result of strong front wheel skid or strong rear wheel skid during cornering. The followings are two possible circumstances in which the tires exceed their lateral grip limit. The VSC system is designed to help control the vehicle behavior by controlling the engine output and the brake at each wheel when the vehicle is under one of the conditions indicated below. ∗ When the front wheels lose grip in relation to the rear wheels (Strong front wheel skid tendency). ∗ When the rear wheels lose grip in relation to the front wheels (Strong rear wheel skid tendency). 2. Electronic Brake–Force Distribution Skid control ECU with actuator distributes appropriate brake–force to front and rear wheels (Control of brake–force distribution to front and rear wheels) corresponding to the vehicle driving conditions. It also makes effective use of rear wheel brake–force to match the loading condition and decelerating of the vehicle, resulting in reducing brake pedal depression and ensuring effective braking. In braking during making a turn, the ECU controls appropriate brake–force distribution to right and left wheels (Control of brake–force distribution to right and left wheels) to ensure stability and braking of the vehicle. 3. Downhill Assist Control Operation The downhill assist control operation controls braking action of each wheel to help prevent an out–of–balance posture of the vehicle when descending a steep hill or traveling at a speed exceeding the threshold of wheel gripping capability. When the downhill assist control is in operation, the brake system controls vehicle speed within the range of 5 to 7 km/h. For the downhill assist control to be operative, all of the following conditions have to be met: ∗ Downhill assist control switch = ON ∗ Transfer L4 selected ∗ Vehicle speed is 5 km/h or more, but less than 25 km/h. ∗ Accelerator pedal OFF ∗ Brake pedal OFF 4. Hill–Start Assist Control Operation When starting on a steep hill for ascending, the hill–start assist control automatically puts the brake on momentarily when the driver switches from the brake pedal to the accelerator pedal, to help the driver start the vehicle safely and smoothly. Please bear in mind, however, that it activates the brake system only for 3 seconds. For the hill–start assist control to be operative all of the following conditions have to be met: ∗ Shift position = D, 2, or L ∗ No vehicle move due to wheel slip ∗ Vehicle speed > 0 km/h 5. Active TRAC (4WD) During rugged off–road driving, this function controls the engine output and the brake fluid pressure that is applied to the slipping wheel, and distributes the drive force that would have been lost through the slippage to the remaining wheels in order to achieve a LSD effect. 6. Auto LSD (2WD) Auto LSD fulfills the function of LSD by using the system of TRAC. It helps ensures to recover from run–off condition and to take off on roads with much travel resistance such as sand. 264 4RUNNER (EM03M0U) : Parts Location Code See Page 32 (2UZ–FE) A9 34 (1GR–FE) 32 (2UZ–FE) A10 Code See Page J2 A J3 B Code 35 (1GR–FE) See Page J35 33 (2UZ–FE) 38 J37 38 35 (1GR–FE) J47 A 38 34 (1GR–FE) J4 38 J48 B 38 A11 34 (1GR–FE) J5 38 J49 C 38 A40 40 J7 38 J50 D 38 A41 40 A42 B14 J8 A 38 J51 E 38 36 J9 B 38 J52 F 38 32 (2UZ–FE) J12 A 38 34 (1GR–FE) J13 B 38 33 (2UZ–FE) P1 35 (1GR–FE) C8 A 37 J14 A 38 P4 39 C9 B 37 J15 B 38 S11 39 C10 C 37 J18 A 38 S12 39 C11 D 37 J20 A 38 S15 39 D1 37 J21 B 38 D5 37 J24 38 E7 37 J25 38 J28 38 S28 A S29 B 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) F9 A 37 F10 B 37 J29 A 38 33 (2UZ–FE) J30 B 38 35 (1GR–FE) J31 A 38 V5 39 33 (2UZ–FE) J32 B 38 Y1 39 J1 J2 A T3 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1L 3E 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EC1 45 (1GR–FE) Engine Wire and Differential Wire (Near the Front Differential) IB2 46 Floor No.2 Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BC2 48 Frame Wire and Floor No.2 Wire (Under the Rear LH Seat) BE1 48 Frame Wire and Skid Control Sensor Wire (Right Side of No.5 Crossmember) IC2 IC3 IC4 IM1 IM2 265 4RUNNER (EM03M0U) ABS, TRAC, VSC, Auto LSD, DAC and HAC : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel IH 46 Instrument Panel Brace LH II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BO 48 Rear Pillar LH EE 266 4RUNNER (EM03M0U) Memo 267 4RUNNER (EM03M0U) AHC and Electric Modulated Air Suspension (BAT) (IG) D1 Data Link Connector 3 R–W 15 IC2 GR–G 4 IC2 22 BC2 17 BC2 11 BC2 R–Y G A F R–Y J4 Junction Connector 5 IC5 D B GR–G R–W B–R P–L R–B R–Y 18 A 10 C 6 C 5 C 20 C IG TC TS 4 22 A 23 A 21 A B BR–Y 2 D BR–W AIR SUS Relay 3 J1 Junction Connector 1 10A AIRSUS NO. 2 4 3 R–Y J18(A) Junction Connector H A 5 IB2 2 SHG 2 G A J4 Junction Connector 5 2 SHRL R–B 1 4 F SHB 1 H A P–L BR–Y L–Y BR–Y L–Y SIL 7 P–L 12 1E B–R 2 TS 12 BR–W 13 J18(A) Junction Connector TC 2 4 H15 Height Control Sensor Rear LH 10A ECU–IG R–B 50A AIR SUS 2 L–B RC SIL SBL2 SHRL SGL2 S13(A), S14(B), S15(C) Suspension Control ECU SLLO 20 BC2 21 BC2 12 BC2 P–G 4 2 1 2 1 W–B B B L1 Low Pressure Tank Valve H14 Height Control Motor P 3 W–B L–B P–G 7 A O B A RM– 26 A L–B J 2(A), J 3(B) Junction Connector W–B GR RM+ 25 A P 6 B O B 1 IB1 L–B W–B 1 BC1 W–B W–B EB 268 4RUNNER (EM03M0U) (BAT) (IG) H16 Height Control Sensor Rear RH 15A IG1 10A STOP SHRR 2 SHG 2 G–W 3 Y–R 20 1E 2 5 S12 Stop Light SW GR W G–R 2 18 BC2 1 4 STOP LP CTRL Relay 3 1 9 BC2 2 Y–R G–W 2 2 2 19 BC2 2 D E D E J1 Junction Connector SHB 1 2 20 A SBR2 24 A SHRR G–Y G–Y G–B B B E J4 Junction Connector LG G–B E LG GR W G–R Y–R 12 B 19 A SGR2 STP S13(A), S14(B), S15(C) Suspension Control ECU V LG L L–W G 13 BC2 15 BC2 10 IC5 9 IC5 11 IC5 V–W V LG L L–W G 1 3 1 3 LOSW 2 E HEIGHT CONTROL OFF GND 5 HSW H12 Height Control SW 2 3 H13 Height Control Compressor H17 Height Control Valve V–W 14 BC2 + MOD2 11 C 6 GND 1 C MOD1 12 C GND2 5 B A B A B A B A A A A J 2(A), J 3(B) Junction Connector TD 24 B W–B DNSW 15 B W–B UPSW 16 B W–B SLEX 8 A W–B SLRR 2 A H19 Height Control Mode Select SW SLRL 1 A W–B W–B W–B W–B W–B 4 W–B W–B W–B A BN J24 Junction Connector A II EB 269 4RUNNER (EM03M0U) AHC and Electric Modulated Air Suspension S28 Skid Control ECU with Actuator DCTY PCTY RLCY RRCY 23 24 11 12 37 IE1 6 IO3 8 C 9 C FLO 1 P–L 1 D15 Door Courtesy SW Rear RH LG 1 D13 Door Courtesy SW Front RH R–G 1 D12 Door Courtesy SW Front LH R–B F A D14 Door Courtesy SW Rear LH 12 IC5 P–B L–R L–O LG H B J18(A), J19(B) Junction Connector R–G R–B ACTY 20 P–L FRO 37 P–B FLO 38 R–Y STPO 16 B5 Body ECU 4 C FRO DOOR S13(A), S14(B), S15(C) Suspension Control ECU TACH E7 Engine Control Module VN LO NR HI BR–B Y–B Y 13 IC5 4 IC5 3 IC5 2 IC5 1 IC5 BR–B Y–B Y 16 C Y–G 17 C Y–G 18 C B–W 15 C B–W 13 B TACH J31(A), J32(B) Junction Connector B–W 1 F B B–W G A F A Y F A J 8(A), J 9(B) Junction Connector Y–B BR–B Y–G H B B–W 270 4RUNNER (EM03M0U) (IG) (BAT) 10A DOME R 7. 5A GAUGE 2 H A 4 1G 2 J 8(A), J 9(B) Junction Connector R R–L R F B C 8(A), C 9(B), C10(C) Combination Meter 16 C Tachometer J7 Junction Connector R 15 C R 10 IC4 D 13 C BR 6 B B–W OFF 5 A Y–G LO 4 A BR–B N 3 A Y–B HI 2 A Y Height Control R D 7 IM1 Y BR Y–B BR–B Y–G B–W ED 271 4RUNNER (EM03M0U) AHC and Electric Modulated Air Suspension System Outline ∗ The electric modulated suspension with height control is a system designed to maintain a constant vehicle height by means of an electro–pneumatic system in the rear suspension to cope with change in load such as passenger number and/or weight of cargo in the vehicle. With the three–height–control switch on the console, the driver can set the vehicle height from the three different height modes (High, normal and low): ”High mode” for rough terrain and ”Low mode” for passenger to get on/off, and for cargo to be loaded/unloaded. ∗ This system has five basic controls as shown below: ∗ Auto leveling control This control maintains a constant rear vehicle height regardless of change in load such as passenger number and/or weight of cargo in the vehicle. ∗ Vehicle height switchover control This control switches the height mode to the mode selected with the height control switch. ∗ High mode (+ 40 mm / 1.6 in.) ∗ Low mode ( – 20 mm / 0.8 in.) ∗ Speed sensing control Regardless of the initial setting of the vehicle height, ”High mode” or ”Low mode,” this control automatically switches the vehicle height mode to the optimum ”Normal mode” in the following conditions: ∗ When the vehicle speed reaches or exceeds 30 km/h with ”High mode,” or; ∗ When the vehicle speed reaches or exceeds 5 km/h with ”Low mode.” ∗ Subsequent control after ignition switch off After the ignition switch is turned OFF, this control lowers the rear vehicle height for passengers to get off, etc. ∗ Height control OFF control If the system is turned OFF with the vehicle height control switch, the vehicle can be jacked up or towed. : Parts Location Code See Page B5 Code See Page Code See Page 36 H14 40 J18 A 38 C8 A 37 H15 40 J19 B 38 C9 B 37 H16 40 C10 C 37 H17 40 J31 A 38 D1 37 H19 37 J32 B 38 D12 40 J1 D13 40 J2 D14 40 J3 D15 40 J4 E7 37 J7 H12 37 J8 A 38 H13 40 J9 B 38 See Page L1 40 A 33 (2UZ–FE) S12 39 B 33 (2UZ–FE) S13 A 39 38 S14 B 39 38 S15 C 39 Relay Blocks (Relay Block Location) 2 22 Engine Room R/B (Engine Compartment Left) 4 23 Engine Room R/B No.4 (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page 38 33 (2UZ–FE) : Relay Blocks Code J24 Junction Block and Wire Harness (Connector Location) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1G 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 272 4RUNNER (EM03M0U) S28 33 (2UZ–FE) : Connector Joining Wire Harness and Wire Harness Code IB1 IB2 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Floor No.2 Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IC2 IC4 IC5 IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 48 Frame Wire and Floor No.2 Wire (Under the Rear LH Seat) BC1 BC2 : Ground Points Code See Page Ground Points Location EB 44 (2UZ–FE) Front Left Fender ED 44 (2UZ–FE) Left Bank Cylinder Head II 46 Instrument Panel Brace RH BN 48 Near the No.5 Crossmember of Side Frame LH 273 4RUNNER (EM03M0U) Multi Mode 4WD (IG) (IG) W–B W–B T3 Transfer Shift Actuator 13 1J 10 J7 Junction Connector Y–R 8 1J W–B 20A 4WD 15A IG1 6 GND GND A M M Y–R A HM1 HM2 HL1 HL2 TM1 TM2 TL1 TL2 TL3 V CDL 7 12 11 2 1 3 4 5 G L L–Y 17 B 26 B 2 B 5 B 25 B L–B GR 4 B L–W R–B 1 B 24 B 23 B (∗1) Y B L–R Y–R H B A R–L J25 Junction Connector 8 R–L H J28 Junction Connector J20 Junction Connector 9 A 6 A 22 B IG P1 HM1 HM2 HL1 HL2 TM1 TM2 TL1 TL2 TL3 Y–R F 9(A), F10(B) 4WD Control ECU N 2–4 22 A LO 8 A GND 15 A DL 16 A 1 A 2 IM1 2 2–4 (∗1) (∗1) GR (∗2) (∗1) GR (∗1) H4 4 L4 W–B H2 GND J33(A), J34(B) Junction Connector 4 A A W–B G–W A B A B A A W–B W–B F11 4WD Control SW 3 LO (∗1) G–W (∗2) D4 Diff. Lock SW 5 W–B L GR C B C A 10 IM1 II1 J14(A), J15(B) Junction Connector 9 6 II1 (∗1) L N J29(A), J30(B) Junction Connector P1 Park/Neutral Position SW 2 6 (∗1) (∗1) P Y–R G–W L (∗2) A J24 Junction Connector II J37 Junction Connector W–B A A IK 274 4RUNNER (EM03M0U) A A IG J5 Junction Connector 2 EC1 3 EC1 LG 1 EC1 1 DM1 C 2 DM2 6 DL1 5 DL2 F 9(A), F10(B) 4WD Control ECU E A 12 B DL2 H B J10(A), J11(B) Junction Connector BR–W 20 A IND2 11 A C 4 EC1 5 EC1 M 4RUNNER (EM03M0U) G–R G–R J20 Junction Connector J31(A), J32(B) Junction Connector G B ED G–R DL1 IND1 BR–W W–B 19 A (∗1) 13 B W–B 9 A (∗1) W–G 24 A (∗1) V–R G B J29(A), J30(B) Junction Connector G A (∗1) DM2 P–L SPD P–L 6 B (∗1) L4 (∗1) H B LG (∗1) B–W DM1 (∗1) 3 B B–W F A V–R G–R (∗1) ADD (∗1) W–L W–B 3 W–L W–L E6 Engine Control Module W–L L4 (∗2) 6 EC1 (∗1) R GR (∗1) ADD R GR (∗1) 18 B W–B GR (∗1) F A J28 Junction Connector W–L J29(A), J30(B) Junction Connector W–L W–B 13 ∗ 1 : 1GR–FE ∗ 2 : 2UZ–FE 2 IC2 15 IM2 V–R W–G G–R (∗1) F A E E IND3 W–B (∗1) 4 GND G–R A11 ADD Actuator BR–W EF 275 Multi Mode 4WD ∗ 1 : 1GR–FE ∗ 2 : 2UZ–FE W–L (BAT) 10A DOME 2 R 2 10 IC4 J7 Junction Connector J 8(A), J 9(B) Junction Connector R R H A V–R W–G D F B W–L (∗1) D R R 21 EXI4 SP1 C 9(B), C10(C), C11(D) Combination Meter 5 B V–R 4 B 13 C BR 12 Speedometer S28 Skid Control ECU with Actuator 16 C 1 1G GR–R 7 IC2 GR–R 7 IM1 BR B 3D (∗1) BR B 3D (∗2) V–R 11 1K V–R W–G(∗1) G–R G–R BR–W BR–W ED 276 4RUNNER (EM03M0U) EE (IG) 7. 5A GAUGE R–L 4 1G C 9(B), C10(C), C11(D) Combination Meter 4LO 6 D 7 D BR–W (∗1) W–G 5 D G–R (∗1) 4WD Center Diff. Lock (∗1) 15 C W–G(∗1) G–R BR–W 277 4RUNNER (EM03M0U) Multi Mode 4WD System Outline Depending on the transfer shift actuator status and ADD actuator (1GR–FE) status, the 4WD control ECU drives the transfer shift actuator and ADD actuator (1GR–FE) to electrically change the gear position selected by the driver according to vehicle speed signal and neutral start switch signal. 1. Shift Select Control Shifting from H2 into H4 position (1GR–FE) When the 4WD control switch is turned from H2 into H4, this signal is input into 4WD control ECU (TERMINAL 2–4). Then, the 4WD control ECU moves the 2–4 select motor (TERMINAL 2, TERMINAL 1) in the transfer shift actuator until the shift fork shaft shifts to the diff. free position, performing a shift into H4 position Switching diff. lock ON when in H4 position. When the diff. lock switch is turned ON with the 4WD control switch in H4 position, this signal is input into the 4WD control ECU (TERMINAL DL). Then, the 4WD control ECU drives the 2–4 select motor (TERMINAL 2, TERMINAL 1) in the transfer shift actuator until the shift fork shaft shifts to the diff. lock position, locking it in H4 position with the diff. lock. Shifting from H4 into L4 position When the 4WD control switch is turned from H4 into L4, this signal is input into 4WD control ECU (TERMINAL LO). Then, the 4WD control ECU drives the H–L select motor (TERMINAL 8, TERMINAL 7) in the transfer shift actuator, shifting the shift fork shaft, performing a shift into L4 position. Switching diff. lock ON when in L4 position. When the diff. lock switch is turned ON with the 4WD control switch in L4 position, this signal is input into the 4WD control ECU (TERMINAL DL). Then, the 4WD control ECU drives the 2–4 select motor (TERMINAL 2, TERMINAL 1) in the transfer shift actuator until the shift fork shaft shifts to the diff. lock position, locking it in L4 position with the diff. lock. 2. Function of Limit Switch H4L limit switch (TERMINAL 12 and TERMINAL 11 of transfer shift actuator) The H4L limit switch in the transfer shift actuator feeds back the current shift position status (H4 or L4) information, which is based on the ON/OFF combination of the two switches, to the 4WD control ECU. 4WD limit switch (TERMINAL 3 (1GR–FE), TERMINAL 4 and TERMINAL 5 of transfer shift actuator) The 4WD limit switch in the transfer shift actuator feeds back the current shift position status (H2 or H4) (1GR–FE) and diff. lock or diff. free status information, which is based on the ON/OFF combination of the two (2UZ–FE) or three (1GR–FE) switches, to the 4WD control ECU. ADD limit switch (TERMINAL 6 and TERMINAL 5 of ADD actuator) (1GR–FE) The ADD limit switch in the ADD actuator feeds back the current front diff. lock or free status information, which is based on the ON/OFF combination of the two switches, to the 4WD control ECU. 3. Shift Limit Control The 4WD control ECU interrupts the shift select control and gives the driver a warning by means of buzzer (Integrated into the ECU) sound and blinking indicator light on the combination meter when the following shift change conditions exist. The warning, however, can be canceled when the 4WD control switch is canceled and the switch position is returned to the original position before the warning occurred. ∗ Shift change (1GR–FE) from H2 into H4 with vehicle traveling at a speed reaching or exceeding 100 km/h (Buzzer sound and blinking 4WD and center diff. lock indicator lights) ∗ Shift change from H4 into L4 with vehicle traveling at a speed reaching or exceeding 5 km/h but with the A/T shift position N range (Buzzer sound and blinking L4 indicator light) 4. ADD Actuator Control (1GR–FE) When switching over between H2 (2WD) and H4 (4WD), the 4WD control ECU controls the way in which power is supplied to the ADD motor in the ADD actuator, as shown below, to run the ADD motor in normal or reverse direction, thereby changing the status of the front diff. from free to lock, or vice versa. For locking front diff. For unlocking front diff. TERMINAL DM1 TERMINAL DM2 TERMINAL DM1 TERMINAL DM2 +B GROUND GROUND +B 278 4RUNNER (EM03M0U) : Parts Location Code See Page A11 Code See Page Code See Page 34 (1GR–FE) J9 B 38 J32 B 38 C9 B 37 J10 A 38 J33 A 38 C10 C 37 J11 B 38 J34 B 38 C11 D 37 J14 A 38 D4 37 J15 B 38 E6 37 J20 38 A 37 J24 38 B F9 F10 37 J25 38 F11 37 J28 38 J5 38 J29 A 38 J7 38 J30 B 38 38 J31 A 38 J8 A J37 P1 S28 T3 38 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1G 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1K 3D : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EC1 45 (1GR–FE) Engine Wire and Differential Wire (Near the Front Differential) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace LH) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IC2 IC4 II1 IM1 IM2 : Ground Points Code ED See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block EF 45 (1GR–FE) Rear Side of Left Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel EE 279 4RUNNER (EM03M0U) Memo 280 4RUNNER (EM03M0U) SRS NOTICE: When inspecting or repairing the SRS, perform service in accordance with the following precautionary instructions and the procedure, and precautions in the Repair Manual applicable for the model year. D Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. D Work must be started more than 90 seconds after the ignition SW is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may deploy.) D When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be cleared. So before starting work, make a record of the contents in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. Some vehicles have power tilt steering, power telescopic steering, power seat and power outside rear view mirror which are all equipped with memory function. However, it is not possible to make a record of these memory contents. So when the work is finished, it will be necessary to explain it to your customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each system, never use a back–up power supply from outside the vehicle. D Before repair, remove the airbag sensor if shocks are likely to be applied to the sensor during repair. D Do not expose the following parts directly to hot air or flame; D Even in cases of a minor collision where the SRS does not deploy, the following parts should be inspected; D Never use SRS parts from another vehicle. When replacing parts, replace with new parts. D For the purpose of reuse, never disassemble and repair the following parts. D If the following parts have been dropped, or have cracks, dents and other defects in their case, bracket, and connector, replace with new one. D Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits of the system. D Information labels are attached to the periphery of the SRS components. Follow the instructions of the notice. D After work on the SRS is completed, check the SRS warning light. D If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ Steering wheel pad Front passenger airbag assembly Side airbag assembly Curtain shield airbag assembly Seat belt pretensioner Center airbag sensor assembly Front airbag sensor assembly Side airbag sensor assembly Rear airbag sensor assembly 281 4RUNNER (EM03M0U) SRS CSL– 14 A 13 A VUCL 4 D 18 D ESCL CSR+ 19 D CSR– VUCR C17 Curtain Shield Airbag Squib RH S26 Side Airbag Squib LH ESCR 9 A ESCR 10 A ICL+ 7 D ICR+ 12 A ICR– (∗1) Y–G 2 (∗1) Y–R (∗1) (∗1) 8 D ICL– 1 2 Y–V Y–O (∗1) Y–V (∗1) 20 D 1 Y–O 2 1 (∗1) 1 (∗1) 4 (∗1) (∗1) G (∗1) R (∗1) 1 A CSL+ VUCR GR–R 2 LG–B CSR– 3 L–W CSR+ 1 (∗1) ESCL 4 (∗1) VUCL 2 LG–B CSL– 3 L–Y CSL+ 15 A C16 Curtain Shield Airbag Squib LH S19 Side Airbag Sensor Rear RH L–B S18 Side Airbag Sensor Rear LH 11 A SFL– SFL+ PR+ PR– 10 D (∗1) 6 E (∗2) 9 D 5 E Y PL– 7 A 1 B Y–B PL+ 8 A 2 B Y E2 28 C Y–B P2– 7 C W–B Y–O P2+ 8 C 1 2 1 2 Y–P Y–V P– 11 C 1 IU1 2 IU1 3 IU1 4 IU1 Y–P Y–B P+ 10 C Y–GR Y W–B 1 A 2 A 1 B 2 B IL1 L 2 D2– Y–GR 17 C D2+ Y–G 16 C Y–G 14 C GSW2 Y–R D+ 13 C E1 27 C Y–R D– 23 C L A30(A), A31(B), A32(C), A33(D), A34(E) Airbag Sensor Assembly 32 F/PS 2 1 4 Spiral Cable 3 E7 Engine Control Module P16 Pretensioner LH A36 Airbag Squib (Steering Wheel Pad) A48(A), A49(B) Airbag Squib (Front Passenger Airbag Assembly) IJ IH 282 4RUNNER (EM03M0U) P17 Pretensioner RH (IG) (IG) ∗ 1 : w/ Side Airbag ∗ 2 : w/o Side Airbag 10A SRS 15A IG1 B12 Buckle SW LH Seat Position Airbag Sensor 8 1J D3 Passenger Seat Belt Warning Light 1 2 4 H PAON P–AB IG+ 13 6 2 H Y–R 3 L–W V R–B 4 A 3 B 3 A (∗1) 8 B (∗2) Y–R A B–O G–Y G–R G–W A (∗1) (∗1) Y–G 2 Y–R 1 A Y–R VS S27 Side Airbag Squib RH Seat Position Airbag Sensor A GND 6 D 5 D SFR+ SFR– J20 Junction Connector B–O Buckle SW J7 Junction Connector Y–R 20 1L 2 A 7 B 5 C IG2 19 A 11 B LBE– LBE+ LSP+ J25 Junction Connector 25 C LSP– 1 C PAON P–AB A30(A), A31(B), A32(C), A33(D), A34(E) Airbag Sensor Assembly 1 +SR –SR 4 A15 Airbag Sensor Front RH A A A B W–B A14 Airbag Sensor Front LH J14(A), J15(B) Junction Connector BR–W 2 –SL ESL SSR+ 16 D 18 A SSR– 13 D VUPR 17 D ESR 15 D 2 4 1 3 2 SSL– VUPL ESL SSR+ SSR– 4 VUPR GR (∗1) P (∗1) LG (∗1) (∗1) L–Y (∗1) GR–L (∗1) P–L (∗1) LG–B (∗1) 3 SSL+ 1 ESR (∗1) B–W 1 +SL W–B BR 2 VUPL 16 A S16 Side Airbag Sensor Front LH S17 Side Airbag Sensor Front RH (∗1) W–R 3 L–W 1 IN2 R25 Roll Sensing of Curtain Shield Airbag Cutoff SW 2 IN2 SSL– 20 A (∗1) B–R 1 IC1 17 A IL1 B–R 1 2 IC1 SSL+ RMSW 21 C (∗1) BR–W –SR 20 C B–W +SR 9 C BR –SL 26 C W–R +SL 15 C A J5 Junction Connector IG 283 4RUNNER (EM03M0U) SRS ∗ ∗ ∗ ∗ (IG) 7. 5A GAUGE : w/ Side Airbag : w/o Side Airbag : w/ Power Seat (Front Passenger' s Seat) : w/o Power Seat (Front Passenger' s Seat) D1 Data Link Connector 3 R–L 4 1G 1 2 3 4 TC F G H 16 IO3 P–L R–Y F A 3A C 3C A 3A R–Y R–Y H J18 Junction Connector G SRS P–L B16(A), (B) Buckle SW RH R–Y 13 J35 Junction Connector SIL 7 R–Y C 8(A), C10(C) Combination Meter RSCA OFF 15 C 2 BI1 LA 19 C SIL TC L P–L 12 C GR R–Y 3 C C 3C 2 A 5 A 9 A DIA BGND BSW O 3(A), O 4(B) Occupant Classification ECU A30(A), A31(B), A32(C), A33(D), A34(E) Airbag Sensor Assembly B 1 BI1 4 BI1 FSR– FSR+ 4 A 8 A W W FSR– 2 D (∗1) 10 E (∗2) B FSR+ 1 D 3 E GND 3 A W–B RMIL B–Y (∗1) L–Y A 3A 6 C 2 A (∗3) 2 B (∗4) 1 A 1 B 2 C V 10 A W–B B W 3 BI1 BM 284 4RUNNER (EM03M0U) (IG) (BAT) 10A IGN 10A ECU–B 2 B–O O6 Occupant Classification Sensor Front RH 4 1B SGD1 SVC2 SIG2 SGD2 1 2 3 1 2 3 BR G W L O B 4 1L W–R SIG1 B A B B SVC1 7 B SIG1 1 B SGD1 12 B SVC2 8 B SIG2 SGD2 B–O 1 2 3 SVC4 SIG4 SGD4 O7 Occupant Classification Sensor Rear LH O8 Occupant Classification Sensor Rear RH BR 6 BI1 B–O 3 SGD3 5 BI1 15 IO3 14 IO3 B–O 2 SIG3 IG 7 A R BR 1 SVC3 +B 1 A W–R 4 B W–R 10 B B SGD4 6 B V SIG4 3 B W SVC4 9 B Y SGD3 5 B GR SIG3 B 3E 2 B O 3(A), O 4(B) Occupant Classification ECU SVC3 B 3E W–R 11 B J31(A), J32(B) Junction Connector B–O SVC1 R B J8 Junction Connector O5 Occupant Classification Sensor Front LH 2 W–R 11 1J 285 4RUNNER (EM03M0U) SRS System Outline ∗ The system reaches an ignition judgment to deploy the following device based on the signals received from the front airbag sensor and deceleration sensor. – Driver Airbag – Front Passenger Airbag – Seat Belt Pretensioner ∗ The system reaches an ignition judgment to deploy the following device based on the signals received from the side airbag sensors. – Side Airbags – Curtain Shield Airbags ∗ The dual–stage SRS airbag system has been used for the driver and front passenger airbags. This system controls the optimal airbag inflation by judging the extent of impact, seat position (driver seat) and whether or not the seat belt is fastened (driver seat) and information from the front passenger occupant classification system. ∗ The front passenger occupant classification system judges whether the front passenger seat is occupied by an adult or child (with child seat) or is unoccupied, according to the load applied to the front passenger seat and whether the seat belt is buckled. Based on the results, it restricts the deployment of the front passenger airbag, front passenger side airbag, and front passenger seat belt pretensioner. In addition, the system informs the driver of the result of the judgment through the use of the AIRBAG ON/OFF indicator lights. ∗ A Roll Sensing Curtain Shield Airbag system has been adopted in order to deploy the curtain shield airbags and the pretensioners, in the event that the vehicle rolls over. ∗ A Roll Sensing Curtain Shield Airbag cutoff SW is provided near the driver side to enable the driver to disable this system. ∗ The airbag sensor assembly transmits a signal to the engine control module in order to stop the fuel pump. : Parts Location Code See Page Code See Page Code See Page 32 (2UZ–FE) C17 40 34 (1GR–FE) D1 37 32 (2UZ–FE) D3 37 34 (1GR–FE) E7 37 A 36 J5 38 A31 B 36 J7 38 A32 C 36 J8 38 A33 D 36 J14 A 38 A34 E 36 J15 B 38 P16 41 A14 A15 A30 A36 O5 O6 O7 O8 42 (*1) 43 (*2) 42 (*1) 43 (*2) 42 (*1) 43 (*2) 42 (*1) 43 (*2) 36 J18 38 P17 41 A48 A 36 J20 38 R25 39 A49 B 36 J25 38 S16 41 A 38 S17 41 B 38 S18 41 38 S19 41 B12 42 (*1) J31 43 (*2) J32 A 42 (*1) B 43 (*2) C8 A 37 C10 C 37 B16 C16 J35 O3 O4 40 A B 42 (*1) 43 (*2) 42 (*1) 43 (*2) : Relay Blocks Code 2 See Page 22 * 1 : Power Seat Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) * 2 : Manual Seat 286 4RUNNER (EM03M0U) S26 S27 42 (*1) 43 (*2) 42 (*1) 43 (*2) : Junction Block and Wire Harness Connector Code 1B See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1L 3A 3C 3E : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC1 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IL1 47 Instrument Panel Wire and Instrument Panel Wire (Right Upper Side of the Glove Box) IN2 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IU1 47 Instrument Panel Wire and Instrument Panel Wire Assembly (Right Upper Side of the Glove Box) BI1 50 (*1) Floor Wire and Seat No.1 Wire (Under the Front RH Seat) 51 (*2) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel IH 46 Instrument Panel Brace LH IJ 46 Instrument Panel Brace RH BM 48 Floor Seat Crossmember RH * 1 : Power Seat * 2 : Manual Seat 287 4RUNNER (EM03M0U) Moon Roof B 5(B) Body ECU (BAT) DCTY 30A POWER PWS 23 B (IG) 10A ECU–IG 21 1 1A W–B B–R 6 1A W–B 3 1A L–O 15 1A W–B 11 1A L 13 1A 8 1 4 10 9 H B R–B F A J18(A), J19(B) Junction Connector R–B 2 1H W–B 2 1 E2 PWS +B IG D12 Door Courtesy SW Front LH E M5 Moon Roof Control ECU M+ M M– CLOSE SPD OPEN 6 5 4 3 UP SLIDE V LG GR 7 P7 Moon Roof Control SW 5 1A 1 1G E 2 W–B W–B A J5 Junction Connector IG 288 4RUNNER (EM03M0U) V–R ∗ 1 : 2UZ–FE ∗ 2 : 1GR–FE (IG) (BAT) 7. 5A GAUGE 10A DOME 2 4 1G R 2 R R–L 10 IC4 D J7 Junction Connector R D H A J 8(A), J 9(B) Junction Connector R F B 16 C Speedometer 15 C 13 C 4 B GR–R C 9(B), C10(C) Combination Meter BR 5 B GR–R V–R 7 IC2 7 IM1 12 SP1 ED BR (∗2) BR (∗1) V–R S28 Skid Control ECU with Actuator EE 289 4RUNNER (EM03M0U) Moon Roof System Outline Current is always applied from the POWER fuse to TERMINAL 10 of the moon roof control ECU. With the ignition SW turned on, the current flows to TERMINAL 9 of the moon roof control ECU. 1. Moon Roof Open/Close Operation For moon roof operation, there are moon roof control switches: ”Slide open/tilt down”; and ”Slide close/tilt up.” When a switch is pressed and held down for a certain period of time, one touch automatic operation takes place in accordance with the function of the switch. 2. Key–Off Operation Roof remains operable – until about 45 seconds elapse after the ignition SW is turned from ON to OFF or until the driver’s seat door is opened and closed, whichever first occurs. However, if an overload reverse operation was going on at that time, the key–off operation continues until it comes to an end. 3. Overload Reverse Operation The moon roof control ECU detects jamming of the moon roof by foreign material, if occurred, from abnormal motor speed signal and reverses the moon roof operation. 4. Deflector Control Function When the roof is slid fully open, the moon roof control ECU automatically adjusts the height of deflector in accordance with the vehicle cruising speed. ∗ When the battery terminal or fuse is disconnected, the roof position has to be reset to its initial position by the moon roof control SW in accordance with the following procedure: (1) Reconnect the battery terminal or fuse. (2) Turn ON the ignition switch. (3) Operate the moon roof control SW to open the roof halfway or more. (4) Then operate the moon roof control SW to fully close the roof. Do not release the switch for at least one second after the roof is fully closed. : Parts Location Code B5 See Page Code B 36 C9 B 37 J8 C10 C 37 J9 D12 40 J5 38 See Page J7 2 See Page 22 41 A 38 P7 41 B 38 J18 A 38 J19 B 38 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A 1G 1H See Page Junction Block and Wire Harness (Connector Location) 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IC2 IC4 IM1 See Page See Page M5 : Relay Blocks Code Code 38 Joining Wire Harness and Wire Harness (Connector Location) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) 290 4RUNNER (EM03M0U) S28 33 (2UZ–FE) 35 (1GR–FE) : Ground Points Code ED EE IG See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block 46 Left Kick Panel 291 4RUNNER (EM03M0U) Shift Lock (ACC) (BAT) (IG) 7. 5A ACC 10A ECU–IG 10A STOP 2 8 1K 28 1J B–R G–W 2 2 E 3C S12 Stop Light SW G J20 Junction Connector G–Y 15 IC3 B B–R 1 G–Y P G E 3C F 3E G–Y 6 7 ACC STP D IG 1 B–R W–B E 8 L–W KLS+ A 3D IJ1 L–W 1 B S6 Shift Lock Control ECU 12 B–R A 3D K3 Key Interlock Solenoid 4 B 3F 3 J15 Junction Connector W–B B 3F A W–B B 3F J5 Junction Connector A A IG W–B W–B W–B W–B A A D B–R P G–Y F 3E J4 Junction Connector J37 Junction Connector A IK A J24 Junction Connector II 292 4RUNNER (EM03M0U) J12 Junction Connector System Outline When the ignition SW is turned to ACC position the current from the ACC fuse flows to TERMINAL 6 of the shift lock control ECU. When the ignition SW is turned to ON position, the current from the ECU–IG fuse flows to TERMINAL 1 of the shift lock control ECU. 1. Shift Lock Mechanism If the brake pedal is depressed with the ignition SW set at ON (The stop light SW is on), the shift lock control ECU is activated, allowing the driver to change the shift lever to a position other than the P position. 2. Key Interlock Mechanism With the ignition SW at ON or ACC position, when the shift lever is put in P position, the current flowing from TERMINAL 12 of the shift lock control ECU to key interlock solenoid is cut off. This causes the key interlock solenoid to turn off (Lock lever disengages from LOCK position) and the ignition key can be turned from ACC to LOCK position. : Parts Location Code See Page Code See Page Code See Page J4 38 J20 38 S6 39 S12 39 J5 38 J24 38 J12 38 J37 38 J15 38 K3 39 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1J 1K See Page Junction Block and Wire Harness (Connector Location) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3C 3D 3E 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IJ1 47 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace RH) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel 293 4RUNNER (EM03M0U) Remote Control Mirror (ACC) (BAT) 7. 5A ACC 20A EFI 2 F 3E 8 1K F 3E 2 P P L 38 IC4 GR P 2 2 17 IA1 C L–W R24 Remote Control Mirror SW 3 ACC CUT Relay C 8 Operation SW Y–B M+ E 6 7 C B 2 2 W–G GR 30 IC4 16 IC3 W–G 3 W–B 4 1 GR Select SW Right /Down Left /Up Down VR 2 Y–B VL 5 L–Y HR 4 RH P–B LH G–R RH P–G HL Up Left Right B LH 2 J6 Junction Connector J38 Junction Connector C L–Y G–R L–R W–B 15 IA1 14 IA1 16 IA1 4 IA2 LG–R Y–B B LG–B C 16 IP1 15 IP1 17 IP1 2 3 1 3 2 1 MH MV M+ MV MH M+ M M M ACCR E8 Engine Control Module W–B L–R G–R L–Y Y–B P–B P–G 17 M A J5 Junction Connector M3 Remote Control Mirror LH M4 Remote Control Mirror RH IG 294 4RUNNER (EM03M0U) : Parts Location Code See Page Code See Page E8 37 J38 40 J5 38 M3 41 J6 38 M4 41 Code R24 See Page 41 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1K 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 3E 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code IA1 IA2 IC3 IC4 IP1 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : Ground Points Code IG See Page 46 Ground Points Location Left Kick Panel 295 4RUNNER (EM03M0U) Engine Control for 2UZ–FE B (ACC) (BAT) 7. 5A ACC (BAT) 20A EFI 15A A/F HEATER 2 2 8 1K L ACC P AM1 2 2 IG1 F 3E B–R W–G L F 3E B–R I18 Ignition SW P 2 1 2 3 3 2 L 3 2 2 2 B 2 2 B GR–B B B W–B 2 W W–G GR R 2 1 2 2 2 5 C/OPN Relay 5 B 5 1 GR–B 1 2 2 B–W 4 2 B 2 2 EFI Relay 3 2 A/F HEATER Relay 2 ACC CUT Relay L P 38 IC4 B–W B B–R R ST2 B–O W–G IG2 6 L 7 AM2 2 2 33 IC4 GR–B 10A EFI NO. 2 W–B 30A AM2 9 IC4 11 IC4 B 1 2 2 1 L–W 2 2 A J4 Junction Connector 4 IM1 B B A L–W J 2(A), J 3(B) Junction Connector B A L–W Battery B A 1 IB2 17 IC3 GR–B B L–W W–B W B A L–W W W–G EB 70 4RUNNER (EM03M0U) GR–B L–W 19 IM2 M 5 A B BO 2 IB1 B A B A B–O B–R FC +B 9 E 30 C 10 E 1 E B B B A A B 4RUNNER (EM03M0U) 2 E +B2 17 E ACCR A B A B C A 16 IC3 B–Y P1 Park/Neutral Position SW N STA Relay P A A 3 E 8 E 8 B 11 C MREL STAR/ NSW 26 A AIV2 2 1 J28 Junction Connector B–Y B–O P B–Y L V13 VSV (Air Switching Valve Bank 2) L–W FPR W–G C P 35 IC4 B A W–G W–G B 6 1D 12 IC4 B–R L IGSW 8 EA1 V12 VSV (Air Switching Valve Bank 1) L–W 11 1J GR–B BATT W–G B–W L B–R J31(A), J32(B) Junction Connector 23 1E G–R C L B–R B–R B 4 W–G 1 10A IGN B–O 2 B–O B–O B–W J31(A), J32(B) Junction Connector B–O 2 B–O 2 J 8(A) Junction Connector B–O 5 F14 Fuel Pump 5 IC4 B–R 2 W–B 4 J4 Junction Connector 3 W–B W–B B–R 2 B–R FUEL PUMP Relay 1 B–Y G–R 2 F8 Fuel Pump Resistor G–R 2 A A J40(A), J41(B) Junction Connector G–R B B 4 EB1 B–R 5 4 STA E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 27 A AIV1 2 1 B L–W L–W L–W L–W W W W–G L–W BL 71 Engine Control for 2UZ–FE B B B–R B–R B–R 1 2 2 I14 Injector No. 6 2 2 2 2 L W Y G R W BR A A J26 Junction Connector R–L 2 I16 Injector No. 8 B–R 1 I15 Injector No. 7 B–R 1 I13 Injector No. 5 1 I12 Injector No. 4 1 I11 Injector No. 3 1 I10 Injector No. 2 1 I9 Injector No. 1 B–R B–R B–R B–R 1 2 R–L B–R B–R B–R B–R B–R Combination Meter B–R 3 C 4 C 5 C 6 C 7 C 3 A 2 A R–L A 2 C # 10 # 20 # 30 # 40 # 50 # 60 # 70 # 80 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VPMP 5 E AIP PPMP 22 E 32 A W–L Canister Pressure Sensor R R–G O L4 Canister Pump Module 1 EB2 W–L Leak Detection Pump Vent Valve M 3 8 9 2 AIP 1 6 2 4 E2 16 IM2 22 IM2 7 IM2 VC L–R 3 BR L–R 42 IE1 L–R BR 43 IE1 BR W–B 9 IE1 W–B O 28 IE1 O 11 IE1 L–W R–G 17 IE1 R–G R R 1 A45 Air Pressure Sensor MPMP 6 E 4 EB2 3 EB2 L–R BR L–W L–W L–W L–R W–B L–W W W L–W BR ED 72 4RUNNER (EM03M0U) B B ∗ 1 : Shielded (ST) 7. 5A STA NO. 2 A24 Accel Position Sensor L–Y 12 C STSW OC2– R–B B–Y W–L LG–B V–W 2 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 V–W L–Y 14 C OC2+ EP2 5 LG–B Y–R 15 C OC1– EP1 1 W–L R–W 16 C OC1+ VCP2 4 B–Y LG 17 C VCP1 3 R–B P 6 IM2 VPA2 6 W–R 1 VPA1 W–R 1 2 C3 Camshaft Timing Oil Control Valve RH 2 C2 Camshaft Timing Oil Control Valve LH 2 1K 18 E 19 E 26 E 27 E 20 E 21 E VPA VPA2 VCPA VCP2 EPA EPA2 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VC VTA1 VTA2 20 A 19 A M+ M– 5 A 4 A GE01 VG THW 17 A 21 A 30 A E2G 29 A THA 22 A G 2 1 VTA1 VTA2 M+ M– 2 3 B 2 B 4 B R Y–B R 4 B–W R–B 6 W–R Y L–R (∗1) L–R R–L L–R 23 A THA E2 +B 5 B 1 B L–W 1 E2G BR T2 Throttle Control Motor Throttle Position Sensor M 1(B) Mass Air Flow Meter E2 3 W BR VC VG E2 Engine Coolant Temp. Sensor L–R 5 BR BR BR BR L–R L–R L–W BR BR L–W L–W D L–W J28 Junction Connector C C 12 IM1 C L–R W L–W D W BR 73 4RUNNER (EM03M0U) C C BR W 1 B 1 B D C 3 4 AF+ AF– 2 +B C C 1 HT D HA2A A1A+ 22 B 30 B 2 B 3 4 AF+ AF– 2 +B W–B 1 HT L–R E J28 Junction Connector J26 Junction Connector W 74 4RUNNER (EM03M0U) G G–W 3 IGT5 A1A– E IGT6 HA1A BR J28 Junction Connector E E E E 33 B OX2B 5 B 3 OX 1 HT 2 +B 4 E1 BR H8 Heated Oxygen Sensor (Bank 2 Sensor 2) IGT4 P A2A– 3 W B–L 3 (∗1) L–Y R–W R–Y R–W R–Y R–Y 2 2 2 2 2 2 I7 Ignition Coil and Igniter No. 7 I6 Ignition Coil and Igniter No. 6 I5 Ignition Coil and Igniter No. 5 I4 Ignition Coil and Igniter No. 4 I3 Ignition Coil and Igniter No. 3 R–W BR 31 B R–L L–W R–W 2 I2 Ignition Coil and Igniter No. 2 R–Y I1 Ignition Coil and Igniter No. 1 R–Y A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A2A+ BR IGT3 Y IGT2 (∗1) LG–B 3 L–W 2 B 23 B B–W LG 3 A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) E2 L IGT1 P R–Y 3 W 1 B W 28 A BR ACIS (∗1) 33 A R PRG BR 2 B V 1(B) VSV (ACIS) 34 A Y–R IGF1 L–W L–W V 2(B) VSV (Purge) Engine Control for 2UZ–FE B B ∗ 1 : Shielded R–Y R–W R–W 3 24 A 8 A 15 A 11 A 10 A 13 A 12 A 14 A IGT7 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module HT2B BR E (∗1) W–B L–R W–B W–B W–B L–W L–W B B (BAT) (BAT) 10A ETCS A32 Airbag Sensor Assembly R–W T8 Transponder Key Computer 10A STOP 2 2 2 2 E 3C 2 G–Y 15 IC3 B B 9 A 25 A IGT8 IGF2 F/PS IMO IMI G–Y 7 E 15 D 16 D 32 D E B G–Y GR L G–B J4 Junction Connector IL1 R–W 2 1 L–R W–R 13 IC4 3 H A E 3C J31(A), J32(B) Junction Connector 2 G–Y 7 G–W EFII 6 S12 Stop Light SW EFIO GR GSW2 23 L I8 Ignition Coil and Igniter No. 8 R–W G–Y 15 E +BM STP E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module L NE+ 21 C Y G NE– 20 C (∗1) R L VV2– 28 C 3 2 B 1 B 2 B C 4(B) Crankshaft Position Sensor 1 B W–B 1 V 4(B) VVT Sensor (Bank 2) 2 2 V 3(B) VVT Sensor (Bank 1) 4 VV2+ 18 C (∗1) 24 C W–B C1 Camshaft Position Sensor +B H6 Heated Oxygen Sensor (Bank 1 Sensor 2) E1 L–W HT BR OX VV1– 25 C (∗1) W 1 29 C B G–Y 3 VV1+ G2– 19 C Y G2+ HT1B 1 A B (∗1) OX1B 18 A 2 B 1 B L–R BR (∗1) W–B L–R W–B W–B W–B L–W ED 75 4RUNNER (EM03M0U) Engine Control for 2UZ–FE B B ∗ 1 : Shielded (BAT) (BAT) 2 50A J/B 10A TAIL 140A ALT 1 2 2 30A DEFOG 2 5 L–W 5 1L 1 G 2 DEFOG Relay 2 Y–G B J16 Junction Connector 1 1C 3 B 2 18 IC4 13 D 12 D E B B–R D B Y–G D 3D Y–G I B 3 J22(A), J23(B) Junction Connector I A G 2 D A J31(A), J32(B) Junction Connector D 3D G G 5 TAIL Relay 1 2 Y–G D A ELS2 ELS1 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module W–B W–B W–B W–B W–B 6 B L–B 7 B E05 W–B E04 W–B 1 IK1 E03 4 B W–B 2 IK1 E02 6 A W–B 8 C E01 7 A W–B 24 D E1 1 C W–B 4WD W–B AC1 W–B ACT 25 D (4WD) THWO 14 D W–B EKNK 28 B (4WD) KNK1 29 B GR–G EKN2 20 B BR–W KNK2 21 B J31(A), J32(B) Junction Connector R G (∗1) B W (∗1) H B L–B E A W–B 7 A K 2(B) Knock Sensor (Bank 2) K1 Knock Sensor (Bank 1) 1 2 B 1 B TWI 2 GR–G R C 3D BR–W 7 EB1 L–B 6 EB1 G B 3 EB1 (∗1) 8 EB1 BR 2 EB1 W (∗1) BR C 3D 18 A 7 B ACT AC1 A16(A), A17(B) A/C Control Assembly EE 76 4RUNNER (EM03M0U) EE B (BAT) F9 4WD Control ECU 50A A/PUMP L4 2 24 2 W–L J29(A), J30(B) Junction Connector (4WD) LG L P–L P–L H B E A J29(A), J30(B) Junction Connector G V Y (4WD) W–L F A 14 IC3 4 IC3 A B 5 IM2 4 E 13 E E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 4 B 5 B 1 A W 30 D SIP SIV VP +B BATT VV 2 A E 1 B BR 6 B L V–R TACH 1 D 3 B DI R–B SPD 8 D B–W EOM 35 D W–B BR EC 9 C W–B ME01 3 B 2 B AIDI G AIRV A43(A), A44(B) Air Injection Control Driver AIRP R V 25 E TC B Y 23 E CANH G G 33 D CANL Y P–L 34 D L4 V L 13 C LG W–L (4WD) 10 IC3 3 EA1 4 EA1 4 IN1 L BR W–B 1 2 W–B 1 A47 Air Switching Valve M W–B A A 2 A46 Air Pump A A J33(A), J34(B) Junction Connector W–B A B G 1 IM2 BR R–B B–W A ED J37 Junction Connector IK W–B BR V–R EQ 77 4RUNNER (EM03M0U) Engine Control for 2UZ–FE (BAT) 7. 5A OBD 2 2 LG L O P–L C 3C Y1 Yaw Rate Sensor 32 IC4 CANH H P V L LG 1 D 2 D 1 E 2 E E A 2 C 1 A 2 A 11 IC2 22 IC2 3 11 11 25 CANL CANH CANL CANH SP1 9 IM2 1 F S28 Skid Control ECU with Actuator 12 W–B BR BR S11 Steering Sensor J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector W–B 1 C W E A ST–Plug W W–B BR E B 2 B B CG 4 A A 1 B B SG 5 J35(A), J36(B) Junction Connector A A 6 CANH BR D1 Data Link Connector 3 BR CANL R 14 BAT Y V 16 TC J22(A) Junction Connector O 13 2 P P–L H CANL W 3 B J18 Junction Connector P–L C 3C GR–R GR–R R–B R–B B–W B–W V–R V–R A ED J5 Junction Connector IG IH 78 4RUNNER (EM03M0U) G A F B R–B 6 B 7 IC2 G A G B BR V–R Tachometer R F B 5 B 4RUNNER (EM03M0U) BR F A V–R Speedometer R R J7 Junction Connector J 8(A), J 9(B) Junction Connector 7. 5A GAUGE J29(A), J30(B) Junction Connector V–R H B J 8(A), J 9(B) Junction Connector B–W R–L H A V–R B–W 4 B GR–R Malfunction Indicator Lamp 15 C J31(A), J32(B) Junction Connector GR–R B–W GR–R 7 A R–B C 8(A), C 9(B), C10(C) Combination Meter (IG) (BAT) 10A DOME R 2 4 1G 2 D D 10 IC4 16 C 13 C 1 1G 11 1K 7 IM1 B 3D B 3D B–W V–R ED 79 Engine Control for 2UZ–FE System Outline The engine control system utilizes a microcomputer and maintains overall control of the engine, transmission etc. An outline of the engine control is given here. 1. Input Signals (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. The engine coolant temp. is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal to TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust emission is detected and is input as a control signal from the heated oxygen sensors to TERMINALS OX1B and OX2B of the engine control module. (4) RPM signal circuit The camshaft position is detected by the camshaft position sensor and is input into TERMINAL G2+ of the engine control module as a control signal. Also, the engine RPM is detected by the crankshaft position sensor and the signal is input into TERMINAL NE+ of the engine control module. (5) Throttle position sensor signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINALS VTA1 and VTA2 of the engine control module. (6) Vehicle speed circuit The vehicle speed sensor detects the vehicle speed, and the signal is input into TERMINAL SPD of the engine control module via the combination meter, from TERMINAL SP1 of the skid control ECU with actuator. (7) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the voltage for engine control module start up power supply is applied through the EFI relay, to TERMINALS +B and +B2 of the engine control module. The current from the IGN fuse flows to TERMINAL IGSW of the engine control module, and voltage is constantly applied to TERMINAL +BM. (8) Intake air volume signal circuit The intake air volume is detected by the mass air flow meter, and is input as a control signal to TERMINAL VG of the engine control module. (9) Stop light SW signal circuit The stop light SW is used to detect whether the vehicle is braking or not, and the signal is input into TERMINAL STP of the engine control module as a control signal. (10) Starter signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor when the engine is cranking is detected, and is input into TERMINAL STA of the engine control module as a control signal. (11) Engine knock signal circuit Engine knocking is detected by the knock sensors, and is input into TERMINALS KNK1 and KNK2 of the engine control module as a control signal. (12) A/C SW signal system The operating voltage of the A/C magnetic clutch is detected and input in the form of a control signal to TERMINAL AC1 of the engine control module. (13) Air fuel ratio signal system The air fuel ratio is detected by air fuel ratio sensor and input as a control signal into TERMINALS A1A+ and A2A+ of engine control module. 80 4RUNNER (EM03M0U) 2. Control System ∗ SFI system The SFI system monitors the engine condition through the signals input from each sensors to the engine control module. The control signal is sent to the engine control module TERMINALS #10, #20, #30, #40, #50, #60, #70 and #80 to operate the injector (Fuel injection). The SFI system controls the fuel injection by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals input from each sensors to the engine control module. The best ignition timing is decided according to this data and the data memorized in the engine control module. The control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5, IGT6, IGT7 and IGT8, and these signals control the igniter to provide the best ignition timing. ∗ Heated oxygen sensor heater control system The heated oxygen sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the heated oxygen sensors to improve their detection performance. The engine control module evaluates the signals from each sensors, and outputs current to TERMINAL HT1B or HT2B to control the heater. ∗ Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the air fuel ratio sensor to improve detection performance of the sensor. The engine control module evaluates the signals from each sensor, current is output to TERMINALS HA1A and HA2A, controlling the heater. ∗ Fuel pump control system The engine control module supplies current to TERMINAL FPR, and controls the operation speed of the fuel pump with the FUEL PUMP relay. ∗ ACIS The ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened and closed in accordance with the driving conditions to control the intake manifold length in two stages, for increased engine output in all ranges from low to high speeds. ∗ ETCS–i The ETCS–i controls the engine output at its optimal level in accordance with the opening of the accelerator pedal, under all driving conditions. ∗ Engine start control system The engine control module allows power to be supplied from the TERMINAL STAR/NSW to the STA relay via park/neutral position SW until complete combustion is confirmed by engine RPM after the detection of ignition SW ST signal by the TERMINAL STSW. With this arrangement, engine can be started without holding the ignition key in the ST position. At the same time, the TERMINAL ACCR is controlled so that the engine control module turns off ACC CUT relay, shutting off power to the accessories. ∗ VVT–i Controls the intake camshaft to an optimal valve timing in accordance with the engine condition. ∗ Air Injection System It is the system to improve exhaust control performance by activating catalyst at early stage, which is realized when air is pressed and sent into the exhaust pipe forcibly by the air injection pump at starting engine in cold condition. 3. Diagnosis System When there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. The malfunctioning system can be found by reading the code displayed on the malfunction indicator lamp. 4. Fail–Safe System When a malfunction has occurred in any system, there is a possibility of causing engine trouble due to continued control based on that system. In that case, the fail–safe system either controls the system using the data (Standard values) recorded in the engine control module memory, or else stops the engine. 81 4RUNNER (EM03M0U) Engine Control for 2UZ–FE : Parts Location Code See Page A12 A13 Code See Page Code See Page 32 (2UZ–FE) I3 33 (2UZ–FE) J33 A 38 32 (2UZ–FE) I4 33 (2UZ–FE) J34 B 38 A16 A 36 I5 33 (2UZ–FE) J35 A 38 A17 B 36 I6 33 (2UZ–FE) J36 B 38 A24 36 I7 33 (2UZ–FE) A32 36 I8 33 (2UZ–FE) J40 A 40 A 32 (2UZ–FE) I9 33 (2UZ–FE) J41 B 40 B A43 A44 J37 38 32 (2UZ–FE) I10 33 (2UZ–FE) J47 A 38 A45 32 (2UZ–FE) I11 33 (2UZ–FE) J48 B 38 A46 32 (2UZ–FE) I12 33 (2UZ–FE) J49 C 38 A47 32 (2UZ–FE) I13 33 (2UZ–FE) J50 D 38 C1 32 (2UZ–FE) I14 33 (2UZ–FE) J51 E 38 C2 32 (2UZ–FE) I15 33 (2UZ–FE) J52 F 38 C3 32 (2UZ–FE) I16 33 (2UZ–FE) 37 K2 33 (2UZ–FE) C4 B 32 (2UZ–FE) C8 A 37 J2 A 33 (2UZ–FE) C9 B 37 J3 B 33 (2UZ–FE) C10 C 37 J4 38 P1 33 (2UZ–FE) D1 37 J5 38 S11 39 E2 32 (2UZ–FE) J7 38 S12 39 A 38 S28 33 (2UZ–FE) B 33 (2UZ–FE) E4 I18 K1 B L4 M1 33 (2UZ–FE) 40 B 33 (2UZ–FE) A 37 J8 E5 B 37 J9 38 T2 E6 C 37 J16 38 T8 E7 D 37 J18 38 V1 B 33 (2UZ–FE) E8 E 37 J22 A 38 V2 B 33 (2UZ–FE) F8 32 (2UZ–FE) J23 B 38 V3 B 33 (2UZ–FE) F9 37 J26 38 V4 B 33 (2UZ–FE) F14 40 J28 38 V12 33 (2UZ–FE) H6 32 (2UZ–FE) J29 A 38 V13 33 (2UZ–FE) H8 32 (2UZ–FE) J30 B 38 Y1 39 I1 33 (2UZ–FE) J31 A 38 I2 33 (2UZ–FE) J32 B 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1C 1D 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1E 1G 1J 1K 1L 3C 3D 3E 82 4RUNNER (EM03M0U) 39 : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) 44 (2UZ–FE) Engine No.2 Wire and Engine Wire (Near the Starter) 46 Floor No.2 Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IK1 47 Instrument Panel Wire and Instrument Panel Wire (Left Upper Side of the Glove Box) IL1 47 Instrument Panel Wire and Instrument Panel Wire (Right Upper Side of the Glove Box) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) EB1 EB2 IB1 IB2 Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 IC4 IM1 IM2 IN1 : Ground Points Code See Page Ground Points Location EB 44 (2UZ–FE) Front Left Fender ED 44 (2UZ–FE) Left Bank Cylinder Head EE 44 (2UZ–FE) Rear Side of Cylinder Block EQ 44 (2UZ–FE) Near the Starter IG 46 Left Kick Panel IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 83 4RUNNER (EM03M0U) Cigarette Lighter (ACC) 10A CIG P–L 17 1L P–L 6 IR1 2 C6 Cigarette Lighter W–B 1 W–B 5 IR1 B 3F W–B B 3F A J24 Junction Connector II 296 4RUNNER (EM03M0U) : Parts Location Code See Page C6 37 Code J24 See Page Code See Page 38 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1L 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 3F 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code IR1 See Page 47 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cigarette Lighter Wiring Assembly (Rear Console) : Ground Points Code II See Page 46 Ground Points Location Instrument Panel Brace RH 297 4RUNNER (EM03M0U) Power Outlet for 12V (ACC) (BAT) 15A PWR OUTLET 7. 5A ACC 1 3 DC SKT Relay 2 5 2 1H 31 1J BR–R W–B 30 1J BR–R BR–R 27 IE1 2 2 P6 Power Outlet (Front) 1 P8 Power Outlet (Rear) A A A A B 3F A IG W–B W–B W–B A B J5 Junction Connector A W–B W–B B 3F J40(A), J41(B) Junction Connector W–B 1 J24 Junction Connector II 298 4RUNNER (EM03M0U) BL BO : Parts Location Code See Page Code See Page Code See Page J5 38 J40 A 40 P6 39 J24 38 J41 B 40 P8 41 : Junction Block and Wire Harness Connector Code 1H 1J 3F See Page Junction Block and Wire Harness (Connector Location) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code IE1 See Page 46 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel II 46 Instrument Panel Brace RH BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 299 4RUNNER (EM03M0U) Power Outlet for 115V (IG) (BAT) 15A AC115V INV 15A IG1 2 E Y–R C E A V Y–R A J1 Junction Connector 2 2 C 2 5 Y–R Y–R AC115V INV Relay 1 3 V 2 H 41 IC4 21 IC4 L H V–R V–R 6 IG 1 4 LG 14 IE1 15 IE1 1 IS1 2 IS1 A A J14(A), J15(B) Junction Connector LG R–W L AC2 7 LG 4 AC1 3 R–W IN 3 W–B E GND R–W M2 Main SW V9 Voltage Inverter IG W–B Y–R 16 IE1 1 A B P5 Power Outlet (115V) A B 4 J40(A), J41(B) Junction Connector J20 Junction Connector L 2 W–B J7 Junction Connector 20 1E Y–R 2 8 1J A B A A A W–B W–B W–B LG J5 Junction Connector IG BO 300 4RUNNER (EM03M0U) BL : Parts Location Code See Page J1 Code 33 (2UZ–FE) J14 35 (1GR–FE) J15 J5 38 J7 38 See Page B 38 M2 39 38 P5 39 40 V9 41 A J41 See Page 38 J20 J40 Code A B 40 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IS1 47 Instrument Panel Wire and Console Box Wire (Rear Console) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 301 4RUNNER (EM03M0U) Automatic Glare–Resistant EC Mirror with Compass (IG) 15A IG1 Y 2 1A 7 I19 Inner Mirror W–B 6 14 1A W–B 2 1H A J5 Junction Connector IG 302 4RUNNER (EM03M0U) : Parts Location Code See Page I19 Code 40 J5 See Page Code See Page 38 : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Ground Points Code IG See Page 46 Ground Points Location Left Kick Panel 303 4RUNNER (EM03M0U) Horn (BAT) 10A HORN 2 W–G 2 10 1E 1 5 HORN Relay 3 13 1K 1 1D J14(A), J15(B) Junction Connector GR–B G–R 2 C A GR–B 1 G–R 6 Horn SW 1 H9 Horn (High) B B C13 Combination SW 304 4RUNNER (EM03M0U) H10 Horn (Low) : Parts Location Code See Page C13 Code 37 H10 32 (2UZ–FE) H9 34 (1GR–FE) See Page 32 (2UZ–FE) J14 Code J15 See Page B 38 34 (1GR–FE) A 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1D 1E 1K See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 305 4RUNNER (EM03M0U) Electric Tension Reducer ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory (IG) 15A IG1 J20 Junction Connector 8 1J H Y–R Y–R H A A A Y–R Y–R 5 IE1 A Y–R J7 Junction Connector A J25 Junction Connector Y–R Y–R 7 IO3 1 1 T12 Tension Reducer Solenoid LH 2 V (∗2) V (∗1) V 2 T13 Tension Reducer Solenoid RH F A F A J43(A), J44(B) Junction Connector 12 BK1 J45(A), J46(B) Junction Connector I B G G (∗2) G (∗1) I B 5 5 B15 Buckle SW LH B17 Buckle SW RH 4 (∗2) J53 Junction Connector W–B (∗1) B A B J43(A), J44(B) Junction Connector (∗1) B W–B 4 W–B W–B A B A A A A W–B (∗2) W–B 1 BK1 W–B (∗1) BL BM 306 4RUNNER (EM03M0U) J45(A), J46(B) Junction Connector : Parts Location Code See Page Code 42 (*1) B15 43 (*2) J43 42 (*1) B17 43 (*2) J7 38 J20 38 See Page J25 38 A J44 B J45 A 42 (*1) 43 (*2) Code See Page J45 A J46 B 43 (*2) 42 (*1) 43 (*2) 42 (*1) J53 42 (*1) 43 (*2) T12 41 42 (*1) T13 41 : Junction Block and Wire Harness Connector Code 1J See Page 25 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) : Ground Points Code See Page Ground Points Location BL 48 Floor Seat Crossmember LH BM 48 Floor Seat Crossmember RH * 1 : Power Seat * 2 : Manual Seat 307 4RUNNER (EM03M0U) Power Seat for Driver’s Seat with Memory (BAT) (IG) (IG) 15A IG1 10A ECU–B 10A ECU–IG 2 2 Y–R B–R W–R 8 1F 8 1J 4 1B A J7 Junction Connector A P1 Park/Neutral Position SW J39 Junction Connector F 2 BK1 8 BK1 5 BK1 6 BK1 Y GR O W 2 3 B 7 B 4 B 8 B P IG Y–R 2 IM1 G–B Y–R 6 P 34 IE1 W–R C A 35 IE1 B–R G–B J25 Junction Connector G–B J18 Junction Connector 8 IM1 F E C A E G–B E R–B C G–B Y–R H J8 Junction Connector W–R E J35 Junction Connector G–B J20 Junction Connector B–R C H R–B Y–R G–B 12 1F DCTY SYSB P27(A), P28(B) Position Control ECU and SW FRV– 4 A G FRV+ 6 A B J18 Junction Connector Y F SLD– 3 A L R–B SLD+ 2 A 2 D12 Door Courtesy SW Front LH M 1 308 4RUNNER (EM03M0U) 2 M 1 P20 Power Seat Motor (Driver' s Seat Front Vertical Control) 1 P24 Power Seat Motor (Driver' s Seat Slide Control) R–B F (BAT) 30A D P/SEAT R–L 29 1J W–B 4 E 24 IE1 S30 Seat Memory SW M1 M2 P V 6 IE1 8 IE1 7 IE1 P V 9 BK1 LG LG 3 LG 2 R–L MRY 1 A LG 15 BK1 17 BK1 J53 Junction Connector A 16 BK1 V LG 2 B 6 B 5 A +B 2 P27(A), P28(B) Position Control ECU and SW W–B 2 J22(A), J23(B) Junction Connector E A Hold W–B Release W–B V B 4 1 J53 Junction Connector B W–B 2 B M D B L3 Lumbar Support Control SW (Driver' s Seat) 1 1 BK1 W–B M B 1 3 GND 1 A P21 Power Seat Motor (Driver' s Seat Lifter Control) 1 LFT– 9 A W LFT+ 7 A P23 Power Seat Motor (Driver' s Seat Reclining Control) P RCL– 10 A BR RCL+ 8 A 5 BL M 2 L5 Lumbar Support Control Motor (Driver' s Seat) W–B SW2 Y SW1 W MMRY W–B P 5 B LG LG A A J5 Junction Connector IG 309 4RUNNER (EM03M0U) Power Seat for Driver’s Seat with Memory System Outline ∗ In the power seat system, the position control ECU and SW receives the operation signal from the power seat control switch via infrared communication to operate each power seat motor and adjust the seat position. ∗ In the event that malfunction occurs during infrared communication, this system has a fail–safe function to only slide or recline the seat. ∗ This system has the following function: ∗ Manual slide operation ∗ Manual reclining control ∗ Manual front vertical control ∗ Manual rear vertical operation ∗ Driving position memory function : Parts Location Code See Page Code See Page Code See Page D12 40 J35 38 P20 42 (*1) J5 38 J39 40 P21 42 (*1) J7 38 J53 42 (*1) P23 42 (*1) J8 38 42 (*1) P24 J18 38 J20 38 J22 A 38 J23 B 38 J25 L3 L5 P1 38 P27 A 42 (*1) 42 (*1) P28 B 42 (*1) 43 (*2) 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1B 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1F 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH * 1 : Power Seat 42 (*1) 43 (*2) * 2 : Manual Seat 310 4RUNNER (EM03M0U) S30 39 Memo 311 4RUNNER (EM03M0U) P24 Power Seat Motor (Driver' s Seat Slide Control) M 1 1 2 M 1 M 2 312 4RUNNER (EM03M0U) 7 1 M 2 (∗1) W (∗1) 2 V Reclining P21 Power Seat Motor (Driver' s Seat Lifter Control) BR 3 (∗1) 5 P 10 (∗1) Front Vertical P23 Power Seat Motor (Driver' s Seat Reclining Control) G Slide (∗1) Down Up Rear Front Down 1 P20 Power Seat Motor (Driver' s Seat Front Vertical Control) 2 (∗1) 6 Up Rear Front LG (∗1) B B B 9 (∗1) Y (∗1) L R–L R–L Power Seat for Driver’s Seat without Memory (BAT) 30A D P/SEAT 29 1J 24 IE1 C A J43(A), J44(B) Junction Connector B B LG LG P18 Power Seat Control SW (Driver' s Seat) 4 Lifter 8 W–B (∗1) ∗ 1 : w/ Power Seat (Front Passenger' s Seat) W–B LG Hold Release W–B W–B A B A B 4 L5 Lumbar Support Control Motor (Driver' s Seat) Y W–B (∗1) W–B A B 1 W 2 (∗1) L3 Lumbar Support Control SW (Driver' s Seat) 5 3 1 M J43(A), J44(B) Junction Connector 2 W–B A A BL 313 4RUNNER (EM03M0U) Power Seat for Driver’s Seat without Memory : Parts Location Code J43 See Page A J44 Code 42 (*1) L3 43 (*2) L5 42 (*1) B L3 See Page 1J 42 (*1) 42 (*1) P23 42 (*1) 43 (*2) P24 42 (*1) 43 (*2) P18 42 (*1) 42 (*1) P20 42 (*1) See Page 25 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IE1 See Page 46 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) : Ground Points Code BL See Page 48 * 1 : Power Seat See Page P21 : Junction Block and Wire Harness Connector Code Code 43 (*2) Ground Points Location Floor Seat Crossmember LH * 2 : Manual Seat 314 4RUNNER (EM03M0U) Memo 315 4RUNNER (EM03M0U) Power Seat for Front Passenger’s Seat (BAT) 30A P P/SEAT G–R 32 1J G–R 2 IO3 C A J45(A), J46(B) Junction Connector LG B B 1 BR 4 W–B 2 1 M 2 3 P 6 Y Reclining 9 L Slide Rear Rear Front Front P19 Power Seat Control SW (Front Passenger' s Seat) 1 P26 Power Seat Motor (Front Passenger' s Seat Slide Control) M 2 P25 Power Seat Motor (Front Passenger' s Seat Reclining Control) A B W–B A A BM 316 4RUNNER (EM03M0U) J45(A), J46(B) Junction Connector : Parts Location Code See Page J45 A J46 B 42 (*1) Code J46 See Page B 43 (*2) 43 (*2) P19 42 (*1) 42 (*1) P25 42 (*1) Code P26 See Page 42 (*1) : Junction Block and Wire Harness Connector Code 1J See Page 25 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code IO3 See Page 47 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Floor Wire (Right Kick Panel) : Ground Points Code BM See Page 48 * 1 : Power Seat Ground Points Location Floor Seat Crossmember RH * 2 : Manual Seat 317 4RUNNER (EM03M0U) Seat Heater Y–R (BAT) (IG) W–B 20 1E 2 S4 Seat Heater SW LH 2 3 A IG C A 2 V Y 13 IE1 12 IE1 H 14 BK1 A R BR B (∗2) BR LG (∗1) 2 5 1 LG 24 IC4 G B R J43(A), J44(B) Junction Connector J25 Junction Connector (∗1) H B 2 (∗2) A Y H A 13 BK1 A (∗1) Y (∗2) V (∗2) V Y–R Y–R G A 25A SEAT HEATER J3 Junction Connector 4 H 1 B SW 2 Y–R 2 Y–R W–B 2 J20 Junction Connector Y–R RV 3 (∗1) 2 E 1 E Y–R C J7 Junction Connector 5 IG Relay 1 B–Y E J1 Junction Connector Y–R Y–R 8 1J W–B 15A IG1 140A ALT S24 Seat Heater LH F 3C 4 6 (∗1) W–B (∗2) W–B B (∗2) B C B J53 Junction Connector 10 IE1 B 9 IO3 (∗1) LG F 3C LG F 3C A B (∗1) A A (∗1) W–B 1 BK1 (∗2) J43(A), J44(B) Junction Connector W–B LG B A W–B 7 BK1 (∗2) LG (∗1) (∗2) LG LG W–B B LG EB BL 318 4RUNNER (EM03M0U) ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory Y–R 3 1 IG E RV SW H B G B 5 W–B H A W–B L G A R R 8 IO3 BR 18 IO3 1 B 3F B 3F B 3F B 3F S25 Seat Heater RH B A A A W–B A B J45(A), J46(B) Junction Connector C B W–B LG W–B 6 B 4 W–B J45(A), J46(B) Junction Connector L 4 R 2 S5 Seat Heater SW RH Y–R W–B LG A BM J24 Junction Connector II A J37 Junction Connector IK 319 4RUNNER (EM03M0U) Seat Heater : Parts Location Code See Page Code 33 (2UZ–FE) J1 35 (1GR–FE) J43 33 (2UZ–FE) J3 35 (1GR–FE) J7 38 J20 38 J24 38 J25 38 See Page J37 J44 38 A B J45 A J46 B 2 See Page 22 J53 42 (*1) S4 39 42 (*1) S5 39 43 (*2) S24 42 (*1) 42 (*1) S25 42 (*1) 43 (*2) 42 (*1) Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) See Page Junction Block and Wire Harness (Connector Location) 1E 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3C 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) : Ground Points Code EB See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BM 48 Floor Seat Crossmember RH * 1 : Power Seat 43 (*2) 43 (*2) : Junction Block and Wire Harness Connector Code See Page B 42 (*1) : Relay Blocks Code Code J46 * 2 : Manual Seat 320 4RUNNER (EM03M0U) Memo 321 4RUNNER (EM03M0U) Engine Control for 1GR–FE (ACC) (BAT) 7. 5A ACC (BAT) 20A EFI 15A A/F HEATER 2 2 8 1K L ACC P AM1 2 2 IG1 F 3E B–R W–G L F 3E B–R I18 Ignition SW P 2 5 1 2 3 3 2 2 L 3 2 2 2 B 2 2 B GR–B B B W–B 2 W W–G GR R 1 2 2 2 5 C/OPN Relay 5 1 GR–B 1 2 2 B–W 4 2 B 2 2 EFI Relay 3 2 A/F HEATER Relay 2 ACC CUT Relay L P 38 IC4 B–W B B–R R ST2 B–O W–G IG2 6 L 7 AM2 2 2 33 IC4 GR–B 10A EFI NO. 2 W–B 30A AM2 9 IC4 11 IC4 B 1 2 2 1 L–W 2 2 A J4 Junction Connector 4 IM1 B B A L–W J 2(A), J 3(B) Junction Connector B A L–W Battery B A 1 IB2 17 IC3 GR–B B L–W W–B W B A L–W W W–G EB 84 4RUNNER (EM03M0U) M 1 5 19 IM2 A B BO A B W–G 2 IB1 B A B A 12 IC4 35 IC4 3 E 8 E 8 B 11 C MREL STAR/ NSW 11 1J B–O B–R 9 E IGSW 30 C FPR 10 E 4RUNNER (EM03M0U) FC 17 E B B B A 16 IC3 B B–O N STA Relay P B B ACCR 1 E +B J27 Junction Connector B–Y L B–Y P1 Park/Neutral Position SW W–G B B–Y W–G B–R C A J31(A), J32(B) Junction Connector 23 1E W–G C P BATT GR–B 10A IGN Y–B C W–G 2 B–O B L 3 1H L B–R 5 IM1 B 4 6 1D B–O 2 B–R B–W J31(A), J32(B) Junction Connector B–O B–O B–W B–O 2 J 8(A) Junction Connector B–O 5 F14 Fuel Pump 5 IC4 B–R 2 W–B 4 J4 Junction Connector 3 W–B W–B B–R 2 B–R FUEL PUMP Relay 1 B–Y Y–B 2 F8 Fuel Pump Resistor Y–B 2 A A J40(A), J41(B) Junction Connector Y–B B–R B–R 5 4 STA E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 2 E +B2 A B A B GR–B B L–W L–W L–W L–W W W W–G BL 85 Engine Control for 1GR–FE (ST) B–R B–R B–R B–R 7. 5A STA NO. 2 B–R B–R 2 1 1 1 1 L–Y 1 R–L R–L 1 I14 Injector No. 6 B–R 2 I13 Injector No. 5 B–R 2 I12 Injector No. 4 B–R 2 I11 Injector No. 3 B–R 2 I10 Injector No. 2 B–R 2 I9 Injector No. 1 G Y L L–Y J27 Junction Connector D D R 4 IM2 B Combination Meter 2 1K 3 C 4 C 5 C 6 C 7 C 12 C R–L D 2 C # 10 # 20 # 30 # 40 # 50 STSW # 60 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module MPMP VPMP 6 E 5 E PPMP 22 E R R–G O L4 Canister Pump Module Canister Pressure Sensor Leak Detection Pump L–R 28 IE1 9 IE1 43 IE1 42 IE1 L–R 11 IE1 BR 17 IE1 W–B BR 4 W–B 2 O 6 O 1 R–G 9 R–G R 8 R 3 L–W Vent Valve M 17 IM2 22 IM2 7 IM2 L–W L–W L–R W–B L–W W W BR EF 86 4RUNNER (EM03M0U) ∗ 1 : Shielded B–Y W–L LG–B V–W 2 R–B EP2 5 W–R EP1 1 34 IC4 31 IC4 26 IC4 9 IC3 29 IC4 8 IC3 V–W 14 C OC2+ VCP2 4 LG–B 15 C OC1– VCP1 3 W–L L–R 16 C OC1+ VPA2 6 B–Y L–W 17 C VPA1 R–B L–B 1 G–Y 1 2 W–R 2 C2 Camshaft Timing Oil Control Valve LH C3 Camshaft Timing Oil Control Valve RH A24 Accel Position Sensor 18 E 19 E 26 E 27 E 20 E 21 E VPA OC2– VPA2 VCPA VCP2 EPA EPA2 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module G–W VTA2 19 A M+ M– 5 A 4 A GE01 VG THW 17 A 21 A 30 A E2G 29 A THA 22 A L B–L R–Y R–W R–B 4 2 1 2 3 A 2 A 4 A VTA2 M+ M– (∗1) 6 VTA1 R L–R P L–R L–R VTA1 20 A G–B VC 23 A BR W E2 +B 5 A 1 A BR BR BR THA L–W 1 3 E2G BR M 1(A) Mass Air Flow Meter E2 T2 Throttle Control Motor Throttle Position Sensor VG BR VC E2 Engine Coolant Temp. Sensor 5 L–R L–W 12 IM1 L–W L–R W W BR L–W 87 4RUNNER (EM03M0U) L–W L–W 1 A 2 +B BR A W A A 31 B 1 B 3 4 AF+ AF– 1 HT A1A+ 22 B 30 B 2 B 3 4 AF+ AF– 2 +B E W–R W–R W–R W–R W–R 2 2 2 2 2 IGT4 1 HT L–W 88 4RUNNER (EM03M0U) I6 Ignition Coil and Igniter No. 6 I5 Ignition Coil and Igniter No. 5 I4 Ignition Coil and Igniter No. 4 I3 Ignition Coil and Igniter No. 3 W–R 8 A 9 A 10 A 11 A 12 A IGT5 13 A IGT6 24 A A1A– HA1A BR E E J28 Junction Connector E L–R L–W 33 B OX2B 5 B 3 OX 1 HT 2 +B 4 E1 BR H8 Heated Oxygen Sensor (Bank 2 Sensor 2) L 3 L GR 3 B HA2A W–R (∗1) A2A– R–L IGT3 A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) IGT2 L LG–B 3 P 3 (∗1) LG W–R W–R BR 2 A 23 B B–W P–L 2 I2 Ignition Coil and Igniter No. 2 W–R I1 Ignition Coil and Igniter No. 1 W–R L–W 2 A A2A+ A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) E2 BR PRG Y IGT1 W BR Y–R 3 W 28 A G–Y ACIS (∗1) 34 A W–L 33 A BR V 2(A) VSV (Purge) 1 A L–W L–W V 1(A) VSV (ACIS) Engine Control for 1GR–FE ∗ 1 : Shielded W–R 3 IGF1 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module HT2B BR E (∗1) BR L–R J27 Junction Connector W L–W (BAT) (BAT) 10A STOP 10A ETCS A32 Airbag Sensor Assembly 2 2 T8 Transponder Key Computer 2 2 G–W G–Y GSW2 EFIO EFII 23 6 7 E 3C E 3C G–Y B GR 32 D 16 D F/PS IMI 15 D 15 IC3 E B B G–Y J4 Junction Connector IL1 L 2 L–R W–R 1 13 IC4 J31(A), J32(B) Junction Connector H A G–Y L GR S12 Stop Light SW 2 G–Y 7 E 15 E +BM IMO STP E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VV2+ 18 C NE– VV2– 28 C BR 21 C 2 A BR 1 A 3 A C 4(A) Crankshaft Position Sensor 3 A L 2 A Y G 1 A V 3(A) VVT Sensor LH (Bank 2) +B 2 R HT V 4(A) VVT Sensor RH (Bank 1) E1 4 1 H6 Heated Oxygen Sensor (Bank 1 Sensor 2) OX L–W 3 NE+ 20 C B VV1– 29 C W VV1+ 19 C (∗1) G HT1B 1 A W (∗1) OX1B 18 A BR 2 A 1 A L–R (∗1) L–R BR BR BR L–R BR BR L–W EE 89 4RUNNER (EM03M0U) Engine Control for 1GR–FE ∗ 1 : Shielded 2 (BAT) (BAT) 1 50A J/B 10A TAIL 140A ALT 30A DEFOG 2 2 2 1 3 2 DEFOG Relay 5 1L 5 Y–G L–W G 2 B J16 Junction Connector 1 1C 18 IC4 Y–G B 5 Y–G G TAIL Relay D 3D I A D A J31(A), J32(B) Junction Connector D 3D 2 D B–R D 1 J22 Junction Connector G 2 3 D B G Y–G I B 12 D 13 D ELS1 ELS2 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module E04 E05 BR–W GR–G BR H B J31(A), J32(B) Junction Connector W B (∗1) (∗1) G R (∗1) L–B W–B 6 B W–B 7 B W–B ME01 3 B W–B E03 4 B W–B E02 6 A W–B E01 7 A W–B E1 1 C W–B AC1 24 D BR ACT 25 D BR THWO 14 D BR EKNK 28 B BR KNK1 29 B BR KNK2 21 B BR EKN2 20 B 2 IK1 1 IK1 BR L–B E A C 3D 1 ED1 2 ED1 5 ED1 7 A 1 A K1 Knock Sensor (Bank 1) K 2(A) Knock Sensor (Bank 2) TWI 1 GR–G 2 2 A BR–W L–B W B C 3D (∗1) BR 4 ED1 G R (∗1) 6 ED1 18 A 7 B ACT AC1 A16(A), A17(B) A/C Control Assembly EE 90 4RUNNER (EM03M0U) EF F 9(A), F10(B) 4WD Control ECU (BAT) A11 ADD Actuator 24 A 7. 5A OBD ADD ADD L4 18 B 3 GR GR (4WD) (4WD) W–L 2 LG L 6 EC1 P–L C C O V P C 3C E A J29(A), J30(B) Junction Connector 32 IC4 C 3C P–L C (4WD) W–L F A GR J28 Junction Connector H B (4WD) J29(A), J30(B) Junction Connector (4WD) 2 LG L P–L GR (4WD) W–L (4WD) 34 D 33 D 23 E J18 Junction Connector A B 15 IM2 H 35 D SPD 8 D 14 TACH 1 D BAT BR R–B B–W V–R W–B CANH W SG J33(A), J34(B) Junction Connector 6 CANL 30 D 5 G–W P 16 TC D1 Data Link Connector 3 CG TAC 4 9 E A B 9 IM2 B–W EOM PSW 13 TC E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 10 C V CANH W–B CANL O 4WD J22 Junction Connector E 1 W–B BR A A B–W W–B R–B B–W A A J37 Junction Connector IK W–B V–R BR P2 Power Steering Oil Pressure SW L4 8 C P–L H 13 C EE J5 Junction Connector IG 91 4RUNNER (EM03M0U) Engine Control for 1GR–FE LG L V P Y1 Yaw Rate Sensor CANH CANL R P V L LG 2 W 3 1 B 2 B 1 D 2 D 1 E 2 E ST–Plug W 11 IC2 22 IC2 W 3 11 11 25 CANL CANH CANL CANH SP1 S11 Steering Sensor 1 F W–B B 2 A B 1 A Y 2 C B 1 C J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector S28 Skid Control ECU with Actuator 12 GR–R GR–R B–W B–W R–B R–B B–W B–W V–R V–R IH 92 4RUNNER (EM03M0U) 7 IC2 GR–R F B R–B V–R 6 B H B 1 1G G A G B BR V–R Tachometer Speedometer R R R J7 Junction Connector J 8(A), J 9(B) Junction Connector H A J29(A), J30(B) Junction Connector V–R B–W R–L 7. 5A GAUGE F B 5 B BR G A J 8(A), J 9(B) Junction Connector F A V–R F A B–W GR–R Malfunction Indicator Lamp 15 C J31(A), J32(B) Junction Connector B–W B–W 4 B B–W GR–R 7 A R–B C 8(A), C 9(B), C10(C) Combination Meter (IG) (BAT) 10A DOME R 2 4 1G 2 D D 10 IC4 16 C 13 C 11 1K 7 IM1 B 3D B 3D B–W V–R EE 93 4RUNNER (EM03M0U) Engine Control for 1GR–FE System Outline The engine control system utilizes a microcomputer and maintains overall control of the engine, transmission etc. An outline of the engine control is given here. 1. Input Signals (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. The engine coolant temp. is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal to TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust emission is detected and is input as a control signal from the heated oxygen sensors to TERMINALS OX1B and OX2B of the engine control module. (4) RPM signal circuit The camshaft position is detected by the VVT sensor (Bank 1) and (Bank 2), and is input into TERMINALS VV1+ and VV2+ of the engine control module as a control signal. Also, the engine RPM is detected by the crankshaft position sensor and the signal is input into TERMINAL NE+ of the engine control module. (5) Throttle position sensor signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINALS VTA1 and VTA2 of the engine control module. (6) Vehicle speed circuit The vehicle speed sensor detects the vehicle speed, and the signal is input into TERMINAL SPD of the engine control module via the combination meter, from TERMINAL SP1 of the skid control ECU with actuator. (7) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the voltage for engine control module start up power supply is applied through the EFI relay, to TERMINALS +B and +B2 of the engine control module. The current from the IGN fuse flows to TERMINAL IGSW of the engine control module, and voltage is constantly applied to TERMINAL +BM. (8) Intake air volume signal circuit The intake air volume is detected by the mass air flow meter, and is input as a control signal to TERMINAL VG of the engine control module. (9) Stop light SW signal circuit The stop light SW is used to detect whether the vehicle is braking or not, and the signal is input into TERMINAL STP of the engine control module as a control signal. (10) Starter signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor when the engine is cranking is detected, and is input into TERMINAL STA of the engine control module as a control signal. (11) Engine knock signal circuit Engine knocking is detected by the knock sensors, and is input into TERMINALS KNK1 and KNK2 of the engine control module as a control signal. (12) A/C SW signal system The operating voltage of the A/C magnetic clutch is detected and input in the form of a control signal to TERMINAL AC1 of the engine control module. (13) Air fuel ratio signal circuit The air fuel ratio is detected and input as a control signal into TERMINALS A1A+ and A2A+ of the engine control module. 94 4RUNNER (EM03M0U) 2. Control System ∗ SFI system The SFI system monitors the engine condition through the signals input from each sensors to the engine control module. The control signal is sent to the engine control module TERMINALS #10, #20, #30, #40, #50 and #60 to operate the injector (Fuel injection). The SFI system controls the fuel injection by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals input from each sensors to the engine control module. The best ignition timing is decided according to this data and the data memorized in the engine control module. The control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 and IGT6, and these signals control the igniter to provide the best ignition timing. ∗ Heated oxygen sensor heater control system The heated oxygen sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the heated oxygen sensors to improve their detection performance. The engine control module evaluates the signals from each sensors, and outputs current to TERMINAL HT1B or HT2B to control the heater. ∗ Air fuel ratio sensor heater control system The air fuel ratio sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emission is low), and warms up the air fuel ratio sensor to improve detection performance of the sensor. The engine control module evaluates the signals from each sensor, current is output to TERMINALS HA1A and HA2A, controlling the heater. ∗ Fuel pump control system The engine control module supplies current to TERMINAL FPR, and controls the operation speed of the fuel pump with the FUEL PUMP relay. ∗ ACIS The ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened and closed in accordance with the driving conditions to control the intake manifold length in two stages, for increased engine output in all ranges from low to high speeds. ∗ ETCS–i The ETCS–i controls the engine output at its optimal level in accordance with the opening of the accelerator pedal, under all driving conditions. ∗ Engine start control system The engine control module allows power to be supplied from the TERMINAL STAR/NSW to the STA relay via park/neutral position SW until complete combustion is confirmed by engine RPM after the detection of ignition SW ST signal by the TERMINAL STSW. With this arrangement, engine can be started without holding the ignition key in the ST position. At the same time, the TERMINAL ACCR is controlled so that the engine control module turns off ACC CUT relay, shutting off power to the accessories. ∗ VVT–i Controls the intake camshaft to an optimal valve timing in accordance with the engine condition. 3. Diagnosis System When there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. The malfunctioning system can be found by reading the code displayed on the malfunction indicator lamp. 4. Fail–Safe System When a malfunction has occurred in any system, there is a possibility of causing engine trouble due to continued control based on that system. In that case, the fail–safe system either controls the system using the data (Standard values) recorded in the engine control module memory, or else stops the engine. 95 4RUNNER (EM03M0U) Engine Control for 1GR–FE : Parts Location Code See Page Code See Page Code J34 See Page A11 34 (1GR–FE) I3 35 (1GR–FE) B A12 34 (1GR–FE) I4 35 (1GR–FE) A13 34 (1GR–FE) I5 35 (1GR–FE) J40 A 40 J37 38 38 A16 A 36 I6 35 (1GR–FE) J41 B 40 A17 B 36 I9 35 (1GR–FE) J47 A 38 A24 36 I10 35 (1GR–FE) J48 B 38 A32 36 I11 35 (1GR–FE) J49 C 38 C2 34 (1GR–FE) I12 35 (1GR–FE) J50 D 38 C3 34 (1GR–FE) I13 35 (1GR–FE) J51 E 38 J52 F 38 C4 A 34 (1GR–FE) I14 35 (1GR–FE) C8 A 37 I18 37 C9 B 37 J2 A 35 (1GR–FE) C10 C 37 J3 B 35 (1GR–FE) D1 E2 37 J4 38 K1 K2 35 (1GR–FE) A L4 M1 35 (1GR–FE) 40 A 35 (1GR–FE) 34 (1GR–FE) J5 38 P1 35 (1GR–FE) E4 A 37 J7 38 P2 35 (1GR–FE) E5 B 37 J8 A 38 S11 39 E6 C 37 J9 B 38 S12 39 E7 D 37 J16 38 S28 35 (1GR–FE) E8 E 37 J18 38 T2 35 (1GR–FE) 34 (1GR–FE) J22 38 T8 39 F8 F9 A 37 J27 38 V1 A 35 (1GR–FE) F10 B 37 J28 38 V2 A 35 (1GR–FE) F14 40 J29 A 38 V3 A 35 (1GR–FE) H6 34 (1GR–FE) J30 B 38 V4 A 35 (1GR–FE) H8 34 (1GR–FE) J31 A 38 I1 35 (1GR–FE) J32 B 38 I2 35 (1GR–FE) J33 A 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1C 1D 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1E 1G 1H 1J 1K 1L 3C 3D 3E 96 4RUNNER (EM03M0U) Y1 39 : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EC1 45 (1GR–FE) Engine Wire and Differential Wire (Near the Front Differential) ED1 45 (1GR–FE) Engine Wire and Sensor Wire (Rear Side of Right Bank Cylinder Block) 46 Floor No.2 Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IK1 47 Instrument Panel Wire and Instrument Panel Wire (Left Upper Side of the Glove Box) IL1 47 Instrument Panel Wire and Instrument Panel Wire (Right Upper Side of the Glove Box) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IB1 IB2 IC2 IC3 IC4 IM1 IM2 : Ground Points Code See Page Ground Points Location EB 45 (1GR–FE) Front Left Fender EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block EF 45 (1GR–FE) Rear Side of Left Bank Cylinder Block IG 46 Left Kick Panel IH 46 Instrument Panel Brace LH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 97 4RUNNER (EM03M0U) B B B–Y 15A IG1 2 Y–R D G–W 2 1 4 B 2 1L 16 1F 5 1 3 2 2 2 E E D E STPO 24 1E 10 1F C A 322 4RUNNER (EM03M0U) E J1 Junction Connector 2 2 S28 Skid Control ECU with Actuator B A R–Y EB B–R (IG) B–R B 8 1J Y–R Y–R Y–R 10A STOP BATT CHG Relay A W–B A STOP LP CTRL Relay Y–R G–W 2 LG F B G–B 1 S12 Stop Light SW P1 Park/Neutral Position SW Y–R Y–R (BAT) B B J 2(A), J 3(B) Junction Connector B J4 Junction Connector G–Y R–Y J25 Junction Connector 2 IM1 G–Y J4 Junction Connector R–Y R G–B R–Y H A W–B R–Y H A J33 Junction Connector A G–Y J40(A), J41(B) Junction Connector Y–R J7 Junction Connector A Y–R(∗2) Y–R(∗1) 2 Y–R J20(A), J21(B) Junction Connector Trailer Towing (BAT) 30A BATT CHG 2 20 1E 2 Y–R Y–R C C 2 3 3 1 3 1 IM1 2 5 B 3 3 E 16 2 IB2 12 1J G–Y B–R R–Y G–Y Y–R(∗2) Y–R(∗1) ∗ 1 : w/ Daytime Running Light ∗ 2 : w/o Daytime Running Light (BAT) (BAT) 50A J/B (BAT) 30A TOWING BRK 10A TAIL (BAT) 30A TOWING 40A TOWING 2 2 L–Y 2 L–B L–Y L–B A D A L–B L D L–Y 2 2 B G L–W 2 GR 5 1L 2 L 4 IB2 25 IC4 3 B LTOT STIN GND 2 4 8 6 3 BG1 4 BG1 C B C B 3 STTL W–B BR G 5 STTR GND 4 6 Y 1 BF1 3 BF1 A B G–Y A A W–B Y R–Y G–Y 1 BG1 B–R 2 BG1 A B J40(A), J41(B) Junction Connector B/UP 2 W BATT B BRK 7 Y W–B 1 TAIL T15 Trailer Socket L A B J14(A), J15(B) Junction Connector Body ECU W–B TRLY 2 BF1 A A W–B RTOT T14 Towing Converter Relay GR TOWING TAIL Relay 3 3 IB2 18 18 IE1 9 LTIN W–B Y 16 1E 3 RTIN J41(B) Junction Connector 1 3 G–Y 3 +B L–O 4 1 R BRK 5 L GND W–B STOP 2 L–R +B 3 G–B 2 1 G–B 5 TAIL T6 Towing Brake Controller 2 B 3 G 1 TAIL Relay 5 3 J39 Junction Connector B J16 Junction Connector 1 1C B–R R–Y G–Y Y–R(∗1) A J5 Junction Connector IG BO W–B Y–R(∗1) W–B Y–R(∗2) W–B Y–R(∗2) BL 323 4RUNNER (EM03M0U) Trailer Towing ∗ 1 : w/ Daytime Running Light ∗ 2 : w/o Daytime Running Light (BAT) 15A TRN–HAZ L–Y 2 L–B B–Y 2 9 1F 20 IC4 15 1F B–Y (∗2) 2 LR +B IG (∗2) Y–R 3 TRL TRR (∗1) B–Y 6 B D2 Turn Signal Flasher Relay 1 (∗2) IF1 Y–R 1 5 IG T9 Turn Signal Flasher Relay 1 (∗2) 4 Y–R LL B–Y (∗2) L–Y (∗2) L–B 3 (∗1) IF1 L–Y 6 (∗1) IF1 (∗2) B–Y (∗2) L–Y 3 L–B IF1 (∗1) 5 5 1J (∗2) L–B 23 1J Y–R(∗2) Y–R(∗1) 324 4RUNNER (EM03M0U) : Parts Location Code See Page D2 J1 J2 B See Page J14 A 38 33 (2UZ–FE) J15 B 38 35 (1GR–FE) A J3 Code 37 J16 Code 38 33 (2UZ–FE) J20 A 38 35 (1GR–FE) J21 B 38 P1 S12 S28 See Page 33 (2UZ–FE) 35 (1GR–FE) 39 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) J25 38 T6 39 35 (1GR–FE) J33 38 T9 39 J4 38 40 T14 41 J5 38 J40 J39 A 40 T15 41 J7 38 J41 B 40 : Relay Blocks Code See Page Relay Blocks (Relay Block Location) 2 22 Engine Room R/B (Engine Compartment Left) 3 23 Engine Room R/B No.3 (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1C 1E 1F 1J 1L See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB2 46 Floor No.2 Wire and Engine Room Main Wire (Left Kick Panel) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BF1 48 Frame No.3 Wire and Floor No.2 Wire (Rear Side of Side Frame LH) BG1 48 Floor No.2 Wire and Frame No.3 Wire (Rear Side of Side Frame LH) : Ground Points Code EB See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender IG 46 Left Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 325 4RUNNER (EM03M0U) Tire Pressure Warning System (IG) D1 Data Link Connector 3 10A ECU–IG SIL B–R G D P–L G H G H J18 Junction Connector V–R P–L J20 Junction Connector R–Y G 13 R–Y B–R 28 1J TC 7 A 3A C 3C B 3D 11 1K A 3A C 3C B 3D 1 1G E A G A V–R V–R R–Y B–R D P–L J12 Junction Connector A 3D F A J35(A), J36(B) Junction Connector J29(A), J30(B) Junction Connector V–R A B G B R–Y P–L V–R A 3D 4 12 3 B–R H B 2 RF5V RDA GND2 IND 8 7 16 6 30 IE1 32 IE1 33 IE1 GR LG–B 12 BD1 11 BD1 1 BD1 GR LG–B J33(A), J34(B) Junction Connector L A B L W–B LG–B T16 Tire Pressure Warning ECU SPD GR GND 11 TC P–B SIL L IG A A 1 4 +5V RDA GND W–B 5 T17 Tire Pressure Warning Antenna and Receiver A J37 Junction Connector IK 326 4RUNNER (EM03M0U) P–B (IG) (BAT) 7. 5A GAUGE ∗ 1 : 2UZ–FE ∗ 2 : 1GR–FE 10A DOME 2 2 R–L R 4 1G R 10 IC4 D J7 Junction Connector R D H A J 8(A), J 9(B) Junction Connector V–R R–L R 5 B 15 C 16 C Speedometer V–R F B 4 B 7 IC2 13 C GR–R 7 IM1 12 S28 Skid Control ECU with Actuator ED BR (∗2) BR SP1 (∗1) P–B BR GR–R 1 A P–B Tire Pressure C 8(A), C 9(B), C10(C) Combination Meter EE 327 4RUNNER (EM03M0U) Tire Pressure Warning System System Outline The air pressure sensor installed in the tire wheel detects the tire air pressure and transmits signals to the vehicle side receiver. When the detected tire air pressure is below a specified level, the warning light in the combination meter comes on to inform the driver. Warnings when the tire pressure is low ∗ When the tire air pressure is below a specified level, the warning light in the combination meter comes on. : Parts Location Code C8 See Page Code See Page Code A 37 J12 38 J35 C9 B 37 J18 38 J36 C10 C 37 J20 38 D1 37 J29 A 38 J7 38 J30 B 38 J37 S28 See Page A 38 B 38 38 33 (2UZ–FE) 35 (1GR–FE) J8 A 38 J33 A 38 T16 39 J9 B 38 J34 B 38 T17 41 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1G 1J 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1K 3A 3C 3D : Connector Joining Wire Harness and Wire Harness Code IC2 IC4 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) : Ground Points Code ED EE IK See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block 46 Right Kick Panel 328 4RUNNER (EM03M0U) Memo 329 4RUNNER (EM03M0U) Rear Window Defogger and Mirror Heater B 4(A), B 5(B) Body ECU (BAT) (IG) (ACC) 15A IG1 140A ALT 7. 5A ACC ACC 22 RDEF GND2 6 16 GND1 4 2 B–R 1 20 1E 2 2 2 E 2 2 W–B 3 2 1H Y–G R 4 3 1B Y–R DEFOG Relay 5 J1 Junction Connector Y–G Y–R R Y–R B–R W–B E W–B 1 B R21(A), R22(B) Rear Window Defogger 1 A W–B 3 BH1 W–B B J3 Junction Connector W–B B A A W–B W–B A B J40(A), J41(B) Junction Connector W–B A A W–B W–B 10 BD1 W–B EB BO 330 4RUNNER (EM03M0U) BL B 4(A), B 5(B) Body ECU DEFSW 1 B DIND 5 B G–R G B–R 4 11 2 Y–G 1 1 30A DEFOG 7 BH1 J6 Junction Connector 10A MIR HEATER DFSW DIND B GND 2 B 7 B D3 Defogger SW 5 5 W–B B 3F B 3F W–B W–B B J38 Junction Connector B B 3F W–B 4 W–B W–B M4 Mirror Heater RH B–L B–L 4 G–B Y–G D 18 IP1 W–B Y–G D 18 IA1 M3 Mirror Heater LH B–L 4 IC4 G–B Y–G 18 IC4 J22 Junction Connector Y–G 36 IE1 B–L 2 W–B 2 B B–L 4 BD1 2 W–B 4 IA2 W–B J5 Junction Connector A IG W–B W–B A A J24 Junction Connector A W–B J37 Junction Connector W–B W–B 4 IP2 A IK II 331 4RUNNER (EM03M0U) Rear Window Defogger and Mirror Heater B 8(A), B 9(B) Back Door ECU BECU MPX2 1 A BECU 5 A SIG GND 6 A 3 A IC+ 11 B IC2 17 B IC1 16 B IC– 23 B L–W B–O W–R 9 BD1 7 BD1 5 BD1 Y–G 40 IE1 2 L–R R 10A ECU–B 4 1B 12 1F BR–R (BAT) 10A ECU–IG (IG) MPX2 23 A 11 W–B SIG 10 B B 4(A), B 5(B) Body ECU B–R W–R W–R W–R 8 1F W–R 2 1 BR–R 2 6 PLS B–R SSRB F F E E J39 Junction Connector W–B 332 4RUNNER (EM03M0U) B11 Back Door Power Window Motor 3 PLS2 E System Outline ∗ Start control Turning the rear window defogger SW ON, with the ignition SW ON and the back door window fully closed, initiates operation of the rear window defogger and illuminates the indicator lamp for 15 minutes. ∗ Stop control When any one of the following conditions exists, rear window defogger operation comes to a stop and the indicator lamp goes out. ∗ The ignition SW is turned from the ON position to either the ACC or OFF position. ∗ The rear window defogger SW is pressed ON again when rear window defogger operation is already under way. ∗ The back door window is open. : Parts Location Code See Page Code See Page Code A 36 B5 B 36 35 (1GR–FE) J40 A 40 B8 A 40 J5 38 J41 B 40 B9 B 40 J6 38 M3 B11 40 J22 38 M4 D3 37 J24 38 R21 A 41 33 (2UZ–FE) J37 38 R22 B 41 35 (1GR–FE) J38 40 J1 J3 33 (2UZ–FE) See Page B4 J39 40 41 41 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1F 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 3F 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) : Connector Joining Wire Harness and Wire Harness Code IA1 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BH1 48 Back Door No.1 Wire and Back Door No.2 Wire (Left Side of Back Door) IA2 IP1 IP2 : Ground Points Code EB See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH 333 4RUNNER (EM03M0U) Navigation, Parking Assist and Audio System (BAT) (ACC) 20A RADIO NO. 1 7. 5A ACC 20A EFI R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display (BAT) ACC 11 G 2 2 CA+ CGND 24 B 21 B V+ V– 22 B 23 B 2 8 1K R W B (∗1) 25 IE1 23 IE1 21 IE1 R W B (∗1) (∗2) B 3C (∗1) B 3C L–Y GR C GR 28 IC4 L–Y P 19 IE1 B 3C J6 Junction Connector C C F 3E (∗1) L–Y L–Y 2 B 1 G 3 BD2 2 BD2 1 BD2 4 BD2 F 3E BR R 5 BH1 4 BH1 10 BH1 W B (∗1) BR B (∗1) W (∗1) GR (∗2) GR 9 BH1 1 2 4 2 BR W–G (∗1) 2 R 4 R 1 (∗1) 3 ACC CUT Relay 2 2 B 3A GR P 2 B 30 IC4 B 3A W GR 38 IC4 L P B 3A 16 IC3 3 W–G T11 Television Camera L–Y (∗2) 17 ACCR GR E8 Engine Control Module (∗2) GR 334 4RUNNER (EM03M0U) ∗ 1 : Shielded ∗ 2 : w/ Rear Seat Entertainment System R+ 29 30 9 R– L+ L– SGN2 NTS4 SGN5 25 6 22 20 BJ1 10 (∗1) (∗2) (∗2) P W (∗2) 16 ID1 21 BJ1 P L (∗2) L (∗2) GR (∗2) 17 ID1 L VV+ 1 C (∗2) (∗2) (∗1) 31 (∗2) 19 BJ1 (∗1) 5 BJ1 (∗2) (∗1) (∗2) G W 18 ID1 (∗2) 8 ID1 G 4 BJ1 R VV– 4 C (∗2) (∗2) R W (∗2) 9 ID1 (∗2) (∗2) W W (∗2) 3 BJ1 CDL– 5 F 11 SGN1 SG3 NTS1 SG7 AUXR AUXL OPEN 8 24 23 7 L–Y 7 5 SLD NTSC SGND 2 AUXL (∗2) G LG (∗2) 9 BJ1 G 4 ID1 (∗2) (∗2) LG W (∗2) 20 ID1 LG (∗2) V W (∗2) 1 AUXR 17 BJ1 (∗2) (∗2) 3 SGND 21 ID1 V (∗2) (∗1) 6 (∗1) 19 ID1 16 BJ1 (∗2) (∗2) (∗1) (∗2) R W 18 BJ1 (∗2) 22 ID1 R G 23 ID1 15 BJ1 (∗2) (∗2) G GR (∗2) 14 BJ1 (∗2) (∗1) (∗2) (∗2) 24 ID1 (∗1) BR (∗2) 13 ID1 13 BJ1 (∗1) LG (∗2) 24 BJ1 (∗2) BR (∗2) R18 Rear Seat Audio Controller 10 ID1 W B 2 BJ1 CDL+ 4 F (∗2) (∗2) B W (∗2) 11 ID1 (∗2) (∗2) (∗1) (∗1) (∗2) V GR (∗2) 7 ID1 (∗2) (∗1) (∗2) LG V G 6 BJ1 6 ID1 (∗2) (∗2) (∗2) G W (∗2) GND6 12 (∗2) (∗2) ACC4 CDR– 3 F 28 SG1 15 L–Y (∗2) 7 BJ1 27 LMUT (∗2) +B2 16 1 BJ1 26 TX– CDR+ 2 F 12 ID1 8 BJ1 13 TX+ CSLD 1 F 5 ID1 10 BJ1 GR 14 3 ID1 LG L (∗2) 11 BJ1 L–Y MUTE 6 F (∗2) (∗2) R LG (∗2) 2 ID1 LG TXM– 10 F (∗2) TXM+ 9 F (∗2) R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display 8 CE (∗2) GR (∗2) V14 Video Terminal GR GR IJ 335 4RUNNER (EM03M0U) Navigation, Parking Assist and Audio System R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display SW1 SGND 4 IV1 1 IT1 2 IT1 3 IT1 4 1 IT1 BR (∗3) (∗1) ARO (∗3) ALO P W 5 (∗3) L 4 L B 3 (∗3) G 2 (∗3) R 12 1 8 E 10 AU1 ASGN AUXO MACC 1 MIC+ MIC– II1 11 EAU SEEK+ 3 2 II1 Y–B 3 IV1 II1 V–W 2 IV1 SW2 6 E (∗3) (∗1) (∗1) (∗3) P (∗3) L (∗3) W (∗3) 3 1 IV1 SWG 7 E 18 B Y–B TSW– 12 B W–R MIC– 20 B W–R 19 B V–W MIC+ MACC 17 B B L ADPG 6 C (∗1) VA– 5 C G VAR+ 2 C R VAL+ 3 C AU2 MODE SEEK– S31 Stereo Jack Adapter T18 Telephone Microphone VOL+ VOL– C13 Combination SW ∗ 1 : Shielded ∗ 3 : w/ Telephone Microphone GR GR BR (∗3) 336 4RUNNER (EM03M0U) R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display IVO+ IVO– SLD1 12 E ANT 13 G 13 E L+ L– R+ R– 9 G 19 G 8 G 18 G SLD 10 G ATX+ 5 G ATX– MUTE 15 G 7 G W–R 18 IO2 W–R W 27 IO2 W B 26 IO2 B (∗1) 34 IO2 (∗1) W 35 IO2 W B 32 IO2 B G 31 IO2 G R 22 A INT+ 29 IO2 R 23 A A37 Antenna Amplifier (∗1) 37 IO2 (∗1) (∗1) P 39 IO2 (∗1) +B P 40 IO2 1 L L B 11 E 3 A 2 A 5 A 4 A 6 A 8 A 7 A 1 A L+ L– R+ R– INT– SLD TX+ TX– MUTE S22(A), S23(B) Stereo Component Amplifier ACC FL+ FL– 6 B FR– RL+ RL– RR+ RR– W 1 2 1 3 BB1 B 1 BB1 L P 2 3 BA1 1 2 1 2 1 2 GR 1 W 3 1 BA1 W W 4 R R 2 3 S21 Door Speaker Front RH No. 2 4 LG 8 IP2 L 3 IP2 V 1 IA2 R–L 3 IA2 R 22 IO2 Y 24 IO2 Y 16 IO2 B 14 IO2 L 10 IO2 LG 12 IO2 V 20 IO2 P R 14 B Y 5 B B 13 B L 4 B LG 18 B V 7 B 21 IO2 S20 Door Speaker Front LH No. 2 38 IO2 FR+ 17 B P GR 12 A D22 Door Speaker Front LH No. 1 D23 Door Speaker Front RH No. 1 R16 Rear Door Speaker LH GR R17 Rear Door Speaker RH BR (∗3) BR (∗3) 337 4RUNNER (EM03M0U) Navigation, Parking Assist and Audio System ∗ 3 : w/ Telephone Microphone R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display (BAT) (IG) 20A RADIO NO. 2 PKB 1 D GND 20 G SPD 15A IG1 REV 3 D 5 D 2 8 1J Y–R W–L R–Y V–R BR LG 2 A 27 IC4 W–L 20 1J J7 Junction Connector Y–R H W4 Woofer 36 IO2 4 1 3 L–B L–R 19 B 9 B 20 B WFR+ 1 B 10 B WFR– +B A 3B B 3D A J33 Junction Connector B +B2 A S22(A), S23(B) Stereo Component Amplifier 23 IO2 B 3D B 3D Y–R A 3B V–R A 3B V–R SPD 11 A 25 IO2 BR (∗3) V–R 16 B BR GND 15 B BR GND2 2 IM1 BR G–B CTR– 12 B G CTR+ 3 B J25 Junction Connector 41 IO2 2 R P1 Park/Neutral Position SW WFL– W–L G–W 8 B B W–L BR B B Y–R 2 J42 Junction Connector R–Y WF– V–R WF+ BR WF– Y–R R–Y B WF+ WFL+ J20 Junction Connector H 1 W–L P4 Parking Brake SW 1 1E LG A R–Y V–R 1 G C5 Center Speaker 1 IM1 V–R R–Y 3 G BR G–B 4 BR G J29 Junction Connector BR V–R (∗3) BR W–B (w/ Side Airbag) BM BP IJ 338 4RUNNER (EM03M0U) (BAT) (IG) 10A DOME 7. 5A GAUGE 2 2 R 4 1G J7 Junction Connector D 10 IC4 R R–L R D H A J 8(A), J 9(B) Junction Connector R F B 16 C 13 C 4 B BR GR–R 5 B V–R C 9(B), C10(C) Combination Meter Speedometer 15 C 7 IC2 7 IM1 GR–R 1 1G 11 1K 12 EE BR BR S28 Skid Control ECU with Actuator (2UZ–FE) V–R (1GR–FE) SP1 ED 339 4RUNNER (EM03M0U) Navigation, Parking Assist and Audio System : Parts Location Code See Page A37 Code 36 C5 See Page J29 Code R26 B 39 R27 C 39 37 J33 A 38 C9 B 37 J34 B 38 S20 C10 C 37 40 S21 J42 See Page 38 41 41 C13 37 D22 40 D23 40 E8 37 R9 D 39 J6 38 R10 E 39 S31 39 J7 38 R11 F 39 T11 41 R12 G 39 T18 41 P1 P4 33 (2UZ–FE) S22 A 41 35 (1GR–FE) S23 B 41 39 S28 33 (2UZ–FE) 35 (1GR–FE) J8 A 38 J9 B 38 R16 41 V14 39 J20 38 R17 41 W4 41 J25 38 R18 41 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1K 3A 3B 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code IA2 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) ID1 46 Radio Installation Wiring Sub Assembly and Instrument Panel Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) II1 46 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace LH) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IO2 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IP2 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IC2 IC3 IC4 IT1 47 Roof Wire and Instrument Panel Wire (Left Kick Panel) IV1 46 Instrument Panel Wire and Console Box No.2 Wire (Rear Console) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD2 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BH1 48 Back Door No.1 Wire and Back Door No.2 Wire (Left Side of Back Door) BJ1 48 Radio Installation Wiring Sub Assembly and Radio Installation Wiring Sub Assembly (Center of Roof) 340 4RUNNER (EM03M0U) : Ground Points Code ED EE See Page Ground Points Location 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IJ 46 Instrument Panel Brace RH BM 48 Floor Seat Crossmember RH BP 48 Rear Pillar RH 341 4RUNNER (EM03M0U) Audio System with 10 Speaker GR (ACC) (BAT) R18 Rear Seat Audio Controller 20A RADIO NO. 1 7. 5A ACC 20A EFI 2 2 GND6 12 +B2 TX+ 16 TX– 14 LMUT 26 13 V LG G (∗1) (∗1) 8 BJ1 (∗1) LG W 10 BJ1 (∗1) 11 BJ1 (∗1) L (∗1) (∗1) BR (∗1) L–Y LG 7 BJ1 (∗1) F 3E 24 BJ1 LG LG P 6 BJ1 (∗1) L–Y GR 2 (∗1) 8 1K 2 ACC4 15 (∗1) (BAT) 28 IC4 2 ID1 3 ID1 5 ID1 V (∗1) G R (∗1) (∗1) 6 ID1 L–Y BR (∗1) 13 ID1 (∗1) GR GR L P J6 Junction Connector C C (∗1) 7 ID1 L–Y F 3E 4 MUTE R 1(A), R 4(B), R 5(C) Radio and Player B 3A B 3A B B 3A 2 6 B ACC 1 A 11 A GND 20 A 2 B 3C B 3C W–G GR BR 1 TXM– GR 3 ACC CUT Relay 2 2 10 B TXM+ L–Y GR 2 9 B GR 30 IC4 GR 38 IC4 P C B 3C 16 IC3 W–G L–Y A 3B A 3B ACCR BR 17 E8 Engine Control Module BR (∗1) IJ 342 4RUNNER (EM03M0U) ∗ 1 : w/ Rear Seat Entertainment System GR GR R18 Rear Seat Audio Controller LG W 9 BJ1 (∗1) LG 17 BJ1 G 24 (∗1) OPEN 8 (∗1) AUXL (∗1) (∗1) V W 16 BJ1 (∗1) (∗1) 18 BJ1 (Shielded) W 15 BJ1 AUXR 7 (∗1) (Shielded) (∗1) R SG7 23 (∗1) (∗1) G GR (∗1) (Shielded) (∗1) 14 BJ1 (∗1) 13 BJ1 (Shielded) (∗1) G W (∗1) 22 7 5 SLD NTSC 3 SGND 1 AUXR G LG 2 4 ID1 (∗1) 20 ID1 (∗1) V 6 SGND (∗1) 21 ID1 (∗1) 19 ID1 (Shielded) R 22 ID1 (∗1) G (∗1) (Shielded) (∗1) 23 ID1 8 AUXL CE V14 Video Terminal G 24 ID1 5 B CDL– R 1(A), R 4(B), R 5(C) Radio and Player ALI ARI ASGN AUXI 16 C 19 C 2 IV1 3 IV1 4 IV1 1 2 ALO ARO L 1 IV1 L 15 C B 17 C G CDL+ SGN5 6 8 ID1 (∗1) R (∗1) (∗1) W R 4 B 5 BJ1 NTS4 G CDR– 9 ID1 (∗1) (∗1) W W (∗1) 3 B 4 BJ1 SGN2 25 R CDR+ 10 ID1 W (∗1) B W (∗1) 2 B 3 BJ1 L– 31 R CSLD 11 ID1 L+ 30 (Shielded) 1 B 2 BJ1 B (∗1) 12 ID1 R– 29 (∗1) (Shielded) (∗1) (∗1) (Shielded) 1 BJ1 (Shielded) R+ 28 (∗1) SG1 27 3 ASGN 4 AUXO S31 Stereo Jack Adapter 343 4RUNNER (EM03M0U) Audio System with 10 Speaker GR GR R G B W (Shielded) W 35 IO2 B 32 IO2 G 31 IO2 R (Shielded) 29 IO2 9 A 19 A 8 A 18 A L+ L– R+ R– 34 IO2 10 A SLD R 1(A), R 4(B), R 5(C) Radio and Player SWG ATX– B Y–B 15 A II1 2 MUTE 7 A W–R 1 ATX+ 5 A W II1 ANT 13 A 8 C W–R V–W 3 SW2 6 C B SW1 7 C 26 IO2 27 IO2 18 IO2 II1 12 10 AU1 SEEK+ +B Y–B V–W W–R 1 11 EAU AU2 A37 Antenna Amplifier MODE SEEK– VOL+ VOL– C13 Combination SW 344 4RUNNER (EM03M0U) W–R W B GR (BAT) 20A RADIO NO. 2 2 W–L 2 R16 Rear Door Speaker LH R G 27 IC4 W 1 BA1 3 BA1 1 BB1 3 BB1 Y R W 14 IO2 16 IO2 24 IO2 22 IO2 W B G R GR W–L W–L B Y R W B (Shielded) B B W–L GR J42 Junction Connector B 2 R 36 IO2 1 Y W–L 38 IO2 W (Shielded) 2 B GR 1 B R17 Rear Door Speaker RH 6 A 4 A 5 A 2 A 3 A 12 A 1 B 10 B 4 B 13 B 5 B 14 B R– R+ L– L+ SLD ACC +B +B2 RL+ RL– RR+ RR– S22(A), S23(B) Stereo Component Amplifier FL+ FL– FR+ CTR+ FR– 7 B CTR– 20 IO2 12 IO2 10 IO2 23 IO2 25 IO2 L 21 IO2 LG G–B 12 B G 3 B L 18 B LG 17 B V 6 B V TX+ 8 A P TX– 7 A P MUTE 1 A 3 IA2 1 IA2 3 IP2 8 IP2 G G–B W–R 4 3 R W 4 3 1 2 1 LG 1 2 D22 Door Speaker Front LH No. 1 C5 Center Speaker L S20 Door Speaker Front LH No. 2 S21 Door Speaker Front RH No. 2 L 2 3 V 4 P B R–L W 1 2 D23 Door Speaker Front RH No. 1 345 4RUNNER (EM03M0U) Audio System with 10 Speaker (IG) (BAT) 10A DOME 7. 5A GAUGE 2 2 4 1G R W4 Woofer J7 Junction Connector D WF– WF+ WF– 2 4 1 3 R D R–L R WF+ 10 IC4 H A J 8(A), J 9(B) Junction Connector L–R R 19 B WFL+ 9 B WFL– 15 C 16 C 5 B 4 B Speedometer 8 B L–B BR G–W F B 20 B WFR+ WFR– S22(A), S23(B) Stereo Component Amplifier 7 IM1 V–R 12 SP1 B 3D G–W 4 3 BR S28 Skid Control ECU with Actuator BR BR 22 IE1 R20 Rear Speaker RH (2UZ–FE) V–R 11 1K B 3D 20 IE1 7 IC2 G BR G–W 10 IO3 BR BR J29 Junction Connector 3 1 1G G BR G–W 4 11 IO3 13 C GR–R D V–R D BR C BR C G–W 41 IO2 (1GR–FE) J42 Junction Connector GR–R SPD 11 A V–R D GND 16 B V–R BR C 15 B C 9(B), C10(C) Combination Meter GND2 DRS– 11 B G–W DRS+ 2 B R19 Rear Speaker LH W–B (w/ Side Airbag) BP BM 346 4RUNNER (EM03M0U) EE ED : Parts Location Code See Page A37 36 C5 Code J9 See Page B Code 38 See Page S20 41 37 J29 38 C9 B 37 J42 40 S22 A 41 C10 C 37 R1 A 39 S23 B 41 C13 37 R4 B 39 D22 40 R5 C 39 D23 40 R16 41 S31 39 E8 37 R17 41 V14 39 J6 38 R18 41 W4 41 J7 38 R19 41 38 R20 41 J8 A S21 41 S28 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1G 1K See Page Junction Block and Wire Harness (Connector Location) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3A 3B 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code IA2 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) ID1 46 Radio Installation Wiring Sub Assembly and Instrument Panel Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) II1 46 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace LH) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IP2 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IV1 46 Instrument Panel Wire and Console Box No.2 Wire (Rear Console) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BJ1 48 Radio Installation Wiring Sub Assembly and Radio Installation Wiring Sub Assembly (Center of Roof) IC2 IC3 IC4 IO2 IO3 : Ground Points Code See Page Ground Points Location ED 44 (2UZ–FE) Left Bank Cylinder Head EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IJ 46 Instrument Panel Brace RH BM 48 Floor Seat Crossmember BP 48 Rear Pillar RH 347 4RUNNER (EM03M0U) Audio System with 6 Speaker (BAT) (BAT) R18 Rear Seat Audio Controller (ACC) 20A RADIO NO. 1 7. 5A ACC 20A EFI +B2 16 2 ACC4 GND6 15 12 TX+ 14 TX– LMUT 26 13 11 BJ1 10 BJ1 V (∗1) G (∗1) L 24 BJ1 (∗1) BR (∗1) GR 6 BJ1 8 BJ1 28 IC4 F 3E 6 ID1 7 ID1 2 ID1 3 ID1 LG (∗1) W (∗1) LG A37 Antenna Amplifier 13 ID1 (∗1) LG (∗1) LG (∗1) LG J6 Junction Connector C C (∗1) P L–Y 7 BJ1 (∗1) 8 1K 2 (∗1) 2 L–Y 2 5 ID1 BR (∗1) GR (∗1) (∗1) 9 C TXM– SWG 1 II1 2 12 10 II1 11 EAU AU2 A 3B W–G AU1 GND 7 A 8 D Y–B V–W L–Y II1 V–W 3 SW2 6 D BR SW1 7 D 2 16 IC3 10 C Y–B +B 4 A W–G 2 ACC 3 A W–R 4 TXM+ R 2(A), R 3(B), R 4(C), R 5(D) Radio and Player W–R 1 B 3A GR 3 ANT ACC CUT Relay L–Y 2 2 SEEK+ MODE A 3B 17 ACCR E8 Engine Control Module V (∗1) G B 3A 8 A 2 (∗1) B R P B 3C (∗1) L–Y GR (∗1) 30 IC4 +B 1 B 3C GR B 3C GR GR 38 IC4 L P (∗1) L–Y L–Y C F 3E SEEK– BR VOL+ VOL– C13 Combination SW BR (∗1) IJ 348 4RUNNER (EM03M0U) 6 C MUTE ∗ 1 : w/ Rear Seat Entertainment System R18 Rear Seat Audio Controller 3 C CDR+ CDR– G (∗1) 9 BJ1 LG 17 BJ1 (∗1) LG 24 (∗1) OPEN 8 W V (∗1) AUXL (∗1) (∗1) (Shielded) 16 BJ1 W (∗1) (Shielded) (∗1) R W AUXR 7 18 BJ1 (∗1) G GR 15 BJ1 (∗1) (∗1) (Shielded) 14 BJ1 SG7 23 (∗1) 22 (∗1) SGN5 6 (Shielded) (∗1) G W (∗1) 7 5 SLD NTSC 3 SGND 1 SGND 2 AUXR AUXL G 4 ID1 (∗1) LG 20 ID1 (∗1) (∗1) V 6 (∗1) 21 ID1 (Shielded) R 19 ID1 (∗1) 22 ID1 (∗1) (∗1) 23 ID1 8 CE V14 Video Terminal G 4 C 24 ID1 G 8 ID1 (Shielded) W 9 ID1 NTS4 13 BJ1 (∗1) R (∗1) 5 BJ1 (∗1) 4 BJ1 SGN2 25 (∗1) L– 31 R W W 2 C CSLD (∗1) 10 ID1 W B 1 C (∗1) (∗1) B W (∗1) 11 ID1 (∗1) 12 ID1 L+ 30 3 BJ1 (∗1) (Shielded) (∗1) 2 BJ1 (∗1) (Shielded) 1 BJ1 (Shielded) R– 29 (∗1) R+ 28 (∗1) SG1 27 5 C CDL+ CDL– R 2(A), R 3(B), R 4(C), R 5(D) Radio and Player 2 D22 Door Speaker Front LH No. 1 1 BA1 3 BA1 1 BB1 3 BB1 L P 1 W 1 R 2 RR– 3 B R 1 RR+ 1 B S21 Door Speaker Front RH No. 2 3 RL– 6 B Y L W LG R 4 S20 Door Speaker Front LH No. 2 2 3 LG V 8 IP2 L 3 IP2 V P 1 IA2 R–L 3 IA2 4 RL+ 2 B W FR– 5 A Y FR+ 1 A B FL– 6 A B FL+ 2 A 1 2 D23 Door Speaker Front RH No. 1 1 2 R16 Rear Door Speaker LH 1 2 R17 Rear Door Speaker RH 349 4RUNNER (EM03M0U) Audio System with 6 Speaker (IG) (BAT) 7. 5A GAUGE 10A DOME 2 4 1G R 2 J7 Junction Connector D 10 IC4 R R–L R D H A J 8(A), J 9(B) Junction Connector R F B 16 C 5 B 4 B C 9(B), C10(C) Combination Meter Speedometer 15 C R 2(A), R 3(B), R 4(C), R 5(D) Radio and Player 4 IV1 B 3D 1 1G 7 IC2 13 C BR 3 IV1 GR–R 2 IV1 V–R 1 IV1 L V–R SPD 3 D L AUXI 19 D B G ASGN 16 D G R ARI 15 D R (Shielded) ALI 17 D 1 2 ALO ARO 3 ASGN 4 AUXO B 3D 11 1K GR–R 7 IM1 EE 350 4RUNNER (EM03M0U) BR (2UZ–FE) S28 Skid Control ECU with Actuator BR SP1 (1GR–FE) S31 Stereo Jack Adapter V–R 12 ED : Parts Location Code See Page A37 Code 36 See Page J7 Code See Page 38 R17 41 C9 B 37 J8 A 38 R18 41 C10 C 37 J9 B 38 S20 41 C13 37 R2 A 39 S21 41 D22 40 R3 B 39 D23 40 R4 C 39 E8 37 R5 D 39 S31 39 J6 38 41 V14 39 R16 S28 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1G 1K See Page Junction Block and Wire Harness (Connector Location) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3A 3B 3C 3D 3E : Connector Joining Wire Harness and Wire Harness Code IA2 See Page Joining Wire Harness and Wire Harness (Connector Location) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) ID1 46 Radio Installation Wiring Sub Assembly and Instrument Panel Wire (Left Kick Panel) II1 46 Instrument Panel Wire and Instrument Panel Wire (Instrument Panel Brace LH) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IP2 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IV1 46 Instrument Panel Wire and Console Box No.2 Wire (Rear Console) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BJ1 48 Radio Installation Wiring Sub Assembly and Radio Installation Wiring Sub Assembly (Center of Roof) IC2 IC3 IC4 : Ground Points Code See Page Ground Points Location ED 44 (2UZ–FE) Left Bank Cylinder Head EE 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IJ 46 Instrument Panel Brace RH 351 4RUNNER (EM03M0U) 3 A 4 A 5 A BR–B Y–G 2 A Y–B Y Illumination N D 4 3 2 L R P OFF LO N HI Illumination Height Control G–B R–Y G–W W G L C 8(A), C 9(B), C10(C), C11(D) Combination Meter Suspension Control ECU 352 4RUNNER (EM03M0U) P–L B–L Transmission Control SW Transmission Control SW Park/Neutral Position SW Transmission Control SW Park/Neutral Position SW Combination Meter 20 D 1 C 19 D 18 D 17 D 16 D 15 D 14 D 4RUNNER (EM03M0U) H A D 3 C 1 IE1 2 IE1 2 MAINT 16 C 11 C 18 B 12 B 13 B L–R R 11 1J Airbag Sensor Assembly 5 C G–Y R (IG) Buckle SW LH 3 Fuel B LG B–O 10A IGN Passenger Seat Belt Warning Light Driver' s Seat Belt 15 C Y–B D B J 8(A), J 9(B) Junction Connector B A Y–B 9 C R A B B–O C A J 8(A), J 9(B) Junction Connector R–L 1 1C J16 Junction Connector G L–W 4 1G BR–R 8 C W–L 5 J10(A), J11(B) Junction Connector G FR FOG Relay HEAD (HI RH) Fuse B 7. 5A GAUGE BR–R 19 B V–G 10 D (IG) F14 Fuel Sender 7 B L–B 2 10A TAIL Body ECU 16 B B–Y G 23 IC4 TAIL Relay G R–W 1 5 1L A/C Control Assembly 7 C W–G Tail (Except USA) Door R–W 50A J/B Park/Neutral Position SW 17 A V–Y Front Fog Beam 2 Rheostat 13 D R–G 12 D Body ECU Combination SW Head (USA) (BAT) (BAT) 10A DOME 2 2 10 IC4 R J7 Junction Connector D F B R C 8(A), C 9(B), C10(C), C11(D) Combination Meter 3 353 Combination Meter TAC TACH 9 13 F B B–W G A 13 IC5 B–W B–W (∗6) (1GR–FE) SPD 3 V–R V–R 5 SPD 3 (∗5) 20 B SPD V 19 B DMIN (∗1) DMOT V–R SPD M5 Moon Roof Control ECU A16(A), A17(B) A/C Control Assembly 8 A R5 Radio and Player B–W (2UZ–FE) R9 Radio and Player with Display V–R S14 Suspension Control ECU J31(A), J32(B) Junction Connector D1 Data Link Connector 3 B–W (2UZ–FE) 5 1A F A W–L BR–B SPD B 3D B 3D B 3D B 3D F A 14 H B Body ECU 1 1G 11 1K J 8(A), J 9(B) Junction Connector V–R Temp. Fuel 6 B R–L 8 IM2 13 C 2 C B–Y 4 B GR–R 8 B BR SRS Buzzer Tachometer C 8(A), C 9(B), C10(C), C11(D) Combination Meter 5 B 3 B Speedometer 2 B B–W V–R V–R 7 IM1 7 IC2 2 I9 Injector No. 1 GR–R 1 SP1 I9 Injector No. 1 ED 354 4RUNNER (EM03M0U) EE A32 Airbag Sensor Assembly 12 BR(1GR–FE) R–L D 3 BR(2UZ–FE) J27 Junction Connector (1GR–FE) R–L A (2UZ–FE) J26 Junction Connector S28 Skid Control ECU with Actuator R–L D A (1GR–FE) R–L (2UZ–FE) LA (∗2) A J2 Junction Connector (∗2) 1 1 2 W1 Washer Level Sensor 6 IM1 5 D 4WD Control ECU 15 A 11 A 4RUNNER (EM03M0U) L–Y 41 IO2 Daytime Running Light Relay (∗4) Turn Signal Flasher Relay (∗3) V–R ∗ ∗ ∗ ∗ ∗ ∗ 1 2 3 4 5 6 Turn RH L–R C 8(A), C 9(B), C10(C), C11(D) Combination Meter Turn LH CRUISE 7 A LG 7 D A/T OIL TEMP G A (∗3) G B V–R G B S22 Stereo Component Amplifier SPD Malfunction Indicator Lamp 9 P 6 D R–B G B 4LO J29(A), J30(B) Junction Connector BR–W V–R 3 (4WD) F9 4WD Control ECU SPD Center Diff. Lock 4WD V–R T16 Tire Pressure Monitor ECU 1 G–R (∗2) Washer V–R E7 Engine Control Module 8 W–G 7 IN1 (∗2) 6 A V–W Oil Pressure G A V–W 8 A LG–B Charge SPD W–B LG–B 16 A GR TACH W–B O1 Oil Pressure SW Generator B–W : w/ Moon Roof : Canada : Except 6 Speaker : w/ Daytime Running Light : w/ Navigation System : 6 Speaker 11 SPD V–R 10 C 6 C Engine Control Module A EB 355 Skid Control ECU with Actuator Airbag Sensor Assembly 18 C Tire Pressure Monitor ECU VSC TRAC 20 C R Y–R 17 C 1 A 10 A L–W P–B L–Y RSCA OFF Tire Pressure VSC OFF (4WD) AUTO LSD (2WD) Slip 12 A (4WD) DAC BR–Y BRAKE 19 A B–L ABS 4 D LG–R Combination Meter C 8(A), C 9(B), C10(C), C11(D) Combination Meter 356 4RUNNER (EM03M0U) : Parts Location Code See Page A16 A 36 A17 B 36 A32 Code See Page 33 (2UZ–FE) J2 36 Code J32 35 (1GR–FE) J7 38 See Page B M5 O1 38 41 33 (2UZ–FE) C8 A 37 J8 A 38 C9 B 37 J9 B 38 R5 39 C10 C 37 J10 A 38 R9 39 C11 D 37 J11 B 38 S14 39 S22 41 D1 37 J16 38 E7 37 J26 38 F9 37 J27 38 F14 40 J29 A 38 33 (2UZ–FE) J30 B 38 35 (1GR–FE) J31 A 38 I9 S28 T16 W1 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 39 33 (2UZ–FE) 35 (1GR–FE) : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 1C 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1K 1L 3D : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC4 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO2 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IC5 IE1 IM1 IM2 : Ground Points Code EB ED EE See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block 357 4RUNNER (EM03M0U) Air Conditioning Y–R (BAT) (IG) 8 1J 15A IG1 60A HEATER 2 2 Y–R Y–R E C E 4 HEATER Relay 2 J1 Junction Connector 2 5 1 2 MG CLT Relay J3 Junction Connector B–Y 3 2 2 2 B 2 1 2 L–B 1 IC4 2 LG–R L–B 2 L B–Y 7. 5A HEATER NO. 2 BR–Y B G–Y 3 IM1 L–B 5 IN1 36 IC4 43 IC4 37 IC4 B–Y 40 IC4 BR–Y 2 W–G 3 B3 Blower Motor Controller 3 4 +B VM GND SI L W–L 1 1 A2 A/C Lock Sensor A/C Magnetic Clutch M B2 Blower Motor G–Y W–B D 1 2 2 D 2 1 3 E Y–R 2 E P3 Pressure SW W–B C Y–R 5 E Y–R Y–R 2 Y–R R 20 1E 2 1 2 Y–G LG–R EB LG–B J24 Junction Connector W–B L LG–B W–B W–B A A II 358 4RUNNER (EM03M0U) Y–R (ACC) A (BAT) P (BAT) J7 Junction Connector 7. 5A ACC 10A DOME F 3E H 2 P 2 F 3E 2 J20 Junction Connector Y–R P 10 IC4 2 GR 3 ACC CUT Relay 4 C A A A GR A 3C B 3A A 3C F B R Y–R B 3A J 8(A), J 9(B) Junction Connector H A H A R 16 IC3 Y–R J7 Junction Connector D C 2 GR W–G 2 D J6 Junction Connector R 1 30 IC4 J25 Junction Connector R 2 2 H L 2 8 1K R 38 IC4 Y–R A 20A EFI L–B W–B IG+ ACC L–B 8 R 2 W–G GR W–B 1 14 7 LIN–B GND B 3F B 3F B 3F W–B D3 Heater Control Panel B 3F W–B B B 3F BR–Y W–B (2UZ–FE) Y–R W–G W–G W–G BR–Y Y–G LG–R LG–R L L LG–B LG–B J37 Junction Connector Y–G W–B A IK 359 4RUNNER (EM03M0U) Air Conditioning A16(A), A17(B) A/C Control Assembly (BAT) 10A ECU–B F B GR–G BR–W 24 D 25 D 1 D L–B TACH AC1 ACT W–B THW L–B THWO 14 D W–G ACCR 17 E E2 21 A 28 A E 4(A), E 7(D), E 8(E) Engine Control Module B–W R 2 IK1 BR–W G A 1 IK1 GR–G W–G B–W F A 2 IM2 ACT 18 A J 8(A) Junction Connector F A W–R AC1 7 B J31(A), J32(B) Junction Connector B 3E TABC 20 A B–W 4 1L MGC 10 B BR–Y B 3E LOCK 19 A W–G W–R 4 1B W–B W–R 2 IG 1 A Y–R VER1 8 B (2UZ–FE) GND 5 A W–B LIN1 4 A L–B +B 2 A 2 W–B W–G W–G BR (1GR–FE) B–L R–L E2 Engine Coolant Temp. Sensor Y–R (2UZ–FE) (2UZ–FE) 2 1 BR–Y L–B Y–G Y–G LG–R LG–R L L LG–B LG–B R 360 4RUNNER (EM03M0U) A16(A), A17(B) A/C Control Assembly 1 B 15 A 6 A TAM 22 A GR 7 A AMHDR(∗1) AMH(∗2) 14 B V–W 3 A AMCDR(∗1) AMC(∗2) 23 B V–R 21 A TPDR(∗1) TP(∗2) 25 A L–O 9 B Y–G SG V–Y TR P S5 L–B TWI LG–B BLW L HR LG–R PSW 39 IC4 GR 2 Y–G A27(A) Air Mix Control Servo Motor LH A26(B) Air Mix Control Servo Motor A19 A/C Room Temp. Sensor Y–G P Y–G Y–G Y–G Y–G L–B L–B 1 A (∗1) 2 B (∗2) 1 5 IC3 Y–G I B M 2 A 1 B P H B D A 5 A (∗1) 4 B (∗2) 4 A 5 B 2 Y–G L–B E A 1 J10(A), J11(B) Junction Connector C 3D J31(A), J32(B) Junction Connector C 3D L–B 3 A 3 B A1 A/C Ambient Temp. Sensor C 3D B 3B P B 3B 3 IM2 L–B Y–G LG–R L–B L LG–B ∗ 1 : Limited ∗ 2 : Except Limited R R 361 4RUNNER (EM03M0U) Air Conditioning A16(A), A17(B) A/C Control Assembly 4 5 3 Y–G A28 Air Mix Control Servo Motor RH 2 P 1 (∗1) 2 (∗1) A29 Air Vent Mode Control Servo Motor Y–G 1 5 M P 1 Y–G M P A25 Air Inlet Control Servo Motor Y–G 2 4 Y–G B 3B (∗1) 3 L–Y 5 AMCPA 24 B (∗1) 4 L–R L–W 3 AMHPA 16 B (∗1) LG–R TPPA 23 A M Y–G AOF 3 B LG AOD 4 B LG–R TPO 17 A P–G AIF 6 B P–L AIR 5 B P–B TPI 16 A Y–G B 3B B 3B L–B L–B R R 362 4RUNNER (EM03M0U) A16(A), A17(B) A/C Control Assembly 24 A 26 A TSDR(∗1) TS(∗2) 12 A DMOT DMIN 19 B 20 B W–L TSPA BR–B TE SPD 8 A V–G A21 A/C Solar Sensor 1 1G P 5 IG1 (∗2) P (∗1) 1 Y–G 11 1K 1 V–R A18 A/C Evaporator Temp. Sensor 2 2 V–R B 3D (∗2) B 3D V–R 3 5 IG1 V–G (∗1) R R 6 IG1 A20 A/C Solar Sensor 2 1 (∗1) B–O 4 IG1 (∗1) (∗1) G B–O (∗2) 6 IG1 V–R (∗1) P Y–G P W–L (∗2) BR–B B 3B L–B L–B ∗ 1 : Limited ∗ 2 : Except Limited R R 363 4RUNNER (EM03M0U) Air Conditioning S28 Skid Control ECU with Actuator (IG) (IG) 7. 5A GAUGE SP1 10A IGN 4 1G 11 1J B–O GR–R 12 R–L B A J 8(A), J 9(B) Junction Connector 7 IC2 3 B 2 B 7 B 16 C BR–B L–B R V–R Temp. 5 B C 9(B), C10(C) Combination Meter 5 C 13 C BR 15 C Speedometer 4 B W–L B–O GR–R D B W–L BR–B 7 IM1 BR (1GR–FE) (2UZ–FE) BR L–B R ED 364 4RUNNER (EM03M0U) EE System Outline 1. Heater Blower Operation Manual operation When the blower speed is set to a certain level using the blower control SW, the A/C control assembly sends the signals to the blower control to control the blower motor speed. Auto operation When the auto SW is pushed, the A/C control assembly sends the signals from various sensors and temperature SW to the blower control to automatically control the blower motor speed. 2. Air Inlet Control Servo Motor Control When the FRESH/RECIRC select SW is set to RECIRC, the motor in the air inlet control servo motor starts rotating to move the damper toward the RECIRC side. Since the damper position is detected by the TERMINAL TPI of the A/C control assembly, the motor is continuously rotated until the damper reaches its stop position. When the FRESH/RECIRC select SW is set to FRESH, the motor in the air inlet control servo motor starts rotating to move the damper toward the FRESH side. Since the damper position is detected by the TERMINAL TPI of the A/C control assembly, the motor is continuously rotated until the damper reaches its stop position. 3. Air Vent Mode Control Servo Motor Control When the mode select SW is pushed, the ECU in the A/C control assembly activates the air vent mode control servo motor. This causes the servo motor to rotate to the position (FACE, BI–LEVEL, FOOT, FOOT/DEF, DEF) selected using the mode select SW, and moves the damper. 4. Air Mix Control Servo Motor Control (Limited) When the temperature control SW on the driver’s side is pressed, the ECU in the A/C control assembly sends a signal to the air mix control servo motor on the driver’s side. This signal drives the motor to reach the temperature set by the temperature control SW on the driver’s side, and moves the damper. Passenger’s side is operated as same as the driver’s side. 5. Air Mix Control Servo Motor Control (Except Limited) When the temperature control SW is pressed, the ECU in the A/C control assembly sends a signal to the air mix control servo motor. This signal drives the motor to reach the temperature set by the temperature control SW, and moves the film damper. 6. Air Conditioning Operation The A/C control assembly receives various signals, I.E., the engine RPM from the engine control module, out side air temperature signal from the A/C ambient temp. sensor and coolant temperature from the engine control module, etc. When the engine is started and the A/C SW (A/C control assembly) is on, a signal is input to the A/C control assembly. As a result, turning the MG CLT relay on, so that the magnetic clutch is on and the A/C compressor operates. If the A/C control assembly detects the following conditions, it stops the air conditioning: ∗ Evaporator outlet air is too low. ∗ There is a marked difference between the compressor speed and the engine speed. ∗ The refrigerant pressure is abnormally high or abnormally low. ∗ The engine speed is too low. ∗ Rapid acceleration occurs. : Parts Location Code See Page A1 A2 Code See Page Code See Page 32 (2UZ–FE) B2 36 34 (1GR–FE) B3 36 J8 J7 A 38 38 32 (2UZ–FE) C9 B 37 J9 B 38 34 (1GR–FE) C10 C 37 J10 A 38 37 J11 B 38 A16 A 36 A17 B 36 D3 E2 32 (2UZ–FE) J20 38 34 (1GR–FE) J24 38 J25 38 A18 36 A19 36 E4 A 37 A20 36 E7 D 37 J31 A 38 A21 36 E8 E 37 J32 B 38 A25 36 A26 B 36 A27 A 36 A28 36 A29 36 J1 J3 J6 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 38 J37 P3 S28 38 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 365 4RUNNER (EM03M0U) Air Conditioning : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1E See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1G 1J 1K 1L 3A 3B 3C 3D 3E 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC2 IC3 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IG1 46 Instrument Panel No.2 Wire and Instrument Panel Wire (Behind the Combination Meter) IK1 47 Instrument Panel Wire and Instrument Panel Wire (Left Upper Side of the Glove Box) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IC4 IM1 IM2 IN1 : Ground Points Code EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block II 46 Instrument Panel Brace RH IK 46 Right Kick Panel EE 366 4RUNNER (EM03M0U) Memo 367 4RUNNER (EM03M0U) Engine Immobiliser System (IG) (BAT) 10A IGN 10A ECU–B D1 Data Link Connector 3 SIL 7 11 1J G 4 1B G J18 Junction Connector I17 Transponder Key Amplifier R–Y W–R 2 B–O B R–Y 2 J8 Junction Connector Transponder Key Coil A 3A 4 1L B–O W–R B A 3A ANT1 B 3E R–Y VC5 9 8 11 12 13 VC5 CODE TXCT AGND EFIO EFII 6 7 14 3 L–R W–B V–W G–Y D W–R +B 5 B A IND LP GND 15 A J33 Junction Connector IMO A CTY C B 4 A B J37 Junction Connector W–B A B J15(B) Junction Connector W–B W–B W–B B 3F W–B 1 B 3F A J24 Junction Connector A IK F 1 K3 Unlock Warning SW B 3F A J18 Junction Connector 7 2 E7 Engine Control Module F R–B IMI D3 Security Indicator Light W–B 16 KSW 10 G–Y GND T8 Transponder Key Computer R–B 1 IG J14(A), J15(B) Junction Connector B–O 2 7 L F W–R B GND 5 LG–R J35 Junction Connector TXCT P–G F B 3E 4 GR–B J31 Junction Connector CODE 1 R–Y B ANT2 II A J5 Junction Connector IG 98 4RUNNER (EM03M0U) D12 Door Courtesy SW Front LH : Parts Location Code See Page D1 37 Code See Page J8 Code See Page 38 J33 38 D3 37 J14 A 38 J35 38 D12 40 J15 B 38 J37 38 E7 37 J18 38 K3 39 I17 37 J24 38 T8 39 J5 38 J31 38 : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1B 1J 1L See Page Junction Block and Wire Harness (Connector Location) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3A 3E 3F : Ground Points Code See Page Ground Points Location IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel 99 4RUNNER (EM03M0U) Multiplex Communication System – BEAN Bus B 4(A), B 6(C) Body ECU MPX3 MPX2 23 A BR–Y BR–R 26 C B J19 Junction Connector 40 IE1 BR–Y BR–R B R 9 BD1 31 MPX1 1 T5 Theft Deterrent ECU MPX2 100 4RUNNER (EM03M0U) B8 Back Door ECU Multiplex Communication System Includes Following Systems ∗ Automatic Light Control ∗ Door Lock Control ∗ Front Fog Light ∗ Garage Door Opener ∗ Headlight ∗ Interior Light ∗ Key Reminder ∗ Light Auto Turn Off System ∗ Mirror Heater ∗ Power Window ∗ Rear Window Defogger ∗ Rear Wiper and Washer ∗ Seat Belt Warning ∗ Theft Deterrent ∗ Wireless Door Lock Control : Parts Location Code See Page Code See Page B4 A 36 B8 40 B6 C 36 J19 38 Code T5 See Page 39 : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) 101 4RUNNER (EM03M0U) Multiplex Communication System – CAN Bus D1 Data Link Connector 3 Y1 Yaw Rate Sensor CANH CANL CANH LG CANL 34 L CANH 33 V CANL 14 P 6 R 2 W 3 E7 Engine Control Module 1 B 2 B 1 D 2 D 1 E 2 E W 2 A 11 IC2 22 IC2 11 11 25 CANL CANH CANL J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector 1 F W–B W Y 1 A B 2 C B 1 C B ST–Plug 3 CANH S11 Steering Sensor S28 Skid Control ECU with Actuator IH 102 4RUNNER (EM03M0U) System Outline CAN has two lines as a pair which make communication with operating voltage. CAN has excellent data speed and error detecting capacity. It consists of vehicle control systems such as engine control module, data link connector 3, skid control ECU with actuator, steering sensor and yaw rate sensor. This system is working for the following systems: ∗ ABS ∗ Auto LSD ∗ Cruise Control ∗ Downhill Assist Control ∗ Electronically Controlled Transmission and A/T Indicator ∗ Engine Control ∗ Hill–Start Assist Control ∗ TRAC ∗ VSC : Parts Location Code See Page D1 E7 Code See Page 37 J49 C 38 37 J50 D 38 J47 A 38 J51 E 38 J48 B 38 J52 F 38 Code S11 S28 Y1 See Page 39 33 (2UZ–FE) 35 (1GR–FE) 39 : Connector Joining Wire Harness and Wire Harness Code IC2 See Page 46 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) : Ground Points Code IH See Page 46 Ground Points Location Instrument Panel Brace LH 103 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU (BAT) (BAT) 50A J/B (ACC) 20A DR/LCK (IG) 7. 5A ACC 15A RR WSH WIG 1 ACC 22 BDR1 12 CLTB 6 C CLTE 21 C CLTS 4 C 2 G–W Y 3 IG1 2 IG1 1 IG1 Y L–W 9 1E G–W 2 L–Y 2 L–Y 2 G–W 1 3 4 CLTB CLTE CLTS A39 Automatic Light Control Sensor L–W 104 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU TRLY HRLY 18 17 2 5 1 R–B R–B TAIL Relay 3 HF2 20 C 2 2 1 1 1 1 8 1B 10A HEAD (LO LH) 10A HEAD (LO RH) 10A HEAD (HI LH) 10A HEAD (HI RH) W W L–W 1 1C 2 19 IC4 2 2 2 2 2 2 2 1 1 R–L 2 R–W H1 Headlight LH (High) R–B 2 W–B H4 Headlight RH (Low) R–Y 2 W–B H2 Headlight LH (Low) R–W 1 2 R–W R–L R–G R–G 23 IC4 R–B R–B W 2 22 IC4 2 3 HEAD Relay 1 R–L 5 R–W R–G 2 B W–B W–B Battery W–B W L–W EB 105 4RUNNER (EM03M0U) Multiplex Communication System – BEAN 3 C 7 C G–O R–W 10 IH1 9 IH1 G–O 16 12 R–L 2 IC3 W–B (∗1) W–B W–B G 8 IH1 R G–R 1 IH1 TAIL C12 Combination SW 10 13 14 8 W–B HF 8 C R–W A 1 C G HEAD ∗ 1 : w/ Daytime Running Light ∗ 2 : w/ Rear Seat Entertainment System ∗ 3 : w/o Rear Seat Entertainment System R B 4(A), B 5(B), B 6(C) Body ECU 2 J15(B) Junction Connector Light Control SW OFF A B Tail Head A B Auto W–B High Flash OFF G–R ON LH RH 11 17 7 1 G–B Dimmer SW Fog Light SW Low R–G R–G 1 Turn SW 2 H3 Headlight RH (High) R–W 3 (∗1) D B R–G E A R–G E A J10(A), J11(B) Junction Connector E A R–G R–G J12(A), J13(B) Junction Connector G–Y R–G (∗1) 10 IN1 B A R–L G–Y(∗1) G–B(∗1) B B R–W R–W R–G R–G W–B W–B W–B W–B W–B A A IG 106 4RUNNER (EM03M0U) J5 Junction Connector W–B B 4(A), B 5(B), B 6(C) Body ECU GND2 PWS 1 2 2 LG W 3 2 1F 25 1J 8 1A 1 1H 1 1A W 2 7 1A (∗2) 5 (∗2) 30A POWER 2 2 1H W W(∗3) (∗2) W(∗3) W(∗2) W(∗3) FR FOG Relay W W(∗3) W–B L W L–O 5 (∗2) W(∗2) 2 L–O 2 13 (BAT) 15A FR FOG 2 ILE 4 POWER Relay (BAT) R–L GND1 16 21 2 3 2 A (∗2) 2 B (∗3) 3 A 3 B 1 A (∗2) 1 B (∗3) L2 Luggage Compartment Light DOOR ON OFF G G–R I20(A), (B) Interior Light G 12 IC3 2 DOOR 2 PWS ON OFF G 3 M5 Moon Roof Control ECU 4 1 1 W(∗2) (∗2) W 1 W(∗3) 1 W–B W–B W–B B 2 F2 Front Fog Light RH G G F1 Front Fog Light LH J3 Junction Connector B W–B W(∗3) W(∗2) W(∗3) 2 W L–O L–O W–B G–Y(∗1) G–Y(∗1) G–B(∗1) G–B(∗1) R–W R–W R–G R–G W–B W–B W–B W–B W–B W–B W–B W–B W–B W–B G EA 107 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU 3 PCYL 25 A RCYL 22 B B–Y Y–R L–R DOWN Y W 6 COM 19 B 9 1K (w/ Vanity Light) 18 1A W–B 12 1A BUP 10 B B–L BDN 8 B 9 IP1 8 BB1 1 UP E 1 I17 Ignition Key Cylinder Light V7 Vanity Light RH B 2 B1 Back Door Power Window Control SW 6 1 J35 Junction Connector 2 2 W 2 1 2 9 1A 6 1E R A A R H 9 BB1 R R R 19 1A H H (Limited) R H A A 4 1A 1 IP2 C B J12(A), J13(B) Junction Connector W (w/ Vanity Light) R (w/ Vanity Light) R R 5 V6 Vanity Light LH P7 Personal Light E D9 Door Courtesy Light Front RH Y (w/ Vanity Light) 1 R–G 1 D11 Door Courtesy Light Rear RH L–R W W(∗2) R–W R 22 1J (Limited) E R J6 Junction Connector E W(∗3) W W L–O L–O L–O L–O W–B W–B G–Y(∗1) G–Y(∗1) G–B(∗1) G–B(∗1) R–W R–W R–G R–G W–B W–B W–B W–B W–B R–W W–B G G ∗ 1 : w/ Daytime Running Light ∗ 2 : w/ Rear Seat Entertainment System ∗ 3 : w/o Rear Seat Entertainment System 108 4RUNNER (EM03M0U) 4 IO3 R R E 3 IE1 J6 Junction Connector R 2 BL1 13 IA1 9 BA1 R 1 2 D10 Door Courtesy Light Rear LH P–G D8 Door Courtesy Light Front LH Y–G 9 IA1 8 BA1 4 IE1 4 4RUNNER (EM03M0U) 1 2 E E DEFOG Relay C A 5 1 3 2 2 2 R 140A ALT R J20(A), J21(B) Junction Connector Y–R P–G W–G DCYL B–R W–R W–R (Limited) 26 A W–B 5 IO3 (Limited) C A (Limited) W–R (Limited) W–R (Limited) C B W–R (Limited) (Limited) LP R (Limited) W–R (Limited) 6 B R (Limited) 1 BL1 W–R (Limited) 1 (Limited) 2 S34 Step Light Rear LH W–R R (Limited) 1 R 2 BM1 S32 Step Light Front LH W–R R (Limited) 2 (Limited) R (Limited) 2 (Limited) R 1 BM1 R (Limited) 1 (Limited) 2 S35 Step Light Rear RH W–R R (Limited) 1 (Limited) S33 Step Light Front RH W–R R B 4(A), B 5(B), B 6(C) Body ECU 21 B LCYL RDEF 6 (BAT) 3 1B 2 2 2 Y–R W W L–O L–O L–O L–O W–B B–R G–Y(∗1) G–Y(∗1) G–B(∗1) G–B(∗1) R–W R–W R–G R–G W–B W–B W–B W–B R–W R–W W–B W–B G G 109 Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU STPI HAZ 3 8 24 1E 14 1J (BAT) (IG) (BAT) W (∗4) 2 W 2 IF1 A (∗1) 2 3 (∗1) (∗1) R–B 42 IC4 F5 Front Turn Signal Light LH G–B 3 R–B (∗1) R–Y (∗1) 1 IN1 (∗1) 2 2 IH1 F6 Front Turn Signal Light RH G–Y 2 3 IH1 LG 2 TFL 4 R–Y B E TFR 2 G–B 2 TSL 7 (∗1) J4 Junction Connector J4 Junction Connector E TSR G–B 3 4 B HAZ 8 (∗1) 1 10 B G–Y 5 STOP LP CTRL Relay G–Y 2 EHW D2 Daytime Running Light Relay Turn Signal Flasher Relay 6 A (∗1) Y–R S12 Stop Light SW 2 1 E Y–R J1 Junction Connector D Y–R 2 (∗1) G–W 20 IC4 B–Y E G–Y E J7 Junction Connector D Y–R Y–R G–B G–W Y–R 8 2 B–Y 8 1J T9 Turn Signal Flasher Relay 20 1E 2 W 10 (∗1) 15A TRN–HAZ (∗4) 15A IG1 10A STOP 2 Y–R Y–R W W L–O L–O L–O L–O B–R B–R G–B(∗1) W–B W–B G–Y(∗1) R–W R–W R–G R–G W–B W–B W–B W–B R–W R–W W–B G G 110 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU P DEFSW P C A G–B GND 7 B 1 B 3F A 3C PBEW 3 DIND SIND 12 GR–G B 3F B 3F A 3C R A W–B A W–B A Y–R E A J25 Junction Connector J22(A), J23(B) Junction Connector D B J 8(A) Junction Connector IG+ 2 R E A W–B E A Y–R C LG G–B J35 Junction Connector (∗1) W–B (∗1) Y–R (∗1) H A W–B Y–R J20(A), J21(B) Junction Connector 9 F B H A C DFSW Y–R E 2 IM1 Y–R IG 1 D2 Daytime Running Light Relay Turn Signal Flasher Relay 8 IM1 DRL D3 Defogger SW Passenger Seat Belt Warning Light Security Indicator Light G–B Y–R G–B 6 12 11 C B P1 Park/Neutral Position SW (∗1) LG–R 2 4 J18(A), J19(B) Junction Connector G–B ∗ 1 : w/ Daytime Running Light ∗ 4 : w/o Daytime Running Light DIND 5 B G 1 B 17 B G–R DRL 7 A Y–R LG W W L–O L–O L–O B–R G L–O B–R R–W R–W R–G R–G W–B W–B W–B W–B R–W R–W A A W–B IG J37 Junction Connector G J5 Junction Connector R A A W–B IK 111 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU 10A SECU/HORN A B G–Y 1 12 +B2 SH– E A J18(A), J19(B) Junction Connector BR–Y 31 KSW MPX1 B A IG T5 Theft Deterrent ECU 10 HORN 5 B 3E A 3D B 3E G–Y A 3D J12(A) Junction Connector P–G J20(A) Junction Connector W–R 6 IC3 +B1 2 C B W–B P–G GR–G GR–G E 29 G–R DSWH 34 B–R IND 25 2 E3 Engine Hood Courtesy SW 1 G A G A G A D A D A J14(A), J15(B) Junction Connector T1 Theft Deterrent Horn BR–B 3 1 B–R B B K3 Unlock Warning SW W–L 10 1K 28 1J BR–Y BR–B 2 IN1 B–R B B G–Y G–Y 10A ECU–IG 8 1F A B (BAT) BR–B (IG) MPX3 26 C BR–Y KSW 14 C G–Y SIG 10 1 B–R W–B B–R B–R W–R W–B B–R W–B G–R 4 B–R LG LG W W B–R L–O L–O G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–B W–R R–W R–W R R A W–B J24 Junction Connector A II 112 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU TOUT 6 A 10A HORN L 2 P9 Power Window Control SW Front RH G–R (Except Limited) (BAT) W–G 2 10 1E 3 1 3 13 1K 1 1D 2 R 2 5 R–B 5 B 4 1 P13 Power Window Motor Front RH L–B 2 1 M 10 IP2 9 IP2 5 IP2 HORN Relay W L–Y L–R L–Y G–R G–R C W C W J7 Junction Connector C C W GR–B 1 C 1 H9 Horn (High) H10 Horn (Low) J33 Junction Connector C W W B B C A GR–B C A J14(A), J15(B) Junction Connector C W B–R B–R LG LG W B–R B–R L–O L–O G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W R–W R R 113 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU RRD G 7 BB1 6 BB1 G L–B L 5 2 1 3 L–Y M 1 R G–B 2 BW 7 12 IA1 2 IA2 L–O R–L 10 IA2 11 B B 11 IA2 5 IA2 B2 16 B–R RRU 18 P15 Power Window Motor Rear RH B 6 G–B 12 IA2 PU 13 W 7 IA2 PD 15 B L–R A A L–R L–Y B A D17 Door Lock Control SW Front LH Power Window Master SW R–B L–Y C B R L–R B A L–Y L–R A A B B R–B J22(A), J23(B) Junction Connector W/L 2 22 C R W/L 1 24 C W W 5 BB1 W 4 P11 Power Window Control SW Rear RH W W W B–R LG LG B–R B–R L–O G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W R–W R R 114 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU 5 2 1 3 E 2 1 1 2 4 5 3 6 D U SSRB PLS PLS2 E UL L 8 5 R–W GND W–B PLS2 17 BR–B PLS 14 W–G 3 W–R VCC G–W 1 DU 4 W–L M P14 Power Window Motor Rear LH 6 BA1 2 L G G–R 7 BA1 G–R L G–W 6 IA2 G–W 9 IA2 DD 9 L RLD 10 L–B RLU 12 L–B D17 Door Lock Control SW Front LH Power Window Master SW 5 IA1 4 IA1 L–W L–O W 4 P10 Power Window Control SW Rear LH B J38 Junction Connector M P12 Power Window Motor Front LH B B W–B W–B B 5 BA1 W R LG LG W–B 4 IA2 B–R B–R W–B W–B G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W R–W R A A J5 Junction Connector IG 115 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU LSWD ACTD 21 A 10 A L–B D UL3 12 A W–R L–O A L2 20 G L–W 1 1K LSWP 30 A 3 1K D18 Door Lock Control SW Front RH Lock 8 IA1 7 IA1 13 IA2 8 IA2 L G W B–R B–W 5 IP1 9 10 8 1 4 6 IA1 W–B W–B L–O 6 IP1 3 W–B 6 L 5 L–R L–W D R A Unlock B–W L–O D L–O L–W A 5 1K L–W J6 Junction Connector UL1 15 L L1 19 M L–W 4 IP2 7 W–B L–O D16 Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH Door Lock Motor Front LH W–B W–B W–B R R LG LG W–B W–B B–R B–R W–B W–B G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W R–W A A IK J37 Junction Connector 116 4RUNNER (EM03M0U) W–B B 4(A), B 5(B), B 6(C) Body ECU ACT– LSR 24 5 9 1L 18 1L 6 1L 16 1L ACTY 20 B 23 1L 11 1L 15 1K 22 1L 10 1L R–G ACT+ 23 12 IC5 B–W L–R W L–B L–R W L–B L–R 7 IP2 2 IP2 10 BA1 11 BA1 12 BA1 10 BB1 11 BB1 12 BB1 B–R B–W W L–B L–R W L–B L–R 7 1 4 6 1 4 6 1 4 R–G L–B 7 IP1 B L–R 4 W–B 9 D20 Door Lock Detection SW Rear LH Door Lock Motor Rear LH 9 4 BA1 4 BB1 W–B W–B D19 Door Lock Detection SW Front RH Door Lock Motor Front RH M W–B W–B 8 M W–B M D21 Door Lock Detection SW Rear RH Door Lock Motor Rear RH DOOR S15 Suspension Control ECU W–B R LG LG W–B W–B W–B B–R B–R W–B R G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W R–W W–B 117 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU 10 1B 6 1B RDA 4 B PRG LMRY 3 B 3 A (IG) L–R G–O R Y–B P–B D 38 IE1 39 IE1 41 IE1 D J7 Junction Connector D R 7 R BZR2 R BZR 9 10 IC4 1 IC3 7. 5A GAUGE 1 W3 Wireless Door Lock Buzzer (BAT) 2 5 +B R 3 PRG R R 2 RDA L–R G–O 4 1G 10A DOME 2 2 R E 1 D7 Door Control Receiver R 2 W–B 2 W–B W–B A B A A 2 DOME Relay 3 R–L 1 2 2 R–W A A W–B A A J40(A), J41(B) Junction Connector 5 R R LG LG W–B W–B W–B W–B B–R B–R R R G G L–O L–O B–R B–R R–W R–W R–G R–G W–B W–B W–R W–R R–W W–B W–B W–B BO 118 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU DRLP DCY2 12 C 11 C SPD KSWO 15 C 14 ∗ 5 : 2UZ–FE ∗ 6 : 1GR–FE H A H A R R F B BR 13 C J 8(A), J 9(B) Junction Connector R–L Head (USA) 13 D R–G V–R 12 D G 10 D 18 B LG Speedometer 16 C R 15 C Beam 5 B R–W 19 B Front Fog V–G 8 C Driver' s Seat Belt C 8(A), C 9(B), C10(C), C11(D) Combination Meter Door 17 A W–L V–Y 1 1G 7 IM1 (∗6) BR BR LG (∗5) R W–B W–B W–B W–B B–R B–R R G L–O L–O B–R B–R R–W R–G (∗6) W–R BR W–R BR W–B (∗5) W–B W–B W–B W–B W–B ED EE 119 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU B16(A), (B) Buckle SW RH 1 A 1 B 2 A (∗11) 2 B (∗12) L S28 Skid Control ECU with Actuator GR C 8(A), C 9(B), C10(C), C11(D) Combination Meter SP1 FSR+ 4 8 W FSR– 4 BI1 1 BI1 7 IC2 4 B A32(C), A33(D), A34(E) Airbag Sensor Assembly L–R G–Y GR–R 2 D 10 E FSR– W 13 B 9 BSW B 12 B 5 BGND B GR–R Buzzer O3 Occupant Classification ECU 12 1 D (∗7) 3 E (∗8) FSR+ PBEW 2 C L–R G–Y W–B W–B W–B W–B B–R B–R L–O L–O B–R B–R W–B W–B W–R W–R W–B W–B W–B W–B 120 4RUNNER (EM03M0U) B 4(A), B 5(B), B 6(C) Body ECU DBKL 13 A G–Y B–R J20(A), J21(B) Junction Connector B B 2 E 7(D) Engine Control Module 1 D A ELS2(∗5) ELS1(∗6) 12 D (∗5) 13 D (∗6) G–Y B Y–G R21(A), R22(B) Rear Window Defogger 2 10A MIR HEATER 2 I A 36 IE1 B–L D B 2 4 BD1 Y–G (∗9) (∗10) G–Y 1 B 30A DEFOG 7 BH1 Y–G L K B L C A 10 BK1 1 2 (∗9) J 8(A), J 9(B) Junction Connector D A 1 A (∗10) J43(A), J44(B) Junction Connector G–Y Y–G 26 IE1 J31(A), J32(B) Junction Connector G–Y D A 18 IC4 4 IC4 Y–G Y–G D A D A D A (∗6) (∗5) Y–G W–B B–R B15 Buckle SW LH 3 Y–G B–L C B J22(A), J23(B) Junction Connector 4 W–B E B A B G–Y A A J53 Junction Connector J43(A), J44(B) Junction Connector W–B (∗10) (∗9) B ∗ 5 : 2UZ–FE ∗ 6 : 1GR–FE ∗ 7 : w/ Side Airbag ∗ 8 : w/o Side Airbag ∗ 9 : w/ Driving Position Memory ∗10 : w/o Driving Position Memory ∗11 : w/ Power Seat (Front Passenger' s Seat) ∗12 : w/o Power Seat (Front Passenger' s Seat) B W–B W–B B–R B–R (∗9) W–B W–B W–B L–O W–B L–O 3 BH1 (∗10) W–B B–R 1 BK1 W–B W–R W–R W–B W–B W–B 10 BD1 W–B W–B W–B W–B W–B (∗9) BL 121 4RUNNER (EM03M0U) Multiplex Communication System – BEAN B 4(A), B 5(B), B 6(C) Body ECU PKB 17 C 4 1L 12 1F 10A ECU–B G B 17 1J A A GR 18 IA1 R–Y B–L 18 IP1 G A E B 1 1E LG B–L B–L 2 W–R 2 B W–R B W–R B J18(A), J19(B) Junction Connector 4 1B GR (BAT) J6 Junction Connector L 14 A R–Y 11 J18(A), J19(B) Junction Connector LG OBD2 BECU 2 B W–B 7 GR SIL D1 Data Link Connector 3 1 EA1 (∗5) 3 EA2 (∗6) GR 5 P4 Parking Brake SW G–B 5 W–B 4 M3 Mirror Heater LH 4 B–L M4 Mirror Heater RH G–B 6 IC4 1 4 L G2 Generator W–B W–B W–R B–R B–R L–O L–O W–B W–B W–R W–B W–B 122 4RUNNER (EM03M0U) W–B Rear Wiper and Washer SW A B C A C A C14 Combination SW B B LG–B 12 HI 2 7 IH1 1 W–B 4RUNNER (EM03M0U) 1 P–L BR–R R–Y P–B J18(A), J19(B) Junction Connector F A PCTY 11 B RLCY 1 1 D15 Door Courtesy SW Rear RH 3 IC3 H B 24 B P–L B A DCTY D14 Door Courtesy SW Rear LH B A 23 B P–B 2 RWINT D13 Door Courtesy SW Front RH R–B RWON D12 Door Courtesy SW Front LH R–B D24 Diode (Rear Wiper) 9 C BR–W 1 1B 10 C GR–R 2 BR–W 1 GR–R B–O WMTR J12(A), J13(B) Junction Connector M GR–R 4 LG–B LG–B 3 J12(A), J13(B) Junction Connector LG–B W2 Washer Motor B 4(A), B 5(B), B 6(C) Body ECU 12 B RRCY 23 A MPX2 37 IE1 6 IO3 40 IE1 BR–R 10 Washer OFF LO ∗ 5 : 2UZ–FE ∗ 6 : 1GR–FE Washer 13 W–R W–R B–R B–R L–O L–O W–B W–B 123 Multiplex Communication System – BEAN B 8(A), B 9(B) Back Door ECU J39 Junction Connector F E F E 2 14 B L–R ACT– 15 B L–B ACT+ 21 B B–R LSE 8 B BR–W POS 7 B G–Y FULL 6 B R–G HALF 5 B V–Y UP 4 B GR–R DOWN 19 B LG–B 1 BR–R E B10 Back Door Opener SW LG–R HSW– 22 B L–O B–R W–R 9 BD1 7 BD1 5 BD1 6 BD1 HSW+ 10 B V–W W–B GND 3 A L BDR 4 A B SIG 6 A L–R BECU 5 A R MPX2 1 A 3 2 1 5 6 4 3 1 2 M T10 Tailgate Control SW B7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW Back Door Lock Motor W–R B–R L–O W–B 124 4RUNNER (EM03M0U) B 8(A), B 9(B) Back Door ECU P W 18 B 12 B 3 B 2 B 1 B G–R P–B BR–B Y–G R–G IC– 23 B L–W IC1 16 B B–O IC2 17 B W–R IC+ 11 B Y–G R–B BDDN 25 B Y–B BDUP 13 B 1 3 5 4 4 5 1 2 6 3 R G SSRB PLS PLS2 E SGND WIP+ WIP– Return Position Furthest Position M Stop M 2 R23 Rear Wiper Motor Rear Wiper Position SW B11 Back Door Power Window Motor 125 4RUNNER (EM03M0U) Multiplex Communication System – BEAN System Outline Communication Outline Communication is made among the body, theft deterrent and back door ECUs. When the ECU receives a signal from related switches, i.e., the rear wiper SW, the body ECU sends signals to the back door ECU, and moves rear wiper. For details, please refer to the new car features and/or the repair manual. 126 4RUNNER (EM03M0U) : Parts Location Code See Page A32 C 36 A33 D 36 A34 E 36 A39 36 B1 36 B4 A 36 B5 B 36 C 36 B6 B7 Code F5 F6 A 40 B9 B 40 B10 40 B11 40 B15 H4 43 (*2) A B16 B 42 (*1) 42 (*1) C8 A 37 C9 B 37 C10 C 37 C11 D 37 40 32 (2UZ–FE) J40 A 40 34 (1GR–FE) J41 B 40 J43 A J44 B 42 (*1) 43 (*2) 42 (*1) 43 (*2) 32 (2UZ–FE) J53 42 (*1) 34 (1GR–FE) K3 39 32 (2UZ–FE) L2 40 34 (1GR–FE) M3 41 32 (2UZ–FE) M4 41 34 (1GR–FE) M5 41 42 (*1) O3 32 (2UZ–FE) 43 (*2) 33 (2UZ–FE) P1 34 (1GR–FE) I17 I20 40 J39 34 (1GR–FE) H10 43 (*2) J38 34 (1GR–FE) 32 (2UZ–FE) H9 43 (*2) 32 (2UZ–FE) 34 (1GR–FE) H3 42 (*1) 38 32 (2UZ–FE) H2 See Page J37 34 (1GR–FE) H1 Code 34 (1GR–FE) 32 (2UZ–FE) G2 40 B8 See Page F2 35 (1GR–FE) 37 P4 39 A 40 P7 41 B 40 P9 41 33 (2UZ–FE) P10 41 35 (1GR–FE) P11 41 33 (2UZ–FE) P12 41 35 (1GR–FE) P13 41 41 J1 C12 37 C14 37 D1 37 D2 37 J4 38 P14 D3 37 J5 38 P15 D7 40 J6 38 R21 A 41 D8 40 J7 38 R22 B 41 D9 40 D10 D11 J3 41 J8 A 38 R23 41 40 J9 B 38 S12 39 40 J10 A 38 S15 39 D12 40 J11 B 38 D13 40 J12 A 38 D14 40 J13 B 38 S32 41 D15 40 J14 A 38 S33 41 D16 40 J15 B 38 S34 41 D17 40 J18 A 38 S35 41 D18 40 J19 B 38 D19 40 J20 A 38 D20 40 J21 B 38 T5 39 D21 40 J22 A 38 T9 39 D24 37 J23 B 38 T10 41 E3 E7 D F1 F2 * 1 : Power Seat S28 T1 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) 32 (2UZ–FE) J24 38 V6 41 34 (1GR–FE) J25 38 V7 41 37 J31 32 (2UZ–FE) J32 A 38 B 38 34 (1GR–FE) J33 38 32 (2UZ–FE) J35 38 W2 W3 33 (2UZ–FE) 35 (1GR–FE) 33 (2UZ–FE) 35 (1GR–FE) * 2 : Manual Seat 127 4RUNNER (EM03M0U) Multiplex Communication System – BEAN : Relay Blocks Code 2 See Page 22 Relay Blocks (Relay Block Location) Engine Room R/B (Engine Compartment Left) : Junction Block and Wire Harness Connector Code 1A See Page Junction Block and Wire Harness (Connector Location) 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 24 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 24 Floor No.2 Wire and Driver Side J/B (Lower Finish Panel) 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 1B 1C 1D 1E 1F 1G 1H 1J 1K 1L 3C 3D 3E 3F : Connector Joining Wire Harness and Wire Harness Code See Page EA1 44 (2UZ–FE) EA2 45 (1GR–FE) IA1 Joining Wire Harness and Wire Harness (Connector Location) Engine No.2 Wire and Engine Room Main Wire (Under the Engine Room R/B) 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 46 Instrument Panel Wire and Engine Room Main Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) IG1 46 Instrument Panel No.2 Wire and Instrument Panel Wire (Behind the Combination Meter) IH1 46 Instrument Panel Wire and Instrument Panel Wire (Behind the Combination Meter) IM1 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BH1 48 Back Door No.1 Wire and Back Door No.2 Wire (Left Side of Back Door) IA2 IC2 IC3 IC4 IC5 IP1 IP2 BI1 50 (*1) 51 (*2) Floor Wire and Seat No.1 Wire (Under the Front RH Seat) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) BL1 48 Floor No.2 Wire and Step Rear Floor LH Wire (Near the Side Step LH) BM1 48 Floor Wire and Step Rear Floor RH Wire (Near the Side Step RH) * 1 : Power Seat * 2 : Manual Seat 128 4RUNNER (EM03M0U) : Ground Points Code EA EB ED See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block IG 46 Left Kick Panel II 46 Instrument Panel Brace RH IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BO 48 Rear Pillar LH EE 129 4RUNNER (EM03M0U) I GROUND POINT W–B B (2UZ–FE) STA Relay 2 IG Relay 2 ER 2 HEATER Relay 2 (2UZ–FE) EC W–B W–B W–B Air Switching Valve W–B W–B EQ DEFOG Relay Noise Filter (Ignition No. 1) Air Pump (2UZ–FE) W–B W–B W–B B B B B B B B B B B J 2(A), J 3(B) Junction Connector B A 2 A/F HEATER Relay 2 BATT CHG Relay 3 B A B A B A W–B W–B Front Parking Light LH W–B Engine Hood Courtesy SW W–B EFI Relay B A W–B W–B W–B W–B AIR SUS Relay 4 W–B W–B W–B W–B W–B (MOD2) W–B W–B A B A B A A A B A A A B (GND3) (EXI3) Skid Control ECU with Actuator (GND1) (GND2) Front Turn Signal Light RH A B A A W–B W–B W–B Brake Fluid Level Warning SW Front Turn Signal Light LH W–B A A W–B Headlight LH (Low) Front Fog Light LH Front Fog Light RH W–B W–B W–B W–B Washer Level Sensor Headlight RH (Low) W–B W–B (GND2) W–B W–B W–B EB 368 4RUNNER (EM03M0U) W–B (GND) Suspension Control ECU W–B J 2(A), J 3(B) Junction Connector (MOD1) (2UZ–FE) Front Wiper Motor EA Front Parking Light RH I (GND) (GND) Ignition Coil and Igniter No. 4 W–B W–B Ignition Coil and Igniter No. 5 W–B W–B Ignition Coil and Igniter No. 6 W–B Transfer Shift Actuator W–B W–B W–B Ignition Coil and Igniter No. 7 Ignition Coil and Igniter No. 2 W–B W–B Ignition Coil and Igniter No. 8 Ignition Coil and Igniter No. 3 W–B W–B Noise Filter (Ignition No. 2) (E01) (E02) (4WD) (E1) (E03) (E04) (E05) W–B 10 IM2 BR BR 7 IM1 BR W–B W–B(4WD) W–B ED W–B Ignition Coil and Igniter No. 2 W–B E B A A (2UZ–FE) BR 4 IN1 A A BR BR W–B 9 IE1 W–B W–B Ignition Coil and Igniter No. 5 W–B Ignition Coil and Igniter No. 6 W–B W–B Ignition Coil and Igniter No. 4 16 IM2 W–B Ignition Coil and Igniter No. 3 W–B 9 IM2 BR BR ED W–B J28 Junction Connector 5 EC1 W–B W–B W–B W–B (ME01) (E05) (E04) 10 IM2 BR 9 IM2 BR 7 IM1 BR BR W–B BR BR W–B (E03) Air Injection Control Driver (SG) Data Link Connector 3 Canister Pump Module (ME01) Engine Control Module (ECC) Combination SW (SG) Data Link Connector 3 (ET) Combination Meter E W–B Noise Filter (Ignition No. 1) E BR (GND) Combination Meter (2UZ–FE) BR (GND) (ET) (2UZ–FE) BR W–B Transfer Shift Actuator Combination SW J35(A), J36(B) Junction Connector W–B Ignition Coil and Igniter No. 1 ADD Actuator (ECC) W–B EE Engine Control Module BR BR W–B Engine Control Module W–B Ignition Coil and Igniter No. 1 BR (E01) (E02) Engine Control Module (E1) W–B EE (1GR–FE) W–B W–B W–B EF 17 IM2 W–B 9 IE1 W–B Canister Pump Module (1GR–FE) 369 4RUNNER (EM03M0U) I GROUND POINT Door Control Receiver W–B Rear Combination Light RH W–B Rear Combination Light LH W–B W–B W–B W–B W–B A A A A A A A A W–B W–B W–B W–B A A License Plate Light Back Door ECU W–B 10 BD1 W–B Power Outlet (Rear) 3 BH1 W–B Rear Window Defogger High Mounted Stop Light 1 BF1 W Trailer Socket A A BO A B A B A B W–B B (∗3) B W–B (∗3) W–B 1 BK1 W–B B B (∗3) (∗3) W–B B (∗4) B A/C Control Assembly (VER1) J43(A), J44(B) Junction Connector W–B W–B A B A B (∗4) A B (∗4) A B A B W–B B 3F Buckle SW LH A A W–B W–B Position Control ECU and SW W–B (∗4) B 3F Seat Heater LH (E) Lumbar Support Control SW (Driver' s Seat) B 3F B 3F W–B (E) B 3F B 3F W–B Seat Heater LH Power Seat Control SW (Driver' s Seat) W–B W–B W–B 5 IR1 Buckle SW LH W–B Cigarette Lighter W–B W–B B 3F B 3F (2UZ–FE) Shift Lock Control ECU Glove Box Light B 3F W–B (GND) Hazard SW W–B (4WD) Defogger SW Heater Control Panel Security Indicator Light Power Outlet (Front) B 3F W–B Downhill Assist Control SW W–B (E) Lumbar Support Control SW (Driver' s Seat) J53 Junction Connector (∗4) Seat Heater SW LH W–B (∗3) W–B Seat Heater SW RH W–B W–B (∗3) BL B 3F W–B (E) (∗4) Towing Converter Relay W–B (∗3) W–B Voltage Inverter W–B W–B Fuel Pump J40(A), J41(B) Junction Connector W–B A B W–B W–B Yaw Rate Sensor A Theft Deterrent ECU 4WD Control SW Height Control Mode Select SW W–B A A W–B W–B A A W–B W–B A J24 Junction Connector II 370 4RUNNER (EM03M0U) Blower Motor Controller Height Control SW W–B I : w/ Daytime Running Light : w/o Daytime Running Light : w/ Driving Position Memory : w/o Driving Position Memory Data Link Connector 3 (CG) W–B W–B 1 2 3 4 W–B E A W–B Remote Control Mirror SW W–B Door Lock Control SW Front LH Power Window Master SW W–B B B A 4 IA2 W–B A W–B E A W–B A W–B W–B Seat Memory SW (∗3) W–B (∗2) 9 IF1 W–B (∗2) (∗1) J5 Junction Connector B B 2 1H W–B A IG 4 BA1 14 1A W–B 6 1A W–B 15 1A W–B Door Lock Detection SW Rear LH W–B W–B 13 1A W–B Door Lock Detection SW Front RH W–B W–B 12 1A A Door Lock Control SW Front RH Turn Signal Flasher Relay Daytime Running Light Relay Turn Signal Flasher Relay W–B A Mirror Heater LH D B W–B J38 Junction Connector B W–B A Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH J22(A), J23(B) Junction Connector D B W–B ∗ ∗ ∗ ∗ 4 IP2 W–B W–B A Inner Mirror (E2) Moon Roof Control ECU (E) (E) (E) Personal Light Moon Roof Control SW POWER Relay W–B Mirror Heater RH 4 BB1 W–B Door Lock Detection SW Rear RH W–B W–B A W–B A J37 Junction Connector DC SKT Relay A B A A Engine Control Module W–B A B A A W–B A B A A W–B 1 IM2 W–B (EC) (2UZ–FE) W–B W W W–B W W–B (2UZ–FE) W–B 3 BI1 W–B W–B W–B (6 Speaker) Occupant Classification ECU W (6 Speaker) A W–B W–B Vanity Light LH A 1 IO3 Transponder Key Computer W 7 1A W–B Engine Control Module 18 1A IK Tire Pressure Warning ECU 4WD Control ECU Body ECU (GND2) J33(A), J34(B) Junction Connector (EOM) (GND1) A B A B Vanity Light RH Luggage Compartment Light Interior Light Seat Heater RH Buckle SW RH Power Seat Control SW (Front Passenger' s Seat) A B J45(A), J46(B) Junction Connector A A BR W–B W–B BM BR (GND) (GND2) Stereo Component Amplifier BP 371 4RUNNER (EM03M0U) I GROUND POINT A B W–B A B W–B Steering Sensor A A W–B A A W–B A A W–B A A W–B A A W–B Key Interlock Solenoid A B Combination SW (EW) Combination SW (EL) (E1) Airbag Sensor Assembly (E2) Diff. Lock SW Rheostat Towing Brake Controller W–B Auto LSD SW (2WD) A A W–B Roll Sensing of Curtain Shield Airbag Cutoff SW J14(A), J15(B) Junction Connector W–B Unlock Warning SW W–B W–B (TB) Combination SW W–B W–B BR (∗6) W–B BR A 3B 24 BJ1 LG 13 ID1 BR BR (∗5) Radio and Player Radio and Player with Display A 3B BR Rear Seat Audio Controller W–B Main SW Junction Connector W–B ∗ 5 : w/ Navigation System ∗ 6 : w/o Navigation System IH Low Pressure Tank Valve W–B W–B Height Control Valve W–B W–B Height Control Compressor W–B Height Control Motor IJ BN 372 4RUNNER (EM03M0U) I : Parts Location Code J2 See Page A J3 Code 33 (2UZ–FE) B J5 See Page J28 38 35 (1GR–FE) J33 A 38 33 (2UZ–FE) J34 B 38 35 (1GR–FE) J35 A 38 38 J36 B 38 J14 A 38 J37 38 J15 B 38 J38 40 J22 A 38 J40 A 40 J23 B 38 J41 B 40 38 J43 A 42 (*1) J24 Code See Page J43 A J44 B J45 A J46 B J53 43 (*2) 42 (*1) 43 (*2) 42 (*1) 43 (*2) 42 (*1) 43 (*2) 42 (*1) : Relay Blocks Code See Page Relay Blocks (Relay Block Location) 2 22 Engine Room R/B (Engine Compartment Left) 3 23 Engine Room R/B No.3 (Engine Compartment Left) 4 23 Engine Room R/B No.4 (Engine Compartment Left) : Junction Block and Wire Harness Connector Code See Page Junction Block and Wire Harness (Connector Location) 1A 24 Roof Wire and Driver Side J/B (Lower Finish Panel) 1H 25 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 28 Instrument Panel Wire and Center J/B (Instrument Panel Brace RH) 3B 3F : Connector Joining Wire Harness and Wire Harness Code See Page Joining Wire Harness and Wire Harness (Connector Location) EC1 45 (1GR–FE) Engine Wire and Differential Wire (Near the Front Differential) IA2 46 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) ID1 46 Radio Installation Wiring Sub Assembly and Instrument Panel Wire (Left Kick Panel) IE1 46 Instrument Panel Wire and Floor No.2 Wire (Left Kick Panel) IF1 46 Instrument Panel Wire and Relay Wire (Behind the Instrument Panel J/B) 47 Engine Wire and Instrument Panel Wire (Right Side of Blower Unit) IM1 IM2 IN1 47 Instrument Panel Wire and Engine Room Main Wire (Right Kick Panel) IO3 47 Instrument Panel Wire and Floor Wire (Right Kick Panel) IP2 47 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IR1 47 Instrument Panel Wire and Cigarette Lighter Wiring Assembly (Rear Console) BA1 48 Rear Door No.2 Wire and Instrument Panel Wire (Left Center Pillar) BB1 48 Rear Door No.1 Wire and Instrument Panel Wire (Right Center Pillar) BD1 48 Back Door No.1 Wire and Floor No.2 Wire (Left Rear Side of Roof) BF1 48 Frame No.3 Wire and Floor No.2 Wire (Rear Side of Side Frame LH) BH1 48 Back Door No.1 Wire and Back Door No.2 Wire (Left Side of Back Door) BI1 50 (*1) 51 (*2) Floor Wire and Seat No.1 Wire (Under the Front RH Seat) BJ1 48 Radio Installation Wiring Sub Assembly and Radio Installation Wiring Sub Assembly (Center of Roof) BK1 50 (*1) Floor No.2 Wire and Seat No.2 Wire (Under the Front LH Seat) * 1 : Power Seat * 2 : Manual Seat 373 4RUNNER (EM03M0U) I GROUND POINT : Ground Points Code EA EB See Page 44 (2UZ–FE) 45 (1GR–FE) 44 (2UZ–FE) 45 (1GR–FE) Ground Points Location Front Right Fender Front Left Fender EC 44 (2UZ–FE) Right Bank Cylinder Head ED 44 (2UZ–FE) Left Bank Cylinder Head 44 (2UZ–FE) Rear Side of Cylinder Block 45 (1GR–FE) Rear Side of Right Bank Cylinder Block EF 45 (1GR–FE) Rear Side of Left Bank Cylinder Block EQ 44 (2UZ–FE) Near the Starter ER 44 (2UZ–FE) Rear Side of Front Right Fender IG 46 Left Kick Panel IH 46 Instrument Panel Brace LH 46 Instrument Panel Brace RH EE II IJ IK 46 Right Kick Panel BL 48 Floor Seat Crossmember LH BM 48 Floor Seat Crossmember RH BN 48 Near the No.5 Crossmember of Side Frame LH BO 48 Rear Pillar LH BP 48 Rear Pillar RH 374 4RUNNER (EM03M0U) Memo 375 4RUNNER (EM03M0U) J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other Parts. 140A ALT 2 60A HEATER 2 HEATER Relay (Point Side) 2 IG Relay (Point Side) 2 25A SEAT HEATER 2 DEFOG Relay (Point Side) 2 50A AIR SUS 2 10A AIRSUS NO.2 50A AM1 2 Ignition SW (AM1) 50A J/B 2 10A MIR HEATER 2 30A DEFOG 2 I18 10A IGN Battery 30A AM2 2 Ignition SW (AM2) 7.5A GAUGE 1 I18 10A SRS 7.5A STA NO.2 20A EFI 2 EFI Relay (Point Side) 2 10A DOME Short Pin 2 20A RADIO NO.1 2 10A ECU-B 10A HEAD (HI RH) HEAD Relay (Point Side) 10A HEAD (HI LH) 2 2 10A HEAD (LO RH) 10A HEAD (LO LH) 376 4RUNNER (EM03M0U) 10A EFI NO.2 2 J Example Starter S1 Parts 7.5A HEATER NO.2 Code or Location 2 4 7.5A DRL 15A IG1 Location 10A ECU-IG 15A RR WSH Electrical Source 1 20A 4WD 30A FR WIP-WSH 50A A/PUMP 7.5A ACC 30A TOWING BRK 1 10A CIG 30A BATT CHG 40A TOWING 2 10A STOP TAIL Relay (Point Side) 15A AC115V INV 1 10A TAIL 1 15A FR FOG 7.5A OBD 10A SECU/HORN 30A P P/SEAT 30A D P/SEAT 1 30A POWER 15A PWR OUTLET 7.5A ALT-S 10A HORN 15A A/F HEATER 15A TRN-HAZ [LOCATION] 40A ABS MTR 2 30A ABS SOL 1 : Driver Side J/B (See Page 24) 2 : Engine Room R/B (See Page 22) 10A ETCS 20A DR/LCK 30A TOWING 20A RADIO NO.2 377 4RUNNER (EM03M0U) J POWER SOURCE (Current Flow Chart) Driver Side J/B (See Page 24) Fuse 7.5A 7.5A ACC GAUGE System Air Conditioning Audio System (10 Speaker) Audio System (6 Speaker) Automatic Light Control Door Lock Control Engine Control (1GR–FE) Engine Control (2UZ–FE) Headlight Interior Light Key Reminder Light Auto Turn Off System Multiplex Communication System (BEAN) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) Power Outlet (12V) Power Window Rear Window Defogger and Mirror Heater Rear Wiper and Washer Remote Control Mirror Seat Belt Warning Shift Lock Theft Deterrent Wireless Door Lock Control ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Active Height Control Suspension and Electric Modulated Air Suspension Air Conditioning Audio System (10 Speaker) Audio System (6 Speaker) Charging Combination Meter Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Door Lock Control Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Interior Light Key Reminder Moon Roof Multi Mode 4WD Multiplex Communication System (BEAN) ∗ These are the page numbers of the first page on which the related system is shown. 378 4RUNNER (EM03M0U) Page 358 342 348 140 202 84 70 130 154 176 142 104 334 298 192 330 186 294 178 292 222 212 258 268 358 342 348 68 352 252 246 202 238 230 84 70 154 176 288 274 104 J Fuse System Page GAUGE Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) Seat Belt Warning SRS Taillight and Illumination Tire Pressure Warning System 334 178 281 162 326 7.5A STA NO.2 Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Starting 238 230 84 70 58 10A CIG Cigarette Lighter 296 ECU–IG ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Active Height Control Suspension and Electric Modulated Air Suspension Automatic Light Control Door Lock Control Headlight Interior Light Key Reminder Light Auto Turn Off System Moon Roof Multiplex Communication System (BEAN) Power Seat (Driver’s Seat w/ Driving Position Memory) Power Window Rear Window Defogger and Mirror Heater Rear Wiper and Washer Seat Belt Warning Shift Lock Theft Deterrent Tire Pressure Warning System Wireless Door Lock Control IGN ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Air Conditioning Combination Meter Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Engine Immobiliser System SRS 7.5A 10A 10A 258 268 140 202 130 154 176 142 288 104 308 192 330 186 178 292 222 326 212 258 358 352 252 246 238 230 84 70 98 281 ∗ These are the page numbers of the first page on which the related system is shown. 379 4RUNNER (EM03M0U) J POWER SOURCE (Current Flow Chart) Fuse System Page 10A SECU/HORN Multiplex Communication System (BEAN) Theft Deterrent Wireless Door Lock Control 10A SRS SRS 281 TAIL Combination Meter Engine Control (1GR–FE) Engine Control (2UZ–FE) Taillight and Illumination Trailer Towing 352 84 70 162 322 IG1 ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Active Height Control Suspension and Electric Modulated Air Suspension Air Conditioning Automatic Glare–Resistant EC Mirror with Compass Back–Up Light Charging Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Door Lock Control Electric Tension Reducer Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Headlight Multi Mode 4WD Multiplex Communication System (BEAN) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) Power Outlet (115V) Power Seat (Driver’s Seat w/ Driving Position Memory) Rear Window Defogger and Mirror Heater Seat Belt Warning Seat Heater SRS Stop Light Taillight and Illumination Trailer Towing Turn Signal and Hazard Warning Light (w/ Daytime Running Light) Turn Signal and Hazard Warning Light (w/o Daytime Running Light) 10A 15A 104 222 212 258 268 358 302 174 68 252 246 202 306 238 230 130 274 104 334 300 308 330 178 318 281 170 162 322 146 150 15A PWR OUTLET Power Outlet (12V) 298 15A RR WSH Multiplex Communication System (BEAN) Rear Wiper and Washer 104 186 20A 4WD Multi Mode 4WD 274 30A D P/SEAT Power Seat (Driver’s Seat w/ Driving Position Memory) Power Seat (Driver’s Seat w/o Driving Position Memory) 308 312 ∗ These are the page numbers of the first page on which the related system is shown. 380 4RUNNER (EM03M0U) J Fuse System Page 30A FR WIP–WSH Front Wiper and Washer 184 30A P P/SEAT Power Seat (Front Passenger’s Seat) 316 POWER Door Lock Control Moon Roof Multiplex Communication System (BEAN) Power Window Rear Wiper and Washer Theft Deterrent Wireless Door Lock Control 202 288 104 192 186 222 212 30A Engine Room R/B (See Page 22) Fuse System Page 7.5A ALT–S Charging 68 7.5A HEATER NO.2 Air Conditioning 358 7.5A OBD Engine Control (1GR–FE) Engine Control (2UZ–FE) 84 70 10A AIRSUS NO.2 Active Height Control Suspension and Electric Modulated Air Suspension 268 DOME ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Active Height Control Suspension and Electric Modulated Air Suspension Air Conditioning Audio System (10 Speaker) Audio System (6 Speaker) Combination Meter Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Door Lock Control Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Garage Door Opener Interior Light Key Reminder Light Auto Turn Off System Moon Roof Multi Mode 4WD Multiplex Communication System (BEAN) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) Power Window Rear Wiper and Washer Seat Belt Warning 10A 258 268 358 342 348 352 252 246 202 238 230 84 70 182 154 176 142 288 274 104 334 192 186 178 ∗ These are the page numbers of the first page on which the related system is shown. 381 4RUNNER (EM03M0U) J POWER SOURCE (Current Flow Chart) Fuse System Page DOME Taillight and Illumination Theft Deterrent Tire Pressure Warning System Wireless Door Lock Control 162 222 326 212 ECU–B ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Air Conditioning Automatic Light Control Door Lock Control Engine Immobiliser System Headlight Interior Light Key Reminder Light Auto Turn Off System Multiplex Communication System (BEAN) Power Seat (Driver’s Seat w/ Driving Position Memory) Power Window Rear Window Defogger and Mirror Heater Rear Wiper and Washer Seat Belt Warning SRS Theft Deterrent Wireless Door Lock Control 258 358 140 202 98 130 154 176 142 104 308 192 330 186 178 281 222 212 EFI NO.2 Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) 238 230 84 70 ETCS Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) 252 246 238 230 84 70 10A HEAD(HI LH) Front Fog Light Headlight Multiplex Communication System (BEAN) 136 130 104 10A HEAD(HI RH) Headlight Multiplex Communication System (BEAN) 130 104 10A HEAD(LO LH) Headlight Multiplex Communication System (BEAN) 130 104 10A HEAD(LO RH) Headlight Multiplex Communication System (BEAN) 130 104 10A HORN Horn Multiplex Communication System (BEAN) 304 104 10A 10A 10A 10A ∗ These are the page numbers of the first page on which the related system is shown. 382 4RUNNER (EM03M0U) J Fuse System Page 10A HORN Theft Deterrent Wireless Door Lock Control 222 212 10A MIR HEATER Multiplex Communication System (BEAN) Rear Window Defogger and Mirror Heater 104 330 10A STOP ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control Active Height Control Suspension and Electric Modulated Air Suspension Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Multiplex Communication System (BEAN) Shift Lock Stop Light Trailer Towing 15A AC115V INV Power Outlet (115V) 300 15A A/F HEATER Engine Control (1GR–FE) Engine Control (2UZ–FE) 84 70 15A FR FOG Front Fog Light Multiplex Communication System (BEAN) 136 104 TRN–HAZ Headlight Multiplex Communication System (BEAN) Trailer Towing Turn Signal and Hazard Warning Light (w/ Daytime Running Light) Turn Signal and Hazard Warning Light (w/o Daytime Running Light) 130 104 322 146 150 DR/LCK Door Lock Control Multiplex Communication System (BEAN) Power Window Theft Deterrent Wireless Door Lock Control 202 104 192 222 212 EFI Air Conditioning Audio System (10 Speaker) Audio System (6 Speaker) Cruise Control (1GR–FE) Cruise Control (2UZ–FE) Electronically Controlled Transmission and A/T Indicator (1GR–FE) Electronically Controlled Transmission and A/T Indicator (2UZ–FE) Engine Control (1GR–FE) Engine Control (2UZ–FE) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) Remote Control Mirror 358 342 348 252 246 238 230 84 70 15A 20A 20A 258 268 252 246 238 230 84 70 104 292 170 322 334 294 ∗ These are the page numbers of the first page on which the related system is shown. 383 4RUNNER (EM03M0U) J POWER SOURCE (Current Flow Chart) Fuse 20A 20A RADIO NO.1 RADIO NO.2 System Page Audio System (10 Speaker) Audio System (6 Speaker) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) 342 348 Audio System (10 Speaker) Navigation System, Parking Assist (Rear View Monitor) and Audio System (w/ Navigation System) 342 334 334 25A SEAT HEATER Seat Heater 318 30A ABS SOL ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control 258 30A AM2 Charging Engine Control (1GR–FE) Engine Control (2UZ–FE) Ignition (1GR–FE) Ignition (2UZ–FE) Starting 68 84 70 64 60 58 30A BATT CHG Trailer Towing 322 30A DEFOG Engine Control (1GR–FE) Engine Control (2UZ–FE) Multiplex Communication System (BEAN) Rear Window Defogger and Mirror Heater 84 70 104 330 30A TOWING Trailer Towing 322 30A TOWING BRK Trailer Towing 322 40A ABS MTR ABS, TRAC, VSC, Auto LSD, Downhill Assist Control and Hill–Start Assist Control 258 40A TOWING Trailer Towing 322 50A AIR SUS Active Height Control Suspension and Electric Modulated Air Suspension 268 50A AM1 Charging 68 50A A/PUMP Engine Control (2UZ–FE) 70 50A J/B Automatic Light Control Light Auto Turn Off System Multiplex Communication System (BEAN) Taillight and Illumination Theft Deterrent Wireless Door Lock Control 140 142 104 162 222 212 60A HEATER Air Conditioning 358 ALT Charging Multiplex Communication System (BEAN) Rear Window Defogger and Mirror Heater Taillight and Illumination 68 104 330 162 140A ∗ These are the page numbers of the first page on which the related system is shown. 384 4RUNNER (EM03M0U) Memo 385 4RUNNER (EM03M0U) K CONNECTOR LIST A1 A2 A9 A10 A11 Black Gray Gray Gray Black 1 2 1 1 2 2 1 2 1 2 3 4 5 6 3 A12 A13 A14 A15 Dark Gray Dark Gray Yellow Yellow 1 2 3 4 1 2 3 4 1 1 2 A16 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 A17 A18 12 1 2 5 A19 A20 A21 Black Black Black 12 12 1 2 3 22 23 24 25 26 A22 1 2 6 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 A24 A25 A26 A27 A28 Black Black Black Black Black 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 A29 A30 A31 A32 Black Yellow Yellow Yellow 1 2 3 4 5 1 2 A B A B 3 4 1 2 3 5 6 7 8 9 101112 13 1415 16 171819 20 1 2 3 4 5 6 7 8 9 101112 386 4RUNNER (EM03M0U) A B 4 5 6 7 8 9 1011121314151617 1819 2021 22 23 2425 26 27 28 K A33 A34 A36 Yellow Yellow Yellow A B 1 2 A A38 Black 1 B 1 1 2 3 4 3 4 2 1 2 3 4 5 6 5 6 7 8 9 101112 7 8 9 101112 13 1415 16 171819 20 A39 A37 A40 A41 A42 A43 Black Black Blue Gray 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 A44 A45 A46 A47 A48 Black Black Gray Black Black 1 2 3 4 5 6 1 2 3 A49 1 1 B1 Orange 1 2 1 2 3 4 5 6 1 2 2 B2 B3 Black Black 1 2 B4 1 2 3 2 4 B5 1 10 1 2 B6 5 6 1 2 3 4 5 6 2 3 4 5 6 7 8 9 3 4 11 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 13 14 15 16 7 8 9 10 11 12 13 14 15 16 17 23 24 25 26 17 18 19 20 18 19 20 21 27 28 29 30 21 22 23 24 22 23 24 25 26 387 4RUNNER (EM03M0U) K CONNECTOR LIST *1 : w/ Power Seat (Front Passenger’s Seat) *2 : w/o Power Seat (Front Passenger’s Seat) B7 B8 B9 Blue 12 3 456 7 8 2 1 1 2 3 4 5 6 7 8 9 101112 13 B10 B11 Gray Black 1 2 1 3 4 3 4 5 6 4 3 14 15 16171819 6 5 B12 B14 Black Gray 1 2 3 4 1 B17 B15 2 B16 B16 (*1) (*2) Gray 1 1 2 3 4 5 2 1 C2 C3 C4 Gray Black Black (1GR–FE) Black 1 2 1 2 2 1 3 C4 C5 C6 (2UZ–FE) Dark Gray C7 2 C8 Gray 1 1 1 2 1 2 3 4 5 6 7 8 9 10 2 2 1 2 3 4 111213141516171819 20 C9 C10 C11 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 111213141516171819 20 111213141516171819 20 111213141516171819 20 C12 1 2 3 4 5 6 7 2 C1 1 1 2 3 4 5 2021222324 25 8 9 10 1112131415 16 17 C13 C14 Black Black 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 10 11 12 131415 16 17 18 388 4RUNNER (EM03M0U) C15 2 1 2 K C16 C17 Black Black D1 Black D2 1 2 1 2 1 2 3 4 5 6 7 8 9 101112 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 D3 D4 D5 Gray Blue 1 2 3 4 1 2 3 4 D7 D8 Gray 1 1 2 3 4 5 6 7 2 1 2 3 4 5 8 9 10 11 12 13 14 D9 D10 D11 D12 D13 D14 D15 Gray Gray Gray Black Black Black Black 1 1 1 1 1 2 1 2 1 D16 2 D17 D18 1 1 2 3 4 1 2 3 5 6 7 8 9 10 4 5 6 D19 2 1 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 D20 D21 D22 D23 D24 Black 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 1 2 2 389 4RUNNER (EM03M0U) K CONNECTOR LIST E1 E2 E3 Gray Gray Dark Gray 1 2 E4 1 2 3 4 1 4 E6 5 6 5 6 28 29 30 31 32 E5 3 4 7 1 2 3 33 34 E7 4 5 6 1 7 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 28 29 28 29 30 E8 1 2 3 4 5 6 7 18 19 20 21 22 23 24 25 26 27 9 101112131415 2 3 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 1 2 30 31 32 31 32 33 34 35 F1 F2 F5 F6 Brown Brown Gray Gray 1 1 2 1 2 2 3 1 2 3 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 28 29 F7 F8 Black Dark Gray 1 2 3 1 F9 2 1 4 5 2 F10 5 6 1 3 4 F11 F14 1 2 3 4 5 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 G1 3 4 7 8 9 10 11 12 13 14 15 16 21 22 23 24 22 23 24 25 26 G2 G3 H1 Black Black Black 1 2 3 17 18 19 20 Black 1 2 1 1 2 3 4 390 4RUNNER (EM03M0U) 2 1 2 K *3 : w/ Rear Spoiler *4 : w/o Rear Spoiler H2 H3 H4 H6 H8 Black Black Black Dark Gray Dark Gray 1 1 2 2 1 2 1 2 1 2 3 4 3 4 H9 H10 H11 H12 H13 H14 Black Black Black Gray Black Gray 1 1 1 1 2 3 4 5 2 1 3 4 5 6 2 H15 H16 H17 H18 H18 Black Black Black (*3) Gray (*4) Brown 2 1 1 1 1 2 2 3 1 2 3 2 1 2 3 4 3 H19 I1 I2 I3 I4 Black Black Black Black Black 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 I5 I6 I7 I8 I9 Black Black Black Black Gray 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 I10 I11 I12 I13 I14 Gray Gray Gray Gray Gray 1 2 1 2 1 2 1 2 1 2 I15 I16 I17 Gray Gray Black 1 2 1 2 1 2 3 4 5 6 I18 7 1 2 3 4 5 6 7 8 391 4RUNNER (EM03M0U) K CONNECTOR LIST *5 : w/ Rear Seat Entertainment System *6 : w/o Rear Seat Entertainment System I19 I20 I20 Black (*5) (*6) 1 1 2 3 4 5 6 7 2 J1 3 1 2 3 A A A B B B C C C C C D D D D E E E E E E E J2 J3 J4 Blue Blue Black J5 A A A A A A A A A A A A A A A B B B B C C C C B B B B B B B B B B B B D D D E E E E F F F F A J6 A A A B B B C C C C C A J7 J8 Blue Blue A B B C C A A B D D D C C A A B B C C C D D E E D D D D E E E E E E E A A A A F F F F G G G H H H H J9 J10 J11 J12 Blue Black Black Black A A B B C C C D D E E A A B B C C A A B B C C A A B B C C F F F F G G G H H H H D E F G H I D E F G H I D D D E E E J13 J14 J15 J16 Black Gray Gray Blue A A B B C C A A A A A A A A A A A A A A A A A A D D D E E E B B B C C C B B B C C C B B B B B B J17 J18 J19 Blue Blue Blue A A A A A A A A B B C C C D D E E A A B B C C C D D E E B B B B B B F F F F G G G H H H H F F F F G G G H H H H 392 4RUNNER (EM03M0U) K J20 J21 J22 J23 Blue Blue Black Black A A B B C C C D D E E A A B B C C C D D E E A A B B C C A A B B C C F F F F G G G H H H H F F F F G G G H H H H D D D E E E D D D E E E J24 J25 J26 J27 Blue A A A A A Blue A A A A A A A A A A A A A A B C C A A B B B B C C A J28 A B B C C A A B DD D C C J29 J30 Blue Blue A A A B B B C C C C C A A B B C C C D D E E A A B B C C C D D E E D D D D E E E E E E E F F F F G G G H H H H F F F F G G G H H H H J31 J32 J33 J34 Black Black Gray Gray A A B B C C A A B B C C A A A A A A A A A A A A D E F G H I D E F G H I B B B C C C B B B C C C J35 J36 Blue Blue A A B B C C C D D E E A A B B C C C D D E E F F F F G G G H H H H F F F F G G G H H H H J37 A J38 A A B C C A A B B B B C C A A A A A J40 J41 Gray Gray A A A B B B B C C C C A A A A A A A A A A A A D D D E E E E F F F F B B B C C C B B B C C C J39 393 4RUNNER (EM03M0U) K CONNECTOR LIST J42 J43 A B B C C A A B D D D C C A A B B A J44 A A A A C C B B DE F GHI J K J46 A A B B A A A C C A J45 A A A A C C B B DE F GHI J K A A A C C DE F GHI J K J47 J48 J49 J50 J51 1 1 1 1 1 2 2 2 2 2 DE F GHI J K J52 1 J53 K1 K2 K2 Gray Black (1GR–FE) Black (2UZ–FE) Gray 1 2 A A A B B A A A B B B B B K3 L1 Blue Black L2 1 1 2 L3 L4 Black 1 2 1 4 3 1 2 2 3 1 2 3 4 5 2 L5 M1 M1 M2 Black (1GR–FE) Black (2UZ–FE) Black Black 1 2 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 M3 2 1 3 5 4 394 4RUNNER (EM03M0U) K M4 M5 1 2 N2 O1 Gray Gray Gray 1 2 1 2 1 3 4 5 6 7 8 9 10 2 1 3 N1 5 4 O3 O4 O5 O6 Black Gray Black Gray 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 1 2 3 1 2 3 O7 O8 P1 P2 P3 Gray Black Gray Black Gray 1 2 3 1 1 2 3 1 5 6 P4 P5 P6 2 7 3 4 1 2 8 9 P7 P8 P9 Black 1 1234 1 1 2 P10 P11 1 2 3 4 5 1 2 1 2 3 4 5 P12 P13 P14 Black Black Black 1 1 2 3 4 5 1 2 3 4 5 2 1 3 4 5 6 2 3 4 5 6 1 2 3 4 5 6 P15 P16 P17 P18 P19 Black Yellow Yellow Black Black 1 1 2 3 4 5 6 2 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 395 4RUNNER (EM03M0U) K CONNECTOR LIST P20 P21 P23 P24 Black Black Black Black 1 2 1 2 1 2 1 2 P27 P28 P25 P26 1 2 1 2 R1 R2 Black 1 2 1 2 3 4 1 R3 R4 3 4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 5 6 7 8 9 10 10 R5 R9 Gray 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 101112 R10 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R11 R12 R13 Blue 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R14 R15 Gray Gray 1 2 3 4 5 6 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 11 12 13 14 15 16 17 18 19 20 R16 R17 1 1 2 2 R18 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 R19 R20 R21 R22 R23 Gray 1 1 2 3 4 1 1 2 3 4 1 2 3 4 5 396 4RUNNER (EM03M0U) K R24 R25 R26 R27 Black Blue 6 7 8 9 1 2 3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 4 5 6 1 2 3 4 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 S2 S2 S3 S4 (1GR–FE) (2UZ–FE) Black Black 1 1 2 3 4 5 6 1 S5 1 S6 S11 1 2 3 4 5 6 S12 S13 Blue 1 2 3 4 5 6 7 8 9 101112 1 1 2 3 4 5 6 7 8 3 9 10111213141516 2 1 4 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 S14 S15 22 23 24 25 26 S16 Yellow 1 2 3 4 1 2 5 6 1 10 3 4 2 3 4 5 6 7 8 9 7 8 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 21 22 17 18 19 20 23 24 25 26 21 22 23 24 27 28 29 30 S17 S18 S19 Yellow Yellow Yellow 1 2 3 4 1 2 3 4 1 2 3 4 S22 S20 S21 1 2 3 4 1 2 3 4 S23 S24 1 2 3 4 5 6 7 8 9 1 10 11 12 13 14 15 16 17 18 19 20 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 2 13 14 15 16 17 18 19 20 21 22 23 24 397 4RUNNER (EM03M0U) K CONNECTOR LIST S25 1 S26 S27 S28 Yellow Yellow Black 1 2 1 2 2 3 4 5 6 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 S29 S30 Black 1 2 1 2 3 4 S31 S32 S33 Gray Gray Gray 1 2 1 2 1 2 3 4 3 4 S34 S35 T1 T2 T3 Gray Gray Black Black Black 1 1 2 1 2 1 2 3 4 5 6 T4 T5 1 2 3 4 7 8 9 10 11 12 T6 Black 1 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 T8 T9 T10 2 4 5 T11 T12 T13 1 2 1 2 1 2 3 4 Gray 12 3 456 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 1 3 398 4RUNNER (EM03M0U) 5 6 K T14 T15 T16 T17 Black 1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 4 5 6 7 8 1 3 9 10111213141516 2 4 6 5 7 T18 V1 V1 V2 V2 Blue (1GR–FE) Brown (2UZ–FE) Black (1GR–FE) Gray (2UZ–FE) Black 1 1 2 3 4 5 2 1 2 1 2 1 V3 V3 V4 V4 V5 (1GR–FE) Black (2UZ–FE) Dark Gray (1GR–FE) Black (2UZ–FE) Dark Gray Black 1 2 3 1 2 1 2 3 1 2 V6 2 1 2 V7 V9 12 3 456 78 2 1 2 1 V11 V12 V13 Black Brown Brown 1 1 1 2 W2 W3 Dark Gray Black 1 2 3 4 1 2 2 W4 V14 W1 Black 1 1 2 3 4 5 6 7 8 2 Y1 2 Z1 Black 1 2 3 4 1 2 3 4 5 1 2 3 4 399 4RUNNER (EM03M0U) K CONNECTOR LIST EA1 EA2 Gray 2 1 4 3 1 2 3 4 1 4 7 2 5 8 3 6 2 5 8 EB1 8 5 6 7 8 ED1 4 7 EB2 3 7 2 6 1 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 IB1 3 2 1 1 2 2 3 4 5 6 7 8 9 10 11 1 8 7 6 5 4 13 12 11 10 9 IB2 1 2 1 2 3 4 5 6 IA1 Dark Gray IA2 1 2 EC1 Gray 2 1 4 3 1 2 3 4 5 3 2 1 6 5 4 1 2 3 4 5 6 6 1 Gray 4 1 2 3 4 3 Gray IC1 Yellow 2 1 4 3 2 1 11 10 9 8 7 6 5 1 2 400 4RUNNER (EM03M0U) Gray 3 2 1 6 5 4 K IC2 Gray 1 2 3 4 5 6 7 8 9 10 11 11 10 9 8 7 6 5 4 3 2 1 12 13 14 15 16 17 18 19 20 21 22 22 21 20 19 18 17 16 15 14 13 12 IC3 Blue 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 IC4 Gray Gray 1 2 3 4 5 6 7 8 9 10 11 20 21 12 13 22 23 14 15 24 25 16 17 8 7 6 5 4 3 2 1 19 29 37 18 30 31 32 26 27 38 39 40 28 36 33 34 35 41 42 43 19 9 21 20 11 10 23 22 13 12 25 24 15 14 27 26 37 29 28 40 39 38 43 42 41 17 16 32 31 30 18 36 35 34 33 IC5 1 2 3 4 5 6 7 8 9 10 11 12 13 5 4 3 2 1 13 12 11 10 9 8 7 6 401 4RUNNER (EM03M0U) K CONNECTOR LIST ID1 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13 IE1 Gray Gray 1 2 3 4 5 6 7 8 10 11 20 21 12 13 22 23 19 24 25 14 15 16 17 8 7 6 5 4 3 2 1 19 9 37 29 26 27 36 33 34 35 21 20 11 10 23 22 13 12 25 24 15 14 27 26 38 39 40 28 18 30 31 32 9 28 40 39 38 41 42 43 43 42 41 IF1 1 2 3 4 5 6 7 8 9 10 11 12 29 37 32 31 30 18 36 5 4 3 2 1 12 11 10 9 8 7 6 II1 IH1 1 2 3 3 2 1 4 5 6 6 5 4 IJ1 3 2 1 4 5 6 6 5 4 35 34 33 IG1 Black 1 2 3 17 16 12 1 2 3 4 5 5 4 3 2 1 6 7 8 9 10 10 9 8 7 6 IK1 2 1 1 2 3 4 5 6 7 7 6 5 4 3 2 1 8 9 10 11 12 13 14 14 13 12 11 10 9 8 402 4RUNNER (EM03M0U) K IL1 IM1 12 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 IN1 5 4 3 2 1 13 12 11 10 9 8 7 6 IM2 Blue 1 2 3 4 5 6 7 8 9 10 11 11 10 9 8 7 6 5 4 3 2 1 12 13 14 15 16 17 18 19 20 21 22 22 21 20 19 18 17 16 15 14 13 12 IN2 1 2 3 4 5 6 7 8 9 10 5 4 3 2 1 10 9 8 7 6 Yellow 2 1 1 2 IO2 Gray Gray 9 10 11 20 21 12 13 22 23 14 15 24 25 16 17 8 7 6 5 4 3 2 1 19 29 37 18 30 31 32 33 34 35 26 27 38 39 40 28 36 41 42 43 19 9 21 20 11 10 23 22 13 12 25 24 15 14 27 26 37 29 28 40 39 38 43 42 41 17 16 32 31 30 18 36 35 34 33 403 4RUNNER (EM03M0U) K CONNECTOR LIST IO3 IP1 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 IP2 1 2 IR1 3 3 4 5 6 7 8 2 2 1 6 5 43 3 4 5 6 8 7 6 5 4 9 10 11 12 13 IU1 Gray IV1 2 1 Yellow 4 4 3 2 1 1 2 3 4 3 2 1 1 2 3 4 BA1 Blue 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 2 1 7 6 5 4 3 12 11 10 9 8 BB1 BC1 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 12 11 10 9 IT1 1 2 3 4 5 1 2 1 IS1 2 1 5 3 4 6 7 8 9 10 11 2 7 6 5 4 3 12 11 10 9 8 404 4RUNNER (EM03M0U) 4 3 2 11 10 9 8 7 6 1 5 K BC2 BD1 1 2 3 4 5 6 7 8 9 10 11 11 10 9 8 7 6 5 4 3 2 1 12 13 14 15 16 17 18 19 20 21 22 22 21 20 19 18 17 16 15 14 13 12 BD2 1 3 BH1 Gray 2 2 1 4 4 3 1 2 3 4 5 6 7 8 9 10 1 7 6 5 4 3 12 11 10 9 8 BF1 2 1 4 3 1 2 3 4 4 3 2 1 BG1 2 BE1 Green 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 3 BI1 Blue 2 1 Gray 3 2 1 6 5 4 1 2 3 4 5 6 5 4 3 2 1 10 9 8 7 6 Black BJ1 1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13 BK1 BL1 5 1 2 6 7 3 4 5 8 9 3 2 2 1 1 9 1011121314151617 4 8 7 BM1 2 1 2 1 1 2 6 1716151413121110 405 4RUNNER (EM03M0U) L PART NUMBER OF CONNECTORS Code A1 Part Name Part Number Code A/C Ambient Temp. Sensor 90980–11070 B4 Body ECU 90980–12562 B5 Body ECU 90980–12560 B6 Body ECU 90980–12561 A/C Lock Sensor A2 A/C Magnetic Clutch A9 ABS Speed Sensor Front LH A10 ABS Speed Sensor Front RH A11 ADD Actuator A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) A14 Airbag Sensor Front LH A15 Airbag Sensor Front RH 90980–11016 Part Name Part Number Back Door Courtesy SW 90980–11003 90980–11858 Back Door Half Latch SW B7 Back Door Lock Detection SW 90980–11452 Back Door Lock Motor 90980–10869 B8 Back Door ECU 90980–10799 B9 Back Door ECU 90980–11877 90980–11856 A16 A/C Control Assembly 90980–12561 A17 A/C Control Assembly 90980–12560 A18 A/C Evaporator Temp. Sensor A19 A/C Room Temp. Sensor A20 A/C Solar Sensor A21 A/C Solar Sensor A22 A/T Shift Lever Illumination A24 Accel Position Sensor 90980–11858 A25 Air Inlet Control Servo Motor A26 Air Mix Control Servo Motor A27 Air Mix Control Servo Motor LH A28 Air Mix Control Servo Motor RH Back Door Opener SW B10 B11 License Plate Light Back Door Power Window Motor 90980–11178 90980–10797 Buckle SW LH 90980–11918 B12 Seat Position Airbag Sensor 90980–10942 B14 Brake Fluid Level Warning SW 90980–11156 90980–11987 B15 Buckle SW LH 90980–12366 90980–12063 B16 Buckle SW RH 90980–11019 B17 Buckle SW RH 90980–12366 C1 Camshaft Position Sensor 90980–11016 C2 Camshaft Timing Oil Control Valve LH C3 Camshaft Timing Oil Control Valve RH 90980–11909 Crankshaft Position Sensor (1GR–FE) C4 90980–11162 90980–12028 A29 Air Vent Mode Control Servo Motor Crankshaft Position Sensor (2UZ–FE) 90980–11162 A30 Airbag Sensor Assembly 82824–50160 C5 Center Speaker 90980–11013 A31 Airbag Sensor Assembly 90980–11869 C6 Cigarette Lighter 90980–10760 A32 Airbag Sensor Assembly 90980–11872 C7 Cigarette Lighter Illumination 90980–11148 A33 Airbag Sensor Assembly 82824–50150 C8 Combination Meter 82824–35040 A34 Airbag Sensor Assembly 90980–11867 C9 Combination Meter 82824–35030 A36 Airbag Squib (Steering Wheel Pad) 90980–12160 C10 Combination Meter 82824–35040 A37 Antenna Amplifier 90980–10870 C11 Combination Meter 82824–35030 A38 Ashtray Illumination 90980–12111 C12 Combination SW 90980–11672 A39 Automatic Light Control Sensor 90980–11107 C13 Combination SW 90980–12552 A40 ABS Speed Sensor Rear LH C14 Combination SW 90980–11594 90980–11299 90980–11900 A41 ABS Speed Sensor Rear RH C15 Cup Holder Illumination A42 Auto LSD SW 90980–10933 C16 Curtain Shield Airbag Squib LH A43 Air Injection Control Driver 90980–12068 C17 Curtain Shield Airbag Squib RH A44 Air Injection Control Driver 90980–11858 D1 Data Link Connector 3 A45 Air Pressure Sensor 90980–10845 A46 Air Pump 90980–11032 A47 Air Switching Valve 90980–11149 A48 Airbag Squib (Front Passenger Airbag Assembly) 90980–12219 A49 Airbag Squib (Front Passenger Airbag Assembly) 90980–12224 B1 Back Door Power Window Control SW 90980–10957 B2 Blower Motor 90980–10385 B3 Blower Motor Controller 90980–11676 90980–12219 90980–11978 Daytime Running Light Relay D2 Turn Signal Flasher Relay 90980–10803 Defogger SW Heater Control Panel D3 Passenger Seat Belt Warning Light 90980–11911 Security Indicator Light D4 Diff. Lock SW D5 Downhill Assist Control SW D7 Door Control Receiver Note: Not all of the above part numbers of the connector are established for the supply. 406 4RUNNER (EM03M0U) 90980–11013 90980–11909 L Code Part Name D8 Door Courtesy Light Front LH D9 Door Courtesy Light Front RH Part Number 90980–11148 Code Part Name Part Number G3 Glove Box Light 90980–11148 H1 Headlight LH (High) 90980–11095 D10 Door Courtesy Light Rear LH H2 Headlight LH (Low) 82824–60460 D11 Door Courtesy Light Rear RH H3 Headlight RH (High) 90980–11095 D12 Door Courtesy SW Front LH H4 Headlight RH (Low) 82824–60460 D13 Door Courtesy SW Front RH H6 Heated Oxygen Sensor (Bank 1 Sensor 2) D14 Door Courtesy SW Rear LH H8 Heated Oxygen Sensor (Bank 2 Sensor 2) D15 Door Courtesy SW Rear RH H9 Horn (High) Door Key Lock and Unlock SW Front LH H10 Horn (Low) D16 D17 D18 D19 Door Lock Detection SW Front LH 90980–10871 90980–12226 H11 Hazard SW 90980–10789 H12 Height Control SW 90980–10797 Door Lock Control SW Front LH H13 Height Control Compressor 90980–11156 H14 Height Control Motor 90980–10990 H15 Height Control Sensor Rear LH Door Lock Detection SW Front RH H16 Height Control Sensor Rear RH Door Lock Motor Front RH H17 Height Control Valve 90980–11143 High Mounted Stop Light (w/ Rear Spoiler) 90980–11272 Power Window Master SW Door Lock Control SW Front RH 90980–12122 90980–10797 Door Lock Motor Rear LH 90980–12226 Door Lock Detection SW Rear RH D21 Door Lock Motor Rear RH Door Speaker Front LH No.1 D23 Door Speaker Front RH No.1 D24 Diode (Rear Wiper) E1 Electronically Controlled Transmission Solenoid 90980–12293 E2 Engine Coolant Temp. Sensor 90980–10735 E3 Engine Hood Courtesy SW 90980–11178 E4 Engine Control Module 90980–12527 E5 Engine Control Module 90980–12528 E6 Engine Control Module 90980–12526 E7 Engine Control Module 90980–12529 E8 Engine Control Module 90980–12525 F1 Front Fog Light LH F2 Front Fog Light RH 90980–10935 90980–10962 90980–11096 Front Parking Light LH 90980–11294 Front Turn Signal Light RH F7 Front Wiper Motor 90980–11599 F8 Fuel Pump Resistor 90980–11156 F9 4WD Control ECU 90980–12560 F10 4WD Control ECU 90980–12561 F11 4WD Control SW 90980–11909 Fuel Pump F14 Fuel Sender 90980–11077 G1 Generator 90980–09365 G2 Generator 90980–11964 90980–11016 High Mounted Stop Light (w/o Rear Spoiler) 90980–11162 Height Control Mode Select SW 90980–10789 I1 Ignition Coil and Igniter No.1 I2 Ignition Coil and Igniter No.2 I3 Ignition Coil and Igniter No.3 I4 Ignition Coil and Igniter No.4 I5 Ignition Coil and Igniter No.5 I6 Ignition Coil and Igniter No.6 I7 Ignition Coil and Igniter No.7 I8 Ignition Coil and Igniter No.8 I9 Injector No.1 I10 Injector No.2 I11 Injector No.3 I12 Injector No.4 I13 Injector No.5 I14 Injector No.6 I15 Injector No.7 I16 Injector No.8 Front Turn Signal Light LH Front Parking Light RH F6 H18 H19 D22 F5 90980–10619 Door Lock Motor Front LH Door Lock Detection SW Rear LH D20 90980–11028 90980–11885 90980–11875 Ignition Key Cylinder Light I17 Transponder Key Amplifier 90980–12092 I18 Ignition SW 90980–11615 I19 Inner Mirror 90980–11794 Interior Light (w/ Rear Seat Entertainment System) 90980–12321 Interior Light (w/o Rear Seat Entertainment System) – I20 J1 Junction Connector J2 Junction Connector J3 Junction Connector J4 Junction Connector 90980–11915 90980–11661 90980–11915 407 4RUNNER (EM03M0U) L PART NUMBER OF CONNECTORS Code Part Number Code J5 Junction Connector Part Name 90980–10976 J51 Junction Connector 90980–12355 J6 Junction Connector 90980–11915 J52 Junction Connector 90980–10871 J7 Junction Connector 90980–11542 J53 Junction Connector 90980–11542 J8 Junction Connector K1 Knock Sensor (Bank 1) J9 Junction Connector K2 Knock Sensor (Bank 2) J10 Junction Connector J11 Junction Connector J12 Junction Connector L1 Low Pressure Tank Valve J13 Junction Connector L2 Luggage Compartment Light L3 Lumbar Support Control SW (Driver’s Seat) 90980–10789 L4 Canister Pump Module 90980–12380 L5 Lumbar Support Control Motor (Driver’s Seat) 90980–10825 Mass Air Flow Meter (1GR–FE) 90980–11317 Mass Air Flow Meter (2UZ–FE) 90980–12292 Main SW 90980–10957 J14 Junction Connector J15 Junction Connector J16 Junction Connector J17 Junction Connector J18 Junction Connector J19 Junction Connector J20 Junction Connector J21 Junction Connector J22 Junction Connector J23 Junction Connector J24 Junction Connector J25 Junction Connector J26 Junction Connector J27 Junction Connector J28 Junction Connector J29 Junction Connector J30 Junction Connector J31 Junction Connector J32 Junction Connector J33 Junction Connector J34 Junction Connector J35 Junction Connector J36 Junction Connector J37 Junction Connector 90980–11915 90980–11661 M1 90980–11915 90980–11661 90980–10976 90980–10803 90980–11542 90980–11915 90980–11661 90980–11915 90980–10976 Junction Connector 90980–11915 J40 Junction Connector J43 Junction Connector J44 Junction Connector J45 Junction Connector J46 Junction Connector J47 Junction Connector J48 Junction Connector J50 Junction Connector 90980–10794 90980–11156 – Remote Control Mirror RH N1 Noise Filter (Ignition No.1) N2 Noise Filter (Ignition No.2) O1 Oil Pressure SW 90980–11363 O3 Occupant Classification ECU 90980–12356 O4 Occupant Classification ECU 90980–12357 O5 Occupant Classification Sensor Front LH 90980–12353 O6 Occupant Classification Sensor Front RH O7 Occupant Classification Sensor Rear LH O8 Occupant Classification Sensor Rear RH 90980–12353 P1 Park/Neutral Position SW 90980–12362 P2 Power Steering Oil Pressure SW 90980–11428 P3 Pressure SW 90980–11149 P4 Parking Brake SW 90980–10871 P5 Power Outlet (115V) 90980–10601 P6 Power Outlet (Front) 90980–10997 90980–10860 90980–10843 90980–12354 Moon Roof Control SW P7 90980–12355 90980–12189 Moon Roof Control ECU 90980–11542 90980–12374 Remote Control Mirror LH M5 90980–11661 Junction Connector J49 Unlock Warning SW Mirror Heater RH M4 J39 Junction Connector 90980–11875 Mirror Heater LH 90980–11542 J42 M2 M3 Junction Connector Junction Connector Part Number Key Interlock Solenoid K3 J38 J41 Part Name Personal Light P8 Power Outlet (Rear) P9 Power Window Control SW Front RH P10 Power Window Control SW Rear LH P11 Power Window Control SW Rear RH P12 Power Window Motor Front LH P13 Power Window Motor Front RH P14 Power Window Motor Rear LH P15 Power Window Motor Rear RH Note: Not all of the above part numbers of the connector are established for the supply. 408 4RUNNER (EM03M0U) 90980–10789 90980–10760 90980–10789 90980–10797 L Code Part Name P16 Pretensioner LH P17 Pretensioner RH Part Number S5 90980–12253 Power Seat Control SW (Driver’s Seat) P19 Power Seat Control SW (Front Passenger’s Seat) P20 Power Seat Motor (Driver’s Seat Front Vertical Control) 90980–10997 P21 Power Seat Motor (Driver’s Seat Lifter Control) P23 Power Seat Motor (Driver’s Seat Reclining Control) P24 Power Seat Motor (Driver’s Seat Slide Control) P25 Power Seat Motor (Front Passenger’s Seat Reclining Control) P26 Power Seat Motor (Front Passenger’s Seat Slide Control) P27 Position Control ECU and SW 90980–10801 P28 Position Control ECU and SW 90980–12551 R1 Radio and Player 90980–12038 R2 Radio and Player 90980–10997 R3 Radio and Player 90980–10996 R4 Radio and Player 90980–12552 R5 Radio and Player 90980–12259 R9 Radio and Player with Display 90980–11909 R10 Radio and Player with Display 90980–12259 90980–10825 R11 Radio and Player with Display 90980–12552 R12 Radio and Player with Display 90980–12038 R13 Rheostat R14 Rear Combination Light LH R15 Rear Combination Light RH R16 Rear Door Speaker LH R17 Rear Door Speaker RH R18 Rear Seat Audio Controller R19 Rear Speaker LH R20 Rear Speaker RH R21 Rear Window Defogger R22 Rear Window Defogger 90980–10797 90980–10935 90980–12556 90980–11013 90980–10359 Rear Wiper Motor 90980–11599 Rear Wiper Position SW R24 Remote Control Mirror SW 90980–11657 R25 Roll Sensing of Curtain Shield Airbag Cutoff SW 90980–11013 R26 Radio and Player with Display 90980–12404 R27 Radio and Player with Display 90980–12209 Starter (1GR–FE) 90980–09463 Starter (2UZ–FE) 90980–09585 S2 S3 Starter 90980–11400 S4 Seat Heater SW LH 90980–10957 Part Name Seat Heater SW RH Part Number 90980–10933 Shift Lock Control ECU S6 P18 R23 Code Transmission Control SW 90980–12552 S11 Steering Sensor 90980–12553 S12 Stop Light SW 90980–11118 S13 Suspension Control ECU 90980–12561 S14 Suspension Control ECU 90980–12560 S15 Suspension Control ECU 90980–12562 S16 Side Airbag Sensor Front LH S17 Side Airbag Sensor Front RH S18 Side Airbag Sensor Rear LH S19 Side Airbag Sensor Rear RH S20 Door Speaker Front LH No.2 S21 Door Speaker Front RH No.2 S22 Stereo Component Amplifier 90980–12554 S23 Stereo Component Amplifier 90980–10821 S24 Seat Heater LH S25 Seat Heater RH S26 Side Airbag Squib LH S27 Side Airbag Squib RH S28 Skid Control ECU with Actuator 90980–12297 S29 Skid Control ECU with Actuator 90980–12294 S30 Seat Memory SW 90980–11090 S31 Stereo Jack Adapter 82824–21030 S32 Step Light Front LH S33 Step Light Front RH S34 Step Light Rear LH S35 Step Light Rear RH T1 Theft Deterrent Horn 90980–12225 90980–11013 90980–10797 90980–11864 90980–11162 90980–10619 Throttle Control Motor T2 Throttle Position Sensor 90980–11858 T3 Transfer Shift Actuator 90980–11664 T4 Turbine Speed Sensor 90980–11156 T5 Theft Deterrent ECU 90980–12557 T6 Towing Brake Controller 90980–11603 T8 Transponder Key Computer 90980–11911 T9 Turn Signal Flasher Relay 90980–10799 T10 Tailgate Control SW 90980–11015 90980–11292 T11 Television Camera T12 Tension Reducer Solenoid LH T13 Tension Reducer Solenoid RH T14 Towing Converter Relay 90980–11535 T15 Trailer Socket 82824–34030 T16 Tire Pressure Warning ECU 90980–12553 T17 Tire Pressure Warning Antenna and Receiver 90980–11909 90980–12063 409 4RUNNER (EM03M0U) L PART NUMBER OF CONNECTORS Code T18 V1 V2 V3 V4 Part Name Part Number Telephone Microphone 90980–12366 VSV (ACIS) (1GR–FE) 90980–11149 VSV (ACIS) (2UZ–FE) 90980–11156 VSV (Purge) 90980–11156 VVT Sensor (Bank 1) (2UZ–FE) 90980–10947 VVT Sensor (Bank 2) (1GR–FE) 90980–12353 VVT Sensor (Bank 1) (1GR–FE) 90980–12353 VVT Sensor (Bank 2) (2UZ–FE) 90980–10947 V5 VSC Warning Buzzer V6 Vanity Light LH V7 Vanity Light RH V9 Voltage Inverter 90980–10906 90980–12322 Code Part Name Part Number V11 Vehicle Speed Sensor (Electronically Controlled Transmission) V12 VSV (Air Switching Valve Bank 1) V13 VSV (Air Switching Valve Bank 2) V14 Video Terminal 90980–12551 W1 Washer Level Sensor 90980–11068 W2 Washer Motor 90980–11028 W3 Wireless Door Lock Buzzer 90980–11142 W4 Woofer 90980–10795 Y1 Yaw Rate Sensor 90980–11904 Z1 Option Connector (TVIP ECU) 90980–10795 90980–10799 Note: Not all of the above part numbers of the connector are established for the supply. 410 4RUNNER (EM03M0U) 90980–11156 90980–11149 Memo 411 4RUNNER (EM03M0U) 1 4RUNNER P o w e r S o u rc e ∗ 1 : 1GR–FE Cold Area Spec. ∗ 2 : 1GR–FE Except Cold Area Spec. S ta rtin g 1 4 3 2 ACC IG1 AM1 7 AM2 IG2 ST2 8 G–B J27(B), J28(A) Junction Connector R I18 Ignition SW B–Y A A A A A A (2UZ–FE) B B B B B B (1GR–FE) 7. 5A STA NO. 2 B–Y 2 R 2 2 1K 5 1 2 IC4 G 6 IM2 (2UZ–FE) 4 IM2 (1GR–FE) G 2 J35 G Junction Connector 5 2 P L–Y W–B S 2(A), (B), S 3(C) Starter Engine Control Module < 5–12> < 5–14> < 6–14> 1 C P B Combination Meter < 31–3> J3 Junction Connector B Y–G(2UZ–FE) Y (1GR–FE) (2UZ–FE) (1GR–FE) B 1 1 A B P1 Park/Neutral Position SW N 4 6 EA1 (2UZ–FE) 4 EA2 (1GR–FE) 1 B–R(2UZ–FE) B–L(∗1) W (∗2) B–Y W–B 2 2 L–Y 2 2 30A AM2 B–Y B–Y B–Y 3 11 IM1 B–Y STA Relay Y–G 4RUNNER (EM03M0U) R 3 1D Battery EB M 415 Front Left Fender B–Y P o w e r S o u rc e R W–B W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R B–R B–R I8 Ignition Coil and Igniter No. 8 I7 Ignition Coil and Igniter No. 7 I6 Ignition Coil and Igniter No. 6 I5 Ignition Coil and Igniter No. 5 I4 Ignition Coil and Igniter No. 4 I3 Ignition Coil and Igniter No. 3 I2 Ignition Coil and Igniter No. 2 I1 Ignition Coil and Igniter No. 1 N1 Noise Filter (Ignition No. 1) N2 Noise Filter (Ignition No. 2) R–W G–B R–Y G–W R–Y G R–W B–L R–Y L–Y R–W L–W R–W LG–B R–Y LG W–B W–B B Battery R–W R–Y W–B Engine Control Module < 5–13> < 5–14> ED Left Bank Cylinder Head Rear Side of Front Right Fender ER EC Right Bank Cylinder Head ED Left Bank Cylinder Head R–W R–W R–W 2 2 2 2 2 2 2 R–Y R–Y 3 3 3 3 3 3 3 2 B–R 4 3 B–R 1 1 B–R 4 4 4 1 B–R 1 1 1 4 2 B–R W–B W–B W–B W–B W–B W–B 1 4 1 B–R B–R 4 3 2 1 1 4 2 B–R B–R 2 4RUNNER (EM03M0U) 2 1 4 2 1 30A AM2 B–R IG2 6 7 AM2 Ig n itio n (2 U Z – F E ) ST2 I18 Ignition SW 7 EA1 1 EB1 B M OVERALL ELECTRICAL WIRING DIAGRAM 416 2 4RUNNER 3 4RUNNER B–R 13 IM1 B–R R W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R W–B B–R B–R I6 Ignition Coil and Igniter No. 6 I5 Ignition Coil and Igniter No. 5 I4 Ignition Coil and Igniter No. 4 I3 Ignition Coil and Igniter No. 3 I2 Ignition Coil and Igniter No. 2 I1 Ignition Coil and Igniter No. 1 W–R L W–R GR W–R LG–B W–R LG W–R P–L W–R Y–R W–B W–B W–R M 417 Rear Side of Left Bank Cylinder Block EF 2 2 2 2 2 N1 Noise Filter (Ignition No. 1) B Battery 3 3 3 3 3 2 2 1 3 1 W–R W–R 4 4 4 4 4 W–R W–R 1 1 1 1 1 4 2 W–B W–B W–B W–B B–R B–R 4 3 2 1 B–R B–R B–R 2 4RUNNER (EM03M0U) 2 1 30A AM2 B–R IG2 6 7 AM2 Ig n itio n (1 G R – F E ) P o w e r S o u rc e ST2 I18 Ignition SW 6 1D 4 1H Engine Control Module < 6–13> < 6–14> P o w e r S o u rc e C h a rg in g 1 ∗ 1 : 2UZ–FE ∗ 2 : 1GR–FE 4 3 2 ACC W–L 2 AM1 IG1 4 L–Y R 7 AM2 IG2 6 B–R 2 1C ST2 15A IG1 Body ECU < 7–39> 6 1D GR W–L W E B 20 1E Y–R J18(A), J19(B) Junction Connector 2 4 1G E 2 A A R–L Junction Connector E 2 2 2 Junction Connector D Y–R 2 EA1 (∗1) 2 EA2 (∗2) GR 1 EA1 (∗1) 3 EA2 (∗2) 1 EA2 2 C 8(A), C10(C) Combination Meter 16 A 1 5 EA1 2 Charge GR 1 W 7. 5A ALT–S 30A AM2 140A ALT 1 J1 2 6 IC4 W GR GR Y–R W R D 15 C 2 1 J1 A A 2 50A AM1 4RUNNER (EM03M0U) 7. 5A GAUGE I18 Ignition SW 2 Y–R G B B J 8(A), J 9(B) Junction Connector GR W B G A GR 1 B S L B IG B B A Battery 4 Y–R 2 W 1 G 1(A), G 2(B) Generator M OVERALL ELECTRICAL WIRING DIAGRAM 418 4 4RUNNER Memo 4RUNNER (EM03M0U) 419 E n g in e C o n tro l (2 U Z – F E ) P o w e r S o u rc e 1 4 3 2 W–R A GR B R C B–R D B–O E B F R–L B–R B–O IG1 8 EA1 B–O 1 2 2 3 2 2 2 2 B–W B B 8 1K J4 Junction Connector 38 IC4 A 2 2 W–B Battery 1 2 17 IC3 4 IM1 ACC CUT Relay 4 L–W 3 A L–W P B 2 GR–B A L 2 P Remote Control Mirror System < 24–3> Navigation System < 28–2> Audio System < 28–2> < 29–2> < 30–2> Parking Assist (Rear View Monitor) System< 28–2> Air Conditioning System < 32–3> B B B 33 IC4 L–W F 3E 11 IC4 W 1 B A J 2(A), J 3(B) Junction Connector B A B 9 IC4 F 3E 30A AM2 1 L–W 2 W W–B W–B 2 P 1 5 2 R–L 1 2 20A EFI 10A ETCS Short Pin 1 B 2 B 2 15A A/F HEATER 2 2 2 2 C/OPN Relay 7. 5A ACC B L L B–R GR W 2 3 2 2 4 1G 2 B 10A IGN 1 2 2 1 K 2 7. 5A GAUGE R 2 2 5 2 10A EFI NO. 2 140A ALT 3 1 2 2 J B–W B 2 1 1 B 5 1D B–R 23 1E B 11 1J 2 EFI Relay 6 1D 2 A/F HEATER Relay B–O B–O W–G 2 5 I18 Ignition SW W–G C I W–G B L B–R ST2 1 1 IG2 6 B–R 10A ECU–B 1 50A AM1 2 7. 5A OBD 50A A/PUMP 2 7 AM2 H L W–G L B–R W–R 4RUNNER (EM03M0U) 2 2 35 IC4 12 IC4 C 2 J4 Junction Connector 2 2 B O R L W–L 2 O ACC 3 W–G 2 AM1 G W–G W–G GR–B B 1 IB2 L–W 12 IM1 L–W 16 IC3 L–W W–G Front Left Fender EB N O P W–G W 2 L M Q M OVERALL ELECTRICAL WIRING DIAGRAM 420 (Cont. next page) 5 4RUNNER (Cont. next page) 5 4RUNNER (Cont' d) E n g in e C o n tro l (2 U Z – F E ) A B E R–L Y V B G B–R B–O L O W–G Tire Pressure Warning ECU < 26–3> L 14 IC3 Multiplex Communication System (CAN)< 15–11> 10 IC3 32 IC4 G Y C 3C V P–L C 3C 5 4 15 SIL TS 12 7 23 E 4 E AIDI 25 E AIRV AIRP E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module ACCR FPR FC 30 C 17 E 10 E GR–B W–G G–R F A J35(A), J36(B) Junction Connector F A 13 E TC R–Y R–Y R–Y R–B Body ECU < 7–38> F A Airbag Sensor Assembly< 20–6> R–B R–Y D R–Y R–Y G B J18(A), J19(B) Junction Connector B Skid Control ECU with Actuator< 15–4> Suspension Control ECU< 18–3> Skid Control ECU with Actuator< 15–4> Suspension Control ECU< 18–3> A 3A R–Y R–Y R–Y BR W–B W–B G–R 9 IM2 B R–Y D D G A R–Y E E G A B J1 Junction Connector A A E B A A G A A 3A A 3A 15 IC2 R–B A A J4 Junction Connector J22 Junction Connector W–B J35(A), J36(B) Junction Connector A B M 1 C 3C Occupant Classification ECU< 20–10> WFSE BR A46 Air Pump A47 Air Switching Valve W–B J40(A), J41(B) Junction Connector A B 2 2 P–L CG Skid Control ECU with Actuator< 15–4> L F14 Fuel Pump 1 P–L SG 4 IN1 G B–R G–R F8 Fuel Pump Resistor M 5 P–L E 1 B 4 IC2 4 H B R–Y Tire Pressure Warning ECU < 26–3> W–G GR–B B B L–W L–W L–W L–W W BR W–B W–B W–B Q BL BO EQ Near the Starter Left Bank Cylinder Head ED K L J5 Junction Connector IG Left Kick Panel M 421 Rear Pillar LH I J A W Floor Seat Crossmember LH H D1 Data Link Connector 3 B–R W–B TC CANL R–B 3 EA1 13 14 CANH R–W G 4 EA1 6 BAT DI BR L B–R B–Y G–R 2 IB1 B–R 16 2 B SIV H A A B E A P–L 3 B SIP W–B 2 19 IM2 P 4 B BR 2 1 O P–L BATT A43(A), A44(B) Air Injection Control Driver VV VP 6 B 2 A 2 5 IC4 H A O 1 A +B 5 2 H A V 5 B 4 1 M Y 3 FUEL PUMP Relay L G R 2 2 B 2 R–Y A B J18(A) Junction Connector F G P–L Airbag Sensor Assembly < 20–6> 4 IC3 P–L D J29(A), J30(B) Junction Connector B–W O 4RUNNER (EM03M0U) Suspension Control ECU< 18–3> W–G C E R–L B–W N A B B–R I K GR B–O H J W–R R F G 8 7 6 GR C D 5 W–R E n g in e C o n tro l (2 U Z – F E ) A B 9 W–R 12 11 10 W–R R–Y C D B–R B–R B–R B–R B–R B–R I16 Injector No. 8 I15 Injector No. 7 I14 Injector No. 6 I13 Injector No. 5 I12 Injector No. 4 I11 Injector No. 3 Park/Neutral Position SW < 1–2> 2 BR W R G Y W P # 60 VTA1 AIP 3 A 7 C # 50 20 A 32 A 2 A # 70 VTA2 19 A 8 B # 80 M+ M– 5 A STAR/NSW GE01 4 A 17 A ACIS THW 21 A PRG 34 A 33 A W–L Y–R R 1 B 1 B V 2(B) VSV (Purge) 2 B V 1(B) VSV (ACIS) 1 2 B L–W L–W BR W BR R 4 EB2 E2 3 5 BR 3 EB2 T2 Throttle Control Motor Throttle Position Sensor VC 2 E2 Engine Coolant Temp. Sensor M– R–L 1 M+ (Shielded) 2 G 4 VTA2 R E2 1 L–R 7 IM2 R–B VC 3 L–R L–R 22 IM2 Y AIP A45 Air Pressure Sensor 2 L–R 3 6 VTA1 1 EB2 W–L 42 IE1 L–R C1 Camshaft Position Sensor 1 L–R 16 IM2 L–W L–R BR W–B W 1 2 2 6 C # 40 VC B L–W 1 1 2 5 C # 30 23 A W 43 IE1 BR W–B O L 9 IE1 4 BR 28 IE1 2 L–R 6 W–B 1 O 11 IE1 9 L–W K B Vent Valve C A R–G 8 R J Leak Detection Pump R R–G M 2 3 1 2 4 C # 20 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module G2+ G2– 19 C 29 C Canister Pressure Sensor 17 IE1 I # 10 L4 Canister Pump Module A B B–R 22 E L 5 E I10 Injector No. 2 6 E 2 3 C 2 C IGSW MPMP VPMP PPMP O B B J31(A), J32(B) Junction Connector A B 2 E A 9 E W J26 Junction Connector +B2 30 D +BM 1 C B–R R–L +B 7 E B–R A A B–O BATT R–B 3 E MREL 1 E GR L W–G 8 E B–R 1 2 R–L 7 A R–L B B 2 B–R B–R B A J31(A), J32(B) Junction Connector B A 1 1 B–O Malfunction Indicator Lamp GR 4RUNNER (EM03M0U) 13 IC4 B I9 Injector No. 1 R–Y B–R B–R Combination Meter< 31–3> B 15 C B–O H L W–G C 8(A), C10(C) Combination Meter G B–O J8 Junction Connector R–L B B–R B–O B–O F 4 EB1 B–R R–L E A GR BR BR BR W BR L–W C L–W ED Left Bank Cylinder Head C D J28 Junction Connector D C D E M OVERALL ELECTRICAL WIRING DIAGRAM 422 (Cont. next page) 5 4RUNNER (Cont' d) 5 4RUNNER (Cont' d) (Cont. next page) E n g in e C o n tro l (2 U Z – F E ) A B C 13 W–R 16 15 14 W–R R–Y R–Y B–O B–O DEFOG Fuse< 7–36> VPA2 VCP1 VCP2 EP1 EP2 6 3 4 1 5 2 VG 30 A 9 A IGT7 E2G 29 A 24 A IGT8 THA E2 22 A 25 A IGF1 28 A 12 C IGF2 STSW 11 C 17 C STA E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module HA2A A2A+ A2A– 1 B 23 B 31 B A1A+ 22 B 15 C 16 C OC1+ A1A– 30 B 14 C OC2+ OC1– HA1A 2 B 12 D OC2– HT2B OX1B 33 B 18 A NE– NE+ 21 C L Y (Shielded) +B 2 HT 1 HT OX +B E1 2 4 3 1 OX HT +B 2 E1 4 E E E E E E E 2 B 1 B C 4(B) Crankshaft Position Sensor AF– 3 J28 Junction Connector AF+ 1 H6 Heated Oxygen Sensor (Bank 1 Sensor 2) 4 W–B W–B W–B W–B W–B BR L–W BR L–W R–L BR EPA2 W–B 3 W C BR 21 E EPA 20 C C C W–B C W–B W BR +B 2 W D HT J26 Junction B–W Connector BR W AF– 1 BR L–W E AF+ 20 E VCP2 G–Y E2 5 B 4 H8 Heated Oxygen Sensor (Bank 2 Sensor 2) +B 1 B L–W D THA 3 A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) E2G 4 B A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) VG 2 B M 1(B) Mass Air Flow Meter V13 VSV (Air Switching Valve Bank 2) L–W 1 L–W V12 VSV (Air Switching Valve Bank 1) 1 3 B 27 E VCPA HT1B B (Shielded) W P (Shielded) R–L BR Y (Shielded) L P B–W (Shielded) BR Y–B B–W W–R P L 2 26 E VPA2 1 A W–B 2 19 E VPA ELS1 OX2B 5 B 18 E 13 D ELS2 V–W 14 A IGT6 V–W 12 A IGT5 C 8 IC3 LG–B AIV1 27 A 13 A LG–B AIV2 26 A IGT4 29 IC4 W–L 10 A IGT3 W–L 11 A IGT2 9 IC3 B–Y 15 A 26 IC4 R–B IGT1 31 IC4 W–R Y–G 8 A B–Y 34 IC4 R–B TAIL Fuse < 10–5> G Y–R P LG R–W D B VPA1 W–R I A J31(A), J32(B) Junction Connector 1 B A24 Accel Position Sensor Y–G C3 Camshaft Timing Oil Control Valve RH C2 Camshaft Timing Oil Control Valve LH 1 B–Y L–Y R–W R–Y G–B G–W G B–L L–Y L–W LG–B LG 4RUNNER (EM03M0U) STA Relay < 1–3> STA NO. 2 Fuse < 1–3> Ignition Coil and Igniters < 2–1> < 2–2> < 2–3> < 2–4> 2 2 A J28 Junction Connector D E D C ED M 423 Left Bank Cylinder Head E n g in e C o n tro l (2 U Z – F E ) A 17 W–R E n g in e Im m o b ilis e r S y s te m (2 U Z – F E ) 20 19 18 W–R B R–Y 4 1B C B–O I17 Transponder Key Amplifier 4 1L 4WD Control ECU < 19–2> W–R Multiplex Communication System (CAN) < 15–11> < 15–12> A/C Control Assembly < 32–12> W–L (4WD) B–W Stop Light SW < 11–1> ANT1 ANT2 B 3E VC5 CODE 1 4 TXCT GND 5 7 B 3E E01 7 A E02 6 A 4WD 8 C E04 7 B E05 6 B E03 4 B ME01 3 B IMI 16 D KSW 10 12 13 CODE TXCT AGND CTY IND 4 3 T8 V–W R–B 5 LP W–B A A Door Courtesy SW Front LH < 7–31> A A J33(A), J34(B) Junction Connector R (Shielded) G A A 7 Unlock Warning SW < 7–19> 7 EB1 Transponder Key Computer D3 Security Indicator Light G–Y 6 EB1 B 3F W–B W–B W–B W–B B 3F B 3F 2 Rear Side of Cylinder Block EE Left Bank Cylinder Head ED A A A IK J24 Junction Connector J37 Junction Connector 1 W–B W–B K1 Knock Sensor (Bank 1) K 2(B) Knock Sensor (Bank 2) 1 B GND 14 W–B 3 EB1 B W W–B 7 11 VC5 L–R A B W–B EFII 6 W–B 8 EB1 EFIO 8 GND 1 IM2 BR 2 B 2 EB1 (Shielded) E IMO 15 D +B W–R BR 1 B 2 B D EOM 35 D W–B V 4(B) VVT Sensor (Bank 2) V 3(B) VVT Sensor (Bank 1) 2 B W–B BR W–B W–B W–B W–B W–B (4WD) W–B W–B R (Shielded) G B W (Shielded) G R (Shielded) L Y 1 B EC 9 C 1 D L E1 1 C 9 IG ACT LG–R EKNK 28 B 2 25 D P–G KNK1 29 B AC1 GR–B EKN2 20 B 24 D THWO W–R VV1– 14 D CANL R–Y E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module VV2+ VV2– KNK2 18 C 28 C 21 B 24 C 34 D CANH STP B–O 33 D 15 E L4 BR–W 13 C F/PS GR–G VV1+ 32 D L–B TACH G–Y 1 D W–L (4WD) F B SPD 25 C 5 IM2 L V–R 8 D J31(A), J32(B) Junction Connector B–W G A (Shielded) 4RUNNER (EM03M0U) Airbag Sensor Assembly< 20–6> Combination Meter< 31–4> < 31–6> Transponder Key Coil W–B Right Kick Panel Instrument Panel Brace RH II M OVERALL ELECTRICAL WIRING DIAGRAM 424 5 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 425 E n g in e C o n tro l (1 G R – F E ) P o w e r S o u rc e 1 4 3 2 W–R A GR B B–R C B–O ACC 3 O 2 AM1 W–L W–G R–L IG1 7 AM2 W–G I B B–O B B B B B–R B 5 1D W–G 23 1E 12 IC4 L 11 1J W–G 3 1H H B–W 2 2 1 7. 5A ACC 1 L L B–R GR W 2 3 2 2 1 3 2 2 2 2 B–W B 2 B 1 F 3E 1 P 11 IC4 4 IM1 W–G Battery 4 17 IC3 1 2 B W–B ACC CUT Relay 2 W–G EB Front Left Fender W–G GR–B B L–W W L–W A L–W 9 IC4 2 A W 3 2 33 IC4 A L–W B B B 2 B A J4 Junction Connector L P Remote Control Mirror System < 24–3> Navigation System < 28–2> Audio System < 28–2> < 29–2> < 30–2> Parking Assist (Rear View Monitor) System< 28–2> Air Conditioning System < 32–4> 38 IC4 J 2(A), J 3(B) Junction Connector B A 2 GR–B F 3E 30A AM2 L–W 20A EFI W 1 2 W–B 1 2 2 W–B 10A ETCS Short Pin 1 2 2 5 B 2 15A A/F HEATER 2 2 2 P 2 R–L 2 3 2 2 1 2 2 2 2 8 1K B B 4 1G 2 5 C/OPN Relay 10A IGN 7. 5A GAUGE 2 1 10A EFI NO. 2 2 2 1 EFI Relay R 5 A/F HEATER Relay 140A ALT 2 W–G G C B–O B–O 10A ECU–B 6 1D B–R 1 1 B–R I18 Ignition SW 35 IC4 W–G L ST2 F L C IG2 6 J4 Junction Connector 50A AM1 7. 5A OBD W–R 4RUNNER (EM03M0U) 2 2 2 B–O 2 2 E O L 2 D 1 IB2 16 IC3 L–W 12 IM1 J K L M N O M OVERALL ELECTRICAL WIRING DIAGRAM 426 (Cont. next page) 6 4RUNNER 6 4RUNNER (Cont' d) (Cont. next page) E n g in e C o n tro l (1 G R – F E ) A B C D 5 W–R 8 7 6 W–R A GR B–R B–R B–O B–O B C R–L E O F 2 GR 7 E BATT ACCR 17 E +BM FC 10 E PSW 10 C G–W GR–B W–G F A H B Tire Pressure Warning ECU < 26–3> 1 P2 Power Steering Oil Pressure SW J35(A), J36(B) Junction Connector R–Y Skid Control ECU with Actuator< 15–4> FPR 30 C Y–B F A 3 E MREL R–Y R–Y F A 8 E TC A 3A R–Y R–Y Body ECU < 7–38> Airbag Sensor Assembly < 20–6> W–B A A W–G GR–B B L–W W L–W R–Y J22 Junction Connector J1 Junction Connector R–Y B G B A 3A 23 E L G A J18(A), J19(B) Junction Connector G A R–Y R–Y R–Y G A B J4 Junction Connector R–B E C 3C A 3A R–Y R–B R–W D A B BR O E J40(A), J41(B) Junction Connector Y–B N 15 IC2 D 9 IM2 W–B Y–B K 4 IC2 F14 Fuel Pump 5 19 IM2 M 7 R–Y B–R M F8 Fuel Pump Resistor W–B A B L 12 4 1 J 15 C 3C SIL R–B BR B–R 2 5 IC4 4 W–B B–R B–Y 2 IB1 B–R 5 C 3C W–G 2 TC D1 Data Link Connector 3 WFSE TS P–L 2 CG 13 CANL E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 2 SG 14 Occupant Classification ECU< 20–10> 5 6 CANH 13 IC4 P–L 9 E A P–L 4 P–L TAC 16 FUEL PUMP Relay P–L B–W BAT 3 1 H A 2 O 2 H A A B B L–W W L–W Rear Pillar LH BO BR BL W–B W–B F G H I A J5 Junction Connector Rear Side of Right Bank Cylinder Block EE IG Left Kick Panel M 427 Floor Seat Crossmember LH E GR 32 IC4 A B P–L J29(A), J30(B) Junction Connector Combination Meter< 31–4> Airbag Sensor Assembly < 20–6> B–W J18(A) Junction Connector Multiplex Communication System (CAN)< 15–11> O B–W R–Y P–L W–G Y–B 4RUNNER (EM03M0U) I Tire Pressure Warning ECU < 26–3> L G H D R–L E n g in e C o n tro l (1 G R – F E ) A 9 W–R 12 11 10 W–R R–Y 5 IM1 B C B–R B–O B–R B–R C2 Camshaft Timing Oil Control Valve LH 1 I A D B G L–R L–W L–B G–Y L Y Y–G 3 C # 10 TAIL Fuse < 10–5> J31(A), J32(B) Junction Connector C3 Camshaft Timing Oil Control Valve RH 1 1 Y–G 2 I14 Injector No. 6 1 G R B 2 C IGSW 5 E I13 Injector No. 5 1 2 2 I12 Injector No. 4 I11 Injector No. 3 I10 Injector No. 2 1 4 C # 20 5 C # 30 VC 22 E 6 C # 40 MPMP VPMP PPMP 6 E B–R B–R B–R B–R 34 A 2 R–L PRG ACIS 33 A J27 Junction Connector +B2 2 E 1 R–L +B 1 E D 9 E W 2 C DEFOG Fuse< 7–36> D D B–O R–B 30 D B–R 2 I9 Injector No. 1 7 A 1 R–L J31(A), J32(B) Junction Connector B A B–R 2 B–O B A B B E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 2 B B–O Malfunction Indicator Lamp 4RUNNER (EM03M0U) C 8(A), C10(C) Combination Meter R–Y B–R B–R Combination Meter < 31–3> B 15 C E B–O J8 Junction Connector R–L B B–R B–O R–L D A 23 A 7 C # 50 VTA1 20 A 17 C # 60 VTA2 19 A M+ 5 A M– 4 A 15 C 16 C OC1+ OC2+ OC1– GE01 17 A THW 30 A 12 D ELS1 OC2– VG 21 A 13 D 14 C E2G 29 A ELS2 THA E2 22 A 28 A L4 Canister Pump Module Rear Side of Left Bank Cylinder Block THA +B E2 1 A 5 A BR EF 4 A BR BR W–B L–W L–W L–W E2G L–W BR W 7 IM2 L–R BR L–W 1 2 A M 1(A) Mass Air Flow Meter E2 3 R L–R 22 IM2 5 42 IE1 L–R 17 IM2 43 IE1 VG R–B 9 IE1 3 A R–W 28 IE1 R–Y 11 IE1 L VC 17 IE1 2 E2 Engine Coolant Temp. Sensor M– B–L 1 M+ T2 Throttle Control Motor Throttle Position Sensor 2 (Shielded) G–W 4 VTA2 P G–B 6 VTA1 L–R 4 BR 1 A 2 BR I 1 A 6 W–B H B L–W W L–W 1 O R G 2 A V 2(A) VSV (Purge) F V 1(A) VSV (ACIS) 2 A 9 W–B 8 L–W 3 R–G C A M Leak Detection Pump Vent Valve G–Y W–L A B L–R R R–G O B B J31(A), J32(B) Junction Connector A B Canister Pressure Sensor BR BR BR L–W W L–R D E F G M OVERALL ELECTRICAL WIRING DIAGRAM 428 (Cont. next page) 6 4RUNNER (Cont' d) (Cont. next page) 6 4RUNNER (Cont' d) E n g in e C o n tro l (1 G R – F E ) A B C 13 W–R 16 15 14 W–R R–Y R–Y B–O B–O A B C A24 Accel Position Sensor 2 8 IC3 V–W 21 E EPA EPA2 NE– VV2– 20 C 28 C NE+ 21 C 1 A C 4(A) Crankshaft Position Sensor 2 A B W (Shielded) 2 A V–W 20 E VCP2 V 3(A) VVT Sensor (Bank 2) 3 A 27 E L 1 A 29 IC4 LG–B VV2+ 18 C VCPA LG–B 26 E VPA2 9 IC3 W–L B–Y 19 E Y 2 A R–B VV1– 29 C 26 IC4 W–L 31 IC4 B–Y R–B J28 Junction Connector 3 A VPA V 4(A) VVT Sensor (Bank 1) E E EP2 5 G R E EP1 1 W–R BR–W GR–G L–B E1 4 1 A E VCP2 4 18 E ACT VV1+ E VCP1 3 34 IC4 25 D 19 C H6 Heated Oxygen Sensor (Bank 1 Sensor 2) HT VPA2 6 W–R A/C Control Assembly < 32–12> Multiplex Communication System (CAN) < 15–11> < 15–12> AC1 G 1 OX +B 24 D THWO HT1B 3 2 14 D CANL 1 A W E1 4 OX1B 18 A 34 D CANH STA (Shielded) +B B–Y OX H8 Heated Oxygen Sensor (Bank 2 Sensor 2) 3 HT 2 STA Relay < 1–3> P B L (Shielded) HT 1 1 33 D 11 C STAR/NSW E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module HT2B OX2B 5 B 33 B R–L +B HA1A A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) AF– 8 B STSW 2 B L 4 12 C IGF1 A1A– AF+ 2 24 A 30 B 3 L–Y IGT6 W–R 13 A P +B 2 BR BR L–W BR L–W R–L W W A BR L–R A L–R G (Shielded) AF– A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) 4 AF+ J27 Junction B–W Connector F BR L–W W L–R A1A+ 22 B BR Y B–W (Shielded) 3 HT E IGT5 A2A– 31 B 1 D 12 A IGT4 L A2A+ 23 B 11 A IGT3 GR 10 A IGT2 HA2A LG–B 9 A IGT1 1 B LG P–L Y–R 4RUNNER (EM03M0U) 8 A Park/Neutral Position SW< 1–2> STA NO. 2 Fuse< 1–3> Ignition Coil and Igniters < 3–2> < 3–3> < 3–4> VPA1 A BR BR D L–R EE M 429 Rear Side of Right Bank Cylinder Block E n g in e C o n tro l (1 G R – F E ) E n g in e Im m o b ilis e r S y s te m (1 G R – F E ) 17 W–R A M OVERALL ELECTRICAL WIRING DIAGRAM 430 6 4RUNNER (Cont' d) 20 19 18 W–R R–Y B 4 1B B–O C I17 Transponder Key Amplifier 4 1L 4WD Control ECU < 19–2> Stop Light SW < 11–1> VC5 1 E02 6 A E04 7 B E05 6 B E03 4 B ME01 3 B EOM IMO 35 D 15 D IMI 16 D EFII 6 7 8 11 12 13 VC5 CODE TXCT AGND T8 Transponder Key Computer GND KSW 14 10 CTY IND 4 3 V–W R–B G–Y W–B W–B W–B W–B W–B BR BR BR W–B W (Shielded) 5 LP D3 Security Indicator Light W B (Shielded) A A A A J33(A), J34(B) Junction Connector A B W–B EE Rear Side of Left Bank Cylinder Block EF A A A IK W–B J37 Junction Connector Rear Side of Right Bank Cylinder Block B 3F W–B K1 Knock Sensor (Bank 1) 2 B 3F B 3F W–B 1 7 W–B 5 ED1 Door Courtesy SW Front LH < 7–31> 2 ED1 Unlock Warning SW < 7–19> 1 ED1 BR 2 A EFIO +B GND BR BR 7 L E01 7 A 1 D L–R K 2(A) Knock Sensor (Bank 2) D GND 5 LG–R E1 1 C 9 IG W–R R G (Shielded) 1 A TXCT P–G EKNK 28 B B R G (Shielded) 6 ED1 4 GR–B 2 STP W–R E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 15 E L4 R–Y 29 B B–O 13 C 4WD KNK1 20 B G–Y EKN2 8 C BR 4 ED1 CODE B 3E W–L (4WD) KNK2 F/PS GR (4WD) L 32 D TACH 21 B ANT2 ANT1 B 3E 15 IM2 B–W SPD W–L (4WD) J31(A), J32(B) Junction Connector 1 D 8 D ADD Actuator < 19–3> Airbag Sensor Assembly < 20–6> B–W V–R F B W–R Combination Meter< 31–4> < 31–6> 4RUNNER (EM03M0U) G A Transponder Key Coil J24 W–B Right Kick Panel Junction Connector II Instrument Panel Brace RH Memo 4RUNNER (EM03M0U) 431 M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) P o w e r S o u rc e 1 4 3 2 B 4(A), B 5(B), B 6(C) Body ECU W–L ACC 3 W–G IG1 4 L–Y 2 AM1 ACC 22 BDR1 BECU 12 11 9 1E 4 1B CLTB 6 C CLTE CLTS 21 C 4 C B–R I18 Ignition SW 5 1D 12 1F 3 IG1 2 IG1 1 IG1 L–Y G–W Y 3 4 CLTE CLTS W–R W–R W–R G–W W–G R–L 1 CLTB Y–R A39 Automatic Light Control Sensor E E 2 2 2 2 W R–B 2 1 W R–B G–W 1 B–Y (∗1) 2 10A DOME 2 1 2 10A ECU–B W R 1 2 2 50A J/B 5 1 2 15A FR FOG 4 2 2 R W–R 2 2 3 L–W 2 50A AM1 DEFOG Relay 1 2 LG 2 W–L 2 W–B B–R R Y–R J1 Junction Connector 4RUNNER (EM03M0U) 4 1G 4 1L Y R 7. 5A GAUGE ST2 G–W 7. 5A ACC 6 1D IG2 6 L–Y 7 AM2 2 2 2 LG 2 2 2 2 2 1 1 2 W–R 5 W–R L–W L–Y Y–R R–L R R B–R B–Y(∗1) R–B R–B W W W–B 1 2 B B 1 3 HEAD Relay 1 20A DR/LCK 1 Short Pin 30A AM2 140A ALT A 2 15A TRN–HAZ 2 Battery ∗ 1 : w/ Daytime Running Light B C D E F G H I J K L M N O P M OVERALL ELECTRICAL WIRING DIAGRAM 432 (Cont. next page) 7 4RUNNER 7 4RUNNER (Cont' d) (Cont. next page) ∗ ∗ ∗ ∗ M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 5 1 2 3 4 : w/ Daytime Running Light : Limited : w/ Rear Seat Entertainment System : w/o Rear Seat Entertainment System 8 7 6 B 4(A), B 5(B), B 6(C) Body ECU PWS TRLY 6 L–R 2 A A H H H 1 2 R R 1 IP2 A A 9 BB1 H R R R 19 1A 6 1E R (∗2) A 22 1J W(∗3) R W(∗4) L–R J35 Junction Connector 1 D11 Door Courtesy Light Rear RH C B E 9 1A 8 BB1 Y D9 Door Courtesy Light Front RH P 2 J12(A), J13(B) Junction Connector R N O W (w/ Vanity Light) 2 R L M 1 R (∗2) K 4 1A (w/ Vanity Light) R J 9 IP1 R H I 1 E R G W (w/ Vanity Light) F 2 R W (∗4) W(∗3) D E W–R L–W L–Y Y–R R–L R R B–R B–Y(∗1) R–B R–B W W W–B DOOR C 5 1 A (∗3) W–B B OFF ON DOOR OFF ON Moon Roof Control ECU < 24–2> TOWING TAIL Relay < 27–3> W–R B 1 UP R–G W L–O L–O W–L L–W L A 2 RCYL 22 B I17 Ignition Key Cylinder Light V7 Vanity Light RH 3 1 B (∗4) 6 V6 Vanity Light LH 2 B (∗4) L2 Luggage Compartment Light 3 B I20(A), (B) Interior Light 3 A 2 A (∗3) P7 Personal Light 1 1H 1 E W(∗3) LG W (∗3) W–B 25 1J 1 PCYL 25 A B1 Back Door Power Window Control SW W W(∗4) COM 19 B 3 DOWN 9 1K W (w/ Vanity Light) W(∗3) W(∗3) 2 2 1F W–B W(∗4) W(∗4) 10 1K 18 1A W(∗4) W(∗3) L 1 1C 2 1H 12 1A W (∗3) 1 1A W (∗3) 1 30A POWER 4RUNNER (EM03M0U) 16 1E 8 1A 1 10A SECU/HORN Taillight and Illumination System< 10–2> 5 7 1A BUP 10 B Y 2 BDN 8 B B–Y 3 TAIL Relay ILE 13 Y–R 1 GND2 16 B–L 5 2 4 POWER Relay 3 GND1 21 18 R–W E J6 Junction Connector R–W LG W–L W–R W L–O W–R L–O L–Y Y–R R–L R R B–R B–Y(∗1) R–B R–B W W W–B W–B B C D E F G H I J K L M N O P Q R S T U V M 433 ∗ 1 : w/ Daytime Running Light ∗ 2 : Limited M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 9 12 11 10 B 4(A), B 5(B), B 6(C) Body ECU W B H I J K L M N O P Q S T U V B A R–W W–B B–R R–W LG W–L W–R W L–O W–R L–O B–R R–W LG W–L W–R W L–O W–R L–O L–Y Y–R R–L R R B–R B–Y(∗1) R–B R–B W W W–B W–B R–L R R B–R W–B(∗1) W–B R R–G R–W G 23 IC4 R–G J25 Junction Connector A A R–W E F R–G D R–W Y–R C 2 H1 Headlight LH (High) 1 R–L 1 W–B 2 J6 Junction Connector B 2 R–L R–B A 1 H4 Headlight RH (Low) Y–R Y–R E 1 2 2 W–B (∗1) Y–R Y–R E A J7 Junction Connector R R R (∗2) E 2 22 IC4 R (∗2) R (∗2) 3 IE1 2 W–B E A W H A D B J22(A), J23(B) Junction Connector B–Y (∗1) B–R B–R Y–R Y–R L–Y H A J20(A), J21(B) Junction Connector F B 20 IC4 2 2 R–Y 8 1F 9 BA1 1 19 IC4 H2 Headlight LH (Low) 28 1J 2 1 2 W–B (∗1) 8 1J E 9 Y–R (∗1) 20 1E TFR 1 B–Y (∗1) R 2 1C TFL IG 6 2 HAZ 2 10A HEAD(HI RH) TSR 4 10A HEAD(HI LH) DRL TSL 10 10A HEAD(LO RH) 8 10A HEAD(LO LH) 7 R–B 2 2 D2 Daytime Running Light Relay Turn Signal Flasher Relay 10A ECU–IG 12 R (∗2) R (∗2) R (∗2) HF2 20 C 8 1B Turn Signal and Hazard Warning Light System< 8–2> < 8–3> 1 2 BL1 4 IO3 A 13 IA1 1 R (∗2) R (∗2) R (∗2) 2 BM1 2 2 R 1 S34 Step Light Rear LH S32 Step Light Front LH 1 1 2 W–R (∗2) W–R (∗2) W–R (∗2) S35 Step Light Rear RH R (∗2) S33 Step Light Front RH 2 1 15A IG1 W–R (∗2) W–R (∗2) W–R (∗2) 4RUNNER (EM03M0U) 2 P–G 1 BL1 D10 Door Courtesy Light Rear LH 4 IE1 D8 Door Courtesy Light Front LH 1 BM1 W–R (∗2) W–R (∗2) W–R (∗2) W–R (∗2) 5 IO3 HRLY 17 1 C A Y–G C A 8 BA1 DRL 7 A W 9 IA1 10 R–B J20(A), J21(B) Junction Connector SIG 1 LG–R (∗1) P–G C B WIG 15A RR WSH LCYL 21 B W–R (∗2) DCYL 26 A W–G LP 6 B W–B Front Left Fender EB W–B Y–R R–L W–B W–B W–B C D E F G H I J K L M N O P Q R S T U V W X M OVERALL ELECTRICAL WIRING DIAGRAM 434 (Cont. next page) 7 4RUNNER (Cont' d) 7 4RUNNER (Cont' d) (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 13 ∗ 1 : w/ Daytime Running Light 16 15 14 B 4(A), B 5(B), B 6(C) Body ECU HEAD 1 C TAIL 8 C 9 IH1 G–R 2 W–B 8 A HF 2 HU OFF 17 B 7 2 1 2 1 B 3F A 3C B 3F B 3F A 3C G J12(A), J13(B) Junction Connector W–B W–B K L M N O P Q R S T U V R–G R–W W–B W–B B–R R–W LG W–L W–R W L–O W–R L–O B–R B–R R–W W–R W L–O W–R L–O B–R W–B R–L R R B–R W–B W–B W–B W–B LG R R–L R R B–R W–B(∗1) Y–R R–L W–B W–B W–B A A A A A A A IG J5 Junction Connector EA Front Right Fender A Right Kick Panel W–B IK D E F G H I J K L M N O P Q R S T U V A A W–B B C W J37 Junction Connector M 435 Left Kick Panel W–B W A R–G W–B J 4 R W–B C12 Combination SW R–L H I HORN Relay < 26–1> E3 Engine Hood Courtesy SW W–B ON W–B F P–G B W–B E G GR–G LG R OFF R–G D B 6 IC3 12 IC3 W–B E A 12 R–W D X J10(A), J11(B) Junction Connector R–G W–B Flash W–B R–G C B A E A 3 DSWH 34 G W–B B B R–G PBEW SIND +B2 3 1 High R–G R–G B 1 IND 25 G–R Low 11 B 7 F2 Front Fog Light RH W–B G E A GND 5 G R–G A B 2 F1 Front Fog Light LH W–B G 10 IN1 2 J3 Junction Connector W–B R–G Fog Light SW R–G 1 Dimmer SW 2 A B 3 G R–W 1 IG+ 2 Y–R AUTO A FR FOG Relay G Head H3 Headlight RH (High) 4RUNNER (EM03M0U) J15(B) Junction Connector Light Control SW Tail 5 HORN P–G 12 W–B EL W–B T DIND W–L 16 14 H 11 GR–G 13 DFSW G–R G–O G R 10 BFG LFG HL 4 2 T5 Theft Deterrent ECU D3 Defogger SW Passenger Seat Belt Warning Light Security Indicator Light G–R (Except Limited) 2 IC3 G–R LG TOUT 6 A G R–L DIND 5 B G–R 10 IH1 DEFSW 1 B R–W G–O G R R–W 8 IH1 HF 7 C G–O G R 1 IH1 A 3 C (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 17 ∗ 5 : w/ Option Connector (TVIP ECU) Except Limited 20 19 18 B 4(A), B 5(B), B 6(C) Body ECU MPX3 KSW 26 C 14 C T5 Theft Deterrent ECU 1 IG +B1 MPX1 2 31 BR–Y B B V B 10 IP2 C C W 5 BA1 5 IA2 R–G R–W B–R R–W B–R R–W W–R W L–O W–R L–O B–R W–B R–L R R B–R W–B W–B W–B W–B LG R W–B II E F G H I J K G L–O W–R L–O A D 1 B W B–R R–G R–W A W–B 4 J24 Junction Connector Instrument Panel Brace RH B W U L–Y A B S T B–R (∗5) 9 IP2 W W–R (∗5) Transponder Key Computer < 5–20> < 6–20> W R A 3D R–B C C W Q B–R B 3E B 3E 5 P9 Power Window Control SW Front RH J7 Junction Connector C W O P A 3D L–R L M N B–R D A 3 2 W–B K L D A 5 IP2 2 W–B I J G A 2 K3 Unlock Warning SW G A 1 +B M G–Y (∗5) BR–Y (∗5) B 3E 3 IG W–R (∗5) H B A 4 MPX1 B–R (∗5) G B A KSW R 1 W–B F B A E A G–Y E A 3D W–R D W J12(A) Junction Connector B–R B–R C D A G–Y J20(A) Junction Connector G B A B W–R B–R T1 Theft Deterrent Horn J18(A), J19(B) Junction Connector G A A B B C B BR–B 4RUNNER (EM03M0U) 1 A B J14(A), J15(B) Junction Connector G–Y BR–Y W–B BR–B 2 IN1 KSW 12 G–Y 10 2 L–B E 29 Z1 Option Connector (TVIP ECU) P13 Power Window Motor Front RH G–Y SH– 1 G–Y BR–Y G–Y W–B W–B R–L R R B–R W–B W–B W–B W–B LG R L M N O P Q R S T U V W X Y Z M OVERALL ELECTRICAL WIRING DIAGRAM 436 7 4RUNNER (Cont' d) 7 4RUNNER (Cont' d) (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 21 24 23 22 B 4(A), B 5(B), B 6(C) Body ECU W/L 1 24 C D17 Door Lock Control SW Front LH Power Window Master SW L–R L–R L–Y A W/L 2 22 C PD L–Y B2 BW RRU 7 RRD R–W 4 5 PLS 3 6 PLS2 E L–W L–O J38 Junction Connector B B B W P11 Power Window Control SW Rear RH 4 P10 Power Window Control SW Rear LH P12 Power Window Motor Front LH B 4 IA2 W–B W–B R–G R–W B–R R–W G G W–B R–L R R B–R W–B W–B W–B W–B LG R B 3 B–R R–W L–O W–R L–O A W–B Z 2 U SSRB W–B Y 1 1 D 4 IA1 L–O W X G–W V L 5 C D E F G H I W–B U UL 8 W–B S T E 1 W–B Q W–G P R 2 BR–B N O W–L M W–R L P14 Power Window Motor Rear LH L K 2 L–B J 5 G–R I G–R H 3 W G B W B–R R–G R–W 1 M 6 BA1 G–W F G–W E W 2 17 14 5 IA1 1 7 BA1 PLS2 GND 3 M 4 5 BB1 L–B C 5 G C W 6 BB1 G–B J33 Junction Connector D C W P15 Power Window Motor Rear RH L G G–B L–O B–R L–Y L–R L–R L–Y L–Y L–R C W 4RUNNER (EM03M0U) 1 VCC PLS 6 IA2 2 M DU 4 L 9 IA2 DD 9 L–B 10 IA2 2 7 BB1 RLD 10 G 11 IA2 12 L 2 IA2 RLU 16 R–L 12 IA1 18 B 7 IA2 11 R 12 IA2 B 6 B A A PU 13 B B A 15 R–B B A C B R A A B B J22(A), J23(B) Junction Connector B W–R L–O W–B R–L R R B–R W–B W–B W–B LG R J K L M N O P Q R S T U M 437 (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 25 28 27 26 B 4(A), B 5(B), B 6(C) Body ECU L1 UL1 15 20 5 1K 1 1K 3 1K B–W LSR 5 9 1L 18 1L 6 1L 23 1L 11 1L 15 1K 22 1L 10 1L W L–B L–R W L–B L–R L–R L–B L–R 3 16 1L 10 BA1 11 BA1 12 BA1 10 BB1 11 BB1 12 BB1 B–W L–O L–W L–O L–W 6 IP1 6 IA1 5 IP1 8 IA1 7 IA1 13 IA2 7 IP1 8 IA2 7 IP2 2 IP2 L–R L–B W L–R L–B W B–W B–R B B–W B–R W G L W–B L–W L–O 9 10 8 1 7 4 1 7 4 6 1 M M 8 6 1 D20 9 Door Lock Detection SW Rear LH Door Lock Motor Rear LH 4 M D21 9 W–B D19 Door Lock Detection SW Front RH Door Lock Motor Front RH 4 M W–B D16 Door Key Lock and Unlock SW Front LH Door Lock Detection SW Front LH Door Lock Motor Front LH W–B W–B W–B W–B Door Lock Detection SW Rear RH Door Lock Motor Rear RH 4 IP2 4 BA1 W–B C D E F G H W–B R–G R–W B–R R–W B–R R–W G I M N O P Q R S T W–B R–L R R B–R W–R L–O W–B W–B R–L R R B–R W–B W–B W–B LG R LG R W–R L–O C D E F W–B L W–B K A B G W–B J U 4 BB1 W–B W–B R–G R–W W–B 4RUNNER (EM03M0U) B ACT– 24 D L–O A ACT+ 23 L–B A LSWP 30 A L R D ACTD 10 A W–R 6 LSWD 21 A G L D 5 A UL3 12 A D18 Door Lock Control SW Front RH Lock Unlock A L–O L–W J6 Junction Connector L2 19 G H I J K L M N O P M OVERALL ELECTRICAL WIRING DIAGRAM 438 7 4RUNNER (Cont' d) 7 4RUNNER (Cont' d) (Cont. next page) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 29 ∗ 6 : w/ Driving Position Memory 32 31 30 B 4(A), B 5(B), B 6(C) Body ECU 41 IE1 10 IC4 F A F A 1 IC3 DRLP 12 C DCY2 11 C W–L RRCY 12 B KSWO 15 C V–G W–L R–Y R 39 IE1 RLCY 11 B V–Y H B F A 38 IE1 PCTY 24 B P–L J7 Junction Connector D D R D V–Y 37 IE1 A B C 6 IO3 R 1 D15 Door Courtesy SW Rear RH 1 R–G R–W R–L R R–W J40(A), J41(B) Junction Connector Y–B 2 1 D14 Door Courtesy SW Rear LH 1 1 D13 Door Courtesy SW Front RH DOME Relay D12 Door Courtesy SW Front LH 2 2 P–L P–B 2 R W–B W–B A A R–B 5 E A A Transponder Key Computer < 5–20> < 6–20> 2 +B 3 A A R–B 5 1 W–B Position Control ECU and SW < 33–2> PRG R–B (∗6) RDA R R 3 R 2 R G–O L–R D7 Door Control Receiver W3 Wireless Door Lock Buzzer 2 DCTY 23 B J18(A), J19(B) Junction Connector R Suspension Control ECU< 18–6> Y–B P–B 4RUNNER (EM03M0U) 1 LMRY 3 A P–B PRG 3 B R–B 6 1B RDA 4 B R 10 1B ACTY 20 B G–O 7 L–R BZR2 9 R–G BZR D E F A B A B C D E F W–B R–G R–W W–B B–R R–W B–R G G W–B G H I J K L M N O P R W–R L–O W–B W–B W–R L–O W–B W–B R–L R R B–R R B–R W–B LG R LG R BO H I J K L M N O P Q R S W–B W–B BL Floor Seat Crossmember LH M 439 Rear Pillar LH G (Cont. next page) ∗ 6 : w/ Driving Position Memory ∗ 7 : w/o Driving Position Memory M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 33 36 35 34 B 4(A), B 5(B), B 6(C) Body ECU DBKL 13 A 10A MIR HEATER 30A DEFOG B–L 18 IC4 4 IC4 J22(A), J23(B) Junction Connector D A B–L Y–G Y–G (1GR–FE) Y–G (2UZ–FE) Y–G Engine Control Module< 6–12> Y–G E B 2 Engine Control Module< 5–15> B–L W–B B–R 10 BD1 W–B Rear Side of Right Bank Cylinder Block EE ED W–B (∗6) W–B (∗7) LG R 1 BK1 W–B (∗6) Left Bank Cylinder Head BL Floor Seat Crossmember LH A B C W–B W–R L–O W–B W–B BR (2UZ–FE) S B H A BR (1GR–FE) R D A 2 2 D W–B Q R B–R W–B D A 2 3 BH1 W–B P A A B R O R21(A), R22(B) Rear Window Defogger W–B N Airbag Sensor Assembly< 20–7> J53 Junction Connector M A B 7 IM1 W–B (∗6) K 4 J43(A), J44(B) Junction Connector J L R W–R L–O W–B W–B F B H A 1 A 1 B W–B (∗7) G Y–G B15 Buckle SW LH L–R BR I W–B B–R 10 BK1 3 R–L J 8(A), J 9(B) Junction Connector H 12 B K B G R–L R–W G 13 B B 13 C D A C B 7 BH1 L (∗6) 10 D C A 1 36 IE1 G–Y (∗6) 15 C 26 IE1 L (∗7) 12 D 4 BD1 J43(A), J44(B) Junction Connector 13 D R–G LG R–W 18 B 1 D A G–Y 16 C D A G–Y (∗7) J 8(A), J 9(B) Junction Connector 17 A 2 Y–G G–Y Front Fog 8 C R F 19 B V–Y E Head (USA) Beam Door 4RUNNER (EM03M0U) D R–G J20(A), J21(B) Junction Connector G–Y V–Y B B B–R 3 1B R W–L Driver' s Seat Belt C Buzzer 6 G–Y B C 8(A), C 9(B), C10(C), C11(D) Combination Meter A V–G RDEF E F G H M OVERALL ELECTRICAL WIRING DIAGRAM 440 7 4RUNNER (Cont' d) L–O W–B B–R L B W–R R LG–B LG–B J39 Junction Connector W–R Turn Signal Flasher Relay< 8–3> < 9–3> STOP LP CTRL Relay < 11–3> Combination Meter < 31–5> Generator < 4–3> Park/Neutral Position SW < 13–12> < 14–9> Data Link Connector 3 < 5–7> < 6–7> LG LG LG P4 Parking Brake SW Skid Control ECU with Actuator< 15–3> Radio and Player with Display< 28–9> J39 Junction Connector B–R F E L–R GR G–B R–Y BR–W J12(A), J13(B) Junction Connector BR–R LG GR–R D24 Diode (Rear Wiper) B–O GR–R LG–B LG–B Rear Wiper and Washer SW M4 Mirror Heater RH W–B Washer W–B W–B H OFF M3 Mirror Heater LH G G–B G–B F W–R L–O W–B W–B E B–L B–L W–B D W2 Washer Motor B–L WR EW +1R C1R F 2 4RUNNER (EM03M0U) C W–B B–R B HI 13 10 12 BR–W BR–R 20 1J 2 1E 1 1E J12(A), J13(B) Junction Connector 1 C A C A C14 Combination SW 5 5 2 B B 4 LO B–L A B A B 17 1J 3 E 3 IC3 6 BD1 B A B A 1 B Washer 4 4 7 IH1 18 IP1 18 IA1 7 BD1 5 BD1 GR–R 40 IE1 9 BD1 1 1B J6 Junction Connector M BDR 4 A 2 B 8(A), B 9(B) Back Door ECU B 4(A), B 5(B), B 6(C) Body ECU BECU 5 A GND 3 A MPX2 1 A 8 MPX2 23 A HAZ 3 SPD STPI 14 L 14 A P 17 B OBD2 17 C PKB 2 B RWINT 9 C RWON 10 C WMTR 40 39 38 37 SIG 6 A B (Cont. next page) 7 4RUNNER (Cont' d) M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) M 441 M u ltip le x C o m m u n ic a tio n S y s te m (B E A N ) 41 44 43 42 B 8(A), B 9(B) Back Door ECU HSW– 22 B BDUP BDDN IC+ IC2 13 B 25 B 11 B 17 B HALF FULL POS ACT+ ACT– LSE 6 B 7 B 8 B 15 B 14 B 21 B 1 2 M 1 3 4RUNNER (EM03M0U) M 5 Return Position Furthest Position B11 Back Door Power Window Motor Stop 2 R23 Rear Wiper Motor Rear Wiper Position SW 4 M B7 Back Door Courtesy SW Back Door Half Latch SW Back Door Lock Detection SW Back Door Lock Motor B–R 4 L–R 6 L–B 5 BR–W WIP– 1 B G–Y 3 E WIP+ 2 B R–G 6 PLS2 W 3 B BR–B PLS P 12 B P–B 2 SGND 18 B G–R 1 L–W 5 G SSRB B–O B10 Back Door Opener SW 4 R IC1 IC– 16 B 23 B W–R Y–G 1 2 R–B Y–B LG–R T10 Tailgate Control SW 1 HSW+ 10 B V–W 2 V–Y GR–R LG–B 3 UP 5 B R–G DOWN 4 B Y–G E 19 B 3 M OVERALL ELECTRICAL WIRING DIAGRAM 442 7 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 443 T u rn S ig n a l a n d H a z a rd W a rn in g L ig h t (w / D a y tim e R u n n in g L ig h t) P o w e r S o u rc e 1 B–Y ACC D2 Daytime Running Light Relay Turn Signal Flasher Relay B IG1 4 B–Y IG L–Y 1 TFL TFR 4 2 E 9 TSL TSR 7 8 HAZ 10 2 IH1 5 1J 9 1F 15 1F 3 IH1 15 1J A D L–Y 2 Turn LH 6 Turn RH R15 Rear Combination Light RH 6 3 Turn R14 Rear Combination Light LH Turn Towing Converter Relay< 27–4> W–B 2 2 10 L–Y L–B 3 W–B 2 6 3 W–B F6 Front Turn Signal Light RH Y–R F5 Front Turn Signal Light LH J20(A), J21(B) Junction Connector 3 L–B 2 L–Y RH 2 H11 Hazard SW Turn Y–R 140A ALT 15A TRN–HAZ F B 1 TR LH 2 H A TB 2 1G L–B D J39 Junction Connector A A 3 TL C12 Combination SW R–Y R–B J7 Junction Connector A 1 3 1G L–Y L–B W G–Y G–B Y–R 50A AM1 1 2 23 1J D A 2 3 Body ECU < 7–39> 2 1 TRR L–Y 14 1J 2 2 TRL 5 L–B 8 1J G–Y Multiplex Communication System< 7–10> W–L 1 IN1 B–Y 4RUNNER (EM03M0U) 15A IG1 42 IC4 G–B R–Y R–B Y–R W–B 2 1C 2 DRL 12 W I18 Ignition SW 20 IC4 4 3 2 6 2 AM1 M OVERALL ELECTRICAL WIRING DIAGRAM 444 8 4RUNNER W–B B W–B C10 Combination Meter 13 B A A A J40(A), J41(B) Junction Connector Right Kick Panel IK J24 BR (2UZ–FE) IG A BR (1GR–FE) Left Kick Panel J37 Junction Connector W–B Front Right Fender A A 7 IM1 A B W–B EA J5 Junction Connector A W–B W–B A W–B W–B W–B W–B A EB A A B 3F B 3F Front Left Fender A A BR E A B 3F J15 Junction Connector W–B W–B Battery A J22(A), J23(B) Junction Connector D B EE ED Junction Connector II Instrument Panel Brace RH Floor Seat Crossmember LH BL BO Rear Pillar LH Rear Side of Right Bank Cylinder Block Left Bank Cylinder Head 9 4RUNNER T u rn S ig n a l a n d H a z a rd W a rn in g L ig h t (w /o D a y tim e R u n n in g L ig h t) P o w e r S o u rc e 1 4 3 2 B–Y T9 Turn Signal Flasher Relay 4 +B ACC 2 AM1 6 IF1 IG1 4 IG LL 1 GND EL 7 5 ER EHW 6 8 W G–Y G–B W–B L–Y Y–R 8 IF1 10 IF1 5 IF1 Y–R 42 IC4 A 15 1F L–Y W–B W–B C10 Combination Meter A A 13 BR A A Turn LH Turn RH R15 Rear Combination Light RH Turn R14 Rear Combination Light LH Turn J40(A), J41(B) Junction Connector J24 BR (2UZ–FE) IK A BR (1GR–FE) Right Kick Panel J37 Junction Connector W–B IG A A 7 IM1 A B W–B Left Kick Panel J5 Junction Connector A W–B W–B EE ED Junction Connector II Instrument Panel Brace RH Floor Seat Crossmember LH BL BO Rear Pillar LH Rear Side of Right Bank Cylinder Block Left Bank Cylinder Head M 445 Front Right Fender 6 B 3F W–B W–B W–B A W–B EA 10 A A EB 3 A A B 3F Front Left Fender L–B L–B Towing Converter Relay< 27–4> B 3F J15 Junction Connector J22(A), J23(B) Junction Connector W–B W–B E A A 6 6 L–B D 2 1G L–Y A J39 Junction Connector D 2 3 W–B 2 L–Y 2 D B Battery H11 Hazard SW 3 2 W–B 2 LH RH C12 Combination SW Turn 3 TR 3 1G L–Y L–B W G–Y G–B A A 3 TB W–B F6 Front Turn Signal Light RH B B R–Y R–B 2 1 TL F5 Front Turn Signal Light LH Y–R 2 9 1F 3 IH1 D J20(A), J21(B) Junction Connector F B 1 2 2 IH1 Y–R 140A ALT 15A TRN–HAZ H A 5 1J 15 1J 2 1 1 IN1 J7 Junction Connector 50A AM1 2 23 1J Body ECU < 7–39> 2 A L–Y 14 1J 2 1 3 IF1 L–B W G–Y G–B W–B R–Y 2 R–B Y–R 8 1J L–Y L–B 7 IF1 W 9 IF1 G–Y 2 IF1 G–B 4 IF1 W–B W–L B–Y 4RUNNER (EM03M0U) 1 IF1 15A IG1 L–Y L–B 2 1C 20 IC4 2 L–B L–Y B–Y I18 Ignition SW LR 3 R R B–R J16(A), J17(B) Junction Connector G G G G G G W–G W–G W–G R25 Roll Sensing of Curtain Shield Airbag Cutoff SW W–G A42 Auto LSD SW M2 Main SW W–B D4 Diff. Lock SW W–B C13 Combination SW B10 License Plate Light RH LH R15 Rear Combination Light RH Stop/Tail R14 Rear Combination Light LH Stop/Tail W–B W–B W–B J16(A), J17(B) Junction Connector W–G W–B W–B W–B W–B Audio System < 28–9> < 29–6> < 30–5> C12 Combination SW F W–B J14(A), J15(B) Junction Connector W–B W–B W–B W–B W–B Rear Pillar LH BO BL H W–B G W–G B A A G G G G F6 Front Parking Light RH F5 Front Parking Light LH G A B J40(A), J41(B) Junction Connector Head Floor Seat Crossmember LH Front Right Fender EA EB G G G Light Control SW A B A B A A A A A B A B B 16 1 1 1 W–G 2 B 6(C) Body ECU 14 2 1 1 2 2 2 A B A B A A A A A A A A 2 2 H EL T 10A TAIL TAIL Relay 50A J/B 30A AM2 50A AM1 OFF Front Left Fender IG Left Kick Panel J5 Junction Connector A W–B Battery Tail 2 G L–W R W–L Short Pin 2 10 10 BD1 8 IH1 1 B B B B W TAIL G 10A DOME TRLY 6 6 140A ALT 3 1 3 2 11 1B 9 1B 18 4 4 4 B B B B B B 5 1L 1 1C 4RUNNER (EM03M0U) 2 2 BH1 13 1F B A B A B G B B I18 Ignition SW 3 BH1 8 C 2 2 BD1 E M OVERALL ELECTRICAL WIRING DIAGRAM 446 IG2 6 1 1 1 1 1 2 2 2 7 AM2 B L–W 1 5 1 2 2 2 2 L–Y J39 Junction Connector ST2 G G IG1 4 C B–R ACC 10 IC4 B L–Y A R 4 3 2 1 D G 2 2 AM1 2 T a illig h t a n d Illu m in a tio n P o w e r S o u rc e B A 2 (Cont. next page) 10 4RUNNER G G G G G G G G G F11 4WD Control SW C7 Cigarette Lighter Illumination W–B A38 Ashtray Illumination W–B W–G A22 A/T Shift Lever Illumination W–G W–G W–G W–G W–G B1 Back Door Power Window Control SW W–G H11 Hazard SW S5 Seat Heater SW RH S4 Seat Heater SW LH C15 Cup Holder Illumination W–G D5 Downhill Assist Control SW W–G H19 Height Control Mode Select SW W–G W–G Engine Control Module< 5–15> < 6–12> W–G W–G W–G W–G G G G G G G W–G A 3F A 3F H12 Height Control SW W–G W–G (∗2) W–G (∗1) R12 Radio and Player with Display J31(A), J32(B) Junction Connector G A 3F A 3F A 3F A 3F A 3F C 3E D3 Defogger SW Heater Control Panel R 1(A), R 2(B), R 3(C) Radio and Player 5 C (∗4) G G G (∗2) G (∗1) G 12 A 3F A 3F 1 4 5 5 5 2 2 2 1 ILL– ILL– I B C 3E 3 2 2 4 IR1 2 IR1 1 W–G H W–G F W–B G W–G W–B H W–G G 10 ILL– 12 A (∗3) 9 4RUNNER (EM03M0U) 2 A (∗3) 3 IR1 1 IR1 1 1 2 2 4 ILL+ G 6 6 1 1 1 2 ILL+ 10 B (∗4) ILL+ (∗5) ILL+B(∗6) 2 D A D 3D D 3D D 3D D 3D G G G G G G G G D 3D D 3D G E D 3D D 3D W–G W–G F G E G D G D B–R B B–R C L–Y C L–Y B ∗ 4 : 6 Speaker ∗ 5 : w/ CD Changer ∗ 6 : w/o CD Changer ∗ 1 : w/ Navigation System ∗ 2 : w/o Navigation System ∗ 3 : Except 6 Speaker T a illig h t a n d Illu m in a tio n A R 8 7 6 5 R A (Cont. next page) 10 4RUNNER (Cont' d) G M 447 T a illig h t a n d Illu m in a tio n A B L–Y 12 11 10 L–Y B–R R C 9 R G 6 1D 2 1C J7 Junction Connector B–R L–Y D ∗ 7 : Except USA D D R 7. 5A GAUGE 15A IG1 E 4 1G 8 1J J7 Junction Connector G 15 16 7 13 Tail (∗7) Illumination H A Illumination H A J20(A) Junction Connector C A J10(A), J11(B) Junction Connector G3 Glove Box Light A B C A 9 Y–R G 1 C10 Combination Meter R A A R–L G Y–R 4RUNNER (EM03M0U) F B J 8(A), J 9(B) Junction Connector H A G 2 G W–B Y–R G R13 B 3F 4 Rheostat BR – 3 W–G W–B W–G E B 7 IM1 A A A A W–G W–G W–B W–B A J24 Junction Connector II Instrument Panel Brace RH A BR (1GR–FE) W–B W–G BR (2UZ–FE) H W–B W–B G W–G E 5 W–G 6 IG J 8(A), J 9(B) Junction Connector ILL– B 3F F 1 T B 3F ED EE J37 Junction Connector IK Right Kick Panel Left Bank Cylinder Head Rear Side of Right Bank Cylinder Block M OVERALL ELECTRICAL WIRING DIAGRAM 448 10 4RUNNER (Cont' d) 11 4RUNNER G–Y Taillight System < 10–3> G–Y Body ECU < 7–39> Y–R G–Y G–Y G–W G–Y 10A STOP G–Y (∗2) H18(A) High Mounted Stop Light H18(B) High Mounted Stop Light W–B (∗2) Stop/Tail R15 Rear Combination Light RH G–Y G–B G–Y G–Y G–Y LG J4 Junction Connector G–B J4 Junction Connector G–B G–B G–B W–B W–B W–B G–Y G–Y G–Y G–Y B Skid Control ECU with Actuator< 15–3> W–B W–B Skid Control ECU with Actuator< 15–3> Shift Lock Control ECU < 30–7> G–Y Suspension Control ECU< 18–5> Skid Control ECU with Actuator< 15–3> Towing Brake Controller< 27–3> Stop/Tail R14 Rear Combination Light LH STOP LP CTRL Relay S12 Stop Light SW J31(A), J32(B) Junction Connector B BO Rear Pillar LH BL M 449 Floor Seat Crossmember LH J40(A), J41(B) A B A A A A A A A A 2 B J40(A), J41(B) Junction Connector Y–R Engine Control Module < 5–17> < 6–18> G–W 140A ALT 15 IC3 Junction Connector Battery B 3 BD1 50A AM1 2 10 BD1 6 6 E E E B E 3C E 1 2 A 2 2 2 2 12 1J W–B (∗1) B E 3C 16 1F 4 4 1 4 G–Y (∗1) 2 2 1 B 2 3 1 D 4RUNNER (EM03M0U) W–L E 3C 1 Y–R B A B A B A J1 Junction Connector C B 20 1E G–Y 15A IG1 1 A H A B 2 G–Y I18 Ignition SW C B E 24 1E 2 1 5 2 E B 1 1 Towing Converter Relay< 27–4> 2 1C ACC D E 2 2 G–W 2 2 IG1 4 2 AM1 4 3 2 1 ∗ 1 : w/ Rear Spoiler ∗ 2 : w/o Rear Spoiler S to p L ig h t P o w e r S o u rc e L–Y P o w e r S o u rc e B a c k – U p L ig h t 1 3 2 ACC 2 AM1 IG1 4 L–Y R–Y 2 1C B I18 Ignition SW J33 1 IM1 W–L R–Y Junction Connector B R–Y 15A IG1 P1 Park/Neutral Position SW 2 8 1J 2 1L 10 1F 2 R–Y Y–R Y–R A J7 Junction Connector 2 2 IM1 50A AM1 J40(A), J41(B) B B A Junction Connector Y–R Y–R C A 1 H H A 3 2 Trailer Socket < 27–4> 2 Back–Up 6 2 R15 Rear Combination Light RH Y–R 1 Back–Up 140A ALT R–Y J25 Junction Connector R–Y J20 Junction Connector R–Y 2 C A C A A R14 Rear Combination Light LH 4RUNNER (EM03M0U) 1 R 6 2 W–B W–B B B A A A A A A W–B Battery J40(A), J41(B) Junction Connector A B W–B BO Rear Pillar LH BL Floor Seat Crossmember LH 4 M OVERALL ELECTRICAL WIRING DIAGRAM 450 12 4RUNNER Memo 4RUNNER (EM03M0U) 451 E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 U Z – F E ) P o w e r S o u rc e 1 R H A B–R R–L ACC 2 AM1 IG1 4 L–Y 7 AM2 IG2 6 B–R 6 1D W–L R D J7 Junction Connector D R L–Y J 8(A), J 9(B) Junction Connector F B 4 3 2 10A IGN 7. 5A GAUGE ST2 R 2 10 IC4 11 1J I18 Ignition SW 2 4 1G R–L GR W–G 2 T4 Turbine Speed Sensor B–O B A B A B A 2 2 S1 S2 10 B SLU– 14 B 27 B NT+ SL1+ 19 B SL1– 18 B 34 B NT– SL2+ 17 B SL2– 16 B 26 B SP2+ THO1 24 B SP2– THO2 32 B 11 3 10 SL2+ SL2– 9 BR R L Y V OT+ OT2+ L SL1– O SL1+ LG SB SLU– GR B SLU+ W–B B 11 IC4 L O B OT– EB Front Left Fender OT2– 1 BR Battery 2 BR E1 Electronically Controlled Transmission Solenoid BR 4 SLT– B 2 E2 28 A L 12 Y–G 5 B–R 13 B–W 6 SLT+ G SR B–Y 14 S2 G–B 7 S1 R–W 15 8 R–B A B W C A SLU+ 15 B L–R B B SLT– 12 B LG–B 1 SLT+ 13 B P–L 1 A B J 2(A), J 3(B) Junction Connector SR 9 B W–L GR 1 B A J31(A), J32(B) Junction Connector Short Pin 1 20A EFI 35 B IGSW 11 B 2 10A ETCS R–L +B2 2 E 2 30A AM2 9 E +BM B B 2 2 L–Y 2 W–B 2 2 +B 2 1 E B 2 E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 7 E BATT Y–R 3 E 2 2 L GR R B W 2 8 E Junction Connector B–O 3 B B J 8(A) MREL 2 13 IC4 GR 2 12 IC4 L EFI Relay 1 1 35 IC4 1 W–R 2 1 W–G 140A ALT 10A DOME 2 5 1 J31(A), J32(B) Junction Connector 1 2 V11 Vehicle Speed Sensor (Electronically Controlled Transmission) 50A AM1 B–O R 4RUNNER (EM03M0U) 2 L A B C M OVERALL ELECTRICAL WIRING DIAGRAM 452 (Cont. next page) 13 4RUNNER (Cont. next page) 13 4RUNNER (Cont' d) E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 U Z – F E ) A B C 5 R 8 7 6 L–Y L–Y A R–L B–L G 17 A M– 21 A GE01 30 A THW 29 A VG 22 A E2G THA VPA 19 E VPA2 26 E 27 E VCPA VCP2 ME01 20 E EPA 21 E 8 D EPA2 SPD OILW 29 D 3 B 15 E STP 9 D 20 D L 4 R D 3 2 11 D 21 D 19 D 10 D G B B B 3 ATL AT4 AT2 ATD 5 2 G–R L L BR W–B W–B W–B W–B W–B W–B W–B 1 IM2 V R–Y P W–B G–R V W–B R–Y 7 IM1 W BR A B G J33(A), J34(B) Junction Connector A A W E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module EC EOM 9 C 35 D 18 E G 4 A 4 P–L 7 B M+ D 3C B–L 8 C E04 5 A S6 Transmission Control SW 4WD VTA2 D A G 1 C 19 A VTA1 G 4 B E1 20 A B–L E03 VC G 3C J 8(A), J 9(B) Junction Connector 23 A D 3C B–L E02 6 A 34 D CANH CANL J10(A), J11(B) Junction Connector 7 A 33 D R 6 B E01 TC F A R–L E05 23 E STA G 3C G 11 C J35(A), J36(B) Junction Connector D B B–L 12 C STAR/ STSW NSW G 3C G B–L B A B B W–B 4RUNNER (EM03M0U) D A Engine Control System < 5–8> < 5–11> < 5–12> < 5–13> < 5–14> < 5–15> < 5–16> < 5–17> < 5–18> 8 B D 3C 13 C 15 A 15 C A A C 8(A), C10(C), C11(D) Combination Meter 16 C BR W–B W–B A/T OIL TEMP 14 D 15 D L 2 B C D E F G A J37 Junction Connector EE EE Rear Side of Cylinder Block IK Right Kick Panel ED Left Bank Cylinder Head M 453 Rear Side of Cylinder Block ∗ 1 : w/ Navigation System ∗ 2 : w/ Driving Position Memory E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (2 U Z – F E ) 9 A Y–R L–Y 2 1C A 2 IM1 Y–R Y–R J25 Junction Connector H 12 11 10 A P1 2 Park/Neutral Position SW RB H Y–R 15A IG1 2L DL NL RL PL 8 3 7 9 1 6 G–B R–Y G–W V L G–R A Y–R 20 IM2 D 3E 9 IM1 21 IM2 10 IM1 8 IM1 1 IM1 V Radio and Player with Display < 28–9> G–R D 3E V G–B G–B G–B (∗2) R–Y G–B G–B R–Y (∗1) R–Y G–W V C B I A D B B A C B B A B A 2 1L 2 1J C A C A E A A B E A J 8(A), J 9(B) Junction Connector C A J35(A) Junction Connector E B C A J33(A), J34(B) Junction Connector A A J10(A), J11(B) Junction Connector F B A A J29(A), J30(B) Junction Connector C A C B G–B G–B R–Y R–Y G–W G–W L V 4WD Control ECU< 19–3> Body ECU < 7–39> G H A V F G–R H A L E E B L D H A J10(A), J11(B) Junction Connector A B E A J35(A), J36(B) Junction Connector E A C G–W NSSL S6 Transmission Control SW B L V 10 L 9 NSSD G–R 4RUNNER (EM03M0U) Skid Control ECU with Actuator<15–3> J7 Junction Connector 8 1J LL Position Control ECU and SW <33–2> A J20 Junction Connector R–Y W G 16 D 3 17 D 4 18 D 19 D D N C 8(A), C10(C), C11(D) Combination Meter 1 C R 20 D P C A C A J18(A), J19(B) Junction Connector M OVERALL ELECTRICAL WIRING DIAGRAM 454 13 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 455 E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (1 G R – F E ) P o w e r S o u rc e 1 4 3 2 R L–Y ACC R 2 AM1 B–R IG1 4 R–L L–Y 6 1D W–L 10 IC4 R 7 AM2 IG2 6 B–R 10A IGN ST2 7. 5A GAUGE 2 2 I18 Ignition SW 2 11 1J 2 Engine Control System < 6–8> < 6–11> < 6–14> < 6–15> < 6–16> < 6–17> J31(A), J32(B) Junction Connector B–O 26 B SP2+ S1 S2 11 B 10 B 12 C 9 E SP2– SR 9 B IGSW SLT+ 13 B 8 B 11 C STSW STAR/ NSW SLT– 12 B SLU+ 15 B 33 D 34 D CANH CANL STA SLU– 14 B SL1+ 19 B SL1– 18 B 23 E 18 E TC SL2+ 17 B 19 E VPA 26 E VPA2 SL2– 16 B 27 E 20 E VCPA VCP2 THO1 24 B EPA THO2 32 B 21 E EPA2 E2 28 A 8 D 15 E SPD 23 A STP E03 4 B VC E04 7 B 20 A E05 6 B 9 BR R L Y V OT+ OT2+ L O W–B B 11 IC4 B L O OT– 2 OT2– 1 BR BR E1 Electronically Controlled Transmission Solenoid Front Left Fender VTA2 ME01 3 B Rear Side of Left Bank Cylinder Block EF W–B W–B SL2– W–B SL2+ LG SB SL1– GR B SL1+ G W SLU– W–B 10 SLU+ BR 3 SLT– L 11 Y–G 4 B–R 12 B–W 5 B–Y 13 G–B 6 SLT+ Battery EB 19 A VTA1 B SR R–W 14 S2 R–B 7 S1 L–R 15 LG–B 8 P–L A B W–L C A 2 J 8(A) Junction Connector B A B A L–Y 34 B NT– GR A B +B2 2 E J31(A), J32(B) Junction Connector B B R–L 27 B NT+ B–O B B 1 Y–R 35 B B A B B W–R 1 E J 2(A), J 3(B) Junction Connector B A V11 Vehicle Speed Sensor (Electronically Controlled Transmission) T4 Turbine Speed Sensor GR W–B 1 B 1 1 20A EFI Short Pin 30A AM2 10A ETCS 2 +BM B–O E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module +B 2 7 E BATT 2 2 2 2 1 13 IC4 3 E MREL L GR R B W 2 2 8 E 2 2 2 GR 3 2 12 IC4 L EFI Relay 2 2 35 IC4 1 W–G 1 1 2 L 140A ALT 2 5 1 W–G L W–G 2 10A DOME 4RUNNER (EM03M0U) 50A AM1 R–L 2 1 2 4 1G A B C M OVERALL ELECTRICAL WIRING DIAGRAM 456 (Cont. next page) 14 4RUNNER 14 4RUNNER (Cont' d) (Cont. next page) E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (1 G R – F E ) A B C 5 R ∗ 1 : w/ Navigation System 8 7 6 R A L–Y R–L R–L Y–R 2 1C A A A Y–R Y–R J7 Junction Connector H A 2 IM1 Y–R Y–R J25 Junction Connector H P1 Park/Neutral Position SW 2 15A IG1 RB J20 Junction Connector LL 2L DL NL RL PL 8 3 7 9 1 6 ATD 10 5 2 E B F B H A A A E B A A C A C A C B V L L C B J33(A), J34(B) Junction Connector A A B A R–Y B A G–W W W–B G L A P–L J37 Junction Connector IK B–L Rear Side of Right Bank Cylinder Block EE P E F G H I J K M 457 Right Kick Panel D R–Y 4WD Control ECU < 19–3> A B B A G–W W P–L G B–L V R–Y P BR BR BR W–B L C J33(A), J34(B) Junction Connector 19 D AT2 H A G–B R–Y (∗1) 21 D NSSL H A R–Y 11 D NSSD G–W 3 AT4 8 IM1 J10(A), J11(B) Junction Connector D B B ATL J29(A), J30(B) Junction Connector 29 D R G B D A G–W OILW F A V 2 V 10 D 4 L 1 C 20 D L 3 J10(A), J11(B) Junction Connector 6 A E1 9 D L Radio and Player with Display< 28–9> G–R E02 I A S6 Transmission Control SW 7 A THA G–W V E01 22 A G E2G 1 IM1 D B 9 4 G–R E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module EOM 35 D 29 A B–L VG J 8(A), J 9(B) Junction Connector 30 A G THW J10(A), J11(B) Junction Connector GE01 10 IM1 V A B D B 9 IM1 G 3C D 3C D 3E D 3C B–L 21 A 17 A M– D 3E E A G–R 4 A G–R B B G M+ E A 21 IM2 D 3C G 3C B–L 5 A B A G–R D A G B–L Engine Control System < 6–11> < 6–12> J35(A), J36(B) Junction Connector 4RUNNER (EM03M0U) Y–R 20 IM2 G–B R–Y G–W V L G–R 8 1J G 3C B E le c tro n ic a lly C o n tro lle d T ra n s m is s io n a n d A /T In d ic a to r (1 G R – F E ) A R ∗ 2 : w/ Driving Position Memory 12 11 10 R B 9 R–L D J7 Junction Connector D R F B G–B C 8(A), C10(C), C11(D) Combination Meter E A C A G–B (∗2) Position Control ECU and SW < 33–2> J18(A), J19(B) Junction Connector Skid Control ECU with Actuator < 15–3> C B G–B C A G–B C A P R N D 4 3 2 L A/T OIL TEMP A B R–Y G–B D 16 C G–B J 8(A), J 9(B) Junction Connector E A 15 C R R–L C C A G–B 20 D 1 C 19 D 18 D 17 D 16 D 15 D 14 D 15 A 2 1L 2 1J 13 C BR P B–L P–L L G 7 IM1 W G L BR K W I J G–W H R–Y F G G–W G–B R–Y E Body ECU < 7–39> 4RUNNER (EM03M0U) C A J 8(A), J 9(B) Junction Connector H A J35(A) Junction Connector P–L B–L P EE Rear Side of Right Bank Cylinder Block M OVERALL ELECTRICAL WIRING DIAGRAM 458 14 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 459 P o w e r S o u rc e A B S , T R A C , V S C , A u to L S D , D o w n h ill A s s is t C o n tro l a n d H ill– S ta rt A s s is t C o n tro l 1 4 3 2 W L–Y ACC 2 AM1 B–R IG1 4 B C L–Y 4WD Control ECU< 19–6> 4WD Control ECU< 19–2> 5 IC2 2 IC2 G–R (4WD) 11 IM2 R–L (4WD) 4RUNNER (EM03M0U) 13 IC2 W–L (4WD) R–W G–B P L R G Stop Light SW < 11–2> I18 Ignition SW Data Link Connector 3 < 5–6> < 5–7> < 6–6> R–L (4WD) 2 Transfer Shift Actuator < 19–4> 1 Parking Brake SW < 7–38> 2 Park/Neutral Position SW < 13–12> < 14–9> ST2 1 STOP LP CTRL Relay < 11–2> < 11–3> B–R A10 ABS Speed Sensor Front RH IG2 6 A9 ABS Speed Sensor Front LH 7 AM2 A 12 IC2 1 IC2 STPO 14 A 45 A 7 A 28 A P STP2 STP 13 A PKB D/G 24 A TS 42 A 21 A 27 A EXI WFSE G–R (4WD) 16 A FR– W–L (4WD) 17 A FR+ R–L (4WD) 3 A FL– R–W 4 A FL+ R–B 18 A +BS R–Y 31 A LG +BM2 G–B 2 B G–Y LG +BM1 G–B Y Y–B Y–B Y–B Y R W W–L 2 A 10 A EXI4 NEO S28(A), S29(B) Skid Control ECU with Actuator 2 2 2 2 2 LBL EXI3 41 A 2 26 A GND1 GND3 1 A 4 B RL+ GND2 20 A 32 A W–G (4WD) 17 IC2 W–G (4WD) W W–B (4WD) B 3F B 3F W–B Front Right Fender BO Rear Pillar LH Instrument Panel Brace RH II A IK A J37 Junction Connector EA W–B W–B 1 J24 Junction Connector W–B Front Left Fender B 3F B 3F 2 A EB D5 Downhill Assist Control SW 3 BE1 4 B W 4 BE1 W 1 B W–B (∗4) 2 2 BC2 3 BC2 A41 ABS Speed Sensor Rear RH W–B (∗4) B W–B : Shielded : 1GR–FE 4WD : w/ Electric Modulated Air Suspension : w/o Electric Modulated Air Suspension ADD Actuator < 19–3> 1 2 3 4 A40 ABS Speed Sensor Rear LH B ∗ ∗ ∗ ∗ 8 IB2 (∗1) 6 BC2 (∗4) 1 BE1 B Battery (∗1) 2 BE1 W W–B W–B W–B 2 1 BC2 (∗4) B B 1 5 BC2 V(∗3) G(∗4) A A 4 BC2 P(∗3) R(∗4) A A 44 A 3 B A J 2(A), J 3(B) Junction Connector A B 18 IC3 GR (∗2) 2 1 W–B 2 1 A B J 2(A), J 3(B) Junction Connector 1 40A ABS MTR 30A ABS SOL 30A AM2 Short Pin 140A ALT 1 1 2 HDCS RR– 19 A W 2 7 IB2 B 2 B14 Brake Fluid Level Warning SW 2 10 IB2 V P 2 2 B 9 IB2 RR+ 5 A V P W–B W–B W–B W–B (2UZ–FE) GR (∗2) LG 50A AM1 1 RL– 6 A Right Kick Panel D E M OVERALL ELECTRICAL WIRING DIAGRAM 460 (Cont. next page) 15 4RUNNER (Cont. next page) 15 4RUNNER (Cont' d) A B S , T R A C , V S C , A u to L S D , D o w n h ill A s s is t C o n tro l a n d H ill– S ta rt A s s is t C o n tro l A B C 5 W 8 7 6 B–R L–Y 10A ECU–B 2 2 R R J7 Junction Connector D HDCW R 33 A 17 C 20 C 4 D 19 A 4 B 13 C 16 C R BR GR–R B–L R L–W (∗5) L–W (2UZ–FE) L–W (∗2) LG–R F B J 8(A), J 9(B) Junction Connector 18 C Y–R BR–Y (4WD) Y–R 13 IM2 7 IC3 12 A BR–Y (4WD) 20 IC2 BR–Y (4WD) Y–R R LG–R B–L 14 IM2 D L–W (∗2) L–W (∗7) L–W (∗6) L–W (∗5) 12 IM2 7 IM1 W–B W–B BR (2UZ–FE) BR (1GR–FE) A B W–B W–B W–B W–B B A IG W–B W–B E A B 10 IC4 H A 9 IC2 G–W (∗7) V–W (∗6) 19 IC2 Speedometer L–W (4WD) 16 IC2 BRAKE VSCW 36 A ABS WT 35 A Slip 15 A V–W (2WD) 18 IC2 INFR IND 34 A R 8 IC2 WA 29 A LG–R 7 IC2 BRL 3 B B–L B W W–B (2WD) J14(A), J15(B) Junction Connector A A A B 11 IC2 GR–R R–W (2WD) 4 22 IC2 SP1 12 A GR–R A42 Auto LSD SW 6 IC2 B W R–W (2WD) 3 CANH 11 A VSC OFF (4WD) AUTO LSD (2WD) IG1 VSC TRAC 46 A BZ DAC 25 A 15 C 2 B–R CANL CSW 2 W–R S28(A), S29(B) Skid Control ECU with Actuator 43 A 1 10A DOME B–R IG2 1 C 8(A), C 9(B), C10(C), C11(D) Combination Meter B–R GR–G 30 A 1 B FRO : 1GR–FE 4WD : w/ Electric Modulated Air Suspension : 1GR–FE 2WD : 2UZ–FE 2WD : 2UZ–FE 4WD 12 1E V5 VSC Warning Buzzer 37 A FLO J4 Junction Connector B–O 38 A 1 B–R B–R B–O L–R (∗3) L–O (∗3) 4RUNNER (EM03M0U) C C F F 2 10A ECU–IG F 2 3 5 6 7 R–L 7. 5A GAUGE 10A IGN J4 Junction Connector ∗ ∗ ∗ ∗ ∗ 28 1J 2 1C 4 1G 2 B–R L–Y R–L B–R Suspension Control ECU< 18–5> 6 1D 23 1E D A B–R W C D E F J5 Junction Connector Rear Side of Right Bank Cylinder Block EE ED Left Bank Cylinder Head M 461 Left Kick Panel A B S , T R A C , V S C , A u to L S D , D o w n h ill A s s is t C o n tro l a n d H ill– S ta rt A s s is t C o n tro l 9 A 12 11 10 B–R B–R W–R 4 1B B M u ltip le x C o m m u n ic a tio n S y s te m (C A N ) G J20 Junction Connector W–R E7 Engine Control Module B–R W–R D A B 3E B 3E E B D A CANH J12(A), J13(B) Junction Connector 6 LG 2 B 1 D 2 D 1 E 2 E ST–Plug 1 C 2 C 1 A 2 A 1 F W B Y B W–B B Y W–B J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector 1 B GND 1 3 3 CANL 34 L P CANH CANH CANH 33 R 11 CANL 2 IG W CANL 2 W ESS 5 R IG1 Y1 Yaw Rate Sensor 1 BAT B–R B–R W–R S11 Steering Sensor 9 CANL 14 V 4RUNNER (EM03M0U) D1 Data Link Connector 3 G 4 1L W–B C D E F W–B W–B B W IH Instrument Panel Brace LH M OVERALL ELECTRICAL WIRING DIAGRAM 462 15 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 463 C ru is e C o n tro l (2 U Z – F E ) P o w e r S o u rc e 1 4 3 2 B–R 6 1D 7 AM2 IG2 6 R–L B–R ST2 15 C 7. 5A GAUGE 10A IGN I18 Ignition SW B–O 3 2 3 E 7 E BATT +BM 16 E 18 D 9 E ST1– IGSW PI CCS +B2 2 E E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 2 D L–B 2 B B 10A ETCS C 8(A), C10(C) Combination Meter 1 E 20A EFI 3 IK1 B A A B A B Junction Connector J31(A), J32(B) Junction Connector L–B J 2(A), J 3(B) 1 B B 2 11 A LG +B W–B B 2 2 1 B B L GR 2 1 J8 Junction Connector B–O 8 E 2 MREL 30A AM2 B–O B–O R–L 2 2 2 GR L W–G 3 CRUISE 11 IC3 Stop Light System< 11–2> 1 EFI Relay 2 C 13 IC4 B A B J31(A), J32(B) Junction Connector 12 IC4 J4 Junction Connector 35 IC4 R–L B C R–L 5 2 B–O 1 4 1G 11 1J B–O 4 23 1E GR 2 R 4RUNNER (EM03M0U) W–G S12 Stop Light SW L 5 CCS C A ON–OFF B B + RES BR W–B 11 IC4 – SET C13 Combination SW 10 IM2 B Battery CANCEL BR ECC EB Front Left Fender 4 BR ED Left Bank Cylinder Head M OVERALL ELECTRICAL WIRING DIAGRAM 464 (Cont. next page) 16 4RUNNER 16 4RUNNER (Cont' d) C ru is e C o n tro l (2 U Z – F E ) 5 8 7 6 E05 6 B E01 7 A E02 6 A E03 4 B E1 1 C 4WD 8 C E04 7 B 28 A 23 E E2 TC 33 D 34 D CANH CANL 23 A 20 A VC VTA1 19 A 5 A VTA2 M+ 4 A M– E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module S1 S2 ME01 EOM 35 D 3 B 11 B 10 B EC 9 C 17 A GE01 SR 9 B 18 E VPA SLT+ 13 B 19 E VPA2 SLT– 12 B 26 E 27 E VCPA VCP2 SLU+ 15 B SLU– 14 B 20 E EPA SL1+ 19 B 21 E 8 D EPA2 SPD SL1– 18 B SL2+ 17 B 15 E STP SL2– 16 B D 21 D W–B 4RUNNER (EM03M0U) Engine Control System < 5–8> < 5–11> < 5–12> < 5–13> < 5–16> < 5–17> < 5–18> BR W–B W–B W–B W–B W–B W–B W–B W–B 1 IM2 W–B Electronically Controlled Transmission and A/T Indicator System< 13–2> < 13–3> < 13–4> < 13–7> A B J33(A), J34(B) Junction Connector A A A A W–B W–B A J37 Junction Connector EE EE Rear Side of Cylinder Block IK Right Kick Panel ED Left Bank Cylinder Head M 465 Rear Side of Cylinder Block C ru is e C o n tro l (1 G R – F E ) P o w e r S o u rc e 1 4 3 2 B–R 6 1D 7 AM2 IG2 6 R–L B–R ST2 15 C 7. 5A GAUGE 10A IGN I18 Ignition SW B–O 3 2 1 E 3 E 7 E BATT +BM 16 E 18 D 9 E ST1– IGSW PI E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module 1 C L–B 20A EFI B A J31(A), J32(B) Junction Connector 5 J28 Junction Connector J 2(A), J 3(B) Junction Connector BR 3 IK1 A B L–B 1 2 D B B 10A ETCS E1 CCS +B2 2 E 2 A B CCS 2 11 A LG +B W–B B 2 2 1 B B L GR 2 1 J8 Junction Connector B–O 8 E 2 MREL 30A AM2 B–O B–O R–L 2 2 2 GR L W–G 3 C 8(A), C10(C) Combination Meter 11 IC3 Stop Light System< 11–2> 1 EFI Relay 2 C 13 IC4 B A B J31(A), J32(B) Junction Connector 12 IC4 J4 Junction Connector 35 IC4 CRUISE C R–L 5 2 R–L B GR 2 4 1G 11 1J B–O 1 23 1E B–O 4 R 4RUNNER (EM03M0U) W–G S12 Stop Light SW L B B C A E BR B B ON–OFF E + RES BR W–B C13 Combination SW 11 IC4 – SET 10 IM2 BR BR B Battery CANCEL ECC EB Front Left Fender 4 BR EE Rear Side of Right Bank Cylinder Block M OVERALL ELECTRICAL WIRING DIAGRAM 466 (Cont. next page) 17 4RUNNER 17 4RUNNER (Cont' d) C ru is e C o n tro l (1 G R – F E ) 5 8 7 6 4RUNNER (EM03M0U) Engine Control System < 6–8> < 6–11> < 6–12> < 6–15> < 6–16> < 6–17> E01 7 A E02 E03 4 B 6 A 28 A 23 E E2 TC E04 7 B E05 6 B 33 D 34 D CANH CANL 23 A VC 20 A 19 A VTA1 5 A VTA2 M+ E 4(A), E 5(B), E 6(C), E 7(D), E 8(E) Engine Control Module ME01 EOM 3 B 35 D 4 A 17 A M– 18 E GE01 S1 S2 11 B 10 B 19 E VPA SR 9 B 26 E VPA2 SLT+ 13 B 27 E 20 E VCPA VCP2 SLT– 12 B SLU+ 15 B 21 E EPA SLU– 14 B 8 D EPA2 SL1+ 19 B 15 E SPD STP SL1– 18 B SL2+ 17 B SL2– 16 B D 21 D W–B W–B W–B W–B W–B BR BR Electronically Controlled Transmission and A/T Indicator System< 14–2> < 14–3> < 14–6> A A J33(A), J34(B) Junction Connector A B W–B A J37 Junction Connector EE EF Rear Side of Left Bank Cylinder Block IK Right Kick Panel M 467 Rear Side of Right Bank Cylinder Block P o w e r S o u rc e A c tiv e H e ig h t C o n tro l S u s p e n s io n a n d E le c tric M o d u la te d A ir S u s p e n s io n 1 4 3 2 R B–R B–R R ACC 2 AM1 L–Y IG1 4 L–Y 2 1C D J7 Junction Connector 7 AM2 10A ECU–IG IG2 6 ST2 R R Data Link Connector 3 < 5–7> D H15 Height Control Sensor Rear LH SHB W–L G–R W GR 19 BC2 SHRL 21 A 20 A SGL2 GR 23 A SBL2 W 22 A SIL G–R 20 C R–W RM– SLLO 26 A SLRL 1 A 7 A SLRR SLEX 2 A 8 A 24 A SBR2 19 A SHRR SGR2 V LG 13 BC2 15 BC2 9 IC5 H19 Height Control Mode Select SW E HEIGHT CONTROL OFF W–B 6 4 W–B W–B 1 BC1 3 LOSW GND 2 G 5 HSW H12 Height Control SW H13 Height Control Compressor W–B + 11 IC5 L–W L 3 1 2 10 IC5 LG 3 H17 Height Control Valve W–B W–B L–B L1 Low Pressure Tank Valve 2 1 V 1 2 H14 Height Control Motor 1 V–W P–G P 4 TD 24 B G V–W 14 BC2 DNSW 15 B L–W P–G 12 BC2 UPSW 16 B L P 21 BC2 O B B 18 BC2 O B B J 2(A), J 3(B) Junction Connector 2 9 BC2 20 BC2 GR 30A AM2 Short Pin 2 R–W RM+ 25 A 3 B A 3 11 BC2 GR–G B 1 1 SHG 2 GR–G TS 1 IB1 140A ALT 2 2 GR 1 5 C TC SHRR S13(A), S14(B), S15(C) Suspension Control ECU 6 B 2 6 C IG 2 2 1 4 L–B 1 4 W–B 2 3 2 50A AIR SUS 50A AM1 R W 2 2 2 10 C 1 17 BC2 BR–W 2 RC SHB 3 R–Y 2 18 A SHG 22 BC2 P–L 2 1 B–R 2 5 2 10A AIRSUS NO. 2 1 4 AIR SUS Relay 1 L–Y 10A DOME 4 5 IC5 F BR–Y 2 J4 Junction Connector R–B L–Y L–Y L–Y BR–Y 5 IB2 P–L BR–Y R 4RUNNER (EM03M0U) 2 F 2 BR–W B–R 10 IC4 I18 Ignition SW SHRL 1 12 1E H16 Height Control Sensor Rear RH Battery L–B W–B W–B A EB Front Left Fender BN J24 Junction Connector A Near the No. 5 Crossmember of Side Frame LH Instrument Panel Brace RH II A B M OVERALL ELECTRICAL WIRING DIAGRAM 468 (Cont. next page) 18 4RUNNER 18 4RUNNER (Cont' d) A c tiv e H e ig h t C o n tro l S u s p e n s io n a n d E le c tric M o d u la te d A ir S u s p e n s io n A B 5 R 8 7 6 B–R B–R R 6 1D 15 C L–R L–O R–G B–W G–B 13 B 8 C 9 C FLO 4 C FRO DOOR VN 15 C LO 18 C BR–B 3 IC5 4 A 3 A 2 A 5 A 13 C BR Y–G Y Y–B BR–B BR–B 7 IM1 BR W–B EB 2 IC5 Y–B A A NR 17 C Y–B A B 1 IC5 Y Y–G A A A B J 2(A), J 3(B) Junction Connector A B Y Y–G W–B W–B W–B W–B 4 IC5 HI 16 C OFF GND2 5 B HI MOD1 12 C N LO GND 1 C Height Control TACH S13(A), S14(B), S15(C) MOD2 16 C 12 IC5 Suspension Control ECU 11 C R R–L R–G B–W Stop Light SW < 11–2> 4RUNNER (EM03M0U) C 8(A), C10(C) Combination Meter STP J 8(A), J 9(B) Junction Connector Body ECU < 7–29> Skid Control ECU with Actuator < 15–5> Combination Meter < 31–4> F B 4 1G 13 IC5 12 B H A 7. 5A GAUGE ED Left Bank Cylinder Head M 469 Front Left Fender P o w e r S o u rc e ∗ 1 : 1GR–FE ∗ 2 : 2UZ–FE M u lti M o d e 4 W D 1 4 3 2 B–R A ACC W–B 2 AM1 IG1 4 L–Y 10 GND B–R 20A 4WD ST2 M I18 Ignition SW 13 1J M HM1 HM2 HL1 HL2 TM1 TM2 TL1 TL2 TL3 CDL 8 7 12 11 2 1 3 4 5 9 G–R W–G(∗1) BR–W B B 6 A 1 B IG 4 B HM1 HM2 17 B 26 B HL1 2 B HL2 5 B TM1 25 B TM2 24 B TL1 23 B TL2 22 B TL3 20 A P1 19 A IND2 11 A IND1 IND3 W–B 50A AM1 SPD BR–W 9 A G–R R–L 2 Junction Connector W–G(∗1) L–B L–W L–Y (∗1) L G GR R–B Y L–R V V–R 2 2 G B J28 B J31(A), J32(B) Junction Connector F A R–L R–L R W–L F 9(A), F10(B) 4WD Control ECU GND 1 1 A DL L4 16 A 24 A DM2 6 B DL1 13 B DL2 12 B GR (∗1) C R (∗1) B–W (∗1) LG (∗1) P–L (∗1) 1 EC1 2 EC1 3 EC1 4 EC1 C W–B (∗1) GR (∗1) 6 EC1 5 EC1 3 1 2 6 5 4 ADD DM1 DM2 DL1 DL2 GND M A11 ADD Actuator II Instrument Panel Brace RH ED : Left Bank Cylinder Head (∗2) EF : Rear Side of Left Bank Cylinder Block (∗1) W–B W–B (∗1) P–L (∗1) LG (∗1) B–W (∗1) R (∗1) GR (∗1) Skid Control ECU with Actuator< 15–2> Left Kick Panel DM1 3 B J24 Junction Connector Junction Connector IG GR (∗1) A GR (∗1) 4 16 IM2 Engine Control Module < 6–17> GND C GR (∗1) J5 L4 W–B A Engine Control Module< 5–17> < 6–17> IK A Skid Control ECU with Actuator< 15–4> Right Kick Panel J37 Junction Connector A W–B W–B A G–W H4 J14(A), J15(B) Junction Connector A B (∗1) F11 4WD Control SW (∗1) Park/Neutral Position SW< 13–11> < 14–8> W–B W–B Battery L (∗1) LO H2 A A J28 C 2 2–4 (∗1) ADD 18 B II1 6 L (∗2) W–L B 4 F A N 22 A Junction Connector 5 W–L A A F A L (∗2) 2 B D4 Diff. Lock SW J33(A), J34(B) Junction Connector 2 P (∗1) GR (∗2) 3 A B 2 H B GR (∗1) 1 1 II1 LO 15 A J29(A), J30(B) Junction Connector W–B 30A AM2 6 2–4 8 A W–L GR (∗1) 2 2 140A ALT 4RUNNER (EM03M0U) Combination Meter < 31–6> W–B 6 GND Skid Control ECU with Actuator < 15–4> IG2 6 W–B 7 AM2 W–B T3 Transfer Shift Actuator 2 1C B C D M OVERALL ELECTRICAL WIRING DIAGRAM 470 (Cont. next page) 19 4RUNNER 19 4RUNNER (Cont' d) M u lti M o d e 4 W D 5 A C D ∗ 1 : 1GR–FE 7 8 B–R A B E A G–R G–R W–G(∗1) G–R B–R B 6 E A BR–W J20(A), J21(B) Junction Connector Skid Control ECU with Actuator < 15–4> G–R 4 1G R–L 5 D 7. 5A GAUGE G–R W–G (∗1) 7 D J10(A), J11(B) Junction Connector H B BR–W 15 C 6 D 4LO 4WD Center Diff. Lock 4RUNNER (EM03M0U) E A 6 1D C10(C), C11(D) Combination Meter M 471 P o w e r S o u rc e SRS 1 ∗ 1 : w/ Side Airbag 4 3 2 W–R ACC W–R W–L 2 AM1 IG1 4 B–O L–Y L–Y R–L 7 AM2 R 2 2 IG2 6 B–R S18 Side Airbag Sensor Rear LH R–L B–O ST2 S19 Side Airbag Sensor Rear RH C16 C17 Curtain Shield Airbag Squib LH Curtain Shield Airbag Squib RH 2 50A AM1 I18 Ignition SW 6 1D VUCL 4 CSR+ 1 3 CSR– VUCR 2 4 ESCR 1 1 2 1 2 Y–V (∗1) Y–O (∗1) Y–O (∗1) Y–V (∗1) GR–R (∗1) L–B (∗1) LG–B (∗1) L–W (∗1) G (∗1) 8 D 7 D R B W 2 2 1 A 15 A 5 C CSL+ IG2 2 CSL– 14 A VUCL 13 A 18 D ESCL CSR+ 4 D 19 D CSR– VUCR 20 D 9 A ESCR 10 A ICR+ ICL– ICL+ ICR– A30(A), A31(B), A32(C), A33(D), A34(E) 2 Airbag Sensor Assembly E2 28 C D– 13 C D+ 14 C D2+ 16 C D2– 17 C Y–O E1 27 C Y–V 30A AM2 Short Pin 1 ESCL B–O 2 2 2 R (∗1) 1 2 CSL– 3 L–Y (∗1) 20 1L CSL+ LG–B (∗1) 140A ALT 1 7. 5A GAUGE 2 10A IGN 10A SRS 2 10A ECU–B 4RUNNER (EM03M0U) 1 4 1G 11 1J P+ 10 C P– 11 C P2+ 8 C P2– 7 C +SL 15 C –SL 26 C +SR 9 C –SR 20 C 1 BR–W B–W BR W–R Y–P Y–GR Y–G Y–R Y–B Y 2 W–B B W–B 1 IU1 Instrument Panel Brace LH 1 IN2 BR–W IH 2 B 2 IN2 B–W IJ 1 B 1 IC1 BR Instrument Panel Brace RH 2 A 2 IC1 W–R A36 Airbag Squib (Steering Wheel Pad) 1 A 4 IU1 Y–P Battery 3 3 IU1 Y–GR 4 Spiral Cable Y–G 1 Y–R 2 2 IU1 2 1 2 1 +SL –SL +SR –SR A48(A), A49(B) A14 A15 Airbag Squib (Front Passenger Airbag Assembly) Airbag Sensor Front LH Airbag Sensor Front RH A B C D M OVERALL ELECTRICAL WIRING DIAGRAM 472 (Cont. next page) 20 4RUNNER (Cont. next page) 20 4RUNNER (Cont' d) ∗ 1 : w/ Side Airbag ∗ 2 : w/o Side Airbag SRS 5 A B C D 8 7 6 W–R W–R B–O B–O L–Y A B L–Y R–L R–L S27 S26 Side Airbag Squib LH 2 15A IG1 SRS P–AB IG+ 6 2 3 C RMIL SFR– L–R 6 C 6 D SFR+ P–L 5 D SFL– 12 C 23 C LA H A R–Y 11 A Y–R Y–R L–W V A SIL GSW2 19 C 2 C TC 25 C PBEW 1 C PAON Y–R J25 Junction Connector L B–Y SFL+ J7 Junction Connector A 2 C L–Y (∗1) 12 A Y–R Combination Meter < 7–34> Data Link Connector 3 < 5–7> < 6–7> A PAON 13 2 IL1 10 A 8 1J D3 Passenger Seat Belt Warning Light L Y–G (∗1) Y–R (∗1) Y–G (∗1) Y–R (∗1) H J20 Junction Connector P–AB A30(A), A31(B), A32(C), A33(D), A34(E) Airbag Sensor Assembly SSL+ 17 A SSL– 20 A VUPL 16 A ESL 18 A SSR+ 16 D SSR– 13 D VUPR 17 D ESR 15 D RMSW 21 C PL+ 8 A PL– 7 A PR+ 9 D 2 B 1 B 5 E PR– 10 D 6 E LSP– 3 A LSP+ 4 A LBE+ 19 A LBE– 2 A FSR+ 1 D 8 B 3 B 11 B 7 B 3 E ESL SSR+ SSR– VUPR ESR A B W–B (∗1) A S16 Side Airbag Sensor Front LH J5 Junction Connector S17 Side Airbag Sensor Front RH Left Kick Panel 2 P16 P17 Pretensioner LH Pretensioner RH 4 BI1 B VUPL 1 B W SSL– 1 W SSL+ 4 G–R 2 2 10 E (∗2) 3 1 BI1 Seat Position Airbag Sensor 3 1 FSR– 2 D (∗1) Y 1 Y–B A A J14(A), J15(B) Junction Connector R25 Roll Sensing of Curtain Shield Airbag Cutoff SW W–B (∗1) 4 1 W–B (∗1) 4 2 Y Y–B B–R (∗1) GR (∗1) P (∗1) LG (∗1) L–Y (∗1) GR–L (∗1) P–L (∗1) LG–B (∗1) L–W (∗1) 3 2 G–Y 4 1 IL1 3 G–W R–B B–R (∗1) 4RUNNER (EM03M0U) Engine Control Module < 5–17> < 6–17> 1 C 8(A), C10(C) Combination Meter 2 2 1C 15 C RSCA OFF 1 Side Airbag Squib RH B VS W GND C D Buckle SW B12 Buckle SW LH Seat Position Airbag Sensor IG M 473 ∗ 3 : w/ Power Seat (Front Passenger' s Seat) ∗ 4 : w/o Power Seat (Front Passenger' s Seat) SRS 9 A B 12 11 10 W–R B–O 4 1B B J8 Junction Connector B W–R B–O B–O 14 IO3 SIG1 1 2 SGD1 3 O7 O8 Occupant Classification Sensor Rear LH Occupant Classification Sensor Rear RH SVC2 SIG2 1 2 SGD2 3 SVC3 SIG3 1 2 SGD3 3 SVC4 SIG4 1 2 SGD4 3 BR B V W Y GR O L W G BR R +B FSR+ 8 A 11 B 7 B SVC1 SIG1 BSW 9 A BGND 5 A 1 B (∗4) B 12 B SVC2 8 B SIG2 2 B SGD2 5 B SVC3 DIA 2 A 2 BI1 9 B SIG3 3 B SGD3 6 B SVC4 10 B SIG4 4 B SGD4 GND O 3(A), O 4(B) Occupant Classification ECU 3 A W–B 1 A (∗3) 2 B SGD1 3 BI1 R–Y 2 A 1 B V GR L W B 16 IO3 W W–B R–Y D SVC1 O6 Occupant Classification Sensor Front RH R BR 1 A IG FSR– O5 Occupant Classification Sensor Front LH 5 BI1 7 A 4 A C 15 IO3 W–R B–O 6 BI1 B 3E W–R 4RUNNER (EM03M0U) B B B 3E J31(A), J32(B) Junction Connector B A 4 1L B16(A), (B) Buckle SW RH Data Link Connector 3 < 5–8> < 6–8> BM Floor Seat Crossmember RH M OVERALL ELECTRICAL WIRING DIAGRAM 474 20 4RUNNER (Cont' d) 21 4RUNNER P o w e r S o u rc e F ro n t W ip e r a n d W a s h e r 1 4 3 2 ACC 2 AM1 IG1 4 L–Y 2 1C I18 Ignition SW W–L 30A FR WIP–WSH 2 22 1E 9 1J L L 50A AM1 L 1 1 2 L–W L–W L–B 14 IC4 L–B L–R 17 IC4 L–R M L 140A ALT 16 IC4 2 L–Y 1 6 IN1 L–Y 2 3 1 4 8 +2 2 B F7 Front Wiper Motor Front Wiper and Washer SW M 2 5 W2 Washer Motor 2 B 4RUNNER (EM03M0U) 2 7 16 +1 +S 17 +B 11 F1 F2 WF EW OFF INT LO HI Washer INT TIME J15 Junction Connector A Wiper Relay W–B Battery C14 Combination SW A 2 W–B W–B A J5 Junction Connector EB Left Kick Panel IG M 475 Front Left Fender 2 IO3 G–R 29 1J 32 1J ∗ 1 : w/ Power Seat (Front Passenger' s Seat) R–L LG Rear Front Rear Front L3 Lumbar Support Control SW (Driver' s Seat) Hold W–B W–B W–B (∗1) W–B BR P Y L Y W W (∗1) V (∗1) BR (∗1) P (∗1) G (∗1) A B P25 Power Seat Motor (Front Passenger' s Seat Reclining Control) 2 P26 Power Seat Motor (Front Passenger' s Seat Slide Control) 2 L5 Lumbar Support Control Motor (Driver' s Seat) 2 P19 LG Release Down Up Rear Front Down B (∗1) M M M P21 Power Seat Motor (Driver' s Seat Lifter Control) P23 Power Seat Motor (Driver' s Seat Reclining Control) P20 Power Seat Motor (Driver' s Seat Front Vertical Control) P24 Power Seat Motor (Driver' s Seat Slide Control) B B (∗1) P (∗1) V (∗1) L P A A L (∗1) B W–B W–B BM Floor Seat Crossmember RH BL J45(A), J46(B) Junction Connector 2 Floor Seat Crossmember LH 1 1 1 A B A B A B J43(A), J44(B) Junction Connector A A 2 2 1 1 Up Y (∗1) L (∗1) 2 4 2 8 7 2 M M M M 2 Rear 2 4 1 3 6 9 Reclining Slide Lifter Reclining 1 1 2 2 G–R R–L LG (∗1) Front 1 Junction Connector J45(A), J46(B) J43(A), J44(B) Junction Connector 30A D P/SEAT L–W 1 3 5 2 50A J/B Power Seat Control SW (Front Passenger' s Seat) 1 P18 Power Seat Control SW (Driver' s Seat) 2 3 5 10 6 9 Front Vertical Slide 140A ALT B B B B C A C A 30A P P/SEAT 1 1C 2 4 4RUNNER (EM03M0U) 1 P o w e r S e a t (D riv e r' s S e a t w /o D riv in g P o s itio n M e m o ry ) P o w e r S o u rc e 4 3 2 1 Pow er Seat (F ro n t P a s s e n g e r' s S e a t) G–R 24 IE1 B B Battery M OVERALL ELECTRICAL WIRING DIAGRAM 476 22 4RUNNER 23 4RUNNER P o w e r S o u rc e ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory S e a t H e a te r 1 2 Y–R 4 3 J25 Junction Connector A A Y–R ACC W–B A 3 Y–R L–Y W–B IG1 4 Y–R 2 AM1 1 3 E B–Y 2 2 2 2 1C IG S5 Seat Heater SW RH W–L S4 Seat Heater SW LH IG I18 Ignition SW W–B 1 E 1 2 RV 2 1 20 1E 8 IO3 L R G A H A H A G B 5 B 3F B 3F B 3F 1 LG S25 Seat Heater RH S24 Seat Heater LH W–B B 24 IC4 B 3F R BR 1 W–B H B G B W–B J45(A), J46(B) Junction Connector 14 BK1 R (∗1) BR (∗2) BR (∗1) LG Y–R 5 Y (∗1) H B J43(A), J44(B) Junction Connector Y R (∗2) (∗2) H V (∗2) Y–R A G A 13 BK1 Y–R 2 E Y–R 2 Y–R 2 2 C J20 Junction Connector J7 Junction Connector C V (∗1) H A 2 1 Y–R Y–R E 18 IO3 12 IE1 8 1J Y–R IG Relay 140A ALT 5 J1 Junction Connector SW 4 L 3 2 RV 2 R V 13 IE1 2 1 SW 4 Y 50A AM1 4RUNNER (EM03M0U) 15A IG1 25A SEAT HEATER F 3C 2 B 4 6 C B J45(A), J46(B) W–B (∗2) Junction Connector B A 1 BK1 BL Floor Seat Crossmember LH A Floor Seat Crossmember RH BM A J24 Instrument Panel Brace RH II J37 Junction Connector Junction Connector Right Kick Panel IK M 477 Front Left Fender A A W–B W–B (∗1) LG EB A B W–B (∗1) A A LG (∗2) LG (∗2) LG Battery LG (∗1) B A B W–B 7 BK1 J53 Junction Connector W–B 10 IE1 J43(A), J44(B) Junction Connector W–B 9 IO3 LG LG B B A B W–B B F 3C C B 6 W–B (∗1) W–B (∗2) F 3C B (∗2) B (∗1) J3 Junction Connector B 2 4 A u to m a tic G la re – R e s is ta n t E C M irro r w ith C o m p a s s P o w e r S o u rc e M oon R oof 1 IG1 4 4 3 2 ACC 3 2 AM1 R e m o te C o n tro l M irro r J6 Junction Connector C C GR W–G GR L–Y W–G L–W 17 IA1 2 1C L–W W–L L–W I18 Ignition SW 5 1D 1 1C R24 Remote Control Mirror SW Operation SW Select SW W–B W–B 16 IA1 4 IA2 Y–B 2 16 IP1 15 IP1 17 IP1 2 3 1 3 2 1 MH MV M+ MV MH M+ M M M3 Remote Control Mirror LH M M M4 Remote Control Mirror RH W–B L–R G–R L–Y Y–B Left Kick Panel Engine Control System< 5–3> < 6–3> W–B J5 Junction Connector P–B P–G B IG B J38 Junction Connector 13 1A Battery A C L–R 4 W–B 2 1H Y–B 2 2 2 B LG–R P7 Moon Roof Control SW 2 14 IA1 LG–B 15 1A Right /Down GR 3 ACC CUT Relay 1 E 6 1A 14 1A C 2 15 IA1 SLIDE W–B 2 30 IC4 P W–B 2 3 UP 7 C 6 4 E 6 G–R 7 M+ 3 L–Y 8 W–B 6 1 38 IC4 LG I19 Inner Mirror 4 F 3E OPEN GR B E CLOSE Left /Up SPD 2 L–Y IG E VR GR E2 RH VL P–B PWS M– 7 LH HR P–G 5 P 2 +B 4 M5 Moon Roof Control ECU M RH HL G–R Y IG 1 LH 5 10 M+ F 3E V 9 L L–O 140A ALT 8 1K 11 1A B–R 2 Down 3 1A Up 2 1A Right 2 P 1 Body ECU < 7–6> 50A AM1 50A J/B 4RUNNER (EM03M0U) 1 10A ECU–IG B Left 15A IG1 2 Combination Meter < 31–5> 2 8 7. 5A ACC 1 2 30A POWER 2 A IG J5 Junction Connector Left Kick Panel M OVERALL ELECTRICAL WIRING DIAGRAM 478 24 4RUNNER 25 4RUNNER C ig a re tte L ig h te r P o w e r O u tle t (1 1 5 V ) P o w e r S o u rc e 1 P o w e r O u tle t (1 2 V ) 4 3 2 L–W V IG1 4 W–G W–G L–W ACC 3 2 AM1 L–Y 5 1D 1 1C 2 1C W–L V L–W I18 Ignition SW 10A CIG 15A IG1 2 V Y–R Y–R Y–R E C 2 2 5 1 B 16 IE1 4 14 IE1 1 W–B 1 A A B 3F A B A B A J24 Junction Connector W–B II Instrument Panel Brace RH Floor Seat Crossmember LH BL Rear Pillar LH BO M 479 Left Kick Panel W–B A A IG W–B W–B J5 Junction Connector Battery A A J40(A), J41(B) Junction Connector W–B 4 B 3F W–B P5 Power Outlet (115V) B A B W–B LG A A J14(A), J15(B) Junction Connector W–B 2 IS1 R–W 2 1 5 IR1 W–B 1 IS1 LG R–W V–R L W–B Y–R Y–R 21 IC4 41 IC4 15 IE1 2 P8 Power Outlet (Rear) IN 3 2 P6 Power Outlet (Front) 1 W–B E 2 W–B LG R–W V–R V L IG 27 IE1 BR–R 4 7 H 6 2 3 C6 Cigarette Lighter 1 GND P–L IG V9 Voltage Inverter AC1 AC2 BR–R 2 M2 Main SW J20 Junction Connector 2 31 1J 6 IR1 3 2 H 1 30 1J 17 1L W–B 140A ALT Y–R Y–R 2 1H BR–R A C 5 2 P–L 1 E AC115V INV Relay A J1 Junction Connector 1 DC SKT Relay 2 2 J7 Junction Connector 1 2 50A AM1 15A AC115V INV 2 3 20 1E 2 Y–R 2 50A J/B 4RUNNER (EM03M0U) 1 8 1J 2 15A PWR OUTLET 7. 5A ACC P o w e r S o u rc e H o rn T ire P re s s u re W a rn in g S y s te m 1 E le c tric T e n s io n R e d u c e r 4 3 2 L–Y ACC IG1 4 2 AM1 W–L B–R 2 1C L–Y 6 1D 7 AM2 IG2 6 ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory R W–L 4 1G I18 Ignition SW 28 1J GND IK W–B W–B Floor Seat Crossmember RH BM A B 1 BK1 A A W–B (∗1) Floor Seat Crossmember LH W–B (∗2) A 1 IO3 W–B J37 Junction Connector Right Kick Panel A A A B 4 BL J43(A), J44(B) Junction Connector RDA W–B (∗1) W–B (∗2) +5V T17 Tire Pressure Warning Antenna and Receiver G (∗2) 4 W–B 1 A B J45(A), J46(B) Junction Connector L Battery Theft Deterrent ECU < 7–16> Horn SW B 5 J43(A), J44(B) Junction Connector 6 C13 Combination SW V (∗2) LG–B J53 Junction Connector B W–B (∗1) LG–B GR A A 4 W–B GR 1 BD1 L 11 BD1 G–R G–R 12 BD1 Y–R A B B B 2 5 5 33 IE1 B15 Buckle SW LH 32 IE1 B17 Buckle SW RH 30 IE1 J33(A), J34(B) Junction Connector H10 Horn (Low) 11 W–B H9 Horn (High) Y–R 16 I B G (∗1) 7 F A 12 BK1 G 8 1 I B GND V (∗1) IG J45(A), J46(B) Junction Connector GND2 2 F A 2 SIL 1 V RDA GR 1 B B 4 LG–B C A RF5V L J14(A), J15(B) Junction Connector 1 C A TC B–R GR–B 10A HORN 12 T16 Tire Pressure Warning ECU 2 2 1 GR–B 2 G–R 2 30A AM2 G–R (Except Limited) W–G R 2 R–Y V–R SPD P–L P–B 3 IND 5 IE1 2 A 3D 6 Junction Connector T12 Tension Reducer Solenoid LH A 3D J7 A A 1 1 A 2 Y–R Y–R 1 1D H J20 Junction Connector Y–R 13 1K H T13 Tension Reducer Solenoid RH 3 D A Y–R 7 IO3 B–R 1 2 D J12 Junction Connector Body ECU < 7–16> 140A ALT A B–R Data Link Connector 3 < 5–7> < 5–8> < 6–7> < 6–8> HORN Relay Combination Meter < 31–6> 5 2 C 8(A), C10(C) Combination Meter 1 Tire Pressure 1 J20 Junction Connector W–G G 10 1E Y–R G 15 C 50A AM1 B 4RUNNER (EM03M0U) 2 8 1J J25 Junction Connector A B–R R–L 2 15A IG1 10A ECU–IG 7. 5A GAUGE B–R M OVERALL ELECTRICAL WIRING DIAGRAM 480 26 4RUNNER 27 4RUNNER P o w e r S o u rc e T ra ile r T o w in g 1 5 5 STTR TAIL BRK BATT GND 1 7 2 6 B W–B L EB IG Rear Pillar LH BO A A Floor Seat Crossmember LH BL M 481 Left Kick Panel A B W–B J5 A B W–B W–B W–B A 1 BF1 J40(A), J41(B) Junction Connector B B Junction Connector Front Left Fender W B L 2 BG1 A B G–Y 3 STTL W–B 4 B/UP G B Battery 3 BG1 G Y J14(A), J15(B) Junction Connector J 2(A), J 3(B) Junction Connector 2 B A 2 BF1 18 IE1 A A T15 Trailer Socket Y W–B 2 L–Y 1 3 BF1 4 BG1 BR 3 6 R BRK 2 Y GND B–R 1 B 30A TOWING 2 IB2 GND RTOT L–R 2 LTOT 1 BG1 STOP 8 STIN T14 L–O +B Towing Brake Controller 3 RTIN Towing Converter Relay 4 T6 2 +B R–Y TAIL 1 4 1 G–B 2 Body ECU < 7–5> B G B–R W–B Y–R 5 L–B 3 IB2 9 LTIN GR Park/Neutral Position SW < 12–3> G–B L C STOP LP CTRL Relay < 11–3> 3 B G–Y E 25 IC4 J1 Junction Connector 4 IB2 5 3 STOP LP CTRL Relay < 11–3> B G B C Turn Signal Flasher Relay< 8–3> < 9–3> TOWING TAIL Relay 2 J16 Junction Connector Y–R 1 3 3 GR 1 5 1L E 2 3 3 3 20 1E 2 140A ALT 5 3 2 10A TAIL 2 2 Taillight and Illumination System< 10–1> 15A IG1 Y–R 1 3 BATT CHG Relay 50A AM1 1 3 L TAIL Relay L–Y W–L 2 30A BATT CHG 1 2 1 2 1C 2 2 50A J/B 40A TOWING 1 2 30A TOWING BRK 2 B–Y L–W B L 2 2 3 GR 4RUNNER (EM03M0U) 2 GR B–Y IG1 4 1 I18 Ignition SW L B L–W 1 1C ACC 2 AM1 4 3 2 N a v ig a tio n S y s te m , P a rk in g A s s is t (R e a r V ie w M o n ito r) a n d A u d io S y s te m (w / N a v ig a tio n S y s te m ) P o w e r S o u rc e 1 4 3 2 W–L BR(∗2) GR(∗2) ACC 3 L–Y(∗2) W–L 2 AM1 IG1 P 2 B (∗1) R BR 1 BD2 B W R (∗1) 3 19 IE1 25 IE1 23 IE1 L–Y B W R (∗1) J6 Junction Connector 1 T11 Television Camera 1 G C 2 21 IE1 C C 2 BD2 BR 4 B 3C GR (∗2) GR Engine Control System< 5–3> < 6–3> 30 IC4 3 BD2 (∗1) B 3C R W B GR B 3C W 10 BH1 (∗1) BR 9 BH1 (∗1) R 5 BH1 (∗1) W 4 BH1 L–Y (∗2) L–Y 2 B 28 IC4 4 BD2 P 1 2 7. 5A ACC 8 1K 20A RADIO NO. 2 50A AM1 1 2 F 3E W W–L 2 4 2 2 2 1 F 3E D L–Y 5 1D 2 2 3 38 IC4 P 1 W–L 23 B B V– 24 B CA+ 21 B CGND 22 B V+ R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display ACC 11 G MACC GND 17 B 20 G MIC+ 19 B MIC– 20 B 2 2 A 3B MACC 3 1 MIC+ MIC– (∗1) A 3B B 3A 4 IT1 BR (∗3) 5 B (∗1) A 3B B 3A 3 IT1 P (∗3) B 3A 2 IT1 L (∗3) 2 W (∗3) 2 GR GR 2 1 IT1 P (∗3) 1 L (∗3) W (∗3) BR 1 GR Short Pin 140A ALT 4RUNNER (EM03M0U) 20A RADIO NO. 1 2 B C 2 ACC CUT Relay W–G L–Y I18 Ignition SW 2 A ∗ 1 : Shielded ∗ 2 : w/ Rear Seat Entertainment System ∗ 3 : w/ Telephone Microphone B BR (∗3) BR GR T18 Telephone Microphone Battery BR (∗2) IJ Instrument Panel Brace RH GR E M OVERALL ELECTRICAL WIRING DIAGRAM 482 (Cont. next page) 28 4RUNNER (Cont. next page) 28 4RUNNER (Cont' d) N a v ig a tio n S y s te m , P a rk in g A s s is t (R e a r V ie w M o n ito r) a n d A u d io S y s te m (w / N a v ig a tio n S y s te m ) A B C D 5 W–L ∗ 1 : Shielded ∗ 2 : w/ Rear Seat Entertainment System 8 7 6 W–L A R18 Rear Seat Audio Controller BR(∗2) GR(∗2) L–Y(∗2) GND6 ACC4 12 15 +B2 27 L– 14 SGN5 6 22 G (∗2) LG (∗2) 20 ID1 4 ID1 G (∗2) (∗1) 1 AUXR 2 8 AUXL CE VV+ SW1 R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) SWG 3 II1 1 II1 12 10 AU1 R G B L A37 1 2 ALO ARO ASGN AUXO Antenna Amplifier 3 4 II1 SEEK+ Y–B 4 IV1 2 W–R V–W 3 IV1 Y–B W–R V–W 2 IV1 8 E L (∗1) G R B B 1 IV1 SW2 6 E 7 E Radio and Player with Display 1 +B V14 Video Terminal 1 C ADPG 6 C 9 BJ1 (∗1) 21 ID1 (∗1) VV– 17 BJ1 LG (∗2) 4 C 24 W (∗2) MUTE OPEN 8 LG (∗2) VA– 5 C 6 F TXM– AUXL 16 BJ1 V (∗2) VAR+ 2 C 10 F 7 W (∗2) TXM+ 3 SGND AUXR V (∗2) 9 F CDL– 6 SGND (∗2) VAL+ 3 C 5 F (∗2) CDL+ (∗2) 4 F 19 ID1 (∗1) ANT 13 G CDR– 18 BJ1 (∗1) SGND 18 B 3 F CDR+ (∗1) TSW– 12 B 2 F 5 NTSC SG7 23 22 ID1 R (∗2) CSLD 23 ID1 W (∗2) 1 F R (∗2) L (∗2) SLD 15 BJ1 G (∗2) (∗2) (∗1) P (∗2) L (∗2) (∗2) (∗1) V (∗2) G (∗2) R (∗2) (∗1) G (∗2) R (∗2) W (∗2) B (∗2) (∗2) L–Y (∗2) GR (∗2) BR (∗2) 7 14 BJ1 GR (∗2) (∗2) 24 ID1 16 ID1 G (∗2) 13 BJ1 (∗1) 17 ID1 (∗2) 21 BJ1 (∗1) 18 ID1 NTS4 W (∗2) 5 ID1 SGN2 25 20 BJ1 GR (∗2) 3 ID1 (∗2) LG (∗2) W (∗2) 2 ID1 19 BJ1 NTS1 11 P (∗2) 8 BJ1 SG3 10 9 L (∗2) V (∗2) 10 BJ1 SGN1 (∗2) G (∗2) 8 ID1 26 11 BJ1 LG (∗2) (∗1) 9 ID1 W (∗2) W (∗2) 10 ID1 LMUT TX– 13 L (∗2) G (∗2) 5 BJ1 (∗1) R (∗2) 4 BJ1 11 ID1 TX+ 31 3 BJ1 W (∗2) 12 ID1 6 ID1 L+ 30 2 BJ1 W (∗2) (∗2) LG (∗2) LG (∗2) LG (∗2) 4RUNNER (EM03M0U) 7 ID1 1 BJ1 R– 29 W (∗2) L–Y (∗2) 7 BJ1 R+ 28 B (∗2) GR (∗2) 6 BJ1 (∗2) BR (∗2) 24 BJ1 13 ID1 SG1 16 11 EAU AU2 MODE SEEK– S31 Stereo Jack Adapter VOL+ VOL– C13 Combination SW GR GR B M 483 E N a v ig a tio n S y s te m , P a rk in g A s s is t (R e a r V ie w M o n ito r) a n d A u d io S y s te m (w / N a v ig a tio n S y s te m ) A 9 W–L ∗ 1 : Shielded 12 11 10 D23 Door Speaker Front RH No. 1 1 2 L LG 4 3 Y R W 3 BB1 ATX– 15 G MUTE 7 G SLD 10 G 4 B FR– 13 B RL+ L+ L– R+ R– R– R+ L– L+ 9 G 19 G 8 G 18 G 4 A 5 A 2 A 3 A SLD 6 A MUTE 1 A TX– 7 A TX+ 8 A ACC 12 A FL+ FL– 6 B WFR– WFL+ 20 B 8 B WFL– 19 B GND2 15 B GND 16 B G–W 2 4 WF+ WF– BR BR 3 WF– BR L–R B G R (∗1) W–R W B 1 WF+ 35 IO2 38 IO2 3 IA2 1 IA2 L R–L GR 3 1 D22 Door Speaker Front LH No. 1 BR 2 W4 Woofer BR V P 1 S20 Door Speaker Front LH No. 2 2 GR 9 B L–B 32 IO2 4 B SPD V 31 IO2 11 A CTR– V 29 IO2 12 B CTR+ 20 IO2 P 34 IO2 WFR+ 17 B P 18 IO2 RR– GR B W W–R (∗1) R G B W W B G R (∗1) W–R W B 27 IO2 3 B 14 B RR+ S22(A), S23(B) Stereo Component Amplifier 21 IO2 26 IO2 5 B RL– V–R ATX+ G–B 18 B FR+ R 9(D), R10(E), R11(F), R12(G), R26(B), R27(C) Radio and Player with Display 5 G G–B 7 B +B2 25 IO2 G 10 B +B G 1 B INT+ 23 IO2 W 23 A W INT– 22 IO2 R 22 A Y IVO– B 12 E 24 IO2 L IVO+ 16 IO2 10 IO2 LG 11 E 12 IO2 W–L SLD1 L P 13 E W–L P REV L 5 D SPD (∗1) R–Y V–R LG 3 D PKB R 14 IO2 1 D Y B B 1 BB1 L B 3 BA1 3 8 IP2 LG B 1 BA1 4 W R W–L 39 IO2 C5 Center Speaker B W–L 40 IO2 3 IP2 J42 Junction Connector R17 Rear Door Speaker RH 1 2 Combination Meter < 31–5> 1 36 IO2 P L (∗1) Park/Neutral Position SW < 13–11> < 14–8> Combination Meter < 31–6> 4RUNNER (EM03M0U) Parking Brake SW < 7–38> 2 S21 Door Speaker Front RH No. 2 W–L 27 IC4 37 IO2 R16 Rear Door Speaker LH 1 2 W–B (w/ Side Airbag) BM Floor Seat Crossmember RH BP Rear Pillar RH M OVERALL ELECTRICAL WIRING DIAGRAM 484 28 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 485 A u d io S y s te m (1 0 S p e a k e r) P o w e r S o u rc e 1 ∗ 1 : w/ Rear Seat Entertainment System 4 3 2 W–L GR R18 Rear Seat Audio Controller ACC 3 2 AM1 W–G IG1 +B2 5 1D 16 8 BJ1 3 ID1 LG (∗1) 2 ID1 8 ID1 W (∗1) LG (∗1) 9 ID1 10 BJ1 5 ID1 R (∗1) G (∗1) B 3A ACC 11 A BR L–Y 4 GND 20 A B 3A GR 2 2 L–Y 3 ACC CUT Relay 1 B 3C B 1 A B 3A GR Short Pin 20A RADIO NO. 2 140A ALT 2 CDL– R 1(A), R 4(B), R 5(C) 2 2 CDL+ Radio and Player GR B 3C GR GR P B 3C L–Y (∗1) L–Y 2 1 A 3B B B 2 A 3B 2 Engine Control System< 5–3> < 6–3> BR GR Battery V (∗1) W (∗1) 5 B G (∗1) B (∗1) 4 B CDR– R (∗1) (∗1) 3 B CDR+ (Shielded) BR (∗1) 2 B GR (∗1) W 50A AM1 2 2 10 ID1 C 30 IC4 38 IC4 1 1 11 ID1 1 B CSLD J6 Junction Connector C GR 2 1 12 ID1 11 BJ1 P C 2 2 GR (∗1) L–Y (∗1) 20A RADIO NO. 1 1 F 3E 2 2 13 ID1 (Shielded) W (∗1) W (∗1) W (∗1) W (∗1) (∗1) LG (∗1) LG (∗1) LG (∗1) P L–Y 2 2 7 ID1 V (∗1) 5 BJ1 G (∗1) 4 BJ1 LMUT 26 L (∗1) 3 BJ1 TX– 13 2 W–L W–L 4RUNNER (EM03M0U) 6 ID1 F 3E 14 (Shielded) 2 BJ1 8 1K 28 IC4 TX+ L– 31 G (∗1) 1 BJ1 L+ 30 R (∗1) 24 BJ1 R– 29 W (∗1) 6 BJ1 R+ 28 B (∗1) BR (∗1) 7 BJ1 SG1 27 (∗1) GR (∗1) 27 IC4 7. 5A ACC GND6 12 L–Y (∗1) L–Y W–L I18 Ignition SW ACC4 15 BR (∗1) IJ Instrument Panel Brace RH 9 B TXM+ 10 B TXM– 6 B MUTE A B M OVERALL ELECTRICAL WIRING DIAGRAM 486 (Cont. next page) 29 4RUNNER (Cont. next page) 29 4RUNNER (Cont' d) A u d io S y s te m (1 0 S p e a k e r) A B 5 W–L ∗ 1 : w/ Rear Seat Entertainment System 8 7 6 W–L GR GR A B R18 Rear Seat Audio Controller SGN2 NTS4 SGN5 25 6 22 AUXL OPEN 8 24 7 16 BJ1 17 BJ1 G (∗1) LG (∗1) 18 BJ1 (Shielded) V (∗1) 15 BJ1 AUXR (∗1) R (∗1) 14 BJ1 (Shielded) G (∗1) (∗1) 13 BJ1 SG7 23 9 BJ1 LG (∗1) (Shielded) W (∗1) W (∗1) (∗1) (Shielded) W (∗1) GR (∗1) (∗1) 32 IO2 35 IO2 R– 10 A SLD 6 A SLD R 1(A), R 4(B), R 5(C) Radio and Player ALI 17 C ARI 15 C SW2 6 C 8 C ANT 13 A ATX+ 5 A 3 A L– L+ TX– 7 A TX+ 8 A GND2 15 B GND 16 B BR 27 IO2 BR 26 IO2 B AU1 2 A R+ W II1 Y–B 10 12 MUTE 1 A W–R 2 W–R V–W 4 IV1 MUTE 7 A W–R II1 W B 1 II1 ATX– 15 A B 3 5 A R– Y–B W–R V–W 3 IV1 SWG SW1 7 C 4 A S22(A), S23(B) Stereo Component Amplifier L 2 IV1 AUXI 19 C (Shielded) G R 1 IV1 ASGN 16 C R 18 A R+ (Shielded) 8 A L– G 19 A L+ B 9 A W V14 Video Terminal 34 IO2 (Shielded) W B CE G 8 R 2 AUXL 31 IO2 W B 29 IO2 G (∗1) 1 AUXR (Shielded) LG (∗1) 3 SGND 4 ID1 20 ID1 V (∗1) 6 SGND G R 21 ID1 (∗1) 5 NTSC 19 ID1 (Shielded) SLD 22 ID1 R (∗1) 7 23 ID1 G (∗1) (∗1) 4RUNNER (EM03M0U) 24 ID1 18 IO2 11 EAU AU2 L B G R 1 +B 1 2 ALO ARO 3 ASGN 4 SEEK+ MODE A37 AUXO SEEK– Antenna Amplifier S31 Stereo Jack Adapter VOL+ W–B (w/ Side Airbag) VOL– Floor Seat Crossmember RH BM Rear Pillar RH BP M 487 C13 Combination SW A u d io S y s te m (1 0 S p e a k e r) A B 9 W–L 11 10 GR W–L GR 2 Y R W W–L 3 BA1 1 BB1 3 BB1 WF+ WF– WF+ WF– 2 4 1 3 L–R L–B BR 24 IO2 16 IO2 G–W W R Y B J42 Junction Connector 14 IO2 22 IO2 V–R 5 B 13 B RL+ W 4 B +B2 R +B Y 10 B 1 B ACC B 12 A W–L W–L GR RL– 8 B 14 B RR+ RR– WFL+ 19 B WFL– 9 B 20 B WFR+ WFR– 11 A SPD S22(A), S23(B) Stereo Component Amplifier FL+ FL– 6 B FR+ 17 B FR– 7 B CTR+ 3 B 18 B CTR– DRS+ 12 B DRS– 2 B 11 B BR G–W G–B G L LG V P 4RUNNER (EM03M0U) B 1 2 1 BA1 B B 1 W4 Woofer B 36 IO2 R17 Rear Door Speaker RH Combination Meter < 31–5> 38 IO2 R16 Rear Door Speaker LH C 21 IO2 20 IO2 12 IO2 23 IO2 10 IO2 D C 25 IO2 D 1 IA2 3 IP2 8 IP2 4 11 IO3 D22 Door Speaker Front LH No. 1 4 3 L 2 LG V P 1 1 22 IE1 Rear Speaker RH BR 2 R20 20 IE1 G–W 1 S21 Door Speaker Front RH No. 2 S20 Door Speaker Front LH No. 2 2 10 IO3 BR 3 3 G–W 4 G–B 3 G W R L R–L 4 D BR G–W 3 IA2 BR G–W L LG V P C J42 Junction Connector 4 1 3 2 D23 Door Speaker Front RH No. 1 C5 Center Speaker R19 Rear Speaker LH 12 M OVERALL ELECTRICAL WIRING DIAGRAM 488 29 4RUNNER (Cont' d) Memo 4RUNNER (EM03M0U) 489 A u d io S y s te m (6 S p e a k e r) P o w e r S o u rc e 1 4 3 2 L–Y P 2 AM1 ACC 3 W–G IG1 4 L–Y R18 Rear Seat Audio Controller ∗ 1 : w/ Rear Seat Entertainment System ACC4 10 BJ1 8 BJ1 (Shielded) W (∗1) W (∗1) W (∗1) W (∗1) LG (∗1) 11 ID1 V (∗1) 12 ID1 11 BJ1 W (∗1) 5 BJ1 LMUT 26 G (∗1) 4 BJ1 LG (∗1) 3 BJ1 TX– 13 L (∗1) 2 BJ1 (Shielded) 1 BJ1 LG (∗1) P 6 ID1 10 ID1 9 ID1 2 ID1 8 ID1 3 ID1 5 ID1 L–Y (∗1) GR (∗1) 5 C V (∗1) G (∗1) 4 C CDR– G (∗1) R (∗1) 3 C CDR+ R (∗1) W (∗1) 2 C (Shielded) B (∗1) GR 4 L–Y (∗1) 2 F 3E B 3A B 3C L–Y 3 GR 1 ACC CUT Relay P P F 3E 14 2 2 B 3C 20A RADIO NO. 1 1 2 TX+ L– 31 GR (∗1) L–Y 2 30 B 3A B 3C 7 ID1 W–L 2 2 F 3E 2 2 4 A 3 A +B W 1 C ACC CSLD CDL+ 9 C CDL– TXM+ GR 50A AM1 2 FL+ 1 38 IC4 R W 1 BB1 3 BB1 Y R 2 1 W D22 Door Speaker Front LH No. 1 3 BA1 L 2 1 BA1 B 3 LG V P 1 RR– 3 B Y B Battery RR+ 1 B B 1 4 S21 Door Speaker Front RH No. 2 2 RL– 6 B W 3 8 IP2 S20 Door Speaker Front LH No. 2 4 L L B 3 IP2 1 IA2 R 2 LG 3 IA2 R–L 2 2 1 A 6 A V P 1 FR+ FL– 2 A P Short Pin 140A ALT 2 Engine Control System< 5–3> < 6–3> 2 1 R 2(A), R 3(B), R 4(C), R 5(D) Radio and Player FR– RL+ 5 A 2 B P 4RUNNER (EM03M0U) L–Y GR C 30 IC4 8 1K 29 L+ G (∗1) C LG (∗1) J6 Junction Connector GR 28 IC4 2 R– R (∗1) 7 BJ1 R+ 28 W (∗1) L–Y (∗1) 6 BJ1 SG1 27 GR C 5 1D 7. 5A ACC GR (∗1) W–L L–Y +B2 16 B (∗1) 15 I18 Ignition SW 1 2 1 2 1 2 D23 R16 R17 Door Speaker Front RH No. 1 Rear Door Speaker LH Rear Door Speaker RH 10 C TXM– 6 C MUTE A B M OVERALL ELECTRICAL WIRING DIAGRAM 490 (Cont. next page) 30 4RUNNER 30 4RUNNER (Cont' d) A u d io S y s te m (6 S p e a k e r) A 5 L–Y 8 7 6 P L–Y B S h ift L o c k R18 Rear Seat Audio Controller OPEN GND6 8 24 12 17 BJ1 9 BJ1 24 BJ1 10A ECU–IG LG (∗1) LG (∗1) (Shielded) W (∗1) W (∗1) (Shielded) W (∗1) GR (∗1) Combination Meter < 31–6> 23 ID1 22 ID1 19 ID1 21 ID1 4 ID1 20 ID1 J20 Junction Connector 13 ID1 AUXR S6 Shift Lock Control ECU 6 8 AUXL CE D E 12 8 1 B–R B–R V14 Video Terminal IG L–W ASGN II1 AU1 4 AUXO AU2 SEEK+ B 3F A 3B B 3F J15 Junction Connector ASGN EAU 3 A MODE W–B B 3F A A BR (∗1) VOL+ IJ Instrument Panel Brace RH Left Kick Panel IG A A IK J37 Junction Connector Right Kick Panel A J24 Junction Connector II Instrument Panel Brace RH M 491 VOL– J5 Junction Connector A W–B W–B S31 Stereo Jack Adapter W–B W–B SEEK– BR C13 Combination SW ARO 3 11 L ALO B G R 2 A 3B W–B 10 Y–B 12 1 II1 W–R V–W 4 IV1 2 B–R 1 K3 Key Interlock Solenoid II1 A 3D 4 BR 3 GND 7 A Y–B W–R V–W 3 IV1 SW2 8 D L (Shielded) G 2 IV1 AUXI 19 D A 3D L–W 16 D 1 IJ1 R 2(A), R 3(B), R 4(C), R 5(D) Radio and Player SW1 SWG 7 D 6 D W–B ARI 15 D R 1 IV1 J12 Junction Connector SPD ANT ALI D STP KLS+ 3 D 7 ACC 2 B–R G–Y P SGND BR (∗1) SGND 1 G (∗1) 3 (Shielded) NTSC 6 LG (∗1) V–R SLD V (∗1) 5 (Shielded) R (∗1) G (∗1) 7 17 D G G 24 ID1 +B 8 A 28 1J B–R 16 BJ1 2 1C Stop Light SW < 11–1> 18 BJ1 BR (∗1) 15 BJ1 AUXL 7 G (∗1) R (∗1) 14 BJ1 AUXR (Shielded) G (∗1) 13 BJ1 SG7 23 LG (∗1) 22 V (∗1) SGN5 6 (Shielded) NTS4 1 B 4RUNNER (EM03M0U) A37 Antenna Amplifier SGN2 25 ∗ 1 : w/ Rear Seat Entertainment System R J 8(A), J 9(B) Junction Connector B–W B–W A/C Control Assembly< 32–11> B Active Height Control Suspension System< 18–6> < 18–7> Electric Modulated Air Suspension System< 18–6> < 18–7> Multiplex Communication System (BEAN)< 7–33> < 7–34> Injector No. 1< 5–10> < 6–10> Taillight and Illumination System< 10–11> R–L Suspension Control ECU< 18–5> Engine Control Module < 5–17> < 6–17> Data Link Connector 3 < 6–6> B–W (1GR–FE) B–W (2UZ–FE) F14 Fuel Sender 3 Park/Neutral Position SW < 1–2> A/C Control Assembly < 32–11> BR–R Y–B F A F A R B–W Y–B BR–R L–B B–Y R–L Short Pin 30A AM2 2 J 8(A), J 9(B) Junction Connector B–O R–L W–L BR–B Door Front Fog Beam Illumination Illumination Head (USA) Tail (Except USA) 2 4 N R W 8 IM2 R A/C Control Assembly < 32–12> Taillight and Illumination System< 10–11> L 3 D R P OFF LO N HI 10A DOME Battery Multiplex Communication System (BEAN) < 7–34> B–R R R 2 H B 2 IE1 1 IE1 2 6 B 11 C 3 C 7 B 16 B 7 C 8 B C 8(A), C 9(B), C10(C), C11(D) 2 A 3 A 4 A 5 A Combination Meter 17 A 2 F B R 2 4RUNNER (EM03M0U) 2 2 Buzzer 13 D 1 16 C 5 C 15 C 3 B 2 B 9 C 12 D 10 D 14 D 15 D 16 D 17 D 18 D 19 D 1 C 20 D D B J7 Junction Connector Height Control 2 H A ST2 11 1J 4 1G B A 10A IGN Electronically Controlled Transmission and A/T Indicator System < 13–8> < 13–10> < 13–11> < 13–12> < 14–10> < 14–11> IG2 6 7 AM2 B–O 6 1D IG1 AM1 F A 1 1 ACC B–R 2 M OVERALL ELECTRICAL WIRING DIAGRAM 492 D 4 3 2 1 B–O I18 Ignition SW 10 IC4 C o m b in a tio n M e te r P o w e r S o u rc e 7. 5A GAUGE D (Cont. next page) 31 4RUNNER ∗ 1 : w/ Moon Roof ∗ 2 : Canada ∗ 3 : Except 6 Speaker C o m b in a tio n M e te r Turn Signal and Hazard Warning Light System< 8–4> < 9–4> Body ECU < 7–39> V–R V (∗1) C 8(A), C 9(B), C10(C), C11(D) V–R DAC Slip VSC TRAC VSC OFF (4WD) AUTO LSD (2WD) A/T OIL TEMP Malfunction Indicator Lamp V–W (∗2) ABS System< 15–7> TRAC System< 15–7> VSC System< 15–7> Auto LSD System< 15–7> Downhill Assist Control System < 15–7> Hill–Start Assist Control System < 15–7> J2 Junction Connector Electronically Controlled Transmission and A/T Indicator System < 13–7> < 14–11> Engine Control System< 5–9> < 6–9> W–B (∗2) Multi Mode 4WD System< 19–5> W1 Washer Level Sensor O1 Oil Pressure SW LG–B Charging System < 4–3> SRS System < 20–6> ABS System< 15–8> TRAC System< 15–8> VSC System< 15–8> Auto LSD System< 15–8> Downhill Assist Control System< 15–8> Hill–Start Assist Control System< 15–8> W–B (∗2) BR (2UZ–FE) Multiplex Communication System (BEAN)< 7–33> < 7–34> < 7–35> Multiplex Communication System (BEAN)< 7–34> Front Left Fender BR (1GR–FE) ABS System< 15–7> TRAC System< 15–7> VSC System< 15–7> Auto LSD System< 15–7> Downhill Assist Control System< 15–7> Hill–Start Assist Control System< 15–7> A 4LO 4WD V–W (∗2) LG–B BR 2 Center Diff. Lock Washer Oil Pressure Turn RH Charge Turn LH BRAKE ABS SRS MAINT Fuel Driver' s Seat Belt Temp. Fuel Tachometer 1 1 18 C Speedometer 7 IM1 20 C 4RUNNER (EM03M0U) 6 IM1 12 A 17 C 15 A 7 A 7 D 6 D 5 D 6 A 16 A Combination Meter 6 C 10 C EB Left Bank Cylinder Head ED A EE M 493 Rear Side of Right Bank Cylinder Block Engine Control Module < 5–17> < 6–17> 8 A 19 A 4 D 2 C 13 C 4 B Tire Pressure Warning ECU < 26–3> J29(A), J30(B) Junction Connector 5 B 4WD Control ECU < 19–1> V–R (4WD) G B V–R G B G A V–R (∗3) 41 IO2 V–R (∗3) Stereo Component Amplifier < 28–12> < 29–11> 1 1G 18 B 13 B 8 C 12 B 19 B V–R Moon Roof Control ECU < 24–2> 8 7 6 5 V–R G B V–R G A B 3D 11 1K V–R Radio and Player with Display < 28–9> Radio and Player < 30–5> B 3D A/C Control Assembly < 32–11> V–R B 3D B 3D 5 1A (Cont. next page) 31 4RUNNER (Cont' d) 7 IN1 C o m b in a tio n M e te r C 8(A), C 9(B), C10(C), C11(D) Combination Meter CRUISE RSCA OFF 4RUNNER (EM03M0U) Tire Pressure 11 A 10 A 1 A 10 11 12 M OVERALL ELECTRICAL WIRING DIAGRAM 494 31 4RUNNER (Cont' d) 9 Cruise Control System< 16–4> < 17–4> SRS System < 20–5> Tire Pressure Warning System < 26–2> Memo 4RUNNER (EM03M0U) 495 P o w e r S o u rc e A ir C o n d itio n in g 1 4 3 2 W–R Y–R A B R Y–R W–R D W–G IG1 4 L–Y 2 AM1 D P Y–R 5 1D R 4 1L C W–G Y–R J7 Junction Connector ACC 3 2 1 Y–R R 4 1B 2 C D A 3C GR J6 Junction Connector ACC GND LIN–B IG+ 8 7 14 2 D3 Heater Control Panel Y–R W–B GR GR L–B W–G W–G 3 W–B B 3A B 3A L W–B LG–B J24 Junction Connector A II J37 Junction Connector W–B Instrument Panel Brace RH W–B (2UZ–FE) Y–G Y–G LG–B A F G H I B 3F 2 A E W–B 3 IM2 B 3F D B 3F W–B B Y–G B 3F B 3F 2 SI 1 EB 2 IM2 VM GND Battery C C W–G 1 W–L B3 Blower Motor Controller +B B A2 A/C Lock Sensor A/C Magnetic Clutch 4 1 BR–Y G–Y W–B 3 Front Left Fender F 3E 30 IC4 L–B G–Y Short Pin 60A HEATER 1 B2 Blower Motor M 40 IC4 2 L–B 2 2 1 1 IC4 3 IM1 L 2 37 IC4 B–Y J3 Junction Connector B R W B 2 2 A 3C R 43 IC4 Engine Control System< 5–3> < 6–3> J1 Junction Connector BR–Y 36 IC4 7. 5A HEATER NO. 2 B 2 GR E L–B L B–Y W–B 2 1 2 F 3E B–Y 2 2 2 2 BR–Y Y–R Y–R E 1 2 1 E E J8 Junction Connector 38 IC4 2 2 140A ALT 1 Y–R Y–R E 10A DOME 10A ECU–B 1 2 20 1E 2 2 4 2 HEATER Relay 3 2 2 P 50A AM1 4 3 H 8 1K R 2 1 1 2 MG CLT Relay H P R W–R 4RUNNER (EM03M0U) C D 2 3 P 2 5 1 ACC CUT Relay 2 2 2 2 2 5 J1 Junction Connector 15A IG1 10 IC4 2 2 7. 5A ACC 8 1J Y–R R W–L 2 1C I18 Ignition SW IK Right Kick Panel J K L M OVERALL ELECTRICAL WIRING DIAGRAM 496 (Cont. next page) 32 4RUNNER (Cont. next page) 32 4RUNNER (Cont' d) ∗ 1 : Limited ∗ 2 : Except Limited A ir C o n d itio n in g A B C 5 W–R Y–R A16(A), A17(B) A/C Control Assembly Y–R 1 IG 1 A PSW 9 B LIN1 4 A MGC 10 B LOCK 19 A GMD 5 A HR 21 A BLW 3 A S5 TR 1 B 15 A P–G 3 4 M 5 A25 Air Inlet Control Servo Motor 4 B (∗2) M 1 A1 A/C Ambient Temp. Sensor 1 A (∗1) 1 B 2 B (∗2) 2 5 IC3 2 1 Y–G 2 A P Y–G L–B Y–G BR–Y W–G Y–G Y–G Y–G Y–G A W–B Y–G L AIF 6 B P–L 5 A (∗1) 5 B Y–G Y–G K AIR 5 B P–B 4 A 3 B GR A Y–G J TPI 16 A GR 2 A 3 A P Y–R I TAM 22 A V–W A27(A) Air Mix Control Servo Motor LH A26(B) Air Mix Control Servo Motor 1 A19 A/C Room Temp. Sensor Y–R H J7 Junction Connector G V–R B 3E W–R LG–R F L–O Y–G Y–R Y–R LG–R 4RUNNER (EM03M0U) E Y–R AMHDR(∗1) AMH(∗2) 14 B 39 IC4 H J20 Junction Connector AMCDR(∗1) AMC(∗2) 23 B A H 5 IN1 TPDR(∗1) TP(∗2) 25 A SG 6 A V–Y P LG–B L W–B W–G BR–Y L–B LG–R A VER1 8 B W–B (2UZ–FE) Y–R A J25 Junction Connector W–R P3 Pressure SW +B 2 A B 3E 2 D 8 7 6 W–B (2UZ–FE) B 3B P B 3B B 3B B Y–G L LG–B M 497 A ir C o n d itio n in g 7 A W–L Combination Meter< 31–4> V–G (∗2) R (∗1) B–O (∗1) L–B L–B GR–G BR–W J31(A), J32(B) Junction Connector J10(A), J11(B) Junction Connector A28 Air Mix Control Servo Motor RH A29 Air Vent Mode Control Servo Motor L–B Y–G P Y–G (∗1) P (∗1) Y–G L–B P (∗2) P (∗1) A18 A/C Evaporator Temp. Sensor A21 A/C Solar Sensor A20 A/C Solar Sensor Combination Meter< 31–3> < 31–4> 1 IK1 BR–B GR–G BR–W L–B V–R B–W R (∗1) B–O (∗1) G L–Y (∗1) L–R (∗1) L–W (∗1) LG–R LG LG–R H B I B Engine Control Module < 5–19> < 6–15> Combination Meter < 31–4> < 31–6> E A D A C 3D C 3D 4RUNNER (EM03M0U) P (∗2) P (∗1) B 3B B B 3B B 3B M M 6 IG1 5 IG1 1 1 2 1 2 1 Y–G Y–G A 2 2 3 2 1 C 3D 5 IG1 6 IG1 4 IG1 2 IK1 5 4 3 5 4 3 V–G (∗2) 20 B 19 B DMIN DMOT AC1 7 B ACT 18 A TWI SPD TABC 8 A 20 A TSDR(∗1) TS(∗2) 12 A TSPA TE AMCPA 26 A 24 A 24 B 16 B 23 A 3 B AMHPA TPPA AOF AOD TPO 4 B 17 A 12 11 10 9 ∗ 1 : Limited ∗ 2 : Except Limited A/C Control Assembly A16(A), A17(B) M OVERALL ELECTRICAL WIRING DIAGRAM 498 32 4RUNNER (Cont' d) 33 4RUNNER P o w e r S e a t (D riv e r' s S e a t w / D riv in g P o s itio n M e m o ry ) P o w e r S o u rc e 1 4 3 2 R–L R–B 35 IE1 M2 2 6 IE1 9 BK1 3 LG 34 IE1 M1 R–L MRY 1 V J39 F Junction Connector W–B E S30 Seat Memory SW P F E LG E G–B 10A ECU–IG 4 1B 8 IE1 7 IE1 A G–B R–B LG 6 BK1 8 BK1 2 BK1 15 BK1 V W–R B–R 1 1C P B–R 5 BK1 8 1F J53 Junction Connector A LG W–L W–R A 17 BK1 16 BK1 2 LG V P LG P 2 5 B DCTY MMRY 2 B 6 B SW1 SW2 5 A +B 3 2 SLD– 3 A FRV+ 6 A FRV– 4 A RCL+ 8 A RCL– 10 A LFT+ 7 A LFT– 9 A GND 1 A W–B W–B W–B W V BR P G B L 1 2 A Y 1 50A AM1 2 1 B B B 1 M J53 Junction Connector 2 Lumbar Support Control SW (Driver' s Seat) W–B M L3 4 Y 1 1 P21 Power Seat Motor (Driver' s Seat Lifter Control) M P23 Power Seat Motor (Driver' s Seat Reclining Control) 1 2 B M W–B V P B 2 M L 2 2 P20 Power Seat Motor (Driver' s Seat Front Vertical Control) 1 1 P24 Power Seat Motor (Driver' s Seat Slide Control) 140A ALT Short Pin 1 W 2 2 Hold 50A J/B Release SLD+ 2 5 2 P27(A), P28(B) Position Control ECU and SW 2 2 3 B LG 2 7 B SYSB W–B W–B 8 B IG 2 Y 4 B 1 GR W O L–W 10A ECU–B W 4RUNNER (EM03M0U) 30A D P/SEAT I18 Ignition SW W–R B–R 2 1C 29 1J 2 L–Y Door Courtesy SW Front LH< 7–31> R–L W–R 12 1F IG1 4 Park/Neutral Position SW < 13–12> < 14–10> ACC 2 AM1 24 IE1 4 B B 2 L5 Lumbar Support Control Motor (Driver' s Seat) D B J22(A), J23(B) Junction Connector 1 BK1 E A W–B W–B Battery A J5 Junction Connector BL Left Kick Panel IG M 499 Floor Seat Crossmember LH [A] Power Source Starting 1 Engine Control 2 4 3 R [L] B-R B-R 15A EFI [H] 12 EA1 R-Y R-Y 1 [E] 1 3 Knock Sensor 1 B B BR BR 3 B B 1 GR GR 4 B-W 4 EFI MAIN Relay B-R B-W 1 H11 Heated Oxygen Sensor 2 Y-R [G] 1 15 3C R-G W-B B-W (2L-T) (2L-T) 4 6 1 R-W 5 BO2 Y-R 3 BR-W BR-W 6 G G 5 G-R G-R 4 Y-R 7 L-Y BR 2 1 FP +B T1 D1 Data Link Connector 1 E1 8 Y-R 6 G-Y G-Y 9 GR-B GR-B W-R W-R BR Fender Apron LH EA BR W-B W-B Fender Apron LH N O 21 EA3 B BR W-R VF 4 3 [K] EA L M Y-R R-G BR W-B W-R W-R Fuel Pump 1 F37 M OX1 17 EA3 R-G 2 1 W-R W-R W-R W-R I12 1 4 EA3 R-G 2 Injector No.4 1 I10 Injector No.2 I11 1 2 L-Y W-R Battery K 16 BS1 B-R 2 Injector No.3 I9 S38 (A), S39 (B) Starter B-R B-R B-R Injector No.1 B-W 2 1 A Y-R Y-R R-G B-R 30A AM2 40A AM1 100A ALT (2L-T) 1 B J Air Flow Meter W-B [D] B-W B Y-R A5 6 EA4 2 [J] Y-R 2 B Circuit Opening Relay R-G 2 A C19 Y-R S40 (A), S41 (B) Starter Relay (Shielded) [C] 2 1 B F G I 3 [F] 7 3C Emission ECU <9-8> 2 2 Y-R B-W W-R W [B] E H B-W (22R-E) 1 A 2 Y-R Y-R W-B B-W (22R-E) B-L (2L-T) B-W(22R-E) D 2 1 1 (2L-T) R 4RUNNER (EM03M0U) 7 EA3 (22R-E) (2L-T) [I] C K2 B-L R-Y B-L W B W-R B-R B-R 2 A 7. 5A IGN B-W ST2 7. 5A ST B-W 5 8 AM2 A B 7 IG2 B B-W (22R-E) W-R W W-R 1 4 B A B-W ST1 B-W W 1 4 AM1 A B B-L ACC I 6 (A),(B) Ignition SW IG1 A ID Left Kick Panel BR EC Intake Manifold RH P Q R S M OVERALL ELECTRICAL WIRING DIAGRAM 412 * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the wiring diagram section. HOW TO READ THIS SECTION [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green P Y GR = Gray = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: 3C indicates that it is inside Junction Block No.3 O = Orange The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: L–Y [G] : Indicates related system. 4RUNNER (EM03M0U) L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Numbered in order from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example : [K] : Indicates and located on ground point. [L] : The same code occuring on the next page indicates that the wire harness is continuous. Indicates Relay Block No.1 M 413 SYSTEMS LOCATION 4RUNNER (EM03M0U) ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Active Height Control Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–2 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–2 Audio System (w/ Navigation System) . . . . . . . . . . . . . . . . . . . . . . . . . 28–2 Audio System (10 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–2 Audio System (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–2 Auto LSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Automatic Glare–Resistant EC Mirror with Compass . . . . . . . . . . . . 24–1 Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–3 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–2 Cruise Control (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–2 Cruise Control (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–2 Downhill Assist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Electric Modulated Air Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–2 Electric Tension Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–4 Electronically Controlled Transmission and A/T Indicator (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–2 Electronically Controlled Transmission and A/T Indicator (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–2 Engine Control (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Engine Control (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Engine Immobiliser System (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . 6–19 Engine Immobiliser System (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . 5–19 Front Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–2 Hill–Start Assist Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–1 Ignition (1GR–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Ignition (2UZ–FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Moon Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–2 Multi Mode 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–2 Multiplex Communication System (BEAN) . . . . . . . . . . . . . . . . . . . . . . 7–3 ∗ Automatic Light Control ∗ Door Lock Control SYSTEMS LOCATION ∗ Front Fog Light ∗ Garage Door Opener ∗ Headlight ∗ Interior Light ∗ Key Reminder ∗ Light Auto Turn Off System ∗ Mirror Heater ∗ Power Window ∗ Rear Window Defogger ∗ Rear Wiper and Washer ∗ Seat Belt Warning ∗ Theft Deterrent ∗ Wireless Door Lock Control Multiplex Communication System (CAN) . . . . . . . . . . . . . . . . . . . . . 15–11 Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–2 Parking Assist (Rear View Monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–2 Power Outlet (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–2 Power Outlet (12V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–4 Power Seat (Driver’s Seat w/ Driving Position Memory) . . . . . . . . . . 33–2 Power Seat (Driver’s Seat w/o Driving Position Memory) . . . . . . . . 22–2 Power Seat (Front Passenger’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . . 22–4 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1~33–1 Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–3 Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–2 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–7 SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Tire Pressure Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–2 TRAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27–2 Turn Signal and Hazard Warning Light (w/ Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Turn Signal and Hazard Warning Light (w/o Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 VSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 M OVERALL ELECTRICAL WIRING DIAGRAM 414 SYSTEM INDEX INTRODUCTION – REPAIR INSTRUCTION IN–27 VEHICLE LIFT AND SUPPORT LOCATIONS 1. 2. 3. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP (a) As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with things of heavy weight. (b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling, or hold the jacking support location using the mission jack. NOTICE FOR USING 4 POST LIFT (a) Follow the instruction manual for a safety operation. (b) Do not damage tires or wheels with a free wheel beam. (c) Using a wheel stopper, fix the vehicle. NOTICE FOR USING JACK AND SAFETY STAND (a) Work in the flat place using a wheel stopper at all times. (b) Use a safety stand with a rubber attachment, as shown in the illustration. (c) Support the specified location with a jack and safety stand accurately. (d) When jacking up the front wheels, release the parking brake and place wheel stoppers only behind the rear wheels. When jacking up the rear wheels, place wheel stoppers only in front of the front wheels. (e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand. (f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground. IN IN–28 IN INTRODUCTION – REPAIR INSTRUCTION (g) When jacking down the vehicle with its front wheels jacked up, release the parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the vehicle with its rear wheels jacked up, place wheel stoppers only behind the front wheels. INTRODUCTION – REPAIR INSTRUCTION IN–29 IN Front JACK POSITION Front Center of crossmember Rear Center of rear axle housing CAUTION: When jacking up the front and rear, make sure the vehicle is not carrying any extra weight. SUPPORT POSITION Safety stand Swing arm type lift D029295E02 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–39 ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. INCORRECT INCORRECT CORRECT D032092E01 Looseness of Crimping Core Wire Terminal Deformation Pull Lightly D025087E03 BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: • As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. • Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connectors is disconnected: Squeeze the connector together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. IN IN–40 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. IN D025088E02 (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is goldplated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. INCORRECT CORRECT D032093E01 (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. INCORRECT INCORRECT INCORRECT Fig. 1 D032094E01 ECU B C OPEN 1 1 2 2 A 1 2 1 2 SENSOR Z017004E02 2. CHECK FOR OPEN CIRCUIT (a) For an open circuit in the wire harness in Fig. 1, the resistance or voltage, as described below. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 2 ECU 1 1 1 2 2 2 SENSOR C A B Z017005E02 IN–41 (b) Check the resistance. (1) Disconnect connectors A and C and measure the resistance between the terminals of the connectors. Standard resistance (Fig. 2) Tester Connection Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kΩ or higher Connector A terminal 2 - Connector C terminal 2 Below 1Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. Fig. 3 ECU SENSOR (2) Disconnect connector B and measure the resistance between the terminals of the connectors. Standard resistance (Fig. 3) Tester connection 1 2 1 2 C 1 1 2 B2 2 B1 A B004722E03 Fig. 4 ECU 5V SENSOR 0 V 1 2 C 5V 1 2 2 B 1 2 A Z017007E02 Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 Ω Connector B2 terminal 2 - Connector C terminal 2 10 kΩ or higher If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard voltage (Fig. 4) Tester Connection Specified Condition Connector A terminal 1 - Body ground 5V Connector B terminal 1 - Body ground 5V Connector C terminal 1 - Body ground Below 1 V If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. IN IN–42 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 5 ECU SHORT 1 2 IN 1 1 2 2 CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). A B C 3. Z017008E02 (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance. Standard resistance (Fig. 6) Fig. 6 ECU SENSOR 1 1 2 2 C Tester Connection 1 2 A B Specified Condition Connector A terminal 1 - Body ground Below 1 Ω Connector A terminal 2 - Body ground 10 kΩ or higher Z017009E02 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7) Fig. 7 ECU SENSOR 1 2 C 1 2 B2 1 2 B1 1 2 A Tester Connection Specified Condition Connector A terminal 1 - Body ground 10 kΩ or higher Connector B2 terminal 2 - Body ground Below 1 Ω Z017808E02 4. If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. CHECK AND REPLACE ECU NOTICE: • The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. • When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch on. • Check that the connectors are fully seated. Check for loose, corroded or broken wires. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Example: Ground IN00383E02 ECU Side Wire Harness Side W/H Side Ground Ground IN00384E03 IN–43 (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ω (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. IN IN–49 INTRODUCTION – TERMS GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS A/C TOYATA TERMS ( )-ABBREVIATIONS SAE TERMS Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal - B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection - CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position - CTOX Continuous Trap Oxidizer - CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection Direct Injection (DI./INJ) DI Distributor Ignition - DLC3 Data Link Connector 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode - ECL Engine Coolant Level - ECM Engine Control Module Engine Electronic Control Unit (ECU) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Distributorless Ignition (DLI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control - FEEPROM Flash Electrically Erasable Programmable Read Only Memory - FEPROM Flash Erasable Programmable Read Only Memory - FF Flexible Fuel - FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module - IN IN–50 INTRODUCTION – TERMS SAE ABBREVIATIONS IN TOYATA TERMS ( )-ABBREVIATIONS SAE TERMS IFI Indirect Fuel Injection Indirect Injection (IDL) IFS Inertia Fuel-Shutoff - ISC Idle Speed Control - KS Knock Sensor Knock Sensor MAF Mass Airflow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure - MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Light Check Engine Light MST Manifold Surface Temperature - MVZ Manifold Vacuum Zone - NVRAM Non-Volatile Random Access Memory - O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On-Board Diagnostic On-Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalytic Convert (OC), CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module - PNP Park/Neutral Position - PROM Programmable Read Only Memory - PSP Power Steering Pressure - PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module - ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E-ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter - SRI Service Reminder Indicator - SRT System Readiness Test - ST Scan Tool - TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range - TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three-Way Catalytic Converter Three-Way Catalytic (TWC) Manifold Converter CCRO IN–51 INTRODUCTION – TERMS SAE ABBREVIATIONS TOYATA TERMS ( )-ABBREVIATIONS SAE TERMS TWC+OC Three-Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter - WU-TWC Warm Up Three-Way Catalytic Converter - 3GR Third Gear - 4GR Fourth Gear - IN INTRODUCTION – HOW TO USE THIS MANUAL IN–1 HOW TO USE THIS MANUAL GENERAL INFORMATION 1. 2. 3. 4. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (3) Final Inspection (b) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations (2) Clean all removed parts (3) Perform a visual check INDEX (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of this manual. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. IN IN–2 INTRODUCTION – HOW TO USE THIS MANUAL Example: Filter Cap Clevis Pin Float Gasket Reservoir Tank IN Washer Grommet Slotted Spring Pin Clip 12 (120,9) Clevis Lock Nut 15 (155,11) Push Rod Cylinder Boot Snap Ring Piston N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part N017080E11 (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Also has information such as specifications and warnings, which are written in boldface text 5. 6. CAUTION (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. TERM DEFINITIONS Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. INTRODUCTION – HOW TO USE THIS MANUAL 7. IN–3 INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English systems are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf) IN IN–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION A VEHICLE IDENTIFICATION AND SERIAL NUMBERS IN 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustration. A: Vehicle Identification Number B: Certification Label 2. ENGINE SERIAL NUMBER AND TRANSMISSION SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine, and the transmission serial number is stamped on the housing, as shown in the illustration. A: Engine Serial Number B: Transmission Serial Number B D027510E01 1GR-FE A 2UZ-FE A750E, A750F B B089792E01 INTRODUCTION – REPAIR INSTRUCTION IN–5 REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS IN D028947 1 Attire • • 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safety operation • • • • • Always wear a clean uniform. Hat and safety shoes must be worn. When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations • • • • Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. IN–6 6 INTRODUCTION – REPAIR INSTRUCTION Removed parts • • • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. IN Seal Lock Adhesive Z011554E03 INCORRECT CORRECT (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. V035007E01 Illustration Symbol Part Name Abbreviation FUSE FUSE IN–7 INTRODUCTION – REPAIR INSTRUCTION Illustration Symbol Part Name Abbreviation MEDIUM CURRENT FUSE M-FUSE IN HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during work, always replace the damaged clip with a new one. IN–8 Shape (Example) INTRODUCTION – REPAIR INSTRUCTION Removal/Installation Remove clips with clip remover or pliers. IN Remove fasteners with clip remover or screwdriver. Remove clips with wide scraper to prevent panel damage. Remove clips by pushing center pin through and prying out shell. INTRODUCTION – REPAIR INSTRUCTION Shape (Example) IN–9 Removal/Installation Remove clips by unscrewing center pin and prying out shell. IN Remove clips by prying out pin and then prying out shell. (h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the damaged claws with a new caps or covers. Shape (Example) Illustration Procedures 1. Using a screwdriver, detach the claws and remove the cap or covers. 1. Using a screwdriver, detach the claws and remove the cap or covers. IN–10 INTRODUCTION – REPAIR INSTRUCTION Shape (Example) Illustration Procedures 1. Using a screwdriver, detach the claws and remove the cap or covers. IN (i) INCORRECT CORRECT REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose. D031750E01 (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a stepdown adapter if necessary. D025064E01 (j) L1 L2 D002612E02 TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL IN–11 INTRODUCTION – REPAIR INSTRUCTION L1 (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. Formula: T' = L2/(L1 + L2) * T L2 D001201E01 T' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} 2. NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The 4RUNNER is equipped with a Supplemental Restraint System (SRS). CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE (1) As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery. IN IN–12 IN INTRODUCTION – REPAIR INSTRUCTION (2) Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. CAUTION: Never use a back-up power source (battery or other) to avoid erasing system memory. The back-up power source may inadvertently power the SRS and cause it to deploy. (3) In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle. (See page RS-389 for steering pad) (See page RS-405 for front passenger airbag assembly) (See page RS-420 for front seat side airbag assembly) (See page RS-414 for curtain shield airbag assembly) (See page SB-12 for front seat outer belt assembly) (4) Never use SRS parts from another vehicle. When replacing parts, use new parts. (5) Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs. (6) Never disassemble and attempt to repair all airbag sensor assemblies and all airbag assemblies. 1. Steering pad 2. Front passenger airbag assembly 3. Front seat side airbag assembly 4. Curtain shield airbag assembly 5. Front seat outer belt assembly (7) Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present. INTRODUCTION – REPAIR INSTRUCTION IN–13 (8) Do not directly expose the airbag sensor assembly or airbag assembly to hot air or flames. (9) Use a voltmeter / ohmmeter with high impedance (minimum=10 kΩ) for troubleshooting electrical circuits. (10)Information labels are attached to the SRS components. Follow the instructions on the labels. (11)After work on the SRS is completed, check the SRS warning light. Mark D030401E10 (b) SPIRAL CABLE (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See page RS-398). (c) STEERING PAD (1) Always place a removed or new steering pad surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button. Example: CORRECT WORNG D025096E13 (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: Z013950E02 (3) Grease or detergents of any kind should not be applied to the horn button. IN IN–14 INTRODUCTION – REPAIR INSTRUCTION (4) Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal (See page RS-389). Activate the airbag in a safe place away from electrical noise. (d) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates. IN Example: CORRECT WRONG D027522E11 (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: Z013951E02 (3) Grease or detergents of any kind should not be applied to the front passenger airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. INTRODUCTION – REPAIR INSTRUCTION IN–15 (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-405). Activate in a safe place, away from electrical noise. (e) FRONT SEAT SIDE AIRBAG ASSEMBLY (1) Always place a removed or new front seat side airbag assembly with the airbag inflation direction facing up. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: D030924E04 (3) Grease or detergents of any kind should not be applied to the front seat side airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-420). Activate in a safe place away from electrical noise. IN IN–16 INTRODUCTION – REPAIR INSTRUCTION (f) IN CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. Example: CORRECT WRONG Clear Plastic Bag D031641E07 CAUTION: The plastic bag is not reusable. NOTICE: Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. Example: D030931E01 (3) Grease or detergents of any kind should not be applied to the curtain shield airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See page RS-414). Activate in a safe place away from electrical noise. INTRODUCTION – REPAIR INSTRUCTION IN–17 (g) FRONT SEAT OUTER BELT ASSEMBLY AND REAR SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) (1) Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat belt to activate, which could cause serious injury. Example: D030370E03 (2) Never disassemble the seat outer belt. (3) Never install the seat outer belt on another vehicle. (4) Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. (6) When disposing of a vehicle or the seat outer belt unit by itself, the seat outer belt should be activated before disposal (See page SB-12). Activate in a safe place away from electrical noise. (7) As the seat outer belt is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat outer belt. (8) Grease, detergents, oil or water should not be applied to the front seat outer belt. (h) AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate. IN IN–18 INTRODUCTION – REPAIR INSTRUCTION (i) IN 3. Negative (-) Cable Negative (-) Battery Terminal D033608E02 INCORRECT D031751E02 (3) Work must be started at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. ELECTRONIC CONTROL (a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. (1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting the cable, turn the ignition switch and headlight dimmer switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable. (3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. (b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. (2) Do not pull the wires when disconnecting electronic connectors. Pull the connector itself. (3) Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. (4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent terminals from bending. INTRODUCTION – REPAIR INSTRUCTION 4. Clamp Track B107182E01 REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS (a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources. (2) Never work in a pit or near a pit as vaporized fuel will collect in those places. (b) REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting the operation. (2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. (3) Avoid using electric motors, working lights and other electric equipments that can cause sparks or high temperatures. (4) Avoid using iron hammers as they may create sparks. (5) Dispose of fuel-contaminated cloth separately using a fire resistant container. 5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS (a) If any metal particles enter inlet system parts, this may damage the engine. (b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials. (c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts. 6. HANDLING OF HOSE CLAMPS (a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position. (b) Replace any deformed or dented clamps with new ones. (c) When reusing a hose, attach the clamp on the clamp track portion of the hose. (d) For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration. D001563E01 Spring Type Clamp IN–19 IN IN–20 INTRODUCTION – REPAIR INSTRUCTION 7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS (a) Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible. (b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensors locations, refer to the section on the applicable components. (c) Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice-versa. (d) Check that the antenna and feeder are correctly adjusted. (e) Do not install any high-powered mobile communication system. 8. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY (VSC) SYSTEM (a) NOTICES WHEN USING DRUM TESTER (1) Before beginning testing, disable the VSC. To disable the VSC, turn the engine switch off and connect SST to terminals TS and CG of the DLC3. SST 09843-18040 NOTICE: • Confirm that the VSC warning light blinks. • VSC system will be reset when the engine is started. • For safety, secure the vehicle with restraint chains while using a wheel dynamometer. (b) NOTICES OF RELATED OPERATIONS TO VSC (1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts. (2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system. WHEN SERVICING FULL-TIME 4WD VEHICLES CAUTION: When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing Repair Manual diagnostic procedures may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator. IN D029374 DLC3 CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS B105749E01 9. IN–21 INTRODUCTION – REPAIR INSTRUCTION Center Differential Lock Indicator Light Center Differential Lock Switch (a) The Full-time 4WD 4RUNNER is equipped with the mechanical lock type center differential system. During tests that require the use of a brake tester or chassis dynamometer, such as braking force tests or speedometer tests, if only the front or rear wheels are to be rotated, it is necessary to set the position of the center differential to FREE or LOCK depending on the type of the test being performed. 4WD Switch D027518E01 Center differential FREE condition Indicator Light OFF Condition Switch OFF Rotate Rotate Center differential switch OFF Indicator light OFF 4WD switch (H4/L4) Either Wheel A lifted wheel can be rotated if only one wheel is lifted up, as long as transmission is in N position. Center differential LOCK condition Condition Indicator Light ON Switch ON Lock Lock D030369E01 Center differential switch ON Indicator light ON 4WD switch (H4/L4) Either Wheel A lifted wheel cannot be rotated even if only one wheel is lifted up, as long as transmission is in N position. NOTICE: Center differential LOCK ←→ FREE selecting procedures: • Operate the switch only when all 4 wheels are stopped or driving in a straight line. • Never operate the switch when any wheel is slipping. • Never operate the switch when any wheel is spinning freely. • Never operate the switch when swerving or cornering. IN IN–22 INTRODUCTION – REPAIR INSTRUCTION Push IN 4WD Switch D027517E01 Center Differential Lock Indicator Light Center Differential Lock Switch (1) Refer to HINT below. HINT: • Center differential LOCK ←→ FREE selecting procedures: Move the vehicle forward or backward slightly if the indicator light does not operate correctly when the center differential lock switch is turned ON or OFF. • 4WD switch H4 ←→ L4 position switching procedures: When switching, always put the shift lever of the transmission in N position. In other positions, the transfer gear cannot be changed. 10. WHEN TESTING BRAKES, SPEEDOMETER, ETC. (a) When carrying out any kind of servicing or testing on a Full-time 4WD 4RUNNER in which the front or rear wheels are to be rotated (braking test, speedometer test), be sure to observe the precautions listed below. Incorrect preparations or test procedures may cause damage as well as unsuccessful test results. Before starting any such servicing or test, be sure to check the following items: • Center differential mode position (FREE or LOCK) 4WD Switch D027518E01 D027519 • Vehicle Stability Control (VSC) system: If the vehicle is equipped with this system, the slip indicator light, the VSC/TRAC warning light and the VSC OFF indicator light come on with the ignition switch turned ON. They will go off in a few seconds. • Whether wheels should be touching the ground or jacked up • Transmission gear position (N position) • 4WD switch position (H4 or L4 position) • Maximum testing vehicle speed • Maximum testing time INTRODUCTION – REPAIR INSTRUCTION D027513 D027514 D027511 IN–23 (b) Using Braking Tester: Test by low-speed type brake tester (Vehicle Speed: Below 0.5 km/h or 0.3 mph) and observe the following instructions before the test. (1) Position the wheels to be tested (front or rear) on the tester. (2) Put the center differential in FREE position. (3) Deactivate the Vehicle Stability Control (VSC) system. (4) Shift the transmission shift lever to N position. HINT: Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to operational condition after the test. Check that the VSC/TRAC warning indicator light goes off when restarting the engine. (c) Using Speedometer Tester: Observe the following instructions and then test with the rear wheels. (1) Position the rear wheels on the tester roller. (2) Position the front wheels on the free roller or jack them up. (3) Put the center differential in FREE position. (4) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. (5) Ensure that the vehicle does not move using chains. NOTICE: The maximum speed should be less than 60 km/h (37 mph) and maximum driving time should be 1 minute. HINT: • Do not suddenly shift gears, brake, accelerate or decelerate. • Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. Check that the VSC warning light goes off when restarting the engine. (d) Using Chassis Dynamometer: Observe the following instructions and then test with the rear wheels. (1) Remove the front propeller shaft. (2) Put the center differential in LOCK position. (3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. (4) Make sure that the vehicle is securely fixed. HINT: • Do not suddenly shift gears, brakes, accelerate or decelerate. • Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. Check that the VSC warning indicator light goes off when restarting the engine. IN IN–24 INTRODUCTION – REPAIR INSTRUCTION IN D027512 (e) On-Vehicle Wheel Balancing: When doing on-vehicle wheel balancing on a fulltime 4WD vehicle, to prevent each wheel from being rotated at different speed in different directions (which could damage the center differential), always be sure to observe the following precautions. (1) All 4 wheels should be jacked up, so they do not touch the ground at all. (2) Put the center differential in LOCK position. (3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. (4) Fully release the parking brake lever. (5) None of the brakes should be applied. (6) Drive the wheels on the wheel balancer with the engine running. (7) Carry out the wheel balancing with the transmission position in D position. HINT: • When balancing, pay attention to the other wheels rotating at the same time. • Do not suddenly shift gears, brake, accelerate or decelerate. • Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine. 11. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause oveheating and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid idling the engine for more than 20 minutes. (c) Avoid a spark jump test. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 12. WHEN TOWING FULL-TIME 4WD VEHICLES • Use one of the methods shown below to tow the vehicle. IN–25 INTRODUCTION – REPAIR INSTRUCTION • If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck). Conditions Towing Method Parking Brake Transmission Shift Lever Position IN 1. Flat Bed Truck Applied Any Position Applied Any Position 2. Wheel Lift Type Truck From Front From Rear D027515E01 NOTICE: Do not use any towing method other than those shown above. • The towing methods shown below are dangerous and can damage the vehicle, so do not use them. NO - Never tow the vehicle using a method in which the wheels that are lifted up cannot rotate. - Do not use the sling type towing method either from the front or rear. - If this towing method is used, either from the front or rear: NO (a) The drive train may heat up and be damaged and the wheels may fly off the dolly. (b) In addition, if the vehicle is equipped with the VSC & TRAC system, the system will apply an internal brake to the rotating wheels when the engine is not shut off. D027516E01 IN–26 IN INTRODUCTION – REPAIR INSTRUCTION 13. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid idling the engine for more than 20 minutes. (c) Avoid performing unnecessary spark jump tests. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION IN A large number of ECU controlled systems are used in the 4RUNNER. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. FOR USING INTELLIGENT TESTER – Before using the intelligent tester, read the tester operator's manual thoroughly. – If the tester cannot communicate with the ECU controlled systems when the tester is connected to the DLC3 with the ignition switch on and the tester turned on, there is a problem on the vehicle side or tester side. (1)If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus (+) line) or ECU power circuit of the vehicle. (2)If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Perform the Self Test procedures outlined in the tester operator's manual. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–31 HOW TO PROCEED WITH TROUBLESHOOTING 1. 1 OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs Result Result Proceed to DTC is output A DTC is not output B B A Go to step 6 IN IN–32 5 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DTC CHART (a) Check the results obtained in step 4. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. IN NEXT 6 Go to step 7 PROBLEM SYMPTOMS CHART (a) Check the results obtained in step 4. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT 7 CIRCUIT INSPECTION OR PARTS INSPECTION (a) Identify the malfunctioning circuit or part. NEXT 8 ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT 9 CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT END 2. CUSTOMER PROBLEM ANALYSIS IN–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis: What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the 4RUNNER has various functions. • The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. • Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following system in the 4RUNNER. System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test) SFI System (1GR-FE) { (with Check Mode) { { SFI System (2UZ-FE) { (with Check Mode) { { Tire Pressure Warning System { { { Rear Air Suspension System { { { { ABS with EBD & BA & TRAC & VSC System { { Electronically Controlled Automatic Transmission [ECT] (1GR-FE) { (with Check Mode) { Electronically Controlled Automatic Transmission [ECT] (2UZ-FE) { (with Check Mode) { Air Conditioning System { { Cruise Control System { { IN IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS • In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1) still occurs, or 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. • Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. • The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. IN 1 DTC CHECK NEXT 2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT 3 SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B B Go to step 5 A 4 SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT 5 DTC CHECK Result Result Proceed to DTC is not output A INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Result Proceed to DTC is output B B IN–35 TROUBLESHOOTING OF PROBLEM INDICATED BY DTC IN A 6 SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B SYSTEM NORMAL A TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem still occurs in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: IN–36 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. IN Vibrate Slightly Shake Slightly Vibrate Slightly B071602E03 D025085E02 (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open relays. (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: • Do not heat to more than 60°C (140°F). Exceeding this temperature may damage the components. • Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: • Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. • Never apply water directly onto the electronic components. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–37 HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. AUTO B107149 (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when electrical load is excessive. (1) Turn on the heater blower, headlight, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is shown in the table below. Item Description DTC No. Indicates the diagnostic trouble code Detection Item Indicates the system or details of the problem Trouble Area Indicates the suspect areas of the problem See Page Indicates the page where the inspection procedures for each circuit is to be found, or gives instruction for checking and repairs. 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem still occurs, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptoms are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is shown in the table below. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem occurs in a completely different system. Item Description Problem Symptom - Circuit Inspection, Inspection Order Indicates the order in which the circuits need to be checked Circuit or Part Name Indicates the circuit or part which needs to be checked See Page Indicates the page where the flowchart for each circuit is located 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is shown in the table below. Item Description Circuit Description The major role, operation of the circuit and its component parts are explained. Diagnostic Trouble Code No. and Detection item Indicates the diagnostic trouble codes, diagnostic trouble code settings and suspected areas for a problem IN IN–38 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Item Description Wiring diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If abnormal, use the inspection procedures to determine whether the problem is located in the sensors, actuators, wire harnesses or ECU. Indicates the condition of the connector of the ECU during the check Connector being checked is connected. Connections of tester are indicated by (+) or (-) after the terminal name. Connector being checked is disconnected. The inspections between a connector and body ground, information about the body ground is not shown in the illustration. IN IN–43 INTRODUCTION – TERMS TERMS ABBREVIATIONS USED IN MANUAL Abbreviations Meaning ABS Anti-Lock Brake System A/C Air Conditioner AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACM Active Control Engine Mount ACSD Automatic Cold Start Device A.D.D Automatic Disconnecting Differential A/F Air-Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately ASSY Assembly A/T, ATM Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension AWD All Wheel Drive Vehicle B+ Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi-Level B/S Bore-Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve CAN Controller Area Network CB Circuit Breaker CCo Catalytic Converter For Oxidation CCV Canister Closed Valve CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel CKD Complete Knock Down COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System IN IN–44 INTRODUCTION – TERMS Abbreviations CTR IN Meaning Center C/V Check Valve CV Control Valve CW Curb Weight DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLC Data Link Connector DLI Distributorless Ignition DOHC Double Overhead Camshaft DP Dash Pot DS Dead Soak DSP Digital Signal Processor DTC Diagnostic Trouble Code DVD Digital Versatile Disc EBD Electric Brake Force Distribution EC Electrochromic ECAM Engine Control And Measurement System ECD Electronically Controlled Diesel ECDY Eddy Current Dynamometer ECT Electronic Controlled Automatic Transmission ECU Electronic Control Unit ED Electro-Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR Exhaust Gas Recirculation EGR-VM EGR-Vacuum Modulator ELR Emergency Locking Retractor EPS Electric Power Steering ENG Engine ES Easy & Smooth ESA Electronic Spark Advance ETCS-i Electronic Throttle Control System-intelligent EVAP Evaporative Emission Control EVP Evaporator E-VRV Electric Vacuum Regulating Valve EX Exhaust FE Fuel Economy FF Front-Engine-Front-Wheel-Drive F/G Fuel Gauge FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up IN–45 INTRODUCTION – TERMS Abbreviations FR Meaning Front F/W Flywheel FW/D Flywheel Damper FWD Front-Wheel-Drive GAS Gasoline GND Ground GPS Global Positioning System GSA Gear Shift Actuator HAC High Altitude Compensator H/B Hatchback H-FUSE High Current Fuse HI High HID High Intensity Discharge (Headlight) HPU Hydraulic Power Unit HSG Housing HT Hard Top HV Hybrid Vehicle HWS Heated Windshield System IC Integrated Circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension ISC Idle Speed Control J/B Junction Block J/C Junction Connector KD Kick-Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left-Hand LHD Left-Hand Drive LIN Local Interconnect Network L/H/W Length, Height, Width LLC Long-Life Coolant LNG Liquefied Natural Gas LO Low LPG Liquefied Petroleum Gas LSD Limited Slip Differential LSP & BV Load Sensing Proportioning and Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX. Maximum MIC Microphone IN IN–46 INTRODUCTION – TERMS Abbreviations MIL IN Meaning Malfunction Indicator Lamp MIN. Minimum MG1 Motor Generator No. 1 MG2 Motor Generator No. 2 MMT Multi-mode Manual Transmission MP Multipurpose MPI Multipoint Electronic Injection MPX Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) MT Mount MTG Mounting N Neutral NA Natural Aspiration NO. Number O2S Oxygen Sensor OC Oxidation Catalyst OCV Oil Control Valve O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option ORVR On-board Refilling Vapor Recovery O/S Oversize P & BV Proportioning and Bypass Valve PBD Power Back Door PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PROM Programmable Read Only Memory PS Power Steering PSD Power Slide Door PTC Positive Temperature Coefficient PTO Power Take-Off PZEV Partial Zero Emission Vehicle P/W Power Window R&P Rack and Pinion RAM Random Access Memory R/B Relay Block RBS Recirculating Ball Type Steering REAS Relative Absorber System R/F Reinforcement RFS Rigid Front Suspension RH Right-Hand RHD Right-Hand Drive RLY Relay ROM Read Only Memory RR Rear IN–47 INTRODUCTION – TERMS Abbreviations Meaning RRS Rigid Rear Suspension RSE Rear Seat Entertainment RWD Rear-Wheel Drive SC Supercharger SCV Swirl Control Valve SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold-Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer-Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TFT TOYOTA Free-Tronic TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMIN PT. TOYOTA Motor Manufacturing Indonesia TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TMT TOYOTA Motor Thailand Co. Ltd. TRAC/TRC Traction Control System TURBO Turbocharge TWC Three-Way Catalyst U/D Underdrive U/S Undersize VCV Vacuum Control Valve VDIM Vehicle Dynamics Integrated Management VENT Ventilator VIM Vehicle Interface Module VGRS Variable Gear Ratio Steering VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve IN IN–48 INTRODUCTION – TERMS Abbreviations VVT-i IN Meaning Variable Valve Timing-intelligent W/ With WGN Wagon W/H Wire Harness W/O Without 1ST First 2ND Second 2WD Two Wheel Drive Vehicle (4 x 2) 3RD Third 4TH Fourth 4WD Four Wheel Drive Vehicle (4 x 4) 4WS Four Wheel Steering System 5TH Fifth PP–6 PREPARATION – 1GR-FE ENGINE MECHANICAL RECOMMENDED TOOLS 09031-00040 Pin Punch . 09040-00011 Hexagon Wrench Set PP (09043-20050) Socket Hexagon Wrench 5 (09043-20060) Socket Hexagon Wrench 6 (09043-20080) Socket Hexagon Wrench 8 (09043-20100) Socket Hexagon Wrench 10 (09043-30140) Straight Hexagon Wrench 14 09042-00010 Torx Socket T30 09043-50100 Bi-hexagon Wrench 10 mm 09200-00010 Engine Adjust Kit 09904-00010 Expander Set HINT: Torx is a registered trademark of Textron Inc. PREPARATION – 1GR-FE ENGINE MECHANICAL PP–7 EQUIPMENT Alignment tester Angle gauge Bar CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator with magnetic base Engine Sling Device Feeler gauge Heater Micrometer OBD II scan tool Piston ring compressor Piston ring expander Plastigage Precision straight edge Radiator cap tester Reamer Slide calipers Spring tester Steel square Tachometer Timing light Tire pressure gauge Toe-in gauge Torque wrench Valve seat cutter V-block Vernier calipers Wooden block Press PP PP–8 PREPARATION – 1GR-FE ENGINE MECHANICAL SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent PP PP–12 PREPARATION – 2UZ-FE ENGINE MECHANICAL RECOMMENDED TOOLS 09031-00040 Pin Punch . 09040-00011 Hexagon Wrench Set PP (09043-20050) Socket Hexagon Wrench 5 (09043-20060) Socket Hexagon Wrench 6 (09043-20080) Socket Hexagon Wrench 8 (09043-20100) Socket Hexagon Wrench 10 (09043-30140) Straight Hexagon Wrench 14 09042-00010 Torx Socket T30 09043-50100 Bi-hexagon Wrench 10 mm 09200-00010 Engine Adjust Kit 09904-00010 Expander Set HINT: Torx is a registered trademark of Textron Inc. PREPARATION – 2UZ-FE ENGINE MECHANICAL PP–13 EQUIPMENT Alignment tester Angle gauge Bar CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator with magnetic base Engine Sling Device Feeler gauge Heater Micrometer OBD II scan tool Piston ring compressor Piston ring expander Plastigage Precision straight edge Radiator cap tester Reamer Slide calipers Spring tester Steel square Tachometer Timing light Tire pressure gauge Toe-in gauge Torque wrench Valve seat cutter V-block Vernier calipers Wooden block Press PP PREPARATION – 1GR-FE ENGINE CONTROL SYSTEM PP–1 1GR-FE ENGINE CONTROL SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–2 EQUIPMENT Service Wire Harness Torque wrench Ohmmeter PP PREPARATION – 1GR-FE ENGINE CONTROL SYSTEM PP–14 PREPARATION – 2UZ-FE ENGINE MECHANICAL SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent PP PP–2 PREPARATION – 2UZ-FE ENGINE CONTROL SYSTEM 2UZ-FE ENGINE CONTROL SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – 2UZ-FE ENGINE CONTROL SYSTEM PP–3 EQUIPMENT Service Wire Harness Torque wrench Ohmmeter PP PP–16 PREPARATION – 1GR-FE FUEL RECOMMENDED TOOLS 09040-00011 Hexagon Wrench Set (09043-20080) Socket Hexagon Wrench 8 09082-00040 TOYOTA Electrical Tester PP (09083-00150) Test Lead Set PREPARATION – 1GR-FE FUEL PP–17 EQUIPMENT Clip Measuring Flask Ohmmeter Radiator cap tester Service Wire Harness Stopwatch Torque wrench PP PREPARATION – 1GR-FE ENGINE MECHANICAL PP–3 1GR-FE ENGINE MECHANICAL PREPARATION SST 09032-00100 Oil Pan Seal Cutter 09201-01055 Valve Guide Bushing Remover & Replacer 5.5 09201-10000 Valve Guide Bushing Remover & Replacer Set 09201-41020 Valve Stem Oil Seal Replacer 09202-70020 Valve Spring Compressor (09202-00010) 09213-54015 (91651-60855) Attachment Crankshaft Pulley Holding Tool Bolt 09222-30010 Connecting Rod Bushing Remover & Replacer 09223-78010 Crankshaft Oil Seal Replacer 09226-10010 Crankshaft Front & Rear Bearing Replacer PP PP–4 PREPARATION – 1GR-FE ENGINE MECHANICAL 09330-00021 Companion Flange Holding Tool 09843-18030 Tacho-pulse Pickup Wire No. 2 09843-18040 Diagnosis Check Wire No. 2 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05030) Claw No.3 PP 09950-60010 Replacer Set (09951-00250) Replacer 25 (09951-00350) Replacer 35 09950-70010 Handle Set PREPARATION – 1GR-FE ENGINE MECHANICAL (09951-07100) Handle 100 (09951-07150) Handle 150 PP–5 PP 09992-00500 Compression Gauge Attachment PREPARATION – 2UZ-FE FUEL PP–19 RECOMMENDED TOOLS 09040-00011 (09043-20080) Hexagon Wrench Set Socket Hexagon Wrench 8 PP 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP–20 EQUIPMENT Clip Measuring Flask Ohmmeter Radiator cap tester Service Wire Harness PP Stopwatch Torque wrench PREPARATION – 2UZ-FE FUEL PP–8 PREPARATION – 2UZ-FE ENGINE MECHANICAL 2UZ-FE ENGINE MECHANICAL PREPARATION SST PP 09032-00100 Oil Pan Seal Cutter 09201-01055 Valve Guide Bushing Remover & Replacer 5.5 09201-10000 Valve Guide Bushing Remover & Replacer Set (09201-01060) Valve Guide Bushing Remover & Replacer 6 09201-41020 Valve Stem Oil Seal Replacer 09202-70020 Valve Spring Compressor (09202-00010) Attachment (09202-01010) Arm 09213-70011 Crankshaft Pully Holding Tool (09213-70020) Bolt (90105-08076) Bolt PREPARATION – 2UZ-FE ENGINE MECHANICAL 09222-30010 Connecting Rod Bushing Remover & Replacer 09223-46011 Crankshaft Front Oil Seal Replacer PP–9 PP 09223-56010 Crankshaft Rear Oil Seal Replacer 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe 09330-00021 Companion Flange Holding Tool 09843-18030 Tacho-pulse Pickup Wire No.2 09843-18040 Diagnosis Check Wire No.2 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05010) Center Bolt 100 PP–10 PREPARATION – 2UZ-FE ENGINE MECHANICAL (09953-05020) Center Bolt 150 (09954-05010) Claw No.1 (09954-05021) Claw No.2 PP 09950-60010 Replacer Set (09951-00240) Replacer 24 (09951-00300) Replacer 30 (09951-00350) Replacer 35 (09951-00440) Replacer 44 (09952-06010) Adapter 09950-70010 Handle Set (09951-07100) Handle 100 09960-10010 Variable Pin Wrench Set PREPARATION – 2UZ-FE ENGINE MECHANICAL (09962-01000) Variable Pin Wrench Arm Assembly (09963-00350) Pin 3.5 PP–11 PP (09963-00500) Pin 5 PP–14 PREPARATION – 1GR-FE FUEL 1GR-FE FUEL PREPARATION SST 09268-31011 PP Injection Measuring Tool Set (90467-13001) Clip (95336-08070) Hose 09268-41047 Injection Measuring Tool Set (09268-41091) NO.7 Union (95336-08070) Hose 09268-41140 Adapter 09268-41400 Clamp 09268-45014 EFI Fuel Pressure Gauge (09268-41200) Gauge (09268-41220) Hose PREPARATION – 1GR-FE FUEL (09268-41250) T Joint (90467-13001) Clip PP–15 PP 09808-14020 Retainer Tool, Fuel Pump (09808-01410) Holder (09808-01420) Claw (09808-01430) Bolt 09842-30080 Wire H EFI Inspection PREPARATION – 2UZ-FE FUEL PP–17 2UZ-FE FUEL PREPARATION SST 09268-31011 Injection Measuring Tool Set (09268-41091) NO.7 Union (09268-41110) Adaptor (09268-41300) Clamp (95336-08070) Hose 09268-45014 EFI Fuel Pressure Gauge (09268-41190) Adapter (09268-41200) Gauge (09268-41210) Hose (90405-06167) I Union (90467-11009) Clip PP PP–18 PREPARATION – 2UZ-FE FUEL 09808-14020 Retainer Tool,Fuel Pump (09808-01410) Holder (09808-01430) Bolt PP 09842-30070 Wire F EFI Inspection PREPARATION – 1GR-FE EMISSION CONTROL PP–19 1GR-FE EMISSION CONTROL PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–20 EQUIPMENT Service Wire Harness Ohmmeter Torque wrench Vacuum gauge Intelligent vacuum pump PP PREPARATION – 1GR-FE EMISSION CONTROL PP–20 PREPARATION – 2UZ-FE EMISSION CONTROL 2UZ-FE EMISSION CONTROL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – 2UZ-FE EMISSION CONTROL PP–21 EQUIPMENT Service Wire Harness Ohmmeter Torque wrench Vacuum gauge Intelligent vacuum pump PP PREPARATION – 1GR-FE INTAKE PP–21 1GR-FE INTAKE PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–22 EQUIPMENT Ohmmeter Intelligent vacuum pump PP PREPARATION – 1GR-FE INTAKE PREPARATION – 1GR-FE LUBRICATION PP–29 EQUIPMENT Alignment tester Angle gauge Dial indicator with magnetic base Feeler gauge Precision straight edge Radiator cap tester Tire pressure gauge Toe-in gauge Torque wrench Wooden block CO/HC meter Straight edge Press PP PP–30 PREPARATION – 1GR-FE LUBRICATION LUBRICANT Item Capacity Oil grade - Classification API grade SL or SJ, Energy-Conserving or ILSAC, multi-grade engine oil Drain and refill PP Dry fill w/ oil filter change 5.2 liters (5.5 US qts, 4.6 lmp. qts) - w/o oil filter change 4.9 liters (5.2 US qts, 4.3 lmp. qts) - 6.0 liters (6.3 US qts, 5.3 lmp. qts) - PREPARATION – 1GR-FE LUBRICATION PP–31 SSM Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent PP PP–22 PREPARATION – 2UZ-FE INTAKE 2UZ-FE INTAKE PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – 2UZ-FE INTAKE PP–23 EQUIPMENT Ohmmeter Intelligent vacuum pump PP PREPARATION – 2UZ-FE LUBRICATION PP–31 EQUIPMENT Alignment tester Angle gauge Dial indicator with magnetic base Feeler gauge Precision straight edge Radiator cap tester Tire pressure gauge Toe-in gauge Torque wrench Wooden block CO/HC meter Straight edge Press PP PP–32 PREPARATION – 2UZ-FE LUBRICATION LUBRICANT Item Capacity Oil grade - Classification API grade SL or SJ, Energy-Conserving or ILSAC, multi-grade engine oil Drain and refill PP Dry fill w/ oil filter change 6.2 liters (6.5 US qts, 5.5 lmp. qts) - w/o oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) - 7.1 liters (7.5 US qts, 6.2 lmp. qts) - PREPARATION – 1GR-FE EXHAUST PP–23 1GR-FE EXHAUST PREPARATION EQUIPMENT Vernier calipers Torque wrench PP PREPARATION – 2UZ-FE LUBRICATION PP–33 SSM Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent PP PP–24 2UZ-FE EXHAUST PREPARATION EQUIPMENT Vernier calipers Torque wrench PP PREPARATION – 2UZ-FE EXHAUST PREPARATION – 1GR-FE COOLING PP–25 1GR-FE COOLING PREPARATION EQUIPMENT Heater Radiator cap tester Slide calipers Thermometer Torque wrench PP PP–26 PREPARATION – 1GR-FE COOLING COOLANT Item Engine coolant PP Capacity 9.8 liters (10.4 US qts, 8.6 lmp. qts) Classification "Toyota Super Long Life Coolant" or similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and nonborate coolant with long-life hybrid organic acid technology PP–26 2UZ-FE COOLING PREPARATION EQUIPMENT Heater Radiator cap tester Slide calipers PP Thermometer Torque wrench PREPARATION – 2UZ-FE COOLING PP–27 PREPARATION – 2UZ-FE COOLING COOLANT Item Engine coolant Capacity 12.3 liters (13.0 US qts, 10.8 lmp. qts) Classification "Toyota Super Long Life Coolant" or similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and nonborate coolant with long-life hybrid organic acid technology PP PREPARATION – 1GR-FE LUBRICATION PP–27 1GR-FE LUBRICATION PREPARATION SST 09226-10010 Crankshaft Front & Rear Bearing Replacer 09228-07501 Oil Filter Wrench PP PP–28 PREPARATION – 1GR-FE LUBRICATION RECOMMENDED TOOLS 09040-00011 (09043-20080) Hexagon Wrench Set Socket Hexagon Wrench 8 PP 09042-00010 HINT: Torx is a registered trademark of Textron Inc. Torx Socket T30 PREPARATION – 2UZ-FE LUBRICATION PP–29 2UZ-FE LUBRICATION PREPARATION SST 09228-07501 Oil Filter Wrench PP PP–30 PREPARATION – 2UZ-FE LUBRICATION RECOMMENDED TOOLS 09040-00011 (09043-20060) Hexagon Wrench Set Socket Hexagon Wrench 6 PP 09904-00010 Expander Set PREPARATION – 1GR-FE IGNITION PP–31 1GR-FE IGNITION PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–32 EQUIPMENT Spark plug cleaner Torque wrench PP PREPARATION – 1GR-FE IGNITION PP–32 PREPARATION – 2UZ-FE IGNITION 2UZ-FE IGNITION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) 09200-00010 (09857-00031) TOYOTA Electrical Tester Test Lead Set Engine Adjust Kit Spark Plug Gap Gauge PREPARATION – 2UZ-FE IGNITION PP–33 EQUIPMENT Spark plug cleaner Torque wrench PP PREPARATION – 1GR-FE STARTING PP–33 1GR-FE STARTING PREPARATION RECOMMENDED TOOLS 09904-00010 (09904-00050) Expander Set No. 4 Claw PP PP–34 EQUIPMENT Ammeter (A) Dial indicator with magnetic base Ohmmeter Pull scale Service Wire Harness PP Torque wrench V-block Vernier calipers Dial indicator PREPARATION – 1GR-FE STARTING PREPARATION – 1GR-FE CHARGING PP–37 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–38 EQUIPMENT Ammeter (A) Ohmmeter Service Wire Harness Torque wrench V-block PP Vernier calipers Press PREPARATION – 1GR-FE CHARGING PP–40 EQUIPMENT Ammeter (A) Dial indicator with magnetic base Ohmmeter Service Wire Harness Torque wrench PP V-block Vernier calipers Press PREPARATION – 2UZ-FE CHARGING PP–34 PREPARATION – 2UZ-FE STARTING 2UZ-FE STARTING PREPARATION RECOMMENDED TOOLS 09082-00040 PP TOYOTA Electrical Tester PREPARATION – 2UZ-FE STARTING PP–35 EQUIPMENT Ammeter (A) Dial indicator with magnetic base Ohmmeter Pull scale Service Wire Harness Torque wrench V-block Vernier calipers Dial indicator PP PREPARATION – A750E AUTOMATIC TRANSMISSION PP–43 RECOMMENDED TOOLS 09040-00011 (09043-20100) Hexagon Wrench Set Socket Hexagon Wrench 10 PP 09070-20010 Moulding Remover (09043-20060) Socket Hexagon Wrench 6 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set PP–44 PREPARATION – A750E AUTOMATIC TRANSMISSION EQUIPMENT Straight edge Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Punch Torque wrench PP Torque converter PP–60 PREPARATION – DIFFERENTIAL RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm 09031-00030 Pin Punch 09044-00020 Torx Socket E10 09905-00012 Snap Ring No.1 Expander 09905-00013 Snap Ring Pliers PP HINT: Torx is a registered trademark of Textron Inc. PREPARATION – DIFFERENTIAL PP–61 EQUIPMENT Dial indicator Micrometer Torque wrench Vernier calipers Press PP PP–62 PREPARATION – DIFFERENTIAL LUBRICANT PP Item Capacity Classification Front differential oil 1.40 +- 0.05 liters (1.48 +- 0.05 US qts, 1.23 +- 0.04 lmp. qts) Hypoid gear oil APL GL-5 Above - 18°C (0 °F): SAE 90 Below - 18°C (0 °F): SAE 80W or 80W - 90 Rear differential oil 3.05 +- 0.05 liters (3.22 +- 0.05 US qts, 2.68 +- 0.04 lmp. qts) Hypoid gear oil APL GL-5 Above - 18°C (0 °F): SAE 90 Below - 18°C (0 °F): SAE 80W or 80W - 90 PREPARATION – 1GR-FE CHARGING PP–35 1GR-FE CHARGING PREPARATION SST 09285-76010 Injection Pump Camshaft Bearing Cone Replacer 09820-00021 Alternator Rear Bearing Puller 09820-00031 Alternator Rotor Rear Bearing Replacer 09820-63010 Alternator Pulley Set Nut Wrench Set (09820-06010) Alternator Rotor Shaft Wrench (09820-06020) Alternator Pulley Set Nut 22 mm Wrench 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 PP PP–36 PREPARATION – 1GR-FE CHARGING (09955-04071) Claw No.7 (09957-04010) Attachment (09958-04011) Holder 09950-60010 Replacer Set (09951-00250) Replacer 25 (09951-00470) Replacer 47 09950-70010 Handle Set (09951-07100) Handle 100 PP PP–45 PREPARATION – A750E AUTOMATIC TRANSMISSION LUBRICANT Item Capacity Classification Automatic transmission fluid Refer to "AUTOMATIC TRANSMISSION FLUID" TOYOTA GENUINE ATF WS PP PP–38 PREPARATION – 2UZ-FE CHARGING 2UZ-FE CHARGING PREPARATION SST PP 09285-76010 Injection Pump Camshaft Bearing Cone Replacer 09820-00021 Alternator Rear Bearing Puller 09820-00031 Alternator Rotor Rear Bearing Replacer 09820-63011 Alternator Pulley Set Nut Wrench Set 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 (09955-04071) Claw No.7 (09957-04010) Attachment PREPARATION – 2UZ-FE CHARGING (09958-04011) Holder 09950-60010 Replacer Set PP–39 PP (09951-00250) Replacer 25 (09951-00470) Replacer 47 09950-70010 Handle Set (09951-07100) Handle 100 PP–46 PREPARATION – A750F AUTOMATIC TRANSMISSION RECOMMENDED TOOLS 09040-00011 (09043-20100) Hexagon Wrench Set Socket Hexagon Wrench 10 PP 09070-20010 Moulding Remover (09043-20060) Socket Hexagon Wrench 6 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set PREPARATION – A750F AUTOMATIC TRANSMISSION PP–47 EQUIPMENT Straight edge Torque converter Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Punch Torque wrench PP PP–40 PREPARATION – A750E AUTOMATIC TRANSMISSION A750E AUTOMATIC TRANSMISSION PREPARATION SST PP 09023-12701 Union Nut Wrench 17mm 09223-15020 Oil Seal & Bearing Replacer 09308-00010 Oil Seal Puller 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe (09316-00051) Replacer D 09320-89010 Transfer Clutch Spring Compressor 09350-30020 TOYOTA Automatic Transmission Tool Set (09350-07020) Oil Pump Puller (09350-07040) No.2 Piston Spring Compressor (09350-07050) No.3 Piston Spring Compressor PREPARATION – A750E AUTOMATIC TRANSMISSION (09350-07060) No.1 Snap Ring Expander (09350-07070) No.2 Snap Ring Expander PP–41 PP (09350-07080) Brake Reaction Sleeve Puller (09350-07090) Brake No.1 Piston Puller (09350-07110) Oil Seal Replacer (09351-32140) Oil Seal Replacer 09350-32014 TOYOTA Automatic Transmission Tool Set (09351-32010) One-way Clutch Test Tool (09351-32020) Stator Stopper 09351-40010 Tool Set, TOYOTA Automatic Transmission 09387-00070 First & Reverse Brake Wrench 09710-30050 Suspension Arm Bushing Replacer PP–42 PREPARATION – A750E AUTOMATIC TRANSMISSION 09843-18040 Diagnosis Check Wire No.2 09950-70010 Handle Set (09951-07100) Handle 100 PP 09992-00095 Automatic Transmission Oil Pressure Gauge Set (09992-00231) Adaptor C (09992-00271) Gauge Assy PP–48 PREPARATION – A750F AUTOMATIC TRANSMISSION LUBRICANT PP Item Capacity Classification Automatic transmission fluid Refer to "AUTOMATIC TRANSMISSION FLUID" TOYOTA GENUINE ATF WS PP–44 PREPARATION – A750F AUTOMATIC TRANSMISSION A750F AUTOMATIC TRANSMISSION PREPARATION SST PP 09023-12701 Union Nut Wrench 17mm 09226-10010 Crankshaft Front & Rear Bearing Replacer 09320-89010 Transfer Clutch Spring Compressor 09350-30020 TOYOTA Automatic Transmission Tool Set (09350-07020) Oil Pump Puller (09350-07040) No.2 Piston Spring Compressor (09350-07050) No.3 Piston Spring Compressor (09350-07060) No.1 Snap Ring Expander (09350-07070) No.2 Snap Ring Expander (09350-07080) Brake Reaction Sleeve Puller (09350-07090) Brake No.1 Piston Puller PREPARATION – A750F AUTOMATIC TRANSMISSION (09350-07110) Oil Seal Replacer (09351-32140) Oil Seal Replacer PP–45 PP 09350-32014 TOYOTA Automatic Transmission Tool Set (09351-32010) One-way Clutch Test Tool (09351-32020) Stator Stopper 09351-40010 Tool Set, TOYOTA Automatic Transmission 09387-00070 First & Reverse Brake Wrench 09843-18040 Diagnosis Check Wire No.2 09992-00095 Automatic Transmission Oil Pressure Gauge Set (09992-00231) Adaptor C (09992-00271) Gauge Assy PP–50 EQUIPMENT Dial indicator with magnetic base Micrometer Torque wrench Plastic hammer Vernier calipers PP PREPARATION – VF4AM TRANSFER PP–51 PREPARATION – VF4AM TRANSFER LUBRICANT Item Capacity Transfer oil 1.4 liters (1.5 US qts, 1.2 lmp. qts) Classification API GL-5 SAE 75W-90 PP PREPARATION – VF4AM TRANSFER PP–47 VF4AM TRANSFER PREPARATION SST 09223-15020 Oil Seal & Bearing Replacer 09223-46011 Crankshaft Front Oil Seal Replacer 09308-00010 Oil Seal Puller 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe (09316-00031) Replacer B (09316-00071) Replacer F 09330-00021 Companion Flange Holding Tool 09515-30010 Rear Wheel Bearing Replacer 09554-30011 Differential Oil Seal Replacer 09555-55010 Differential Drive Pinion Bearing Replacer PP PP–48 PREPARATION – VF4AM TRANSFER 09612-65014 Steering Worm Bearing Puller (09612-01030) Claw C (09612-01050) Hanger Pin with Nut PP 09631-32020 Seal Ring Tool 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04030) Center Bolt 200 (09954-04010) Arm 25 (09955-04051) Claw No.5 (09957-04010) Attachment (09958-04011) Holder PREPARATION – VF4AM TRANSFER 09950-60010 Replacer Set (09951-00320) Replacer 32 PP–49 PP (09951-00570) Replacer 57 (09951-00590) Replacer 59 09950-70010 Handle Set (09951-07100) Handle 100 PP–52 PREPARATION – VF4AM TRANSFER SSM Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent PP PP–50 PREPARATION – VF4BM TRANSFER VF4BM TRANSFER PREPARATION SST PP 09223-15020 Oil Seal & Bearing Replacer 09223-46011 Crankshaft Front Oil Seal Replacer 09308-00010 Oil Seal Puller 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe (09316-00031) Replacer B (09316-00071) Replacer F 09330-00021 Companion Flange Holding Tool 09515-30010 Rear Wheel Bearing Replacer 09554-30011 Differential Oil Seal Replacer 09555-55010 Differential Drive Pinion Bearing Replacer PREPARATION – VF4BM TRANSFER 09612-65014 (09612-01030) PP–51 Steering Worm Bearing Puller Claw C PP (09612-01050) Hanger Pin with Nut 09631-32020 Seal Ring Tool 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04030) Center Bolt 200 (09954-04010) Arm 25 (09955-04051) Claw No.5 (09957-04010) Attachment (09958-04011) Holder PP–52 PREPARATION – VF4BM TRANSFER 09950-60010 Replacer Set (09951-00320) Replacer 32 (09951-00570) Replacer 57 (09951-00590) Replacer 59 09950-70010 Handle Set (09951-07100) Handle 100 PP PREPARATION – VF4BM TRANSFER PP–53 EQUIPMENT Dial indicator with magnetic base Micrometer Torque wrench Plastic hammer Vernier calipers PP PP–54 PREPARATION – VF4BM TRANSFER LUBRICANT PP Item Capacity Transfer oil 1.4 liters (1.5 US qts, 1.2 lmp. qts) Classification API GL-5 SAE 75W-90 PREPARATION – PROPELLER SHAFT PP–53 PROPELLER SHAFT PREPARATION SST 09325-40010 Transmission Oil Plug 09332-25010 Propeller Shaft Center Bearing Replacer 09636-20010 Upper Ball Joint Dust Cover Replacer PP PP–54 EQUIPMENT Torque wrench Dial indicator with magnetic base Spring tension gauge PP PREPARATION – PROPELLER SHAFT PREPARATION – VF4BM TRANSFER PP–55 SSM Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent PP PP–54 PREPARATION – DRIVE SHAFT DRIVE SHAFT PREPARATION SST PP 09240-00020 Wire Gauge Set 09520-01010 Drive Shaft Remover Attachment 09520-24010 Differential Side Gear Shaft Puller (09520-32040) Shocker Set 09521-24010 Rear Axle Shaft Puller 09527-10011 Rear Axle Shaft Bearing Remover 09628-62011 Boll Joint Puller 09950-00020 Bearing Remover PREPARATION – DRIVE SHAFT PP–55 RECOMMENDED TOOLS 09905-00012 Snap Ring No.1 Expander PP PP–56 EQUIPMENT Torque wrench PP PREPARATION – DRIVE SHAFT PREPARATION – DIFFERENTIAL PP–55 DIFFERENTIAL PREPARATION SST 09223-00010 Cover & Seal Replacer 09223-15020 Oil Seal & Bearing Replacer 09226-10010 Crankshaft Front & Rear Bearing Replacer 09308-00010 Oil Seal Puller 09308-10010 Oil Seal Puller 09316-60011 Transmission & Transfer Bearing Replacer (09316-00011) Replacer Pipe (09316-00021) Replacer A (09316-00051) Replacer D 09330-00021 (09330-00030) Companion Flange Holding Tool Pin PP PP–56 PREPARATION – DIFFERENTIAL 09350-20015 (09369-20040) TOYOTA Automatic Transmission Tool Set Piston Spring Compressor Set PP 09502-12010 Differential Bearing Replacer 09504-00011 Differential Side Bearing Adjusting Nut Wrench 09506-30012 Differential Drive Pinion Rear Bearing Cone Replacer 09554-22010 Differential Oil Seal Replacer 09554-30011 Differential Oil Seal Replacer 09556-22010 Drive Pinion Front Bearing Remover 09564-32011 Differential Preload Adaptor 09608-32010 Steering Knuckle Oil Seal Replacer 09612-65014 Steering Worm Bearing Puller (09612-01020) Claw B PREPARATION – DIFFERENTIAL (09612-01050) 09636-20010 PP–57 Hanger Pin with Nut Upper Ball Joint Dust Cover Replacer PP 09930-00010 Drive Shaft Nut Chisel 09950-00020 Bearing Remover (09951-00680) Replacer 68 (09951-00890) Replacer 89 09950-30012 Puller A Set (09951-03010) Upper Plate (09953-03010) Center Bolt (09954-03010) Arm (09955-03030) Lower Plate 130 (09956-03020) Adapter 18 PP–58 PREPARATION – DIFFERENTIAL (09956-03030) Adaptor 20 09950-40011 Puller B Set (09951-04010) Hanger 150 (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09953-04030) Center Bolt 200 (09954-04010) Arm 25 (09955-04011) Claw No.1 (09955-04061) Claw No.6 (09957-04010) Attachment (09958-04011) Holder PP PREPARATION – DIFFERENTIAL 09950-60010 Replacer Set (09951-00380) Replacer 38 PP–59 PP (09951-00390) Replacer 39 (09951-00480) Replacer 48 (09951-00550) Replacer 55 09950-60020 Replacer Set No.2 (09951-00680) Replacer 68 (09951-00730) Replacer 73 (09951-00810) Replacer 81 09950-70010 Handle Set (09951-07150) Handle 150 PP–64 PREPARATION – AXLE RECOMMENDED TOOLS 09905-00012 PP Snap Ring No.1 Expander PREPARATION – AXLE PP–65 EQUIPMENT Torque wrench Dial indicator with magnetic base Spring tension gauge PP PP–66 EQUIPMENT Torque wrench PP PREPARATION – SUSPENSION CONTROL PREPARATION – AXLE PP–61 AXLE PREPARATION SST 09023-00101 Union Nut Wrench 10 mm 09308-00010 Oil Seal Puller 09318-12010 Transfer Bearing Adjusting Nut Wrench 09521-25011 Rear Axle Shaft Puller 09521-25023 Rear Axle Shaft Puller Attachment 09527-17011 Rear Axle Shaft Bearing Remover 09611-12010 Tie Rod End Puller 09628-62011 Boll Joint Puller 09649-17010 Steering Knuckle Tool 09650-17011 Hub Bolt Remover 09710-30021 Suspension Bushing Tool Set PP PP–62 PREPARATION – AXLE (09710-03051) Bushing Replacer 09930-00010 Drive Shaft Nut Chisel 09950-40011 Puller B Set (09951-04020) Hanger 200 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 (09955-04061) Claw No.6 (09957-04010) Attachment (09958-04011) Holder 09950-60020 Replacer Set No.2 PP (09951-00770) Replacer 77 PREPARATION – AXLE 09950-70010 Handle Set (09951-07100) Handle 100 PP–63 PP (09951-07150) 09951-01000 Handle 150 Replacer 100 PREPARATION – SUSPENSION PP–67 RECOMMENDED TOOLS 09040-00011 (09043-20060) Hexagon Wrench Set Socket Hexagon Wrench 6 PP PP–68 EQUIPMENT Torque wrench Dial indicator with magnetic base Tire pressure gauge Alignment tester Toe-in gauge PP Angle gauge PREPARATION – SUSPENSION PP–64 PREPARATION – SUSPENSION CONTROL SUSPENSION CONTROL PREPARATION SST 09730-00010 PP Tube Remover PREPARATION – SUSPENSION CONTROL PP–65 RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–72 PREPARATION – BRAKE LUBRICANT PP Item Capacity Brake fluid - Classification SAE J1703 or FMVSS No. 116 DOT3 PREPARATION – SUSPENSION PP–65 SUSPENSION PREPARATION SST 09023-00101 Union Nut Wrench 10 mm 09223-00010 Cover & Seal Replacer 09612-30012 Steering Worm Bearing Puller 09613-26010 Steering Worm Bearing Cone Remover 09628-00011 Ball Joint Puller 09628-62011 Boll Joint Puller 09632-36010 Steering Vane Pump Bearing Replacer 09710-22021 Front Suspension Bushing Tool Set (09710-01031) Upper Arm Bushing Replacer (09710-01071) Lower Arm Bushing Remover (09710-01081) Lower Arm Bushing Replacer PP PP–66 PREPARATION – SUSPENSION 09710-26010 Rear Suspension Bushing Tool Set (09710-05061) Replacer (09710-05081) Rear Base 09727-00060 Arm Set C 09727-30021 Coil Spring Compressor PP (09727-00010) Bolt Set (09727-00031) Compressor 09950-00020 Bearing Remover 09950-60010 Replacer Set (09951-00400) Replacer 40 09950-60020 (09951-00890) Replacer Set No.2 Replacer 89 PP–74 PREPARATION – STEERING COLUMN RECOMMENDED TOOLS 09031-00030 Pin Punch 09042-00010 Torx Socket T30 PP (09043-20060) 09904-00010 (09904-00050) HINT: Torx is a registered trademark of Textron Inc. Socket Hexagon Wrench 6 Expander Set No. 4 Claw PREPARATION – STEERING COLUMN PP–75 EQUIPMENT Torque wrench PP PP–68 PREPARATION – TIRE AND WHEEL TIRE AND WHEEL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – TIRE AND WHEEL PP–69 EQUIPMENT Torque wrench Dial indicator with magnetic base Wheel balancer PP PREPARATION – POWER STEERING PP–77 RECOMMENDED TOOLS 09025-00010 Torque Wrench (30 kgf-cm) 09042-00010 Torx Socket T30 PP 09905-00012 HINT: Torx is a registered trademark of Textron Inc. Snap Ring No.1 Expander PP–78 EQUIPMENT Caliper gauge Vernier caliper Dial indicator Feeler gauge Micrometer PP Torque wrench PREPARATION – POWER STEERING PREPARATION – BRAKE CONTROL PP–69 BRAKE CONTROL PREPARATION RECOMMENDED TOOLS 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PP PP–70 EQUIPMENT Torque wrench PP PREPARATION – BRAKE CONTROL PP–79 PREPARATION – POWER STEERING LUBRICANT Item Capacity Power steering fluid (Total) 0.7 liters (0.7 US qts, 0.6 lmp.qts) Classification ATF DEXRON II or III PP PP–80 PREPARATION – POWER STEERING SSM Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent PP PP–70 PREPARATION – BRAKE BRAKE PREPARATION SST PP 09023-00101 Union Nut Wrench 10 mm 09709-29018 LSPV Gauge Set PREPARATION – BRAKE PP–71 EQUIPMENT Micrometer Hexagon wrench (5 mm) Dial indicator with magnetic base Dial indicator or dial indicator with magnetic base Brake drum gauge Slide calipers Torque wrench PP PP–80 PREPARATION – AIR CONDITIONING RECOMMENDED TOOLS 09040-00011 (09043-30140) Hexagon Wrench Set Straight Hexagon Wrench 14 PP 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09070-20010 Moulding Remover 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set 09904-00010 Expander Set (09904-00050) HINT: Torx is a registered trademark of Textron Inc. No. 4 Claw PREPARATION – AIR CONDITIONING PP–81 EQUIPMENT Voltmeter Anmeter Ohmmeter Vinyl tape Hexagon wrench 4 mm (0.15 in.) Hexagon wrench 14 mm (0.55 in.) Gas leak detector Dial indicator with magnetic base Radiator cap tester Torque wrench PP PREPARATION – PARKING BRAKE PP–71 PARKING BRAKE PREPARATION RECOMMENDED TOOLS 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09070-20010 Moulding Remover HINT: Torx is a registered trademark of Textron Inc. PP PP–72 EQUIPMENT Torque wrench Slide calipers PP PREPARATION – PARKING BRAKE PP–82 PREPARATION – AIR CONDITIONING LUBRICANT PP Item Capacity Classification Compressor oil - ND-OIL 8 or equivalent PP–72 PREPARATION – STEERING COLUMN STEERING COLUMN PREPARATION SST 09316-60011 PP (09316-00051) Transmission & Transfer Bearing Replacer Replacer D 09921-00010 Spring Tension Tool 09950-40011 Puller B Set (09951-04010) Hanger 150 (09952-04010) Slide Arm (09953-04020) Center Bolt 150 (09954-04010) Arm 25 (09955-04061) Claw No.6 (09958-04011) Holder 09950-50013 Puller C Set PREPARATION – STEERING COLUMN (09951-05010) Hanger 150 (09952-05010) Slide Arm PP–73 PP (09953-05020) Center Bolt 150 (09954-05021) Claw No.2 PP–74 PREPARATION – POWER STEERING POWER STEERING PREPARATION SST PP 09023-12701 Union Nut Wrench 17mm 09023-38201 Union Nut Wrench 12mm 09612-00012 Rack & Pinion Steering Rack Housing Stand 09616-00011 Steering Worm Bearing Adjusting Socket 09628-62011 Boll Joint Puller 09631-00350 Steering Rack Cover 35 09631-12071 Steering Rack Oil Seal Test Tool (09633-00010) Packing 09631-20060 Bearing Guide Nut Wrench 09631-20081 Seal Ring Tool 09631-20120 Cylinder End Stopper Nut Wrench PREPARATION – POWER STEERING 09640-10010 (09641-01010) PP–75 Power Steering Pressure Gauge Set Gauge Assy PP (09641-01030) Attachment B (09641-01060) Attachment E 09922-10010 Variable Open Wrench 09950-60010 Replacer Set (09951-00180) Replacer 18 (09951-00250) Replacer 25 (09951-00300) Replacer 30 (09951-00320) Replacer 32 (09951-00390) Replacer 39 (09952-06010) Adapter PP–76 PREPARATION – POWER STEERING 09950-70010 Handle Set (09951-07100) Handle 100 (09951-07150) Handle 150 (09951-07200) Handle 200 PP 09960-10010 Variable Pin Wrench Set (09962-01000) Variable Pin Wrench Arm Assembly (09963-01000) Pin 10 PP–78 PREPARATION – AIR CONDITIONING AIR CONDITIONING PREPARATION SST PP 07110-58060 Air Conditioner Service Tool Set (07117-58060) Refrigerant Drain Service Valve (07117-58070) T-Joint (07117-58080) Quick Disconnect Adapter (07117-58090) Quick Disconnect Adapter (07117-78050) Refrigerant Charging Gauge (07117-88060) Refrigerant Charging Hose (07117-88070) Refrigerant Charging Hose (07117-88080) Refrigerant Charging Hose 09870-00015 A/C Quick Joint Puller No.1 09870-00025 A/C Quick Joint Puller No.2 PREPARATION – AIR CONDITIONING 09960-10010 (09962-01000) PP–79 Variable Pin Wrench Set Variable Pin Wrench Arm Assembly PP (09963-00500) Pin 5 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–83 EQUIPMENT Torque wrench Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.) Diameter: 6.0 mm (0.236 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Plastic bag Airbag disposal PP PREPARATION – SEAT BELT PP–85 EQUIPMENT Torque wrench PP PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–81 SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION SST 09082-00700 SRS Airbag Deployment Tool 09082-00750 Airbag Deployment Wire Sub-harness No.3 09082-00780 Airbag Deployment Wire Sub-harness No.6 09082-00802 Airbag Deployment Wire Sub-Harness No. 8 (09082-10801) Wire A (09082-20801) Wire B (09082-30801) Wire C 09843-18060 SRS Check Wire PP PP–82 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM RECOMMENDED TOOLS 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester PP (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PP–90 EQUIPMENT Torque wrench PP PREPARATION – WIPER AND WASHER PREPARATION – WIPER AND WASHER PP–91 SSM 08850-00065 Butyl Tape Set PP PREPARATION – SEAT BELT PP–83 SEAT BELT PREPARATION SST 09082-00700 SRS Airbag Deployment Tool 09082-00770 Airbag Deployment Wire Sub-harness No.5 PP PP–84 PREPARATION – SEAT BELT RECOMMENDED TOOLS 09082-00040 PP TOYOTA Electrical Tester PP–84 PREPARATION – THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00050 PP TOYOTA Electrical Tester Set PREPARATION – ENGINE IMMOBILISER PP–85 ENGINE IMMOBILISER PREPARATION SST 09843-18040 Diagnosis Check Wire No.2 PP PP–86 PREPARATION – ENGINE IMMOBILISER RECOMMENDED TOOLS 09082-00040 (09083-00150) PP TOYOTA Electrical Tester Test Lead Set PP–86 PREPARATION – CRUISE CONTROL CRUISE CONTROL PREPARATION RECOMMENDED TOOLS PP 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PREPARATION – CRUISE CONTROL PP–87 EQUIPMENT Torque wrench PP PREPARATION – LIGHTING PP–87 LIGHTING PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–88 PREPARATION – WIPER AND WASHER WIPER AND WASHER PREPARATION SST 09843-18040 PP Diagnosis Check Wire No.2 PREPARATION – WIPER AND WASHER PP–89 RECOMMENDED TOOLS 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester PP (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PREPARATION – DOOR LOCK PP–89 DOOR LOCK PREPARATION RECOMMENDED TOOLS 09082-00050 TOYOTA Electrical Tester Set PP PP–90 PREPARATION – METER METER PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set PREPARATION – METER PP–91 EQUIPMENT Torque wrench Tape To avoid surface damage PP PREPARATION – AUDIO / VISUAL PP–91 AUDIO / VISUAL PREPARATION RECOMMENDED TOOLS 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09070-20010 Moulding Remover 09082-00040 TOYOTA Electrical Tester (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PP PP–92 EQUIPMENT Torque wrench PP PREPARATION – AUDIO / VISUAL PREPARATION – PARK ASSIST / MONITORING PP–95 SSM 08850-00065 Butyl Tape Set PP PP–98 PREPARATION – WINDSHIELD / WINDOWGLASS SSM Toyota Genuine Windshield Glass Adhesive or Equivalent PP PP–92 PREPARATION – NAVIGATION NAVIGATION PREPARATION RECOMMENDED TOOLS PP 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09070-20010 Moulding Remover 09082-00040 TOYOTA Electrical Tester (09083-00150) HINT: Torx is a registered trademark of Textron Inc. Test Lead Set PREPARATION – NAVIGATION PP–93 EQUIPMENT Torque wrench PP PREPARATION – ENGINE HOOD / DOOR PP–101 EQUIPMENT Clip remover Hand riveter Tape To avoid surface damage Torque wrench PP PP–102 PREPARATION – ENGINE HOOD / DOOR SSM 08850-00065 PP Butyl Tape Set Toyota Genuine Adhesive 1324, Three bond 1324 or Equivalent PREPARATION – PARK ASSIST / MONITORING PP–93 PARK ASSIST / MONITORING PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–94 EQUIPMENT Torque wrench PP PREPARATION – PARK ASSIST / MONITORING PP–102 PREPARATION – EXTERIOR SSM Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent PP PP–94 PREPARATION – HORN HORN PREPARATION RECOMMENDED TOOLS 09082-00050 PP TOYOTA Electrical Tester Set PREPARATION – OTHER SYSTEM PP–95 OTHER SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–96 EQUIPMENT Torque wrench PP PREPARATION – OTHER SYSTEM PP–96 PREPARATION – WINDSHIELD / WINDOWGLASS WINDSHIELD / WINDOWGLASS PREPARATION RECOMMENDED TOOLS 09082-00040 PP TOYOTA Electrical Tester PREPARATION – WINDSHIELD / WINDOWGLASS PP–97 EQUIPMENT Adhesive Knife Piano wire Plastic sheet Sealer gun Torque wrench Tape Wooden block or similar object PP PREPARATION – INSTRUMENT PANEL PP–97 INSTRUMENT PANEL PREPARATION RECOMMENDED TOOLS 09041-00030 Torx Driver T30 09042-00010 Torx Socket T30 09070-20010 Moulding Remover PP PP–98 PREPARATION – INSTRUMENT PANEL EQUIPMENT Torque wrench Tape PP To avoid surface damage PP–98 PREPARATION – SEAT SEAT PREPARATION RECOMMENDED TOOLS PP 09042-00010 Torx Socket T30 09082-00040 TOYOTA Electrical Tester (09083-00150) Test Lead Set PREPARATION – SEAT PP–99 EQUIPMENT Hog ring pliers Hog ring Torque wrench Tape To avoid surface damage Scraper PP PREPARATION – ENGINE HOOD / DOOR PP–99 ENGINE HOOD / DOOR PREPARATION SST 09812-00010 Door Hinge Set Bolt Wrench 09812-00020 Door Hinge Set Bolt Wrench PP PP–100 PREPARATION – ENGINE HOOD / DOOR RECOMMENDED TOOLS 09041-00020 Torx Driver T25 09042-00010 Torx Socket T30 09042-00020 Torx Socket T40 09050-00032 Air Drill 09050-20010 Air Riveter PP PP–100 PREPARATION – EXTERIOR EXTERIOR PREPARATION RECOMMENDED TOOLS PP 09050-00032 Air Drill 09050-02050 Nose Piece No.4 09050-20010 Air Riveter 09070-20010 Moulding Remover PREPARATION – EXTERIOR PP–101 EQUIPMENT Adhesive tape To avoid surface damage. Clip remover Knife Protective tape To avoid surface damage. Torque wrench PP PREPARATION – INTERIOR PP–101 INTERIOR PREPARATION RECOMMENDED TOOLS 09070-20010 Moulding Remover PP PP–102 PREPARATION – INTERIOR EQUIPMENT Adhesive tape To avoid surface damage. Clip remover Protective tape Torque wrench PP To avoid surface damage. PP–102 PREPARATION – SLIDING ROOF SLIDING ROOF PREPARATION RECOMMENDED TOOLS PP 09041-00020 Torx Driver T25 09082-00040 TOYOTA Electrical Tester PREPARATION – MULTIPLEX COMMUNICATION PP–103 MULTIPLEX COMMUNICATION PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester Test Lead Set PP PP–104 PREPARATION – CAN COMMUNICATION CAN COMMUNICATION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester Test Lead Set SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut No Mark No Mark (w/ Washer) 4N No Mark (w/ Washer) No Mark 5N (4T) 6N 7N (5T) 8N No Mark 10N (7T) 11N 12N HINT: • *: Nut with 1 or more marks on one side surface of the nut. • Use a nut with the same nut strength classification number (or greater) as the bolt strength classification number when tightening parts with a bolt and nut. Example: • Bolt = 4T • Nut = 4N or more SS SS–10 SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened Engine under cover sub-assembly No. 1 x Frame assembly Camshaft bearing cap x Cylinder head subassembly SS 10 mm (0.39 in.) head 12 mm (0.47 in.) head N*m kgf*cm ft.*lbf 29 296 21 9.0 92 80 in.*lbf 24 245 18 Chain tensioner No. 1 x Cylinder head sub-assembly 10 102 7 Chain tensioner No. 2 x Cylinder head sub-assembly 19 194 14 Chain tensioner No. 3 x Cylinder head sub-assembly 19 194 14 Camshaft timing gear assembly x Camshaft 100 1,020 74 Camshaft timing gear or sprocket x Camshaft 100 1,020 74 Timing chain cover plate x Timing chain or belt cover sub-assembly 9.0 92 80 in.*lbf Ignition coil assembly x Cylinder head cover sub-assembly 10 102 7 V-bank cover sub-assembly x Intake air surge tank 7.5 76 66 in.*lbf Engine hanger No. 1 x Cylinder head sub-assembly RH 33 336 24 Engine hanger No. 2 x Cylinder head sub-assembly LH 33 336 24 Spark plug x Cylinder head sub-assembly 20 204 15 Oil filler cap housing x Cylinder head cover sub-assembly LH 9.0 92 80 in.*lbf Camshaft timing oil control valve assembly x Cylinder head cover subassembly 9.0 92 80 in.*lbf Oil filter bracket sub-assembly x Timing chain or belt cover sub-assembly 19 194 14 Engine mounting bracket front No. 1 RH x Cylinder block sub-assembly 43 435 31 Engine mounting bracket front No. 1 LH x Cylinder block sub-assembly 43 435 31 Engine mounting insulator front No. 1 RH x Frame assembly 38 387 28 Engine mounting insulator front No. 1 LH x Frame assembly 38 387 28 Engine wire No. 2 (ground cable) x Cylinder block sub-assembly 13 133 9 Hood sub-assembly x Hood hinge assembly RH & LH 13 133 10 18 184 13 9.0 92 80 in.*lbf Hood support RH & LH x Body Engine rear oil seal retainer x Cylinder block sub-assembly Nut Bolt Knock sensor x Cylinder block sub-assembly Water outlet pipe No. 1 x Cylinder block sub-assembly 10 102 7 20 204 15 10 102 7 1st 36 367 27 2nd Turn 180° Turn 180° Turn 180° 36 367 27 Turn 180° Turn 180° Turn 180° 30 306 22 Chain vibration damper No. 1 x Cylinder block sub-assembly 19 194 14 Idle gear No. 1 x Cylinder block sub-assembly 60 612 44 Cylinder head sub-assembly RH x Cylinder block sub-assembly Recessed head 1st Cylinder head sub-assembly LH x Cylinder block sub-assembly 2nd 14 mm (0.55 in.) head Timing chain or belt cover sub-assembly x Cylinder head and block Water pump assembly x Timing chain or belt cover sub-assembly 10 mm (0.39 in.) head 12 mm (0.47 in.) head Oil pan drain plug x Oil pan sub-assembly No. 2 17 92 80 in.*lbf 23 235 17 41 35 in.*lbf Bolt A 21 214 15 Bolt B 21 214 15 Bolt C 10 102 7 Nut 21 214 15 9.0 92 80 in.*lbf 9.0 92 80 in.*lbf Oil strainer sub-assembly x Oil pan sub-assembly Oil pan sub-assembly No. 2 x Oil pan subassembly 235 4.0 Oil pan stud bolt x Oil pan sub-assembly Oil pan sub-assembly x Cylinder block and timing chain or belt cover 23 9.0 Bolt Nut 10 102 7 40 408 30 SS–11 SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL Part Tightened N*m kgf*cm ft.*lbf 250 2,549 184 Bolt A 10 102 7 Bolt B 9.0 92 80 in.*lbf Nut 9.0 92 80 in.*lbf Bolt A 10 102 7 Crankshaft pulley x Crankshaft Cylinder head cover sub-assembly x Cylinder head sub-assembly RH Cylinder head cover sub-assembly LH x Cylinder head sub-assembly LH Bolt B 9.0 92 80 in.*lbf Nut 9.0 92 80 in.*lbf Ventilation valve x Cylinder head cover sub-assembly LH 27 275 20 Oil control valve filter plug x Cylinder head sub-assembly 62 632 46 Crankshaft position sensor x Cylinder block sub-assembly 10 102 7 VVT sensor x Timing chain or belt cover sub-assembly 8.0 82 71 in.*lbf Cylinder block water drain cock sub-assembly x Cylinder block subassembly 25 255 18 Oil level gauge guide x Cylinder head sub-assembly 9.0 92 80 in.*lbf Oil pan sub-assembly x Transmission 37 377 27 Idler pulley sub-assembly No. 1 x Timing chain or belt cover subassembly 54 551 40 Idler pulley sub-assembly No. 2 x Timing chain or belt cover subassembly 39 398 29 V-ribbed belt tensioner assembly x Cylinder block sub-assembly 36 367 27 Vane pump assembly x Cylinder block sub-assembly 43 438 32 Intake air surge tank x Intake manifold 26 265 19 Surge tank stay x Intake air surge tank and cylinder head 21 214 15 Throttle body bracket x Throttle body with motor and cylinder head 21 214 15 Oil baffle plate x Surge tank stay No. 1 9.0 92 80 in.*lbf Ground cable x Cylinder head sub-assembly 8.0 82 71 in.*lbf Water by-pass joint RR x Cylinder head sub-assembly 9.0 92 80 in.*lbf Intake manifold x Cylinder head sub-assembly 26 265 19 Exhaust manifold sub-assembly RH x Cylinder head sub-assembly RH 30 306 22 Exhaust manifold sub-assembly LH x Cylinder head sub-assembly LH 30 306 22 Manifold stay x Exhaust manifold sub-assembly RH and transmission 40 408 30 Manifold stay No. 2 x Exhaust manifold sub-assembly LH and transmission 40 408 30 Transmission oil filler tube sub-assembly x Cylinder head sub-assembly 12 122 9 Cool air inlet No. 1 x Body 12 122 9 Drive plate & ring gear sub-assembly x Crankshaft 83 846 61 A 4.0 41 35 in.*lbf B Stud bolt x Cylinder head sub-assembly and cylinder head LH 9.0 92 80 in.*lbf Union x Cylinder head sub-assembly and cylinder head LH 15 150 11 With Head taper screw plug x Cylinder head sub-assembly and cylinder head LH 80 816 59 Connecting rod cap x Connecting rod 1st 25 250 18 2nd Turn 90° Turn 90° Turn 90° 12 pointed head 1st Main bearing cap x Cylinder block subassembly Stud bolt x Cylinder block sub-assembly 61 622 45 Turn 90° Turn 90° Turn 90° 12 mm head 26 262 19 A 11 112 8.1 2nd B 4.5 46 40 in.*lbf C 4.0 41 35 in.*lbf 9.0 92 80 in.*lbf Sub-assembly oil nozzle No. 1 x Cylinder block sub-assembly SS SS–15 SERVICE SPECIFICATIONS – 2UZ-FE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil pan sub-assembly No. 2 x Drain plug 39 398 29 Cylinder head cover sub-assembly LH x Ventilation valve sub-assembly 27 275 20 Bolt 18 183 13 Nut 18 183 13 Oil pump assembly x Oil cooler assembly Water by-pass joint FR x Cylinder head 18 185 13 Water by-pass pipe x Cylinder block 18 185 13 Starter assembly x Cylinder block 39 400 29 Starter assembly x Engine wire No. 2 9.8 100 7.2 Water by-pass joint RR x Cylinder head 18 185 13 Knock sensor x Cylinder block 45 450 33 Crankshaft position sensor x Oil pump assembly 6.5 65 58 in.*lbf Camshaft position sensor x Cylinder head 7.5 80 66 in.*lbf Ignition coil assembly x Cylinder head cover Fan bracket sub-assembly x Cylinder block V-ribbed belt tensioner assembly x Cylinder block 7.5 80 66 in.*lbf 12 mm head 16 160 12 14 mm head 32 326 24 Bolt 16 160 12 Nut Timing belt cover sub-assembly No. 2 x Cylinder block Timing chain or belt cover No. 2 x Cylinder block 16 160 12 16 160 12 Bolt 7.5 80 66 in.*lbf Nut 7.5 80 66 in.*lbf Timing belt cover sub-assembly No. 3 LH x Cylinder block 7.5 80 66 in.*lbf Pump bracket x Cylinder block 43 438 32 Oil cooler pipe x Cylinder block Bolt 7.5 80 66 in.*lbf Nut 7.5 80 66 in.*lbf Harness bracket x Cylinder block 8.0 80 71 in.*lbf Engine mounting bracket x Cylinder block 36 367 27 Wire harness heat insulator No. 2 x Cylinder block 17 175 13 Intake manifold assembly x Cylinder head 18 185 13 Engine mounting bracket x Frame brackets 38 387 28 Exhaust manifold x Cylinder head 44 450 33 Exhaust manifold heat insulator x Exhaust manifold 7.5 80 69 in.*lbf Oil level gauge guide x Cylinder head 15 155 11 Transmission oil filler tube x Cylinder head 12 122 9 Fan with fluid coupling x Fan bracket sub-assembly 29 296 21 Bolt 47 475 34 Nut 25 255 18 Bolt 43 438 32 Nut 43 438 32 Compressor x Cylinder block Vane pump assembly x Cylinder block Fan shroud x Radiator assembly 5.0 51 44 in.*lbf Air cleaner assembly x Body 12 122 9 Throttle body cover x Intake manifold assembly 7.5 80 66 in.*lbf Hood x Body 13 133 10 8.0 82 71 in.*lbf 16 158 11 31 311 23 7.5 76 66 in.*lbf Engine rear oil seal retainer x Cylinder block Oil pump assembly x Cylinder block Bolt A, B, C and E Bolt D Oil strainer sub-assembly x Cylinder block Oil pan sub-assembly x Cylinder block Bolt A and D 7.5 76 66 in.*lbf Bolt B, C and nut 28 286 21 SS SS–16 SERVICE SPECIFICATIONS – 2UZ-FE ENGINE MECHANICAL Part Tightened Oil pan baffle plate x Oil pan sub-assembly Oil pan sub-assembly No. 2 x Oil pan sub-assembly Water pump assembly x Cylinder block Cylinder head x Cylinder block SS Bearing cap x Cylinder head N*m kgf*cm ft.*lbf 7.5 76 66 in.*lbf 7.5 76 66 in.*lbf Bolt 21 214 15 Stud bolt and nut 18 184 13 1st 40 408 30 2nd Turn 90° Turn 90° Turn 90° 3rd Turn 90° Turn 90° Turn 90° Bolt C 7.5 76 66 in.*lbf Other 16 163 12 Timing belt plate RR x Cylinder head 7.5 76 66 in.*lbf Timing belt idler sub-assembly No. 2 x Cylinder block 35 352 25 Timing belt idler sub-assembly No. 1 x Cylinder block 35 352 25 Camshaft timing pulley x Camshaft 108 1,101 80 Chain tensioner assembly x Oil pump assembly 26 270 19 Timing belt No. 1 over x Cylinder block 7.5 76 66 in.*lbf Crankshaft damper x Crankshaft 245 2,498 181 Idler pulley sub-assembly No. 2 39 398 29 Oil filler cap housing x Cylinder head cover 7.5 76 66 in.*lbf Spark plug x Cylinder head 17.5 178 13 Connecting rod cap x Connecting rod Main bearing cap x Cylinder block 1st 25 250 18 2nd Turn 90° Turn 90° Turn 90° 1st 27 275 20 2nd Turn 90° Turn 90° Turn 90° Cylinder head cover x Cylinder head Drive plate & ring gear x Crankshaft 6.0 60 53 in.*lbf 1st 49 500 36 2nd Turn 90° Turn 90° Turn 90° 7.5 76 66 in.*lbf Camshaft drive gear x Camshaft timing tube assembly Camshaft timing tube assembly x Camshaft 78 795 58 Screw plug x Camshaft timing tube assembly 15 152 11 Timing belt plate RR x Cylinder head 7.5 76 66 in.*lbf SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Stud Bolt Normal Recess Bolt Weld Bolt Class Deep Recess Bolt No Mark No Mark No Mark 4T 5T w/ Washer w/ Washer 6T 7T 8T 9T 10T 11T SS SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SPECIFIED TORQUE FOR STANDARD BOLTS Class 4T SS 5T 6T 7T 8T 9T 10T 11T Diameter (mm) Pitch (mm) Specified torque N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf 8 1.25 12.5 130 9 14 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 Hexagon head bolt Hexagon flange bolt 16 1.5 115 1,150 83 - - - 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf 8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 36 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - - 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf 8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 16 1.5 170 1,750 127 - - - 6 1 10.5 110 8 12 120 9 8 1.25 25 260 19 28 290 21 10 1.25 52 530 38 58 590 43 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 1.5 230 2,300 166 - - - 8 1.25 29 300 22 33 330 24 10 1.25 61 620 45 68 690 50 12 1.25 110 1,100 80 120 1,250 90 8 1.25 34 340 25 37 380 27 10 1.25 70 710 51 78 790 57 12 1.25 125 1,300 94 140 1,450 105 8 1.25 38 390 28 42 430 31 10 1.25 78 800 58 88 890 64 12 1.25 140 1,450 105 155 1,600 116 8 1.25 42 430 31 47 480 35 10 1.25 87 890 64 97 990 72 12 1.25 155 1,600 116 175 1,800 130 SS–4 SERVICE SPECIFICATIONS – 1GR-FE ENGINE CONTROL SYSTEM 1GR-FE ENGINE CONTROL SYSTEM SERVICE DATA Throttle body Standard throttle valve opening angle 60% or more Accelerator pedal position sensor SS Voltage (ACCEL POS) Voltage (ACCEL POS#2) Camshaft timing oil control valve assembly Accelerator pedal released 0.5 to 1.1 V Accelerator pedal depressed 2.6 to 4.5 V Accelerator pedal released 1.2 to 2.0 V Accelerator pedal depressed 3.4 to 5.3 V VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled at 20°C (68°F) 6.9 to 7.9 Ω at 20°C (68°F) 0.3 to 100 Ω at 20°C (68°F) 120 to 280 kΩ at 20°C (68°F) 2.32 to 2.59 kΩ at 80°C (176°F) 0.310 to 0.326 kΩ 1-2 Continuity 3-5 No continuity 3-5 Continuity (Apply battery voltage terminal 1 and 2) 1-2 Continuity 3-5 No continuity 3-5 Continuity (Apply battery voltage terminal 1 and 2) Camshaft timing oil control valve assembly Resistance Throttle with Motor body assembly Resistance Knock sensor Resistance Engine coolant temperature sensor Resistance Circuit opening relay Specified condition EFI relay Specified condition SS–5 SERVICE SPECIFICATIONS – 1GR-FE ENGINE CONTROL SYSTEM TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Throttle with motor body assembly x Intake air surge tank 11 112 9 Air cleaner assembly x Cylinder head cover sub-assembly 8.0 82 71 in.*lbf Air cleaner assembly x Intake air surge tank 8.0 82 71 in.*lbf V-bank cover x Air cleaner assembly 7.5 76 66 in.*lbf V-bank cover x Intake air surge tank 7.5 76 66 in.*lbf Knock sensor x Cylinder block sub-assembly 20 204 15 Water outlet pipe No. 1 x Cylinder block sub-assembly 10 102 7 ECM x Body 13 133 10 Accelerator pedal rod assembly x Body 5.0 51 44 in.*lbf SS SERVICE SPECIFICATIONS – 2UZ-FE ENGINE CONTROL SYSTEM SS–5 2UZ-FE ENGINE CONTROL SYSTEM SERVICE DATA Throttle body Standard throttle valve opening percentage 60% or more Accelerator pedal released 0.5 to 1.1 V Accelerator pedal depressed 2.6 to 4.5 V Accelerator pedal released 1.2 to 2.0 V Accelerator pedal depressed 3.4 to 5.3 V at -20°C (-4°F) 12.5 to 16.9 kΩ at 20°C (68°F) 2.19 to 2.67 kΩ at 60°C (140°F) 0.50 to 0.68 kΩ at 20°C (68°F) 6.9 to 7.9 Ω Accelerator pedal position sensor Voltage (ACCEL POS) Voltage (ACCEL POS#2) Mass air flow meter Resistance Camshaft timing oil control valve assembly Resistance Throttle with motor body Resistance at 20°C (68°F) 0.3 to 100 Ω Knock control sensor at 20°C (68°F) 120 to 280 kΩ Approx. 20°C (68°F) 2.32 to 2.59 kΩ Approx. 80°C (176°F) 0.310 to 0.326 kΩ Engine coolant temperature sensor Resistance Circuit opening relay Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) EFI relay Specified condition SS SS–6 SERVICE SPECIFICATIONS – 2UZ-FE ENGINE CONTROL SYSTEM TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Throttle body assembly x Intake manifold 14 143 10 V-bank cover x Intake manifold 7.5 80 66 in.*lbf Knock sensor x Cylinder block assembly 20 204 15 Intake manifold x Cylinder head 18 185 13 V-bank cover bracket x Intake manifold 7.5 76 66 in.*lbf Wire bracket x Intake manifold 7.5 76 66 in.*lbf ECM x Body 13 133 10 Accelerator pedal rod assembly x Body 5.0 51 44 in.*lbf SS–6 SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL 1GR-FE ENGINE MECHANICAL SERVICE DATA Ignition timing Terminals TC and CG of DLC3 connected 10 +- 2° BTDC idle (Transmission in neutral) Terminals TC and CG of DLC3 disconnected 7 to 24° BTDC idle (Transmission in neutral) Idle speed SS Compression 700 +- 50 rpm (Transmission in neutral) Compression pressure 1.3 MPa (13.3 kgf/cm2, 189 psi) or more Minimum pressure 1.0 MPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder 0.1 MPa (1.0 kgf/cm2, 15 psi) or less Valve clearance Intake (cold) Exhaust 0.15 to 0.25 mm (0.006 to 0.010 in.) 0.29 to 0.39 mm (0.011 to 0.015 in.) Intake manifold Intake air surge tank side warpage Maximum Cylinder head side warpage 0.8 mm (0.031 in.) 0.2 mm (0.008 in.) Exhaust manifold Warpage Maximum 0.7 mm (0.028 in.) Camshaft timing gear assembly Diameter (with chain) Large gear 115.5 mm (4.547 in.) Small gear 73.1 mm (2.878 in.) Camshaft timing gear or sprocket Diameter (with chain) 73.1 mm (2.878 in.) Crankshaft timing gear or sprocket Diameter (with chain) 61.0 mm (2.402 in.) Idle gear No. 1 Diameter (with chain) 61.0 mm (2.402 in.) Cylinder head set bolt Outside diameter Standard 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum 10.7 mm (0.421 in.) Maximum 146.8 mm (5.780 in.) Maximum 146.8 mm (5.780 in.) Chain Elongation No. 2 chain Elongation Idle gear shaft Idle gear shaft diameter 22.987 to 23.000 mm (0.9050 to 0.9055 in.) Idle gear inside diameter 23.02 to 23.03 mm (0.9063 to 0.9067 in.) Oil clearance Standard 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum 0.093 mm (0.0037 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Maximum 1.0 mm (0.039 in.) Chain tensioner assembly No. 2 Worn depth Chain tensioner assembly No. 3 Worn depth Chain tensioner slipper Worn depth Chain vibration damper No. 1 Worn depth Chain vibration damper No. 2 Worn depth SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL SS–7 Cylinder head sub-assembly Warpage Maximum 0.10 mm (0.0039 in.) Intake valve Valve stem diameter 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Valve face angle Margin thickness Overall length 44.5° Standard 1.0 mm (0.039 in.) Minimum 0.5 mm (0.020 in.) Standard 106.95 mm (4.2106 in.) Minimum 106.40 mm (4.1890 in.) Exhaust valve Valve stem diameter 5.465 to 5.480 mm (0.2152 to 0.2158 in.) Valve face angle 44.5° Margin thickness Overall length Standard 1.0 mm (0.039 in.) Minimum 0.5 mm (0.020 in.) Standard 105.80 mm (4.1653 in.) Minimum 105.30 mm (4.1457 in.) Maximum 2.0 mm (0.079 in.) at 33.3 mm (1.311 in.) 186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) Inner compression spring Deviation Free length Tension 47.80 mm (1.8819 in.) Intake valve guide bush Inside diameter Oil clearance 5.51 to 5.53 mm (0.2169 to 0.2177 in.) Standard 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Maximum 0.08 mm (0.0031 in.) Bush bore diameter 10.295 to 10.315 mm (0.4053 to 0.4061 in.) Protrusion height 9.3 to 9.7 mm (0.366 to 0.382 in.) Exhaust valve guide bush Inside diameter Oil clearance 5.51 to 5.53 mm (0.2169 to 0.2177 in.) Standard 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum 0.10 mm (0.0039 in.) Bush bore diameter 10.295 to 10.315 mm (0.4053 to 0.4061 in.) Protrusion height 9.3 to 9.7 mm (0.366 to 0.382 in.) Valve lifter Diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.) Lifter bore diameter Oil clearance 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum 0.08 mm (0.0031 in.) No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.) No. 1 camshaft Journal diameter Circuit runout Cam lobe height Oil clearance Thrust clearance No. 2 camshaft Maximum 0.06 mm (0.0024 in.) Standard 44.168 to 44.268 mm (1.7389 to 1.7428 in.) Minimum 44.018 mm (1.7330 in.) Standard No. 1 journal 0.008 to 0.038 mm (0.0003 to 0.0015 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum No. 1 journal 0.07 mm (0.0028 in.) Other journals 0.10 mm (0.0039 in.) Standard 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum 0.11 mm (0.0043 in.) SS SS–8 SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL Journal diameter Circuit runout Cam lobe height Oil clearance SS Thrust clearance No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.) Maximum 0.06 mm (0.0024 in.) Standard 44.580 to 44.680 mm (1.7551 to 1.7591 in.) Minimum 44.430 mm (1.7492 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum 0.10 mm (0.0039 in.) Standard 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum 0.11 mm (0.0043 in.) No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.) Maximum 0.06 mm (0.0024 in.) No. 3 camshaft sub-assembly Journal diameter Circuit runout Cam lobe height Oil clearance Thrust clearance Standard 44.168 to 44.268 mm (1.7389 to 1.7428 in.) Minimum 44.018 mm (1.7330 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum 0.10 mm (0.0039 in.) Standard 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum 0.11 mm (0.0043 in.) No. 4 camshaft sub-assembly Journal diameter Circuit runout Cam lobe height Oil clearance Thrust clearance No. 1 journal 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journals 22.959 to 22.975 mm (0.9039 to 0.9045 in.) Maximum 0.06 mm (0.0024 in.) Standard 44.580 to 44.680 mm (1.7551 to 1.7591 in.) Minimum 44.430 mm (1.7492 in.) Standard No. 1 journal 0.040 to 0.079 mm (0.0016 to 0.0031 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum 0.10 mm (0.0039 in.) Standard 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum 0.11 mm (0.0043 in.) Ring pin for cylinder head sub-assembly and cylinder head LH Protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) Straight pin for cylinder head sub-assembly and cylinder head LH A Protrusion height 17.5 to 19.5 mm (0.689 to 0.768 in.) B 7.5 to 8.5 mm (0.295 to 0.335 in.) C 7.0 to 9.0 mm (0.276 to 0.354 in.) Tight plug for cylinder head sub-assembly and cylinder head LH Depth Connecting rod thrust clearance Connecting rod oil clearance Crankshaft thrust clearance Cylinder block warpage Cylinder bore diameter Piston diameter 1.5 mm (0.059 in.) Standard 0.15 to 0.30 mm (0.0059 to 0.0118 in.) Maximum 0.35 mm (0.0138 in.) Standard 0.026 to 0.046 mm (0.0010 to 0.0018 in.) Maximum 0.066 mm (0.0025 in.) Standard 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum 0.30 mm (0.0118 in.) Maximum 0.05 mm (0.0020 in.) Standard 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum 94.132 mm (3.7060 in.) 93.910 to 93.920 mm (3.6972 to 3.6976 in.) SERVICE SPECIFICATIONS – 1GR-FE ENGINE MECHANICAL Standard 0.080 to 0.102 mm (0.0031 to 0.0040 in.) Maximum 0.13 mm (0.0051 in.) Connecting rod out-of-alignment Maximum 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Connecting rod twist Maximum 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) Oil clearance Connecting rod bushing inside diameter 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Piston pin diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Oil clearance Piston ring groove clearance Piston ring end gap Connecting rod bolt diameter Standard 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum 0.050 mm (0.0020 in.) No. 1 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil 0.07 to 0.15 mm (0.0028 to 0.0060 in.) Standard No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.) No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.) Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum No. 1 1.0 mm (0.039 in.) No. 2 1.1 mm (0.043 in.) Oil (Side rail) 1.0 mm (0.039 in.) Standard 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum 7.0 mm (0.276 in.) Crankshaft bearing cap set bolt diameter Standard 10.0 to 10.2 mm (0.393 to 0.402 in.) Crankshaft circle runout Maximum 0.06 mm (0.0024 in.) Main journal diameter Main journal taper and out-of-round 71.988 to 72.000 mm (2.8342 to 2.8346 in.) Maximum Crank pin diameter Crank pin taper and out-of-round Crankshaft oil clearance 0.02 mm (0.0008 in.) 55.992 to 56.000 mm (2.2044 to 2.2047 in.) Maximum 0.02 mm (0.0008 in.) Standard 0.018 to 0.030 mm (0.0007 to 0.0012 in.) Maximum 0.046 mm (0.0018 in.) SS–9 SS SS–12 SERVICE SPECIFICATIONS – 2UZ-FE ENGINE MECHANICAL 2UZ-FE ENGINE MECHANICAL SERVICE DATA Ignition timing Terminals TC and CG of DLC3 connected Idle speed SS Compression 5 to 15° BTDC at idle (Transmission in neutral) 650 to 750 r/min Compression pressure 1,373 kPa (14.0 kgf/cm2, 199 psi) or more Minimum pressure 1,030 kPa (10.5 kgf/cm2, 149 psi) Difference between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) Valve clearance Intake (cold) 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust (cold) 0.25 to 0.35 mm (0.010 to 0.014 in.) Maximum 0.10 mm (0.039 in.) Cylinder head Warpage Valve seat Refacing angle 30°, 45°, 60° Contacting angle 45° Contacting width 1.0 to 1.4 mm (0.039 to 0.055 in.) Valve guide bushing bore diameter Cylinder head seat bolt thread inside diameter Protrusion height STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) STD 9.810 to 9.960 mm (0.3862 to 0.3921 in.) Minimum 9.70 mm (0.3819 in.) Intake 9.2 to 9.8 mm (0.362 to 0.386 in.) Exhaust 8.2 to 8.8 mm (0.323 to 0.346 in.) Valve guide bushing Inside diameter Outside diameter (for repair part) 5.510 to 5.530 mm (0.2169 to 0.2177 in.) STD 10.285 to 10.306 mm (0.4049 to 0.4057 in.) O/S 0.05 10.335 to 10.356 mm (0.4069 to 0.4077 in.) STD Intake 95.05 mm (3.7421 in.) Valve Valve overall length Exhaust 95.10 mm (3.7441 in.) Minimum Intake 94.55 mm (3.7224 in.) Exhaust 94.60 mm (3.7244 in.) Valve face angle Stem diameter Stem oil clearance Margin thickness 44.5° Intake 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Exhaust 5.465 to 5.480 mm (0.2152 to 0.2157 in.) STD Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD IN 1.25 mm (0.049 in.) EX 1.4 mm (0.055 in.) Minimum 0.5 mm (0.020 in.) Maximum 2.0 mm (0.079 in.) Valve spring Deviation Free length 54.1 mm (2.130 in.) Installed tension at 35.0 mm (1.378 in.) 210 to 226 N (21.4 to 23.0 kgf*cm, 47.2 to 50.7 lbf) Valve lifter Lifter diameter 30.968 to 30.976 mm (1.2192 to 1.2195 in.) SERVICE SPECIFICATIONS – 2UZ-FE ENGINE MECHANICAL Lifter bore diameter Oil clearance SS–13 31.000 to 31.016 mm (1.2205 to 1.2211 in.) STD 0.024 to 0.050 mm (0.0009 to 0.0020 in.) Maximum 0.07 mm (0.0028 in.) STD Intake 0 to 0.040 mm (0 to 0.0016 in.) Exhaust 0.030 to 0.070 mm (0.0012 to 0.0028 in.) Minimum Intake 0.12 mm (0.0047 in.) Exhaust 0.10 mm (0.0039 in.) Camshaft Thrust clearance Journal oil diameter STD 0.030 to 0.071 mm (0.012 to 0.0028 in.) Maximum 0.10 mm (0.0039 in.) Maximum 0.08 mm (0.0031 in.) STD Intake 41.94 to 42.04 mm (1.6512 to 1.6551 in.) Exhaust 41.96 to 42.06 mm (1.6520 to 1.6559 in.) Minimum Intake 41.79 mm (1.6453 in.) Exhaust 41.81 mm (1.6461 in.) Journal diameter Circuit runout Cam lobe height Camshaft gear backlash 26.954 to 26.970 mm (1.0612 to 1.0618 in.) STD 0.020 to 0.200 mm (0.0008 to 0.0079 in.) Maximum 0.30 mm (0.0118 in.) Camshaft gear bolt washer end free distance 18.2 to 18.8 mm (0.717 to 0.740 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Main bearing cap bolt tension portion diameter Maximum 0.07 mm (0.0028 in.) STD Mark 1 94.002 to 94.010 mm (3.7009 to 3.7012 in.) Mark 2 94.010 to 94.023 mm (3.7012 to 3.7017 in.) Mark 3 94.023 to 94.031 mm (3.7017 to 3.7020 in.) Maximum STD 94.231 mm (3.7099 in.) O/S 0.5 94.731 mm (3.7296 in.) STD 10.760 to 10.970 mm (0.4236 to 0.4319 in.) Minimum 10.40 mm (0.4094 in.) STD Mark 1 93.902 to 93.912 mm (3.6969 to 3.6973 in.) Mark 2 93.912 to 93.920 mm (3.6973 to 3.6976 in.) Mark 3 93.920 to 93.930 mm (3.6976 to 3.6980 in.) Piston and piston ring Piston diameter Piston oil clearance Piston ring groove clearance Piston ring end gap O/S 0.5 94.402 to 94.430 mm (3.7168 to 3.7177 in.) STD 0.090 to 0.111 mm (0.0035 to 0.0044 in.) Maximum 0.13 mm (0.0051 in.) No. 1 0.030 to 0.080 mm (0.0012 to 0.0032 in.) No. 2 0.020 to 0.060 mm (0.0008 to 0.0024 in.) No. 1 0.300 to 0.400 mm (0.0118 to 0.0158 in.) No. 2 0.400 to 0.550 mm (0.0158 to 0.0217 in.) Oil 0.130 to 0.380 mm (0.0051 to 0.0150 in.) Maximum No. 1 1.10 mm (0.0433 in.) No. 2 1.30 mm (0.0512 in.) Oil 0.90 mm (0.0354 in.) Camshaft timing tube assembly Journal oil diameter STD 0.036 to 0.057 mm (0.0014 to 0.0022 in.) Maximum 0.075 mm (0.0030 in.) STD 0.160 to 0.290 mm (0.0063 to 0.0114 in.) Maximum 0.35 mm (0.0138 in.) Connecting rod Thrust clearance Connecting rod thickness 22.880 to 22.920 mm (0.9008 to 0.9024 in.) SS SS–14 SERVICE SPECIFICATIONS – 2UZ-FE ENGINE MECHANICAL Connecting rod oil clearance Connecting rod bearing center wall thickness SS STD 0.021 to 0.047 mm (0.0008 to 0.0019 in.) Maximum 0.065 mm (0.0026 in.) Mark 2 1.487 to 1.490 mm (0.0585 to 0.0587 in.) Mark 3 1.490 to 1.493 mm (0.0587 to 0.0588 in.) Mark 4 1.493 to 1.496 mm (0.0588 to 0.0589 in.) Mark 5 1.496 to 1.499 mm (0.0589 to 0.0590 in.) Mark 6 1.499 to 1.502 mm (0.0590 to 0.0591 in.) Mark 7 1.502 to 1.505 mm (0.0591 to 0.0593 in.) Rod bend Maximum per 100 mm (3.94 in.) 0.05 mm (0.0020 in.) Rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.) Bushing inside diameter 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Piston pin diameter 21.997 to 22.006 mm (0.8660 to 0.8664 in.) Bushing oil clearance Connecting rod bolt tension portion diameter STD 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum 0.05 mm (0.0020 in.) STD 7.200 to 7.300 mm (0.2835 to 0.2874 in.) Maximum 7.00 mm (0.2756 in.) STD 0.020 to 0.220 mm (0.0008 to 0.0087 in.) Maximum 0.30 mm (0.0118 in.) STD 2.440 to 2.490 mm (0.0961 to 0.0980 in.) Crankshaft Thrust clearance Thrust washer thickness U/S 0.125 Main journal bore diameter on cylinder block Main journal oil clearance No. 1 and No. 5 STD 0.028 to 0.046 mm (0.0011 to 0.0018 in.) Others STD 0.040 to 0.058 mm (0.0016 to 0.0023 in.) No. 1 and No. 5 Maximum 0.065 mm (0.0026 in.) Others Maximum 0.065 mm (0.0026 in.) Main journal diameter Main bearing center wall thickness 2.503 to 2.553 mm (0.0985 to 0.1005 in.) 72.000 to 72.016 mm (2.8347 to 2.8353 in.) 66.988 to 67.000 mm (2.6373 to 2.6378 in.) No. 1 and No. 5 Mark 3 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark 4 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark 5 2.493 to 2.496 mm (0.0982 to 0.0983 in.) Mark 6 2.496 to 2.499 mm (0.0983 to 0.0984 in.) Mark 7 2.499 to 2.502 mm (0.0984 to 0.0985 in.) Other Mark 1 2.481 to 2.484 mm (0.0977 to 0.0978 in.) Mark 2 2.484 to 2.487 mm (0.0978 to 0.0979 in.) Mark 3 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark 4 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark 5 Crank pin diameter 2.493 to 2.496 mm (0.0981 to 0.0983 in.) 51.982 to 52.000 mm (2.0465 to 2.0472 in.) Circle runout Maximum 0.04 mm (0.0016 in.) Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.) SERVICE SPECIFICATIONS – 1GR-FE FUEL SS–17 1GR-FE FUEL SERVICE DATA Fuel pressure 281 to 287 kPa (2.87 to 2.93 kgf/cm2, 40.8 to 41.7 psi) Fuel pressure 147 kPa (1.5 kgf/cm2, 21 psi) or more Fuel injector Resistance at 20°C (68°F) 11.6 to 12.4 Ω Injection volume 76 to 91 cm2 (4.6 to 5.5 cu in.) per 15 seconds Difference between each cylinder 15 cm3 (0.9 cu in.) or less Fuel leakage 1 drop or less per 12 minutes Fuel pump resister Resistance at 20°C (68°F) 0.70 to 0.76 Ω at 20°C (68°F) 0.2 to 3.0 Ω 1-2 Continuity 3-4 Continuity 3-5 No continuity Fuel Pump Resistance Fuel pump relay assembly Specified condition SS SS–18 SERVICE SPECIFICATIONS – 1GR-FE FUEL TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Fuel delivery pipe sub-assembly x Intake manifold 15 153 11 Intake air surge tank x Intake manifold 28 286 21 Intake air surge tank x Throttle body bracket 21 214 16 Intake air surge tank x Surge tank stay No. 1 21 214 16 Intake air surge tank x Surge tank stay No. 2 21 214 16 Fuel pressure regulator assembly x Fuel delivery pipe sub-assembly 9.0 92 80 in.*lbf Fuel tank x Body 40 408 30 Fuel tank protector sub-assembly No. 1 x Body 20 204 15 SS–18 SERVICE SPECIFICATIONS – 2UZ-FE FUEL 2UZ-FE FUEL SERVICE DATA Fuel pressure 265 to 304 kPa (2.7 to 3.1 kgf/cm2, 38 to 44 psi) Fuel pressure 147 kPa (1.5 kgf/cm2, 21 psi) or more Fuel injector Resistance SS at 20°C (68°F) 13.4 to 14.2 Ω Injection volume 56 to 69 cm2 (3.4 to 4.2 cu in.) per 15 seconds Difference between each cylinder 13 cm3 (0.8 cu in.) or less Fuel leakage 1 drop or less per 12 minutes Fuel pump resister Resistance at 20°C (68°F) 0.70 to 0.76 Ω Fuel suction with pump & gage tube assembly Resistance at 20°C (68°F) 0.2 to 3.0 Ω 1-2 Continuity 3-4 Continuity 3-5 No continuity Fuel pump relay assembly Specified condition SS–19 SERVICE SPECIFICATIONS – 2UZ-FE FUEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Delivery pipe x Intake manifold 21 214 16 Delivery pipe No. 2 x Intake manifold 21 214 16 Fuel hose x Delivery pipe 39 400 29 Vacuum switching valve assembly No. 1 x Intake manifold 18 185 13 Fuel pipe sub-assembly No. 3 x Intake manifold 7.5 80 66 in.*lbf Fuel pipe sub-assembly No. 1 x Delivery pipe 39 400 29 Throttle body cover sub-assembly x Intake manifold 7.5 80 66 in.*lbf Fuel tank x Body 40 408 30 Fuel tank protector sub-assembly No. 1 x Body 20 204 15 SS SERVICE SPECIFICATIONS – 1GR-FE EMISSION CONTROL SS–19 1GR-FE EMISSION CONTROL SERVICE DATA VSV for charcoal canister at 20°C (68°F) 25 to 30 Ω at 100°C (212°F) 32 to 42 Ω at 20°C (68°F) 26 to 30 Ω Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) Resistance 1 (HT) - 4 (AF-) No continuity Resistance Vacuum switching valve assembly No. 1 Resistance Air fuel ratio sensor (Bank 1, Bank 2) Heated oxygen sensor No. 2 (Bank 1, Bank 2) Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Resistance 1 (HT) - 4 (E1) No continuity Power source voltage VC - E2 4.5 to 5.5 V Power output voltage PTNK - E2 3.0 to 3.6 V Vapor pressure sensor SS SS–20 SERVICE SPECIFICATIONS – 1GR-FE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Charcoal canister x Body 20 204 15 Charcoal canister filter No. 2 x Body 20 204 15 SS–20 SERVICE SPECIFICATIONS – 2UZ-FE EMISSION CONTROL 2UZ-FE EMISSION CONTROL SERVICE DATA VSV for charcoal canister Resistance at 20°C (68°F) 25 to 30 Ω at 100°C (212°F) 32 to 42 Ω at 20°C (68°F) 26 to 30 Ω VSV for EVAP SS Resistance Heated oxygen sensor Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Resistance 1 (HT) - 4 (E1) No continuity Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Resistance 1 (HT) - 4 (E1) No continuity Heated oxygen sensor No. 2 (Bank 1) Heated oxygen sensor No. 2 (Bank 2) Resistance 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) Resistance 1 (HT) - 4 (E1) No continuity AIP-E2 1.0 to 2.2 V 1-2 33 to 39 Ω at 20°C (68°F) Pressure sensor Voltage Vacuum switching valve assembly Resistance 1-Body ground 10 MΩ or higher 2-Body ground 10 MΩ or higher SS–21 SERVICE SPECIFICATIONS – 2UZ-FE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Charcoal canister x Body 20 204 15 Charcoal canister filter No. 2 x Body 20 204 15 Air pump assembly x Air pump bracket 10 102 7 Air pump assembly with bracket x Cylinder block assembly 16 163 12 Air switching valve assembly x Air pump bracket 16 163 12 Pressure sensor x Air pump bracket 5.0 51 44 in.*lbf Air switching valve assembly No. 2 x water by-pass joint rear 10 102 7 Air tube No. 3 x Air switching valve assembly No. 2 10 102 7 Air tube No. 3 x Exhaust manifold 10 102 7 Air tube No. 2 x Air switching valve assembly No. 2 10 102 7 Air tube No. 2 x Exhaust manifold 10 102 7 SS SERVICE SPECIFICATIONS – 1GR-FE INTAKE SS–21 1GR-FE INTAKE SERVICE DATA VSV for ACIS Resistance at 20°C (68°F) 33 to 39 Ω SS SS–22 SERVICE SPECIFICATIONS – 2UZ-FE INTAKE 2UZ-FE INTAKE SERVICE DATA Vacuum switching valve assembly for IAC valve Resistance SS Between each terminal 33 to 39 Ω at 20°C (68°F) Between each terminal-Body ground 10 MΩ or higher SS–23 SERVICE SPECIFICATIONS – 1GR-FE EXHAUST 1GR-FE EXHAUST TORQUE SPECIFICATIONS N*m kgf*cm ft.*lbf Exhaust pipe assembly front x Exhaust manifold Part Tightened 62 630 46 Exhaust front pipe assembly No. 2 x Exhaust pipe assembly center (Bolt) 48 490 35 Exhaust front pipe assembly No. 2 x Exhaust pipe assembly center (Nut) 62 630 46 Exhaust pipe assembly center x Tail pipe 48 490 35 Heated oxygen sensor x Exhaust pipe assembly front 44 450 33 Heated oxygen sensor x Exhaust front pipe assembly No. 2 44 450 33 SS SS–24 SERVICE SPECIFICATIONS – 2UZ-FE EXHAUST 2UZ-FE EXHAUST TORQUE SPECIFICATIONS Part Tightened Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe SS N*m kgf*cm ft.*lbf 62 633 46 Bolt 48 489 35 Nut 62 633 46 Center exhaust pipe x Tail pipe 48 489 35 Heated oxygen sensor x Front exhaust pipe 44 450 30 SERVICE SPECIFICATIONS – 1GR-FE COOLING SS–25 1GR-FE COOLING SERVICE DATA Water inlet with thermostat Valve opening temperature Valve lift 80 to 84°C (176 to 183°F) at 95°C (203°F) 8 mm (0.31 in.) or more Radiator cap Relief valve opening pressure Standard 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi) Minimum 78 kPa (0.8 kgf/cm2, 11.4 psi) SS SS–26 SERVICE SPECIFICATIONS – 1GR-FE COOLING TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Cylinder block water drain cock plug x Cylinder block water drain cock 13 130 9 Water pump assembly x Timing chain or belt cover sub-assembly (10 mm (0.39 in.) head) 9.0 92 80 in.*lbf Water pump assembly x Timing chain or belt cover sub-assembly (12 mm (0.47 in.) head) 23 235 17 Idler pulley sub-assembly No. 2 x Timing chain or belt cover subassembly 39 398 29 Water inlet x Timing chain or belt cover sub-assembly 9.0 92 80 in.*lbf Fan shroud x Radiator 5.0 51 44 in.*lbf Fan with fluid coupling x Water pump 21 214 15 V-bank cover x Intake air surge tank 7.5 76 66 in.*lbf Engine under cover sub-assembly No. 1 x Frame assembly 29 296 21 Water inlet with thermostat x Water inlet 9.0 92 80 in.*lbf Radiator x Radiator support 18 184 13 SS–26 SERVICE SPECIFICATIONS – 2UZ-FE COOLING 2UZ-FE COOLING SERVICE DATA Thermostat Valve opening temperature Valve lift 80 to 84°C (176 to 183°F) at 95°C (203°F) 10 mm (0.39 in.) or more Radiator cap SS Relief valve opening pressure Standard 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi) Minimum 78 kPa (0.8 kgf/cm2, 11.4 psi) SS–27 SERVICE SPECIFICATIONS – 2UZ-FE COOLING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm Drain plug x Union on cylinder block 13 130 9 Fan x Fluid coupling 5.5 55 47 in.*lbf Water pump x Cylinder block ft.*lbf Bolt 21 215 16 Stud bolt and nut 18 185 13 Water inlet housing x Water pump 18 185 13 Water inlet x Water inlet housing 19 195 14 Radiator x Radiator support 18 184 13 Fan shroud x Radiator 5.0 51 44 in.*lbf Radiator reserve tank x Fan shroud 5.0 51 44 in.*lbf SS SERVICE SPECIFICATIONS – 1GR-FE LUBRICATION SS–27 1GR-FE LUBRICATION SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf/cm2, 4.2 psi) or more at 3,000 rpm 294 to 588 kPa (3.0 to 6.0 kgf/cm2, 43 to 85 psi) Oil pump Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0.06 to 0.16 mm (0.0024 to 0.0063 in.) 0.16 mm (0.0063 in.) 0.03 to 0.09 mm (0.0012 to 0.0035 in.) 0.09 mm (0.0035 in.) 0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.) SS SS–28 SERVICE SPECIFICATIONS – 1GR-FE LUBRICATION TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Oil pressure switch x Oil filter bracket sub-assembly 15 152 11 Oil pan drain plug x Oil pan sub-assembly No. 2 40 408 30 Timing chain cover sub-assembly x Cylinder head and block 23 235 17 Oil filter bracket sub-assembly x Timing chain cover sub-assembly 19 194 14 Camshaft timing oil control valve assembly x Timing chain cover subassembly 9.0 92 80 in.*lbf Ignition coil assembly x Cylinder head cover sub-assembly 10 102 7 V-bank cover x Intake air surge tank 7.5 76 66 in.*lbf Oil pump relief valve x Oil pump cover 49 500 36 Oil pump cover x Timing chain or belt cover sub-assembly 9.0 92 80 in.*lbf Oil pipe x Timing chain or belt cover and oil pump cover 9.0 92 80 in.*lbf Oil cooler assembly x Oil filter bracket sub-assembly 68 693 50 SS–28 SERVICE SPECIFICATIONS – 2UZ-FE LUBRICATION 2UZ-FE LUBRICATION SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf/cm2, 4.2 psi) or more at 3,000 rpm 294 to 588 kPa (3.0 to 6.0 kgf/cm2, 43 to 85 psi) Oil pump SS Tip clearance Standard Maximum Side clearance Standard Maximum Body clearance Standard Maximum 0.060 to 0.180 mm (0.0024 to 0.0071 in.) 0.18 mm (0.0071 in.) 0.030 to 0.090 mm (0.0012 to 0.0035 in.) 0.09 mm (0.0035 in.) 0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.325 mm (0.0128 in.) SS–29 SERVICE SPECIFICATIONS – 2UZ-FE LUBRICATION TORQUE SPECIFICATIONS Part Tightened No. 2 oil pan x Drain plug Oil pump x Cylinder block 14 mm head Others N*m kgf*cm ft.*lbf 39 398 29 31 311 23 16 160 11 Oil pump body cover x Oil pump body 10 105 7 Oil pump relief valve x Oil pump body 49 500 36 Oil cooler x Oil filter bracket 69 700 51 SS SERVICE SPECIFICATIONS – 1GR-FE IGNITION SS–29 1GR-FE IGNITION SERVICE DATA Spark plug Recommended spark plug DENSO made NGK made K20HR-U11 LFR6C-11 Electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum electrode gap 1.41 mm (0.056 in.) VVT sensor Voltage VVT+ - VVT1- 3.375 to 4.950V (Hi), 0.450 to 1.375V (Lo) VVT2+ - VVT2- 3.375 to 4.950V (Hi), 0.450 to 1.375V (Lo) Crankshaft position sensor Resistance at Cold 1,630 to 2,740 Ω at Hot 2,065 to 3,225 Ω SS SS–30 SERVICE SPECIFICATIONS – 1GR-FE IGNITION TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Spark plug x Cylinder head 20 204 14 Ignition coil x Cylinder head cover 10 102 7 VVT sensor x Timing chain cover sub-assembly 8.0 82 71 in.*lbf V-bank cover x Intake air surge tank sub-assembly and Air cleaner assembly 7.5 76 66 in.*lbf Crankshaft position sensor x Cylinder block 10 102 7 V-ribbed belt tensioner and Cooler compressor assembly 25 255 18 Engine under cover assembly rear x Frame assembly 29 296 21 SS–30 SERVICE SPECIFICATIONS – 2UZ-FE IGNITION 2UZ-FE IGNITION SERVICE DATA Spark plug Recommended spark plug DENSO made NGK made SS SK20R11 1FR6A11 Electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum electrode gap 1.3 mm (0.051 in.) Correct insulation resistance 10 MΩ or more VVT sensor Resistance at Cold 835 to 1,400 Ω at Hot 1,060 to 1,645 Ω at Cold 1,630 to 2,740 Ω at Hot 2,065 to 3,225 Ω Crankshaft position sensor Resistance SS–31 SERVICE SPECIFICATIONS – 2UZ-FE IGNITION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Spark plug x Cylinder head 20 204 15 Ignition coil (with igniter) x Cylinder head cover 7.5 76 66 in.*lbf Camshaft position sensor x LH cylinder head 7.5 80 66 in.*lbf Crankshaft position sensor x Oil pump 6.5 65 58 in.*lbf SS SS–39 SERVICE SPECIFICATIONS – A750E AUTOMATIC TRANSMISSION TORQUE SPECIFICATIONS 2UZ-FE: Part Tightened Park/neutral position switch Bolt Nut Transmission control cable x Automatic transmission Engine mounting insulator rear No. 1 x Automatic transmission N*m kgf*cm ft.*lbf 13 130 9 7 71 62 in.*lbf 12 122 9 65 663 48 17 mm head 71 720 53 14 mm head 37 380 27 48 490 35 Flywheel housing under cover x Automatic transmission 18 184 13 Oil cooler tube clamp 5.0 50 43 in.*lbf Automatic transmission x Engine Torque converter clutch x Drive plate Oil cooler outlet tube No. 1 x Automatic transmission 34 346 25 Oil cooler inlet tube No. 1 x Automatic transmission 34 346 25 Oil filler tube 12 122 9 Exhaust pipe x Exhaust manifold 62 630 46 Exhaust pipe x Exhaust pipe 48 490 35 Front suspension member bracket LH x Body 33 336 24 Front suspension member bracket x Body 33 336 24 Speed sensor x Automatic transmission 5.4 55 48 in.*lbf Drain plug x Oil pan 20 204 15 Transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf A 10 100 7 B 11 110 8 Oil strainer x Valve body 10 100 7 Oil pan x Transmission case 4.4 45 39 in.*lbf Shift solenoid valve S1 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve S2 x Valve body 10 100 7 Transmission wire clamp x Valve body Shift solenoid valve SR x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLU, SL2 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLT, SL1 x Valve body 6.4 65 56 in.*lbf Valve body x Transmission case 11 110 8 Transmission flange x Output shaft 126 1,280 92 Floor shift assembly x Body 12 122 9 Overflow plug x Automatic transmission 20 204 15 Refill plug x Automatic transmission 39 400 29 Frame crossmember sub-assembly No. 3 Bolt & Nut 72 734 53 Bolt 18 184 13 1GR-FE: Part Tightened Park/neutral position switch N*m kgf*cm ft.*lbf Bolt 13 130 9 Nut 6.9 70 61 in.*lbf 14 143 10 Transmission control cable x Automatic transmission Engine mounting insulator rear No. 1 x Automatic transmission Automatic transmission x Engine Torque converter clutch x Drive plate 65 663 48 17 mm head 71 720 53 14 mm head 37 380 27 48 490 35 SS SS–40 SERVICE SPECIFICATIONS – A750E AUTOMATIC TRANSMISSION Part Tightened Engine rear mounting member x Body Nut Bolt Transmission control cable bracket No. 1 x Automatic transmission SS N*m kgf*cm ft.*lbf 72 735 53 18 184 13 14 143 10 Oil cooler tube clamp 5 51 43 in.*lbf Oil cooler outlet tube No. 1 x Automatic transmission 34 346 25 Oil cooler inlet tube No. 1 x Automatic transmission 34 346 25 Exhaust pipe x Exhaust manifold 62 630 46 Exhaust pipe x Exhaust pipe 48 490 35 Front suspension member bracket LH x Body 33 336 24 Front suspension member bracket x Body 33 336 24 Speed sensor x Automatic transmission 5.4 55 48 in.*lbf Drain plug x Oil pan 28 285 21 Transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf Transmission wire clamp x Valve body A 11 110 8 B 10 100 7 Oil strainer x Valve body 10 100 7 Oil pan x Transmission case 4.4 45 39 in.*lbf Shift solenoid valve S1 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve S2 x Valve body 10 100 7 Shift solenoid valve SR x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLU, SL2 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLT, SL1 x Valve body 6.4 65 56 in.*lbf Valve body x Transmission case 11 110 8 Floor shift assembly x Body 14 143 10 Overflow plug x Automatic transmission 20 204 15 Refill plug x Automatic transmission 39 400 29 Wire harness x Automatic transmission 8.0 83 71 in.*lbf Propeller shaft heat insulator x Frame crossmember 33 336 24 Oil cooler assembly x Body 5.0 51 44 in.*lbf Transmission control cable assembly x Body 5.5 56 49 in.*lbf SS–43 SERVICE SPECIFICATIONS – A750F AUTOMATIC TRANSMISSION TORQUE SPECIFICATIONS 2UZ-FE: Part Tightened Park/neutral position switch Bolt Nut Transmission control cable x Automatic transmission Engine mounting insulator rear No. 1 x Automatic transmission N*m kgf*cm ft.*lbf 13 130 9 7 71 62 in.*lbf 12 122 9 65 663 48 17 mm head 71 720 53 14 mm head 37 380 27 48 490 35 Flywheel housing under cover x Automatic transmission 18 184 13 Oil cooler tube clamp 5.0 50 43 in.*lbf Automatic transmission x Engine Torque converter clutch x Drive plate Oil cooler outlet tube No. 1 x Automatic transmission 34 346 25 Oil cooler inlet tube No. 1 x Automatic transmission 34 346 25 Oil filler tube 12 122 9 Exhaust pipe x Exhaust manifold 62 630 46 Exhaust pipe x Exhaust pipe 48 490 35 Front suspension member bracket LH x Body 33 336 24 Front suspension member bracket x Body 33 336 24 Speed sensor x Automatic transmission 5.4 55 48 in.*lbf Drain plug x Oil pan 20 204 15 Transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf A 10 100 7 B 11 110 8 Oil strainer x Valve body 10 100 7 Oil pan x Transmission case 4.4 45 39 in.*lbf Shift solenoid valve S1 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve S2 x Valve body 10 100 7 Transmission wire clamp x Valve body Shift solenoid valve SR x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLU, SL2 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLT, SL1 x Valve body 6.4 65 56 in.*lbf Valve body x Transmission case 11 110 8 Transmission flange x Output shaft 126 1,280 92 Floor shift assembly x Body 12 122 9 Overflow plug x Automatic transmission 20 204 15 Refill plug x Automatic transmission 39 400 29 Frame crossmember sub-assembly No. 3 Bolt & Nut 72 734 53 Bolt 18 184 13 1GR-FE: Part Tightened Park/neutral position switch N*m kgf*cm ft.*lbf Bolt 13 130 9 Nut 6.9 70 61 in.*lbf 14 143 10 Transmission control cable x Automatic transmission Engine mounting insulator rear No. 1 x Automatic transmission Automatic transmission x Engine Torque converter clutch x Drive plate 65 663 48 17 mm head 71 720 53 14 mm head 37 380 27 48 490 35 SS SS–44 SERVICE SPECIFICATIONS – A750F AUTOMATIC TRANSMISSION Part Tightened Engine rear mounting member x Body Nut Bolt Transmission control cable bracket No. 1 x Automatic transmission SS N*m kgf*cm ft.*lbf 72 735 53 18 184 13 14 143 10 Oil cooler tube clamp 5 51 43 in.*lbf Oil cooler outlet tube No. 1 x Automatic transmission 34 346 25 Oil cooler inlet tube No. 1 x Automatic transmission 34 346 25 Exhaust pipe x Exhaust manifold 62 630 46 Exhaust pipe x Exhaust pipe 48 490 35 Front suspension member bracket LH x Body 33 336 24 Front suspension member bracket x Body 33 336 24 Speed sensor x Automatic transmission 5.4 55 48 in.*lbf Drain plug x Oil pan 28 285 21 Transmission wire set bolt x Automatic transmission 5.4 55 48 in.*lbf Transmission wire clamp x Valve body A 11 110 8 B 10 100 7 Oil strainer x Valve body 10 100 7 Oil pan x Transmission case 4.4 45 39 in.*lbf Shift solenoid valve S1 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve S2 x Valve body 10 100 7 Shift solenoid valve SR x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLU, SL2 x Valve body 6.4 65 56 in.*lbf Shift solenoid valve SLT, SL1 x Valve body 6.4 65 56 in.*lbf Valve body x Transmission case 11 110 8 Floor shift assembly x Body 14 143 10 Overflow plug x Automatic transmission 20 204 15 Refill plug x Automatic transmission 39 400 29 Wire harness x Automatic transmission 8.0 83 71 in.*lbf Propeller shaft heat insulator x Frame crossmember 33 336 24 Oil cooler assembly x Body 5.0 51 44 in.*lbf Transmission control cable assembly x Body 5.5 56 49 in.*lbf SERVICE SPECIFICATIONS – 1GR-FE STARTING SS–31 1GR-FE STARTING SERVICE DATA Starter (1.6 kW type) Rated voltage and output power No-load characteristics 12 V 1.6 kW Current 90 A or less at 11.5 V Starter armature assembly Commutator length Standard 3.1 mm (0.122 in.) Minimum 3.8 mm (0.150 in.) Standard 9.0 mm (0.354 in.) Minimum 4.0 mm (0.158 in.) Maximum 5.0 mm (0.197 in.) Starter commutator end frame assembly Brush holder length Starter armature assembly Snap ring length Starter (2.0 kW type) Rated voltage and output power No-load characteristics 12 V 2.0 kW Current 100 A or less at 11.5 V Starter armature assembly Circle runout Commutator diameter Undercut depth Maximum 0.05 mm (0.0020 in.) Standard 35.0 mm (1.378 in.) Minimum 34.0 mm (1.339 in.) Standard 0.7 mm (0.028 in.) Minimum 0.2 mm (0.008 in.) Starter yoke Shunt coil resistance at 20°C (68°F) 1.5 to 1.9 Ω Brush Brush length Standard 15.0 mm (0.591 in.) Minimum 9.0 mm (0.354 in.) Starter brush holder assembly Brush spring load Standard 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum 12.7 N (1.3 kgf, 2.9 lbf) Starter relay assembly Specified condition 1-2 Continuity 3-5 No continuity SS SS–32 SERVICE SPECIFICATIONS – 1GR-FE STARTING TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Starter assembly x Transmission housing 37 377 27 Starter assembly x Terminal 30 9.8 100 7 Starter commutator end frame assembly x Starter drive housing assembly (Starter Assembly 1.6 kW) 6.0 61 53 in.*lbf Starter drive housing assembly x Repair service starter kit (Starter Assembly 1.6 kW) 7.5 76 66 in.*lbf Lead wire x Repair service starter kit (Starter Assembly 1.6 kW) 10 102 7.4 Commutator end frame x Brush holder (Starter Assembly 2.0 kW) 3.8 39 34 in.*lbf Starter drive housing assembly x Magnetic Starter Switch (Starter Assembly 2.0 kW) 9.3 95 82 in.*lbf Commutator end frame x Starter drive housing assembly (Starter Assembly 2.0 kW) 9.3 95 82 in.*lbf Lead wire x Terminal C of starter (Starter Assembly 2.0 kW) 5.9 60 52 in.*lbf Engine wire x Cylinder block 13 133 10 SS–46 SERVICE SPECIFICATIONS – VF4AM TRANSFER TORQUE SPECIFICATIONS Part Tightened N*m kgf cm ft*lbf Transfer case lower protector x Transfer 18 184 13 Transfer x Transfer adaptor 24 240 17 Front bearing retainer sub-assembly x Front case SS 11.5 117 8 Transfer case cover sub-assembly x Front case 18 185 13 Output shaft companion flange sub-assembly lock nut 118 1,200 87 Extension housing sub-assembly rear x Case rear 12 120 9 Front case x Case rear 28 285 21 Gear shift fork No. 2 x Transfer shift actuator assembly 24 245 18 Shift shaft stopper x Case rear 19 195 14 CTR differential lock fork sub-assembly x Transfer shift actuator assembly 24 245 18 Transfer shift actuator assembly x Case rear 20 200 14 Case No. 1 plug (Filler plug) x Case rear 37 380 27 Case No. 1 plug (Drain plug) x Case rear 37 380 27 Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf Transfer case plug x Front case 18.6 190 14 SERVICE SPECIFICATIONS – 2UZ-FE STARTING SS–33 2UZ-FE STARTING SERVICE DATA Rated voltage and output power No-load characteristics Brush length Spring installed load Starter (1.4 kW type) 12 V 1.4 kW Current Standard 15.5 mm (0.610 in.) Minimum 10.0 mm (0.394 in.) Standard 17.6 to 23.5 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf) Minimum 11.8 N (1.20 kgf, 2.7 lbf) Standard 30.0 mm (1.181 in.) Minimum 29.0 mm (1.142 in.) Standard 0.6 mm (0.024 in.) Minimum 0.2 mm (0.008 in.) Maximum 0.05 mm (0.0020 in.) Commutator Diameter Undercut depth Circle runout Rated voltage and output power No-load characteristics Brush length Spring installed load Starter (2.0 kW type) 90 A or less at 11.5 V 12 V 2.0 kW Current 100 A or less at 11.5 V Standard 15.0 mm (0.591 in.) Minimum 9.0 mm (0.354 in.) Standard 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum 12.7 N (1.3 kgf, 2.9 lbf) Standard 35.0 mm (1.378 in.) Minimum 34.0 mm (1.339 in.) Standard 0.7 mm (0.028 in.) Minimum 0.2 mm (0.008 in.) Maximum 0.05 mm (0.0020 in.) Commutator Diameter Undercut depth Circle runout Field frame Shunt coil resistance at 20°C (68°F) 1.5 to 1.9 Ω SS SS–34 SERVICE SPECIFICATIONS – 2UZ-FE STARTING TORQUE SPECIFICATIONS Part Tightened End cover x Brush holder Starter hosing x Magnetic switch End cover with field frame x Magnetic switch SS N*m kgf*cm ft.*lbf 1.4 kW type 1.5 15 13 in.*lbf 2.0 kW type 3.8 39 34 in.*lbf 1.4 kW type 5.9 60 52 in.*lbf 2.0 kW type 9.3 95 82 in.*lbf 1.4 kW type 5.9 60 52 in.*lbf 2.0 kW type 9.3 95 82 in.*lbf Lead wire of field coil x Terminal C 5.9 60 52 in.*lbf Wire clamp, Starter wire x Starter 9.8 100 86 in.*lbf Starter x Cylinder block 39 400 29 SS–48 SERVICE SPECIFICATIONS – VF4BM TRANSFER TORQUE SPECIFICATIONS Part Tightened N*m kgf cm ft*lbf Transfer case lower protector x Transfer 18 184 13 Transfer x Transfer adaptor 24 240 17 Front bearing retainer sub-assembly x Front case SS 11.5 117 8 Transfer case cover sub-assembly x Front case 18 185 13 Output shaft companion flange sub-assembly lock nut 118 1,200 87 Extension housing sub-assembly rear x Case rear 12 120 9 Front case x Case rear 28 285 21 Gear shift fork No. 2 x Transfer shift actuator assembly 24 245 18 CTR differential lock fork sub-assembly x Transfer shift actuator assembly 24 245 18 Transfer shift actuator assembly x Case rear 20 200 14 Case No. 1 plug (Filler plug) x Case rear 37 380 27 Case No. 1 plug (Drain plug) x Case rear 37 380 27 Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf Transfer case plug x Front case 18.6 190 14 SS–34 SERVICE SPECIFICATIONS – 1GR-FE CHARGING 1GR-FE CHARGING SERVICE DATA ACC relay Specified condition SS 1-2 Continuity 3-4 Continuity 3-5 No continuity Battery Voltage Except maintenance-free battery at 20°C (68°F) Standard specific gravity 12.5 to 12.9 V 1.25 to 1.29 at 20°C (68°F) Voltage regulator Regulating voltage 13.2 to 14.8 V Generator brush holder assembly Brush length Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) Generator rotor assembly Resistance Slip ring diameter at 20°C (68°F) 2.3 to 2.7 Ω Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) SS–35 SERVICE SPECIFICATIONS – 1GR-FE CHARGING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Manifold stay x Transmission housing and Exhaust manifold 40 408 30 Steering sliding yoke x Steering intermediate shaft No. 2 36 370 27 Generator assembly x V-ribbed belt tensioner and cylinder head 43 438 32 Generator assembly x Wire harness clamp bracket 8.0 82 71 in.*lbf Generator assembly x Terminal B 9.8 100 7 Wire harness stay x Body 8.0 82 71 in.*lbf V-bank cover x Intake air surge tank sub-assembly and Air cleaner assembly 7.5 76 66 in.*lbf Engine under cover sub-assembly No. 1 x Frame assembly 29 296 21 Engine under cover assembly rear x Frame assembly 29 296 21 Retainer plate x Drive end frame assembly generator 2.6 27 23 in.*lbf Generator coil assembly x Drive frame assembly generator 5.8 59 51 in.*lbf Generator brush holder assembly x Generator coil assembly 1.8 18 16 in.*lbf Generator rear end cover x Generator coil assembly 4.6 47 41 in.*lbf Generator pulley x Generator rotor assembly 110 1,122 81 SS SERVICE SPECIFICATIONS – 2UZ-FE CHARGING SS–35 2UZ-FE CHARGING SERVICE DATA Battery Maintenance-free Voltage at 20°C (68°F) Rated output Rotor coil resistance Generator Slip ring diameter Brush exposed length Voltage regulator Regulating voltage 12.5 to 12.9 V 12 V 100 A at 20°C (68°F) 2.3 to 2.7 Ω Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) 13.2 to 14.0 V SS SS–36 SERVICE SPECIFICATIONS – 2UZ-FE CHARGING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Water by-pass joint RR x Cylinder head 18 185 13 Water by-pass pipe x Water pump 18 185 13 Bolt 18 185 13 Nut 18 185 13 Bearing retainer x Drive end frame 2.6 2.7 23 in.*lbf Rectifier end frame x Drive end frame 5.8 59 51 in.*lbf 110.5 1,125 81 Intake manifold x Cylinder head SS Generator pulley x Rotor SS–36 SERVICE SPECIFICATIONS – A750E AUTOMATIC TRANSMISSION A750E AUTOMATIC TRANSMISSION SERVICE DATA 2UZ-FE: Line pressure (Wheel locked) Engine idling SS D position 362 to 423 kPa (3.7 to 4.3 kgf*cm2, 53 to 61 psi) R position 495 to 576 kPa (5.0 to 5.9 kgf*cm2, 71 to 84 psi) AT stall (Throttle valve fully open) Engine stall revolution Time lag Engine idle speed (A/C OFF) D position 1,235 to 1,332 kPa (12.6 to 13.6 kgf*cm2, 179 to 193 psi) R position 1,229 to 1,350 kPa (12.5 to 13.8 kgf*cm2, 178 to 196 psi) D position 2,200 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds N position Drive plate runout Max. Torque converter runout Max. Torque converter clutch installation distance 700 +- 50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 17.1 mm (0.673 in.) Shift schedule D position (Throttle valve fully open) (Throttle valve fully close) 1→2 52 to 64 km/h (32 to 40 mph) 2→3 97 to 108 km/h (60 to 67 mph) 3→4 138 to 154 km/h (86 to 96 mph) 4→5 186 to 200 km/h (116 to 124 mph) 5→4 181 to 194 km/h (112 to 121 mph) 4→3 126 to 139 km/h (78 to 86 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) 4→5 50 to 56 km/h (31 to 35 mph) 5→4 26 to 31 km/h (16 to 19 mph) 1→2 52 to 64 km/h (32 to 40 mph) 4 position (Throttle valve fully close) 2→3 97 to 108 km/h (60 to 67 mph) 3→4 138 to 154 km/h (86 to 96 mph) 5→4 198 to 212 km/h (122 to 132 mph) 4→3 126 to 139 km/h (78 to 86 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) 1→2 52 to 64 km/h (32 to 40 mph) 3 position (Throttle valve fully open) 2 position 2→3 97 to 108 km/h (60 to 67 mph) 4→3 139 to 151 km/h (86 to 94 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) SERVICE SPECIFICATIONS – A750E AUTOMATIC TRANSMISSION (Throttle valve fully open) 1→2 52 to 64 km/h (32 to 40 mph) 3→2 92 to 103 km/h (57 to 64 mph) 2→1 40 to 46 km/h (25 to 29 mph) 2→1 40 to 46 km/h (25 to 29 mph) SS–37 L position (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 72 to 79 km/h (45 to 49 mph) Lock-up OFF 65 to 71 km/h (40 to 44 mph) 4 position 4th gear Lock-up ON 117 to 125 km/h (73 to 78 mph) Lock-up OFF 110 to 117 km/h (68 to 73 mph) 1GR-FE: Line pressure (Wheel locked) Engine idling D position 362 to 423 kPa (3.7 to 4.3 kgf*cm2, 53 to 61 psi) R position 484 to 565 kPa (4.9 to 5.8 kgf*cm2, 70 to 82 psi) AT stall (Throttle valve fully opened) Engine stall revolution Time lag D position 1,282 to 1,381 kPa (13.1 to 14.1 kgf*cm2, 186 to 200 psi) R position 1,218 to 1,338 kPa (12.4 to 13.6 kgf*cm2, 177 to 194 psi) D positions 2,400 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position Drive plate runout Max. Torque converter runout Max. Torque converter clutch installation distance 700 +- 50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 17.1 mm (0.673 in.) Shift schedule D position (Throttle valve fully open) (Throttle valve fully close) 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 3→4 140 to 154 km/h (87 to 96 mph) 4→5 179 to 189 km/h (111 to 117 mph) 5→4 171 to 182 km/h (106 to 113 mph) 4→3 125 to 134 km/h (78 to 83 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 4→5 46 to 51 km/h (29 to 32 mph) 5→4 27 to 33 km/h (17 to 21 mph) 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 3→4 140 to 154 km/h (87 to 96 mph) 5→4 191 to 202 km/h (119 to 126 mph) 4→3 125 to 134 km/h (78 to 83 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 4 position (Throttle valve fully open) 3 position SS SS–38 (Throttle valve fully open) SERVICE SPECIFICATIONS – A750E AUTOMATIC TRANSMISSION 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 4→3 133 to 143 km/h (83 to 88 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 2 position (Throttle valve fully open) SS 1→2 50 to 61 km/h (31 to 38 mph) 3→2 88 to 98 km/h (55 to 61 mph) 2→1 39 to 44 km/h (24 to 27 mph) 2→1 42 to 48 km/h (26 to 30 mph) L position (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 57 to 63 km/h (35 to 39 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) Lock-up ON 69 to 74 km/h (43 to 46 mph) Lock-up OFF 61 to 67 km/h (38 to 42 mph) 4 position 4th gear SS–40 SERVICE SPECIFICATIONS – A750F AUTOMATIC TRANSMISSION A750F AUTOMATIC TRANSMISSION SERVICE DATA 2UZ-FE: Line pressure (Wheel locked) Engine idling SS D position 362 to 423 kPa (3.7 to 4.3 kgf*cm2, 53 to 61 psi) R position 495 to 576 kPa (5.0 to 5.9 kgf*cm2, 71 to 84 psi) AT stall (Throttle valve fully open) Engine stall revolution Time lag Engine idle speed (A/C OFF) D position 1,235 to 1,332 kPa (12.6 to 13.6 kgf*cm2, 179 to 193 psi) R position 1,229 to 1,350 kPa (12.5 to 13.8 kgf*cm2, 178 to 196 psi) D position 2,200 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds N position Drive plate runout Max. Torque converter runout Max. Torque converter clutch installation distance 700 +- 50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 17.1 mm (0.673 in.) Shift schedule D position (Throttle valve fully open) (Throttle valve fully close) 1→2 52 to 64 km/h (32 to 40 mph) 2→3 97 to 108 km/h (60 to 67 mph) 3→4 138 to 154 km/h (86 to 96 mph) 4→5 186 to 200 km/h (116 to 124 mph) 5→4 181 to 194 km/h (112 to 121 mph) 4→3 126 to 139 km/h (78 to 86 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) 4→5 50 to 56 km/h (31 to 35 mph) 5→4 26 to 31 km/h (16 to 19 mph) 1→2 52 to 64 km/h (32 to 40 mph) 4 position (Throttle valve fully close) 2→3 97 to 108 km/h (60 to 67 mph) 3→4 138 to 154 km/h (86 to 96 mph) 5→4 198 to 212 km/h (122 to 132 mph) 4→3 126 to 139 km/h (78 to 86 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) 1→2 52 to 64 km/h (32 to 40 mph) 3 position (Throttle valve fully open) 2 position 2→3 97 to 108 km/h (60 to 67 mph) 4→3 139 to 151 km/h (86 to 94 mph) 3→2 85 to 93 km/h (53 to 58 mph) 2→1 40 to 46 km/h (25 to 29 mph) SERVICE SPECIFICATIONS – A750F AUTOMATIC TRANSMISSION (Throttle valve fully open) 1→2 52 to 64 km/h (32 to 40 mph) 3→2 92 to 103 km/h (57 to 64 mph) 2→1 40 to 46 km/h (25 to 29 mph) 2→1 40 to 46 km/h (25 to 29 mph) SS–41 L position (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 72 to 79 km/h (45 to 49 mph) Lock-up OFF 65 to 71 km/h (40 to 44 mph) 4 position 4th gear Lock-up ON 117 to 125 km/h (73 to 78 mph) Lock-up OFF 110 to 117 km/h (68 to 73 mph) 1GR-FE: Line pressure (Wheel locked) Engine idling D position 362 to 423 kPa (3.7 to 4.3 kgf*cm2, 53 to 61 psi) R position 484 to 565 kPa (4.9 to 5.8 kgf*cm2, 70 to 82 psi) AT stall (Throttle valve fully opened) Engine stall revolution Time lag D position 1,282 to 1,381 kPa (13.1 to 14.1 kgf*cm2, 186 to 200 psi) R position 1,218 to 1,338 kPa (12.4 to 13.6 kgf*cm2, 177 to 194 psi) D positions 2,400 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position Drive plate runout Max. Torque converter runout Max. Torque converter clutch installation distance 700 +- 50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 17.1 mm (0.673 in.) Shift schedule D position (Throttle valve fully open) (Throttle valve fully close) 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 3→4 140 to 154 km/h (87 to 96 mph) 4→5 179 to 189 km/h (111 to 117 mph) 5→4 171 to 182 km/h (106 to 113 mph) 4→3 125 to 134 km/h (78 to 83 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 4→5 46 to 51 km/h (29 to 32 mph) 5→4 27 to 33 km/h (17 to 21 mph) 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 3→4 140 to 154 km/h (87 to 96 mph) 5→4 191 to 202 km/h (119 to 126 mph) 4→3 125 to 134 km/h (78 to 83 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 4 position (Throttle valve fully open) 3 position SS SS–42 (Throttle valve fully open) SERVICE SPECIFICATIONS – A750F AUTOMATIC TRANSMISSION 1→2 50 to 61 km/h (31 to 38 mph) 2→3 97 to 106 km/h (60 to 66 mph) 4→3 133 to 143 km/h (83 to 88 mph) 3→2 83 to 89 km/h (52 to 55 mph) 2→1 39 to 44 km/h (24 to 27 mph) 2 position (Throttle valve fully open) SS 1→2 50 to 61 km/h (31 to 38 mph) 3→2 88 to 98 km/h (55 to 61 mph) 2→1 39 to 44 km/h (24 to 27 mph) 2→1 42 to 48 km/h (26 to 30 mph) L position (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 57 to 63 km/h (35 to 39 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) Lock-up ON 69 to 74 km/h (43 to 46 mph) Lock-up OFF 61 to 67 km/h (38 to 42 mph) 4 position 4th gear SS–44 SERVICE SPECIFICATIONS – VF4AM TRANSFER VF4AM TRANSFER SERVICE DATA Output shaft rear Drive sprocket thrust clearance Drive sprocket radial clearance SS STD 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Max. 0.24 mm (0.0094 in.) STD 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Max. 0.06 mm (0.0024 in.) Gear shift fork No. 2 claw thickness 10 mm (0.3937 in.) High and low clutch sleeve groove distance 10.5 mm (0.4134 in.) Gear shift fork No. 2 to high and low clutch sleeve clearance STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) CTR differential lock fork claw thickness 10 mm (0.3937 in.) Front drive clutch sleeve groove distance 10.5 mm (0.4134 in.) CTR differential lock fork to front drive clutch sleeve clearance STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) Rear output shaft journal outer diameter Part A Part B Part C STD 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Min. 27.98 mm (1.1016 in.) STD 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Min. 31.98 mm (1.2591 in.) STD 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Min. 34.98 mm (1.3772 in.) STD 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Min. 36.98 mm (1.4559 in.) Input shaft journal outer diameter Min. 47.59 mm (1.8736 in.) Input shaft bushing diameter Max. 48.14 mm (1.8953 in.) Part D Input shaft Mark A Input gear stopper snap ring thickness 2.10 to 2.15 mm (0.0827 to 0.0846 in.) B 2.15 to 2.20 mm (0.0846 to 0.0866 in.) C 2.20 to 2.25 mm (0.0866 to 0.0886 in.) D 2.25 to 2.30 mm (0.0886 to 0.0906 in.) E 2.30 to 2.35 mm (0.0906 to 0.0925 in.) F 2.35 to 2.40 mm (0.0925 to 0.0945 in.) G 2.40 to 2.45 mm (0.0945 to 0.0965 in.) H 2.45 to 2.50 mm (0.0965 to 0.0984 in.) J 2.50 to 2.55 mm (0.0984 to 0.1004 in.) K 2.55 to 2.60 mm (0.1004 to 0.1024 in.) L 2.60 to 2.65 mm (0.1024 to 0.1043 in.) M 2.65 to 2.70 mm (0.1043 to 0.1063 in.) N 2.70 to 2.75 mm (0.1063 to 0.1083 in.) P 2.75 to 2.80 mm (0.1083 to 0.1102 in.) Q 2.80 to 2.85 mm (0.1102 to 0.1122 in.) R 2.85 to 2.90 mm (0.1122 to 0.1142 in.) S 2.90 to 2.95 mm (0.1142 to 0.1161 in.) T 2.95 to 3.00 mm (0.1161 to 0.1181 in.) U 3.00 to 3.05 mm (0.1181 to 0.1201 in.) SERVICE SPECIFICATIONS – VF4AM TRANSFER SS–45 Planetary gear STD Pinion gear thrust clearance Pinion gear radial clearance 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) STD 0.009 to 0.038 mm (0.0004 to 0.0015 in.) Max. 0.038 mm (0.0015 in.) Mark Input bearing shaft snap ring thickness Low planetary gear bearing press in depth 1 1.45 to 1.50 mm (0.0571 to 0.0591 in.) 2 1.50 to 1.55 mm (0.0591 to 0.0610 in.) 3 1.55 to 1.60 mm (0.0610 to 0.0630 in.) 4 1.60 to 1.65 mm (0.0630 to 0.0650 in.) 5 1.65 to 1.70 mm (0.0650 to 0.0669 in.) 7.7 to 8.3 mm (0.303 to 0.327 in.) SS SS–46 SERVICE SPECIFICATIONS – VF4BM TRANSFER VF4BM TRANSFER SERVICE DATA Output shaft rear Drive sprocket thrust clearance Drive sprocket radial clearance SS STD 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Max. 0.24 mm (0.0094 in.) STD 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Max. 0.06 mm (0.0024 in.) Gear shift fork No. 2 claw thickness 10 mm (0.3937 in.) High and low clutch sleeve groove distance 10.5 mm (0.4134 in.) Gear shift fork No. 2 to high and low clutch sleeve clearance STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) CTR differential lock fork claw thickness 10 mm (0.3937 in.) Front drive clutch sleeve groove distance 10.5 mm (0.4134 in.) CTR differential lock fork to front drive clutch sleeve clearance STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) Rear output shaft journal outer diameter Part A Part B Part C STD 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Min. 27.98 mm (1.1016 in.) STD 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Min. 31.98 mm (1.2591 in.) STD 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Min. 34.98 mm (1.3772 in.) STD 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Min. 36.98 mm (1.4559 in.) Input shaft journal outer diameter Min. 47.59 mm (1.8736 in.) Input shaft bushing diameter Max. 48.14 mm (1.8953 in.) Part D Input shaft Mark A Input gear stopper snap ring thickness 2.10 to 2.15 mm (0.0827 to 0.0846 in.) B 2.15 to 2.20 mm (0.0846 to 0.0866 in.) C 2.20 to 2.25 mm (0.0866 to 0.0886 in.) D 2.25 to 2.30 mm (0.0886 to 0.0906 in.) E 2.30 to 2.35 mm (0.0906 to 0.0925 in.) F 2.35 to 2.40 mm (0.0925 to 0.0945 in.) G 2.40 to 2.45 mm (0.0945 to 0.0965 in.) H 2.45 to 2.50 mm (0.0965 to 0.0984 in.) J 2.50 to 2.55 mm (0.0984 to 0.1004 in.) K 2.55 to 2.60 mm (0.1004 to 0.1024 in.) L 2.60 to 2.65 mm (0.1024 to 0.1043 in.) M 2.65 to 2.70 mm (0.1043 to 0.1063 in.) N 2.70 to 2.75 mm (0.1063 to 0.1083 in.) P 2.75 to 2.80 mm (0.1083 to 0.1102 in.) Q 2.80 to 2.85 mm (0.1102 to 0.1122 in.) R 2.85 to 2.90 mm (0.1122 to 0.1142 in.) S 2.90 to 2.95 mm (0.1142 to 0.1161 in.) T 2.95 to 3.00 mm (0.1161 to 0.1181 in.) U 3.00 to 3.05 mm (0.1181 to 0.1201 in.) SERVICE SPECIFICATIONS – VF4BM TRANSFER SS–47 Planetary gear STD Pinion gear thrust clearance Pinion gear radial clearance 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Max. 0.84 mm (0.0331 in.) STD 0.009 to 0.038 mm (0.0004 to 0.0015 in.) Max. 0.038 mm (0.0015 in.) Mark Input bearing shaft snap ring thickness Low planetary gear bearing press in depth 1 1.45 to 1.50 mm (0.0571 to 0.0591 in.) 2 1.50 to 1.55 mm (0.0591 to 0.0610 in.) 3 1.55 to 1.60 mm (0.0610 to 0.0630 in.) 4 1.60 to 1.65 mm (0.0630 to 0.0650 in.) 5 1.65 to 1.70 mm (0.0650 to 0.0669 in.) 7.7 to 8.3 mm (0.303 to 0.327 in.) SS SS–48 SERVICE SPECIFICATIONS – PROPELLER SHAFT PROPELLER SHAFT SERVICE DATA PROPELLER SHAFT ASSEMBLY FRONT Propeller shaft runout Maximum: 0.3 mm (0.012 in.) Universal joint spider bearing axial play Maximum: 0 mm (0 in.) Maximum: 0.3 mm (0.012 in.) PROPELLER SHAFT ASSEMBLY SS Propeller shaft runout SS–49 SERVICE SPECIFICATIONS – PROPELLER SHAFT TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 88 897 65 88 897 65 PROPELLER SHAFT ASSEMBLY FRONT Propeller shaft flange yoke x Companion flange PROPELLER SHAFT ASSEMBLY Propeller shaft x Companion flange SS SERVICE SPECIFICATIONS – DRIVE SHAFT SS–49 DRIVE SHAFT SERVICE DATA FRONT AXLE HUB SUB-ASSEMBLY Front axle hub backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub deviation Maximum: 0.05 mm (0.0020 in.) Rear axle shaft backlash Maximum: 0.05 mm (0.0020 in.) Rear axle shaft deviation Maximum: 0.05 mm (0.0020 in.) Rear axle shaft runout Maximum: 1.5 mm (0.0591 in.) Rear axle shaft flange runout Maximum: 0.05 mm (0.0020 in.) REAR AXLE SHAFT LH SS SS–50 SERVICE SPECIFICATIONS – DRIVE SHAFT TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Front axle hub assembly x Lock nut 235 2,396 173 Steering knuckle x Tie rod end 91 928 67 Steering knuckle x Stabilizer link 70 714 52 Disc brake caliper x Steering knuckle 123 1,254 91 Disc brake caliper x Brake tube 15 155 11 Front brake tube bracket set bolt 26 296 21 ABS speed sensor wire harness bracket set bolt 13 133 10 FRONT AXLE HUB SUB-ASSEMBLY LH SS ABS speed sensor set bolt 8.3 85 73 in.*lbf Steering knuckle x Upper ball joint 110 1,122 81 Steering knuckle x Lower ball joint 160 1,630 118 Steering knuckle x Front axle w/ ABS rotor bearing assembly 80 816 59 Front wheel adjusting nut x Front axle w/ ABS rotor bearing assembly 275 2,804 203 Front wheel 112 1,142 83 123 1,254 91 Rear axle shaft w/ backing plate x Disc brake caliper 47 480 35 ABS speed sensor set nut 8.3 85 73 in.*lbf REAR AXLE SHAFT Axle housing x Rear axle shaft Rear brake tube x Master cylinder 15 155 11 Rear wheel 112 1,142 83 SS–54 SERVICE SPECIFICATIONS – DIFFERENTIAL TORQUE SPECIFICATIONS Part tightened N*m kgf*cm ft*lbf Differential carrier assembly front (4WD) Companion flange x Drive pinion SS See page DF-12, DF-35 Propeller shaft x Companion flange 88 897 65 Differential front mounting support No. 1 x Frame 137 1,400 101 Differential front mounting support No. 2 x Frame 137 1,400 101 Differential front mounting support No. 2 x Front differential tube assembly 160 1,630 118 Differential front mounting support No. 1 x Differential carrier assembly front 186 1,900 137 Differential front mounting support No. 2 x Differential carrier assembly front 145 1,479 107 Differential front mounting support No. 3 x Differential carrier assembly front 108 1,100 80 Front differential mount nut No. 1 87 887 64 Ring gear x Differential case 97 985 71 Differential carrier assembly front x Breather tube 13 133 10 Differential carrier assembly front x Side bearing retainer 50 510 37 Differential carrier assembly front x Differential case 110 1,122 81 Drain plug 65 660 48 Filler plug 39 400 29 Front wheel 112 1,142 83 Differential carrier assembly rear Companion flange x Drive pinion See page DF-53 Rear axle housing x Backing plate 66 670 48 Propeller shaft x Companion flange 88 897 65 Differential carrier assembly rear x Rear axle housing 20 204 15 Differential carrier assembly rear x Bearing cap 85 867 63 Differential case x Ring gear 97 985 71 Bearing cap x adjusting nut lock 13 130 9 10 101 7.3 47 480 35 Companion flange x Stud bolt 2WD Drive Type: Differential RH case x Differential LH case Differential vacuum actuator assembly x Front differential tube assembly 1GR-FE (4WD) Drain plug 21 210 15 49 500 36 Filler plug 49 500 36 Rear wheel 112 1,142 83 SS–59 SERVICE SPECIFICATIONS – SUSPENSION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tie rod end lock nut 88 897 65 Shock absorber piston rod x Suspension support sub-assembly 25 260 18 Shock absorber (upper) x Frame 64 650 47 Shock absorber (Reas) bracket x Frame 29 300 21 Stabilizer link x Steering knuckle 70 710 52 Hub nut 112 1,140 83 Shock absorber x Lower arm 135 1,380 100 Upper arm x Steering knuckle arm 110 1,120 81 Skid control sensor x Upper arm 13 130 9 ft*lbf Upper arm x Body 115 1,170 85 Lower arm x Suspension cross member 135 1,380 100 Lower arm x Lower ball joint attachment 140 1,430 103 Lower ball joint attachment x Steering knuckle arm 160 1,630 118 Stabilizer bracket x Body 40 410 30 Shock absorber x Body 25 255 18 Hub nut 112 1137 83 Shock absorber x Rear axle housing 98 1000 72 Shock absorber bracket (REAS) x Fram 29 296 21 Brake tube x Brake hose 15 155 11 Upper control arm x Rear axle housing 80 816 59 Upper control arm x Fram 80 816 59 Lower control arm x Rear axle housing 130 1326 96 Lower control arm x Fram 130 1326 96 Lower control arm x Parking brake cable 13 127 9 Lateral control rod x Rear axle housing 130 1326 96 Lateral control rod x Fram 130 1326 96 Stabilizer bar x Stabilizer link 70 714 52 Stabilizer bar x Rear axle housing 30 306 22 Stabilizer link x Fram 15 153 11 Center control absorber (REAS) x Fram 29 296 21 Center control absorber bracket (REAS) x Fram 29 296 21 Tube protector (REAS) x Fram 29 296 21 Center control absorber tube (REAS) x Fram 29 296 21 SS SS–50 SERVICE SPECIFICATIONS – DIFFERENTIAL DIFFERENTIAL SERVICE DATA Differential carrier assembly front (1GR-FE (4WD)) Differential drive pinion preload (at starting) New bearing Reused bearing Total preload (at starting) SS 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) Drive pinion preload plus 0.20 to 0.63 N*m (2.0 to 6.4 kgf*cm, 1.8 to 5.6 in.*lbf) Differential ring gear backlash 0.11 to 0.18 mm (0.0043 to 0.0071 in.) Differential side gear backlash 0 to 0.15 mm (0 to 0.00591 in.) Front differential carrier oil seal Oil seal drive in depth 4.35 +- 0.45 mm (0.171 +- 0.018 in.) Oil seal drive in depth 0 +- 0.45 mm (0 +- 0.0177 in.) Oil seal drive in depth 5.3 +- 0.5 mm (0.2087 +- 0.0197 in.) Front differential side oil seal Front differential side tube oil seal Front differential side gear needle roller bearing Bearing press in depth 1.7 +- 0.3 mm (0.067 +- 0.012 in.) Differential clutch sleeve and clutch sleeve fork clearance Max. 0.35 mm (0.0138 in.) Differential carrier assembly front (2UZ-FE (4WD)) Companion flange vertical runout Max. 0.10 mm (0.0039 in.) Differential drive pinion preload (at starting) New bearing Reused bearing 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 14 in.*lbf) 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) Total preload (at starting) Drive pinion preload plus 0.25 to 0.45 N*m (2.5 to 4.6 kgf*cm, 2.2 to 4.0 in.*lbf) Differential ring gear backlash 0.13 to 0.18 mm (0.0051 to 0.0071 in.) Differential case runout Max Side gear backlash 0.04 mm (0.0018 in.) 0 to 0.15 mm (0 to 0.00591 in.) Front differential carrier oil seal Oil seal drive in depth 4.35 +- 0.45 mm (0.171 +- 0.018 in.) Oil seal drive in depth 0 +- 0.3 mm (0 +- 0.012 in.) Front differential side oil seal Front differential side tube oil seal Oil seal drive in depth 5.3 +- 0.5 mm (0.209 +- 0.020 in.) Differential side gear backlash 0.05 to 0.20 mm (0.002 to 0.008 in.) Differential ring gear backlash 0.13 to 0.18 mm (0.0051 to 0.0071 in.) Differential carrier assembly front (4WD) Companion flange lateral runout Max. 0.10 mm (0.0039 in.) SERVICE SPECIFICATIONS – DIFFERENTIAL SS–51 1.48 to 1.52 mm (0.0583 to 0.0598 in.) 1.53 to 1.57 mm (0.0602 to 0.0618 in.) 1.58 to 1.62 mm (0.0622 to 0.0638 in.) 1.63 to 1.67 mm (0.0642 to 0.0657 in.) Front differential side gear thrust washer thickness 1.68 to 1.72 mm (0.0661 to 0.0677 in.) 1.73 to 1.77 mm (0.0681 to 0.0697 in.) 1.78 to1.82 mm (0.0701 to 0.0717 in.) 1.83 to 1.87 mm (0.0720 to 0.0736 in.) 1.88 to1.92 mm (0.0740 to 0.0756 in.) 1.59 to 1.61 mm (0.0626 to 0.0634 in.) 1.62 to 1.64 mm (0.0638 to 0.0646 in.) 1.65 to 1.67 mm (0.0650 to 0.0657 in.) 1.68 to 1.70 mm (0.0661 to 0.0669 in.) 1.71 to 1.73 mm (0.0673 to 0.0681 in.) 1.74 to 1.76 mm (0.0685 to 0.0693 in.) 1.77 to 1.79 mm (0.0697 to 0.0705 in.) 1.80 to 1.82 mm (0.0709 to 0.0717 in.) 1.83 to 1.85 mm (0.0720 to 0.0728 in.) 1.86 to 1.88 mm (0.0732 to 0.0740 in.) 1.89 to 1.91 mm (0.0744 to 0.0752 in.) 1.92 to 1.94 mm (0.0756 to 0.0764 in.) 1.95 to 1.97 mm (0.0768 to 0.0776 in.) 1.98 to 2.00 mm (0.0780 to 0.0787 in.) Front differential ring gear thrust washer thickness 2.01 to 2.03 mm (0.0791 to 0.0800 in.) 2.04 to 2.06 mm (0.0803 to 0.0811 in.) 2.07 to 2.09 mm (0.0815 to 0.0823 in.) 2.10 to 2.12 mm (0.0827 to 0.0835 in.) 2.13 to 2.15 mm (0.0839 to 0.0846 in.) 2.16 to 2.18 mm (0.0850 to 0.0858 in.) 2.19 to 2.21 mm (0.0862 to 0.0870 in.) 2.22 to 2.24 mm (0.0874 to 0.0882 in.) 2.25 to 2.27 mm (0.0886 to 0.0894 in.) 2.28 to 2.30 mm (0.0898 to 0.0906 in.) 2.31 to 2.33 mm (0.0909 to 0.0917 in.) 2.34 to 2.36 mm (0.0921 to 0.0929 in.) 2.37 to 2.39 mm (0.0933 to 0.0941 in.) 2.40 to 2.42 mm (0.0945 to 0.0953 in.) 2.43 to 2.45 mm (0.0957 to 0.0965 in.) 2.46 to 2.48 mm (0.0969 to 0.0976 in.) SS SS–52 SERVICE SPECIFICATIONS – DIFFERENTIAL 1.69 to 1.71 mm (0.0665 to 0.0673 in.) 1.72 to 1.74 mm (0.0677 to 0.0685 in.) 1.75 to 1.77 mm (0.0689 to 0.0697 in.) 1.78 to 1.80 mm (0.0701 to 0.0709 in.) 1.81 to 1.83 mm (0.0713 to 0.0720 in.) 1.84 to 1.86 mm (0.0724 to 0.0732 in.) 1.87 to 1.89 mm (0.0736 to 0.0744 in.) 1.90 to 1.92 mm (0.0748 to 0.0756 in.) 1.93 to 1.95 mm (0.0760 to 0.0768 in.) SS 1.96 to 1.98 mm (0.0772 to 0.0780 in.) 1.99 to 2.01 mm (0.0783 to 0.0791 in.) Rear differential drive pinion plate washer thickness 2.02 to 2.04 mm (0.0795 to 0.0803 in.) 2.05 to 2.07 mm (0.0807 to 0.0815 in.) 2.08 to 2.10 mm (0.0819 to 0.0827 in.) 2.11 to 2.13 mm (0.0831 to 0.0839 in.) 2.14 to 2.16 mm (0.0843 to 0.0850 in.) 2.17 to 2.19 mm (0.0854 to 0.0862 in.) 2.20 to 2.22 mm (0.0866 to 0.0874 in.) 2.23 to 2.25 mm (0.0878 to 0.0886 in.) 2.26 to 2.28 mm (0.0890 to 0.0898 in.) 2.29 to 2.31 mm (0.0902 to 0.0909 in.) 2.32 to 2.34 mm (0.0913 to 0.0921 in.) Differential carrier assembly rear Companion flange vertical runout Max 0.10 mm (0.0039 in.) Max 0.10 mm (0.0039 in.) Max 0.07 mm (0.0028 in.) Max 0.07 mm (0.0028 in.) Companion flange lateral runout Differential ring gear runout Rear differential case runout Differential drive pinion preload (at starting) New bearing Reused bearing 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf) Total preload (at starting) Differential ring gear backlash 0.13 to 0.18 mm (0.0051 to 0.0071 in.) Rear differential case side gear backlash LH 0.05 to 0.20 mm (0.0002 to 0.008 in.) Rear differential case side gear backlash RH 0.05 to 0.20 mm (0.0002 to 0.008 in.) Rear differential carrier oil seal Oil seal drive in depth 0.7 +- 1.3 mm (0.0276 +- 0.0512 in.) 0.9 mm (0.0354 in.) 1.0 mm (0.0394 in.) Rear differential side gear thrust washer thickness 1.1 mm (0.0433 in.) 1.2 mm (0.0472 in.) 1.3 mm (0.0512 in.) SERVICE SPECIFICATIONS – DIFFERENTIAL SS–53 Differential carrier assembly rear 1.70 mm (0.0669 in.) 1.73 mm (0.0681 in.) 1.76 mm (0.0693 in.) 1.79 mm (0.0705 in.) 1.82 mm (0.0717 in.) 1.85 mm (0.0728 in.) 1.88 mm (0.0740 in.) 1.91 mm (0.0752 in.) 1.94 mm (0.0764 in.) 1.97 mm (0.0776 in.) Rear differential drive pinion plate washer thickness 2.00 mm (0.0787 in.) 2.03 mm (0.0799 in.) 2.06 mm (0.0811 in.) 2.09 mm (0.0823 in.) 2.12 mm (0.0835 in.) 2.15 mm (0.0846 in.) 2.18 mm (0.0858 in.) 2.21 mm (0.0870 in.) 2.24 mm (0.0882 in.) 2.27 mm (0.0894 in.) 2.30 mm (0.0906 in.) 2.33 mm (0.0917 in.) SS SERVICE SPECIFICATIONS – AXLE SS–55 AXLE SERVICE DATA FRONT AXLE HUB SUB-ASSEMBLY Front axle hub backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub deviation Maximum: 0.05 mm (0.0020 in.) Rear axle shaft backlash Maximum: 0.05 mm (0.0020 in.) Rear axle shaft deviation Maximum: 0.05 mm (0.0020 in.) Rear axle shaft runout Maximum: 1.5 mm (0.0591 in.) Rear axle shaft flange runout Maximum: 0.05 mm (0.0020 in.) REAR AXLE SHAFT LH SS SS–56 SERVICE SPECIFICATIONS – AXLE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Front axle hub assembly x Lock nut 235 2,396 173 Steering knuckle x Tie rod end 91 928 67 Steering knuckle x Stabilizer link 70 714 52 Disc brake caliper x Steering knuckle 123 1,254 91 Disc brake caliper x Brake tube 15 155 11 Front brake tube bracket set bolt 26 296 21 ABS speed sensor wire harness bracket set bolt 13 133 10 FRONT AXLE HUB SUB-ASSEMBLY LH SS ABS speed sensor set bolt 8.3 85 73 in.*lbf Steering knuckle x Upper ball joint 110 1,122 81 Steering knuckle x Lower ball joint 160 1,630 118 Steering knuckle x Front axle w/ ABS rotor bearing assembly 80 816 59 Front wheel adjusting nut x Front axle w/ ABS rotor bearing assembly 275 2,804 203 Front wheel 112 1,142 83 123 1,254 91 Rear axle shaft w/ backing plate x Disc brake caliper 47 480 35 ABS speed sensor set nut 8.3 85 73 in.*lbf REAR AXLE SHAFT Axle housing x Rear axle shaft Rear brake tube x Master cylinder 15 155 11 Rear wheel 112 1,142 83 SS–56 SERVICE SPECIFICATIONS – SUSPENSION CONTROL SUSPENSION CONTROL SERVICE DATA Amount of change in vehicle height HIGH position: 40 mm (1.57 in.) LOW position: -20 mm (-0.79 in.) Difference between the right side and the left side SS measure vehicle height value: Air suspension using the intelligent tester value: not Using the intelligent tester value: Difference between the tester value and vehicle height (D-C measurement): 10 mm (0.39 in.) or less 5 mm (0.20 in.) or less 0.2 V or less 5 mm (0.20 in.) or less Height control sensor link standard length: Reas 6.5 to 15.0 mm (0.26 to 0.59 in.) Joint gap space dimension of gap: 1 mm (0.04 in.) SS–57 SERVICE SPECIFICATIONS – SUSPENSION CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Height control sensor link x Upper control arm assembly 5.4 55 48 in.*lbf Height control sensor link lock nut 5.4 55 48 in.*lbf Height control compressor assembly x Height control dryer assembly 6.4 65 57 in.*lbf Height control bracket x Frame 29 300 21 Height control compressor assembly x Height control bracket 5.9 60 52 in.*lbf Height control filter x Height control bracket 6.4 65 57 in.*lbf Rear disc wheel 112 1,140 83 Height control reservoir assembly x body 29 300 21 Suspension control ECU x body 7.8 80 69 in.*lbf Height control sensor sub-assembly x body 13 133 10 SS SERVICE SPECIFICATIONS – SUSPENSION SS–57 SUSPENSION SERVICE DATA Vehicle height (2WD Except air suspension) UZN210L-GKAGKA Front A-B: Rear C-D: 71.7 mm (2.82 in.) UZN210L-GKAZKA Front A-B: 113.5 mm (4.47 in.) Rear C-D: 72.3 mm (2.85 in.) GRN210L-GKPGKA Front A-B: 110.5 mm (4.35 in.) Rear C-D: 70.9 mm (2.79 in.) Front A-B: 110.4 mm (4.35 in.) Rear C-D: 71.3 mm (2.81 in.) Front A-B: 112.7 mm (4.44 in.) Rear C-D: 81.4 mm (3.20 in.) UZN215L-GKAGKA Front A-B: 99.9 mm (3.93 in.) Rear C-D: 71.6 mm (2.82 in.) UZN215L-GKAZKA Front A-B: 99.8 mm (3.93 in.) Rear C-D: 72.1 mm (2.84 in.) GRN215L-GKPGKA Front A-B: 99.8 mm (3.93 in.) Rear C-D: 71.3 mm (2.81 in.) GRN215L-GKPZKA Front A-B: 99.8 mm (3.93 in.) Rear C-D: 71.9 mm (2.83 in.) Front A-B: 99.2 mm (3.91 in.) Rear C-D: 78.9 mm (3.11 in.) GRN210L-GKPZKA 113.6 mm (4.47 in.) Vehicle height (2WD Air suspension) UZN210L-GKAZKA Vehicle height (4WD Except air suspension) Vehicle height (4WD Air suspension) UZN215L-GKAZKA Front wheel alignment Toe-in (total) 0°05' +- 0°10' (0.08° +- 0.16°) 1 +- 2 mm (0.04 +- 0.08 in.) Rack end length difference 1.0 mm (0.04 in.) or less Inside wheel 37°00' (35°00' to 38°00') Wheel angle (2WD) 37.00° (35.00° to 38.00°) Outside wheel: Reference 32°30' 32.50° Wheel angle (4WD) Inside wheel 36°40' (34°40' to 37°40') 36.67° (34.67° to 37.67°) Outside wheel: Reference 32°53' 32.88° Camber 2WD Except air suspension -0°28' +- 45' (-0.47° +- 0.75°) Right-left error 2WD Air suspension 45' (0.75°) or less -0°30' +- 45' (-0.50° +- 0.75°) Right-left error 45' (0.75°) or less -0°09' +- 45' (-0.15° +- 0.75°) 4WD Except air suspension Right-left error 4WD Air suspension 45' (0.75°) or less -0°10' +- 45' (-0.17° +- 0.75°) Right-left error 45' (0.75°) or less SS SS–58 SERVICE SPECIFICATIONS – SUSPENSION Caster 2WD Except air suspension 3°23' +- 45' (3.38° +- 0.75°) Right-left error 45' (0.75°) or less 2WD Air suspension 3°33' +- 45' (3.55° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Except air suspension 3°13' +- 45' (3.22° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Air suspension SS Front wheel alignment 3°22' +- 45' (3.37° +- 0.75°) Right-left error 45' (0.75°) or less Steering axis inclination 2WD Except air suspension 12°58' +- 45' (12.97° +- 0.75°) Right-left error 45' (0.75°) or less 2WD Air suspension 13°00' +- 45' (13.00° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Except air suspension 12°39' +- 45' (12.65° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Air suspension 12°40' +- 45' (12.67° +- 0.75°) Right-left error 45' (0.75°) or less Upper arm ball joint turning torque 4.5 N*m (46 kgf*cm, 40 in.*lbf) or less Front suspension Lower arm ball joint turning torque 3.0 N*m (31 kgf*cm, 27 in.*lbf) or less Stabilizer link ball joint turning torque 2.0 N*m (20 kgf*cm, 18 in.*lbf) or less Rear suspension Stabilizer link ball joint turning torque 0.05 to 2.0 N*m (0.5 to 20 kgf*cm, 0.4 to 0.7 in.*lbf) A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 set bolt center C: Ground clearance of rear wheel center D: Ground clearance of strut rod set bolt center SS–60 SERVICE SPECIFICATIONS – TIRE AND WHEEL TIRE AND WHEEL SERVICE DATA Cold tire inflation pressure: (Except MEXICO) SS Cold tire inflation pressure: (MEXICO) Tire size: P265/60R18 109H Front, Rear P265/65R17 110S Front, Rear 220 kPa (2.2 kgf*cm2, 32 psi) P265/70R16 111S Front, Rear Tire size: P265/65R17 112S Front, Rear P265/70R16 111S Front, Rear Tire runout Imbalance after adjustment 200 kPa (2.0 kgf*cm2, 29 psi) 3.0 mm (0.118 in.) or less 265/70R16: 8 g (0.018 lb) or less 265/65R17: 7 g (0.015 lb) or less SS–61 SERVICE SPECIFICATIONS – TIRE AND WHEEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tire pressure monitor valve x Disc wheel 4.0 41 35 in.*lbf Tire pressure monitor receiver set bolt 9.0 92 80 in.*lbf Hub nut 103 1,050 76 SS SS–61 SERVICE SPECIFICATIONS – BRAKE CONTROL BRAKE CONTROL TORQUE SPECIFICATIONS N*m kgf*cm ft.*lbf Front speed sensor x Steering knuckle Part Tightened 8.3 85 73 in.*lbf Rear speed sensor x Axle hub 8.3 85 73 in.*lbf SS SS–62 SERVICE SPECIFICATIONS – BRAKE BRAKE SERVICE DATA SS Brake pedal height (from dash panel) 166.1 to 176.1 mm (6.539 to 6.933 in.) Rod operating adapter length 232.5 to 242.5 mm (9.154 to 9.547 in.) Brake pedal free play Pedal free play: 1 to 6 mm (0.04 to 0.24 in.) Stop light switch clearance 0.5 to 2.5 mm (0.020 to 0.098 in.) Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf) More than 55 mm (2.17 in.) Front pad lining thickness Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) Front disc thickness Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) Front disc runout Maximum disc runout: 0.05 mm (0.0020 in.) Rear pad lining thickness Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Rear disc thickness Standard thickness: 18.0 mm (0.709 in.) Minimum thickness: 16.0 mm (0.630 in.) Rear disc runout Maximum disc runout: 0.20 mm (0.0079 in.) SS–63 SERVICE SPECIFICATIONS – BRAKE TORQUE SPECIFICATIONS Part Tightened N*m Bleeder plug kgf*cm ft.*lbf 11 112 8 Brake pedal sub-assembly x Brake pedal support sub-assembly 34.3 350 25 Brake pedal support sub-assembly x Body 14.2 145 10 Brake pedal support sub-assembly x Brake pedal support reinforcement 34.3 350 25 Front disc brake cylinder x Steering knuckle 123 1,254 91 Flexible hose x Disc brake cylinder assembly rear 31 316 23 Rear disc brake cylinder mounting x Axle hub 105 1,071 77 Rear disc brake cylinder mounting x Disc brake cylinder assembly rear 88 897 65 Flexible hose x Disc brake cylinder assembly rear 31 316 23 Skid control ECU assembly set bolt 5.0 51 44 in.*lbf Junction block assembly x Reinforcement 8.4 85 74 in.*lbf Master cylinder solenoid set bolts 32 326 24 Brake master cylinder x Pin 7.8 80 69 in.*lbf Rod Operating adapter lock nut 26 260 19 Master cylinder push rod clevis lock nut 26 260 19 Brake booster pump x Brake booster accumulator 57 585 42 Brake master cylinder x Brake booster pump bracket No. 2 7.8 80 69 in.*lbf Master cylinder solenoid x Brake booster pump assembly wire harness 2.9 30 26 in.*lbf Brake master cylinder assembly Brake actuator tube No.1 union nuts 14 (15) 143 (155) 10 (11) Brake line union nut 14 (15) 145 (158) 10 (11) Brake master cylinder x Brake actuator bracket No. 1 7.8 80 69 in.*lbf Brake master cylinder x Brake actuator bracket No. 3 7.8 80 69 in.*lbf Brake master cylinder x Master cylinder reservoir 1.7 17 15 in.*lbf Brake master cylinder set nuts 14 145 10 ( ): For use without SST SS SERVICE SPECIFICATIONS – PARKING BRAKE SS–63 PARKING BRAKE SERVICE DATA Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 5 to 7 clicks Rear brake disc inside diameter (Standard) 210 mm (8.27 in.) Rear brake disc inside diameter (Maximum) 211 mm (8.30 in.) Parking brake shoe lining thickness (Standard) 4.0 mm (0.158 in.) Parking brake shoe lining thickness (Maximum) 1.0 mm (0.039 in.) SS SS–64 SERVICE SPECIFICATIONS – PARKING BRAKE TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Wheel nut 112 1,137 83 Parking brake lock nut (Front side) 13 127 9 Parking brake lock nut (Rear side) 5.4 55 48 in.*lbf Parking brake pedal x Body 13 127 9 Floor heat insulator x Body 13 127 9 Parking brake cable assembly No. 1 x Body (Bolt) 13 127 9 Parking brake cable assembly No. 1 x Body (Nut) 6.0 61 53 in.*lbf Parking brake cable assembly No. 3 x Fram 13 127 9 Parking brake cable assembly No. 3 x Backing plate 8.0 82 71 in.*lbf SS–64 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN SERVICE DATA Steering wheel free play SS Maximum 30 mm (1.18 in.) SS–65 SERVICE SPECIFICATIONS – STEERING COLUMN TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm Steering wheel set nut 50 510 37 Steering wheel pad set screw ("Torx" screw) 8.8 90 78 in.*lbf Steering column assembly set nut 26 270 20 Main shaft assembly x Steering intermediate shaft 36 360 20 Steering sliding yoke x Intermediate shaft No. 2 36 360 27 Power steering gear box x Intermediate shaft No. 2 36 360 27 Steering sliding yoke x Intermediate shaft 36 360 27 Telescopic lever lock bolt x Telescopic lever 23 240 17 Steering column protector x Steering column ft.*lbf 6 60 52 in.*lbf Turn signal bracket x Steering column 5.7 58 50 in.*lbf Tilt steering bolt 20 204 15 SS SERVICE SPECIFICATIONS – POWER STEERING SS–65 POWER STEERING SERVICE DATA POWER STEERING FLUID Fluid level rise Maximum: 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed Minimum: 8,336 kPa (85 kgf/cm2, 1,209 psi) STEERING WHEEL Steering effort at idle speed (Reference) 6 N*m (60 kgf*cm, 53 in.*lbf) POWER STEERING VANE PUMP Vane pump rotating torque Vane pump shaft and vane pump housing oil clearance 0.28 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less STD: Maximum: 0.03 to 0.05 mm (0.0012 to 0.0020 in.) 0.07 mm (0.0028 in.) Vane plate height Minimum: 8.6 mm (0.33858 in.) Vane plate thickness Minimum: 1.397 mm (0.05500 in.) Vane plate length Minimum: 14.991 mm (0.59020 in.) Clearance between the rotor groove and plate Maximum: 0.033 mm (0.00130 in.) Spring free length Minimum: 33.2 mm (1.307 in.) POWER STEERING GEAR Total preload (Tie rod rotating torque) (Turning) 0.29 to 1.96 N*m (2.9 to 20.0 kgf*cm, 2.57 to 17.35 in.*lbf) Total preload in center position (Control valve rotating torque) (Turning) 1.35 to 1.55 N*m (13.77 to 15.81 kgf*cm, 11.94 to 13.71 in.*lbf) SS SS–66 SERVICE SPECIFICATIONS – POWER STEERING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 24 240 17 POWER STEERING VANE PUMP Vane pump housing rear x Vane pump housing front SS Pressure port union 83 850 61 Suction port union set bolt 13 130 9 Vane pump assembly x Vane pump bracket rear 43 438 32 Vane pump assembly x Stud bolt 22 224 16 Vane pump pulley set nut 44 449 32 Pressure feed tube assembly x Vane pump assembly 51 520 38 Pressure feed tube assembly clamp set bolt 7.8 80 69 in.*lbf POWER STEERING LINK ASSEMBLY Control valve housing set bolt 18 184 13 Bering guide nut 25 250 18 Rack guide spring cap 25 250 18 Rack guide spring cap lock nut 69 (65) 700 (660) 51 (48) Power steering rack x Rack end 103 (98) 1,050 (1,000) 76 (72) 88 897 65 25 (23) 250 (230) 18 (17) 100 1,020 74 44 (42) 449 (428) 32 (31) 28 286 21 Tie rod assembly lock nut Turn pressure tube union nut Power steering link assembly set bolt and nut Pressure feed and return tubes x Control valve housing Pressure feed tube clamp set bolt Outlet return tube 44 (42) 449 (428) 32 (31) Tie rod end x steering knuckle 91 928 67 Stabilizer bar front bracket set bolt 40 408 30 ( ): For use without SST SS–66 SERVICE SPECIFICATIONS – AIR CONDITIONING AIR CONDITIONING SERVICE DATA SS Refrigerant charge volume (Standard) 570 to 630 g (20.1 to 22.22 oz.) Magnetic clutch clearance (2UZ-FE) 0.35 to 0.60 mm (0.013 to 0.023 in.) Magnetic clutch clearance (1GR-FE) 0.35 to 0.60 mm (0.013 to 0.023 in.) SS–67 SERVICE SPECIFICATIONS – AIR CONDITIONING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Air conditioning tube assembly x Cooler evaporator sub-assembly No. 1 3.5 35 30 in.*lbf Air conditioner unit assembly x Body 5.5 55 48 in.*lbf Air conditioner unit assembly x Instrument panel reinforcement 9.8 100 87 in.*lbf Wiring harness x Instrument panel reinforcement 83 85 73 in.*lbf Steering column assembly x Instrument panel reinforcement 26 265 19 AIR CONDITIONER UNIT BLOWER UNIT Blower assembly x Body 5.5 55 48 in.*lbf Blower assembly x Instrument panel reinforcement 9.8 100 87 in.*lbf 18 183 13 COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) Magnet clutch hub x Cooler compressor assembly Compressor and magnetic clutch x Engine (Bolt) 46 469 34 Compressor and magnetic clutch x Engine (Nut) 24 245 18 Discharge hose sub-assembly x Compressor and magnetic clutch 9.8 100 87 in.*lbf Suction hose sub-assembly x Compressor and magnetic clutch 9.8 100 87 in.*lbf 18 183 13 Compressor and magnetic clutch x Engine 24 245 18 Discharge hose sub-assembly x Compressor and magnetic clutch 9.8 100 87 in.*lbf Suction hose sub-assembly x Compressor and magnetic clutch 9.8 100 87 in.*lbf COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) Magnet clutch hub x Cooler compressor assembly CONDENSER Cap x Cooler condenser core 2.9 29 25 in.*lbf Cooler condenser core x Body 5.4 55 48 in.*lbf Air conditioning tube assembly x Cooler condenser core 5.4 55 48 in.*lbf Discharge hose sub-assembly x Cooler condenser core 5.4 55 48 in.*lbf SS SS–67 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATIONS N*m kgf*cm ft.*lbf Steering pad x Steering wheel assembly Part Tightened 8.8 90 78 in.*lbf Steering wheel assembly x Steering column assembly 50 510 37 Front passenger airbag assembly x Instrument panel reinforcement 20 200 14 Curtain shield airbag assembly x Body 9.8 100 87 in.*lbf Center airbag sensor assembly x Body 17.5 178 13 Front airbag sensor x Body (Length A) 7.5 76 66 in.*lbf Front airbag sensor x Body (Length B) 9.0 92 80 in.*lbf Side airbag sensor x Body 17.5 178 13 Rear airbag sensor x Body 17.5 178 13 Seat position airbag sensor x Front seat assembly LH 8.0 82 71 in.*lbf SS SS–68 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf FRONT SEAT BELT SS Front seat outer belt assembly RH (Upper part of retractor) x Body 8.5 87 75 in.*lbf Front seat outer belt assembly RH (Lower part of retractor) x Body 42 430 31 Front seat inner belt assembly x Front seat 42 430 31 Front shoulder belt anchor adjuster assembly x Body 42 430 31 Front seat outer belt floor anchor x Body 42 430 31 Front seat outer belt shoulder anchor x Body 42 430 31 42 430 31 REAR SEAT BELT (2nd seat type) Rear seat belt assembly outer center x Body Rear seat 3 point type belt assembly inner x Body 42 430 31 Rear seat inner with center belt assembly x Body 42 430 31 Rear seat 3 point type belt assembly outer (Upper part of retractor) x Body 8.5 87 75 in.*lbf Rear seat 3 point type belt assembly outer (Lower part of retractor) x Body 42 430 31 Rear seat 3 point type belt assembly outer (Floor anchor side) x Body 42 430 31 REAR SEAT BELT (3rd seat type) 3 point type belt assembly LH x Rear seat assembly 42 430 31 Rear seat 3 point type belt assembly inner x Body 42 430 31 Rear seat belt assembly inner x Body 42 430 31 Rear No. 1 seat belt assembly inner LH x Body 42 430 31 Rear seat 3 point type belt assembly outer (Upper part of retractor) x Body 8.5 87 75 in.*lbf Rear seat 3 point type belt assembly outer (Lower part of retractor) x Body 42 430 31 Rear seat 3 point type belt assembly outer (Floor anchor side) x Body 42 430 31 Rear seat 3 point type belt assembly outer (Shoulder anchor side) x Body 42 430 31 SS–69 SERVICE SPECIFICATIONS – WIPER AND WASHER WIPER AND WASHER TORQUE SPECIFICATIONS N*m kgf*cm ft.*lbf Wiper motor x Wiper link Part Tightened 7.5 76 66 in.*lbf Wiper link x Body 7.0 71 62 in.*lbf Wiper arm x Wiper link 25 255 18.4 Rear wiper motor x Body 5.5 56 49 in.*lbf Rear wiper motor x Rear wiper arm 5.5 56 49 in.*lbf SS SS–70 SERVICE SPECIFICATIONS – HORN HORN TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf 20 199 15 20 199 15 HIGH PITCHED HORN ASSEMBLY High pitched horn assembly x Body LOW PITCHED HORN ASSEMBLY SS Low pitched horn assembly x Body SS–71 SERVICE SPECIFICATIONS – OTHER SYSTEM OTHER SYSTEM TORQUE SPECIFICATIONS Part Tightened Voltage inverter assembly x Body N*m kgf*cm ft*lbf 7.0 71 62 in.*lbf SS SS–72 SERVICE SPECIFICATIONS – MIRROR MIRROR TORQUE SPECIFICATIONS Part Tightened Outer rear view mirror assembly x Front door SS N*m kgf*cm ft*lbf 8.0 82 71 in.*lbf SS–73 SERVICE SPECIFICATIONS – INSTRUMENT PANEL INSTRUMENT PANEL TORQUE SPECIFICATIONS Part Tightened Instrument Panel Reinforcement x Passenger Airbag N*m kgf*cm ft*lbf 20 204 15 SS SS–74 SERVICE SPECIFICATIONS – SEAT SEAT TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf 8.0 82 71 in.*lbf FRONT SEAT ASSEMBLY LH (MANUAL SEAT TYPE) Seat position airbag sensor x Seat adjuster assembly Seatback cover bracket x Seat adjuster assembly SS 5.5 56 48 in.*lbf Front seat Inner belt assembly LH x Seat adjuster assembly (w/ Side airbag) 42 428 31 Front seat assembly LH x Body 37 375 27 8.0 82 71 in.*lbf FRONT SEAT ASSEMBLY LH (POWER SEAT TYPE) Seat position airbag sensor x Seat adjuster assembly Seatback cover bracket x Seat adjuster assembly 5.5 56 48 in.*lbf Front seat Inner belt assembly LH x Seat adjuster assembly (w/ Side airbag) 42 428 31 Front seat assembly LH x Body 37 375 27 42 428 31 REAR NO. 1 SEAT ASSEMBLY Seat belt assembly outer center x Body Bolt Nut Seatback hinge x Seatback frame 42 428 31 37 377 27 Seatback hinge x Body 18 184 13 Seatlock striker x Body 18 184 13 Seatback hinge center x Body 18 184 13 Seatback hinge center x Seatback frame 37 377 27 Armrest assembly center x Seatback assembly 8.0 82 71 in.*lbf No. 1 seat hinge assembly x Seat cushion frame 18 184 13 No. 1 seat hinge assembly x Body 37 377 27 REAR NO. 1 SEAT (3rd SEAT) Rear No. 1 seat LH and RH x Body 37 375 27 Rear seat belt inner x Rear seat cushion frame 42 430 31 Rear seat belt inner No. 2 x Rear seat cushion frame 42 430 31 Rear seat 3-joint type belt assembly LH x Rear seat cushion frame 42 430 31 Rear seatback frame x Rear seat cushion frame 50 510 37 REAR NO. 2 SEAT (3rd SEAT) Seat No. 1 cushion frame x Rear seat frame 18 185 13 Rear seat belt inner x Rear seat frame 42 430 31 SS–75 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR ENGINE HOOD / DOOR TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf Auxiliary catch hook x Hood 8.0 82 71 in.*lbf Auxiliary catch release lever x Hood 8.0 82 71 in.*lbf Hood x Hood hinge 13 130 10 Hood x Hood lock 8 82 71 in.*lbf Hood bulge x Hood 5.5 56 49 in.*lbf Hood support x Hood 17.5 180 13 Radiator grille x Hood 5.5 56 49 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door frame sub-assembly rear lower x Door panel 5 51 42 in.*lbf Door glass x Door panel 8 82 71 in.*lbf Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 Door lock x Door panel 5.0 51 42 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 4 41 35 in.*lbf Door outside handle frame x Door panel 4 41 35 in.*lbf Door wire x Door panel 8 82 71 in.*lbf Front NO. 2 speaker x Door Panel 5 51 42 in.*lbf HOOD FRONT DOOR Outer view mirror x Door panel Power window regulator motor x Window regulator Window regulator x Door panel 8 82 71 in.*lbf 5.4 55 48 in.*lbf 8 82 71 in.*lbf REAR DOOR Division bar x Door panel 5 51 44 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door glass x Door panel 8 82 71 in.*lbf Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 Door lock x Door panel 5.5 56 49 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 4 41 35 in.*lbf Door outside handle frame x Door panel 4 41 35 in.*lbf Outer view mirror x Door panel Power window regulator motor x Window regulator Window regulator x Door panel 8 82 71 in.*lbf 5.4 55 48 in. lbf 8 82 71 in.*lbf BACK DOOR Door glass x Door panel 8 82 71 in.*lbf Door hinge x Door panel 8 82 71 in.*lbf Door hinge x Body 8 82 71 in.*lbf Door lock x Door panel 8 82 71 in.*lbf Door lock cylinder x Door panel 5.5 56 49 in.*lbf Door lock striker x Body 27 275 20 Dumper rubber x Body 5.5 56 49 in.*lbf SS SS–76 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR N*m kgf*cm ft*lbf Power window regulator motor x Window regulator Part Tightened 1.7 17 15 in.*lbf Stopper lower x Door panel 5.5 56 49 in.*lbf 8 82 71 in.*lbf Window regulator x Door panel SS SS–77 SERVICE SPECIFICATIONS – EXTERIOR EXTERIOR TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf Front bumper reinforcement x Body 58 591 43 Front bumper cover x Radiator grille lower 7.5 77 66 in.*lbf Bolt: 8.0 82 71 in.*lbf Screw: 3.0 31 27 in.*lbf Front bumper side support x Body 3.0 31 27 in.*lbf Front bumper reinforcement plate x Body 8.0 82 71 in.*lbf Nut: 5.0 51 44 in.*lbf Bolt: 8.0 82 71 in.*lbf No. 2 rear bumper reinforcement x Body 25 255 18 Rear bumper side mounting bracket x Body 8.0 82 71 in.*lbf Rear bumper bar reinforcement x Body 5.0 51 44 in.*lbf Rear bumper end retainer x Body 3.0 31 27 in.*lbf Rear bumper retainer upper x Body 3.0 31 27 in.*lbf Bolt: 8.0 82 71 in.*lbf Screw: 5.0 51 44 in.*lbf Rear spoiler x Back door 7.0 71 62 in. lbf Rear spoiler x Center stop light 2.5 25 22 in.*lbf 10.0 102 7.4 Side step bracket x Body 19.5 199 14 Side step bracket x LH Step sub-assembly 5.0 51 44 in.*lbf Rear quarter outside moulding sub-assembly x Body 5.0 51 44 in.*lbf Front wheel opening extension sub-assembly x Body 5.0 51 44 in.*lbf FRONT BUMPER Front bumper cover x Body Front bumper side mounting bracket x Body REAR BUMPER Rear bumper cover x Body REAR SPOILER ROOF DRIP SIDE FINISH MOULDING LH Roof rack bracket front LH x Body LH STEP SUB-ASSEMBLY OUTSIDE MOULDING Step sub-assembly x Body 5.0 51 44 in.*lbf Rocker panel moulding sub-assembly x Body 5.0 51 44 in.*lbf Front door outside moulding sub-assembly 5.0 51 44 in.*lbf SS SS–78 SERVICE SPECIFICATIONS – INTERIOR INTERIOR TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf ROOF HEADLINING SS Front seat outer belt x Body 42 430 31 Rear seat outer belt x Body 42 430 31 SERVICE SPECIFICATIONS – SLIDING ROOF SS–79 SLIDING ROOF SERVICE DATA Sliding roof Difference in level between sliding roof weatherstrip and roof panel Front end and rear end 0 +- 1.5 mm (0 +- 0.059 in.) Corner of rear side 0 +- 2.0 mm (0 +- 0.079 in.) Difference in level between sliding roof glass and roof panel front end and rear end Front end and rear end 6.7 +- 0.7 mm (0.264 +- 0.028 in.) SS SS–80 SERVICE SPECIFICATIONS – SLIDING ROOF TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft*lbf Sliding roof glass assembly x Drive cable 4.0 41 35 in.*lbf Sliding roof housing sub-assembly x Body 5.5 56 49 in.*lbf Sliding roof housing sub-assembly x Sliding roof drive gear 5.4 55 48 in.*lbf MAINTENANCE – OUTSIDE VEHICLE MA–1 OUTSIDE VEHICLE GENERAL MAINTENANCE Check the parts of the vehicle described below on a daily basis. Performing maintenance checks on the vehicle is the owner's responsibility. The owner may take the vehicle to a service center but it is recommended that the owner perform the checks. In most cases, special tools are not required. The procedures for general maintenance are as follows. 1. GENERAL NOTES • Maintenance requirements very depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES (a) Check the tire pressure with a gauge. Make adjustments if necessary. (b) Check the surfaces of tires for cuts, damage or excessive wear. 3. WHEEL NUTS (a) Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION Check the maintenance schedule in the owner's manual supplement. 5. WINDSHIELD WIPER BLADES (a) Check the blades for wear or cracks when they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS (a) Check under the vehicle for leaking fuel, oil, water and other fluids. NOTICE: If you smell gasoline fumes or notice any leaks, locate the cause and correct it. 7. DOORS AND ENGINE HOOD (a) Check that all of the doors operate smoothly, and that all the latches lock securely. (b) When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening. MA MA–2 MAINTENANCE – INSIDE VEHICLE INSIDE VEHICLE GENERAL MAINTENANCE Check the parts of the vehicle described below on a daily basis. Performing maintenance checks on the vehicle is the owner's responsibility. The owner may take the vehicle to a service center but it is recommended that the owner perform the checks. In most cases, special tools are not required. The procedures for general maintenance are as follows. MA 1. GENERAL NOTES • Maintenance requirements very depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Determine the appropriate time to service the vehicle using either miles driven or time (months) elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance unless noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink. Also, check that they have enough brightness. 3. WARNING LIGHTS AND BUZZERS (a) Check that all the warning lights and buzzers are working. 4. HORNS (a) Check that the horn is working. 5. WINDSHIELD GLASS (a) Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check that the washers are aimed properly. Also, check that the washer fluid hits the center of the operating range of each wiper on the windshield. (b) Check that the wipers streak or not. Replace the wiper if necessary. 7. WINDSHIELD DEFROSTER (a) When the heater or air conditioner is on the defroster setting, check that air comes out of the defroster outlet. 8. REAR VIEW MIRROR (a) Check that the rear view mirror is securely mounted. 9. SUN VISORS (a) Check that the sun visors move freely and are securely mounted. MAINTENANCE – INSIDE VEHICLE MA–3 10. STEERING WHEEL (a) Check that the steering wheel has the proper free play. Also check for steering difficulty, unusual noises (See page SR-2). 11. SEATS (a) Check that the seat adjusters, seatback recliner and other front seat controls operate smoothly. (b) Check that all the latches lock securely in all positions. (c) Check that the locks hold securely in all positions. (d) Check that the headrests move up and down smoothly and that the locks hold securely in all latched positions. (e) When the rear seatbacks are folded down, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 13. ACCELERATOR PEDAL (a) Check that the pedal operates smoothly. In other words, check that the pedal does not have uneven pedal resistance or become stuck in certain positions. 14. BRAKE PEDAL (a) Check that the pedal operates smoothly. (b) Check that the pedal has the proper reserve distance and free play (See page BR-8). (c) Start the engine and check the brake booster function. 15. BRAKES (a) In a safe place, check that the vehicle remains straight when applying the brakes. 16. PARKING BRAKE (a) Check that the pedal or lever has the proper range of motion (See page PB-1). (b) On a low incline, check that the parking brake alone can stabilize the vehicle. 17. AUTOMATIC TRANSMISSION "PARK" MECHANISM (a) Check the lock release button of the shift lever for proper and smooth operation. (b) When the shift lever is in the P position and all brakes are released on a low incline, check that the vehicle is stable. MA MA–4 MAINTENANCE – UNDER HOOD UNDER HOOD GENERAL MAINTENANCE 1. GENERAL NOTES • Maintenance requirements very depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or time elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance unless noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID (a) Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL (a) Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and free of leaves, dirt and bugs. (b) Check the hoses for cracks, kinks, rotting or loose connections. 5. BATTERY ELECTROLYTE LEVEL (a) Check that the electrolyte level of all the battery cells is between the upper and lower lines on the case. HINT: If the electrolyte level is difficult to see, lightly shake the vehicle. 6. BRAKE FLUID LEVEL (a) Check that the brake fluid levels are near the upper level line on the see-through reservoirs. 7. ENGINE DRIVE BELT (a) Check the drive belt for fraying, cracks, wear or oiliness. 8. ENGINE OIL LEVEL (a) Check the level on the dipstick with the engine turned off. 9. POWER STEERING FLUID LEVEL (a) Check the level on the dipstick. (b) The level should be in the "HOT" or "COLD" range depending on the fluid temperature. MA 10. AUTOMATIC TRANSMISSION FLUID (a) Visually check the overflow plug and oil pan for fluid leaks or traces of fluid. MAINTENANCE – UNDER HOOD MA–5 11. EXHAUST SYSTEM (a) Check for unusual exhaust sounds or abnormal exhaust fumes. Locate the cause and correct it. MA MA–6 MAINTENANCE – ENGINE ENGINE GENERAL MAINTENANCE HINT: Inspect these items on a cooled down engine. 1. Type See procedures 2UZ-FE See page EM-19 2. MA REPLACE TIMING BELT INSPECT DRIVE BELT Type See procedures 1GR-FE See page EM-6 2UZ-FE See page EM-6 3. REPLACE SPARK PLUGS Type See procedures 1GR-FE See page IG-3 2UZ-FE See page IG-1 4. REPLACE ENGINE OIL AND OIL FILTER Type See procedures 1GR-FE See page LU-1 2UZ-FE See page LU-1 5. REPLACE ENGINE COOLANT Type See procedures 1GR-FE See page CO-1 2UZ-FE See page CO-1 6. INSPECT EXHAUST PIPES AND MOUNTINGS (a) Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 7. INSPECT BATTERY Type See procedures 1GR-FE See page CH-3 2UZ-FE See page CH-3 8. INSPECT AIR CLEANER FILTER (a) Remove the air filter. (b) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. (c) Reinstall the air filter. 9. REPLACE AIR CLEANER FILTER (a) Replace the air filter with a new one. 10. INSPECT FUEL TANK CAP GASKET A054323 Type See procedures 1GR-FE See page EC-2 2UZ-FE See page EC-5 MA–7 MAINTENANCE – ENGINE 11. INSPECT FUEL LINES AND CONNECTIONS AND FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS (a) Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. 12. INSPECT CHARCOAL CANISTER Type See procedures 1GR-FE See page EC-2 2UZ-FE See page EC-5 13. INSPECT VALVE CLEARANCE Type See procedures 1GR-FE See page EM-8 2UZ-FE See page EM-7 MA MA–8 MAINTENANCE – BRAKE BRAKE GENERAL MAINTENANCE 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection. (a) Using a mirror, check the entire circumference and length of the brake lines and hoses for: • Damage • Wear • Deformation • Cracks • Corrosion • Leaks • Bends • Twists (b) Check all the clamps for tightness and the connections for leakage. (c) Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system. (d) Check that the lines are installed properly and pass through the center of the grommets. 2. INSPECT BRAKE PEDAL (See page BR-8) 3. INSPECT PARKING BRAKE (See page PB-1) 4. INSPECT BRAKE LININGS AND DRUMS (a) Check the brake linings and drums. Also check the brake linings of parking brake. HINT: • If a squealing or scraping noise is heard from the brake while driving, check the pad wear indicator. • If there are traces of the indicator contacting the disc rotor, the disc pad should be replaced. 5. INSPECT FRONT BRAKE (a) Check the front brake pads and discs (See page BR-40). 6. INSPECT REAR BRAKE (a) Check the rear brake pads, discs linings and drums (See page BR-46). 7. INSPECT OR CHANGE BRAKE FLUID (See page BR-3) Fluid: SAE J1703 or FMVSS No. 116 DOT3 P009958E01 MA S002432 MA–9 MAINTENANCE – CHASSIS CHASSIS GENERAL MAINTENANCE 1. INSPECT STEERING LINKAGE & GEAR HOUSING (a) Check the steering wheel free play (See page SR2). (b) Check the steering linkage for looseness or damage. (1) Check that the tie rod ends do not have excessive play. (2) Check that the dust seals and boots are not damaged. (3) Check that the boot clamps are not loose. (4) Check that the steering gear housing is not damaged. (5) Check that the connector are properly connected to the steering gear housing. 2. INSPECT STEERING GEAR HOUSING OIL (a) Check the steering gear housing oil leakage. If leakage is found, check and repair the cause. 3. INSPECT BALL JOINT AND DUST COVER (a) Inspect the ball joints for excessive looseness. (1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires. (2) Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. (3) Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels. (4) Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is any play, replace the ball joint. (b) Check the dust cover for damage. 4. INSPECT DRIVE SHAFT BOOTS (a) Check the drive shaft boots for loose clamps, grease leakage, kinks or damage. 5. CHECK AUTOMATIC TRANSMISSION FLUID (a) Visually check the transmission for fluid leakage. If oil is leaking, find the cause and repair it. Type See procedures A750F See page AT-316 A750E See page AT-304 MA MA–10 MAINTENANCE – CHASSIS 6. MA INSPECT TRANSFER OIL (for 4WD) (a) Visually check the transfer for oil leakage. If oil is leaking, find the cause and repair it. Type See procedures VF4AM See page TF-3 VF4BM See page TF-3 7. INSPECT FRONT DIFFERENTIAL OIL SEAL (for 4WD) (See page DF-3) 8. INSPECT REAR DIFFERENTIAL OIL (See page DF-3) 9. INSPECT FRONT AND REAR SUSPENSION Type See procedures Front Suspension See page SP-12 Rear Suspension See page SP-38 10. LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS (a) 4WD: Lubricate propeller shaft, referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting. A: Propeller Shaft Spider B: Propeller Shaft Sliding Yoke B A C C: Double-Cardan Joint C C B065528E03 Grease grade Spider Lithium base chassis grease NLGI No. 2 Slide yoke and double-cardan joint Molybdenum disulphide lithium base chassis grease NLGI No. 2 (b) Tighten the bolts for propeller shaft. Type See procedures 2WD See page PR-6 4WD See page PR-12 11. ROTATE TIRES (See page TW-2) MAINTENANCE – BODY MA–11 BODY GENERAL MAINTENANCE 1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY (a) Where necessary, tighten all the parts of the chassis. • Front axle and suspension • Drive train • Rear axle and suspension • Brake system • Engine mounting, etc. (b) Where necessary, tighten all the parts of the body. • Seat belt system • Seat • Doors and hood • Body mountings • Fuel tank • Exhaust pipe system, etc. 2. REPLACE AIR CONDITIONING FILTER (a) Remove the glove compartment assembly. (b) Remove the filter case from the filter outlet. (c) Remove the filter from the filter case. (d) Replace the filter with a new one. (e) Installation is in the reverse order. 3. ROAD TEST (a) Check the engine and chassis for abnormal noises. (b) Check that the vehicle does not wander or pull to one side. (c) Check that the brakes work properly and do not drag. (d) Do setting of the parking brake shoes. 4. BODY INSPECTION (a) Check the body exterior for dents, scratches and rust. (b) Check the underbody for rust and damage. If necessary, replace or repair. 5. FINAL INSPECTION (a) Check the operation of the body parts. (1) Hood • Auxiliary catch operates properly. • Hood locks securely when closed. (2) Front and rear doors • Door locks operate properly. • Doors close properly. (3) Back door • Door lock operates properly. (4) Seats • Seat adjusts easily and locks securely in any position. • Front seatback locks securely in any position. MA MA–12 MAINTENANCE – BODY • Folding-down rear seatbacks lock securely. (5) Be sure to deliver a clean car. Especially check. • Steering wheel • Shift lever knob • All switch knobs • Door handles • Seats MA ES–3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION ENGINE ROOM R/B - A/F SENSOR HEATER RELAY - EFI RELAY COMBINATION METER ASSEMBLY - FUEL PUMP RELAY - EFI FUSE - ETCS FUSE - STARTER RELAY DLC3 - STARTER NO. 2 FUSE CHARCOAL CANISTER ASSEMBLY - CIRCUIT OPENING RELAY AIR FUEL RATIO SENSOR (BANK 1) ECM MASS AIR FLOW METER VAPOR PRESSURE SENSOR ASSEMBLY THROTTLE BODY (THROTTLE W/ MOTOR BODY ASSEMBLY) FUEL SUCTION W/PUMP AND GAUGE TUBE ASSEMBLY ACCELERATOR PEDAL ROD (ACCELERATOR PEDAL POSITION SENSOR) HEATED OXYGEN SENSOR (BANK 1) VSV FOR EVAP HEATED OXYGEN SENSOR (BANK 2) VSV FOR ACIS AIR FUEL RATIO SENSOR (BANK 2) A119838E06 ES ES–4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IGNITION COIL ASSEMBLY ES FUEL INJECTOR ASSEMBLY KNOCK SENSOR (BANK 1) VVT SENSOR (BANK 1) ENGINE COOLANT TEMPERATURE SENSOR CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 1) VVT SENSOR (BANK 2) KNOCK SENSOR (BANK 2) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (BANK 2) CRANKSHAFT POSITION SENSOR A119839E07 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–5 HOW TO PROCEED WITH TROUBLESHOOTING HINT: The intelligent tester can be used in steps 2, 3, 4, 6 and 9. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CONNECT INTELLIGENT TESTER TO DLC3 HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 3 CHECK DTC AND FREEZE FRAME DATA (a) Check the DTC(s) and freeze frame data (See page ES31). HINT: Record or print DTCs and freeze frame data, if necessary. NEXT 4 CLEAR DTC AND FREEZE FRAME DATA (a) Clear the DTC(s) and freeze frame data (See page ES31). NEXT 5 CONDUCT VISUAL INSPECTION NEXT 6 SET CHECK MODE DIAGNOSIS (a) Set the check mode (See page ES-35). NEXT 7 CONFIRM PROBLEM SYMPTOMS HINT: If the engine does not start, perform steps 9 and 11 first. ES ES–6 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result B Result Proceed to Malfunction does not occur A Malfunction occurs B GO TO STEP 9 A 8 ES SIMULATE SYMPTOMS NEXT 9 CHECK DTC (a) Check the DTC (See page ES-31). Result B Result Proceed to Trouble code A No code B GO TO STEP 11 A 10 REFER TO DTC CHART HINT: Refer to the DTC chart (See page ES-50). NEXT GO TO STEP 13 11 CONDUCT BASIC INSPECTION HINT: Refer to "BASIC INSPECTION" (See page ES-7). Result B A Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B GO TO STEP 16 ES–7 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 REFER TO PROBLEM SYMPTOMS TABLE HINT: Refer to "PROBLEM SYMPTOMS TABLE" (See page ES21). Result Result Proceed to Malfunctioning circuit confirmed A Malfunctioning parts confirmed B B GO TO STEP 16 ES A 13 CHECK ECM POWER SOURCE CIRCUIT HINT: Refer to "ECM POWER SOURCE CIRCUIT" (See page ES372). NEXT 14 CONDUCT CIRCUIT INSPECTION Result Result Proceed to Malfunction not confirmed A Malfunction confirmed B B GO TO STEP 17 A 15 CHECK FOR INTERMITTENT PROBLEMS HINT: Refer to "CHECK FOR INTERMITTENT PROBLEMS" (See page ES-7). NEXT GO TO STEP 17 16 NEXT CONDUCT PARTS INSPECTION ES–8 17 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IDENTIFY PROBLEM NEXT 18 ADJUST AND/OR REPAIR NEXT ES 19 NEXT END CONDUCT CONFIRMATION TEST 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–9 CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS HINT: For use of the intelligent tester only: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with an intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic. (a) Clear DTCs (See page ES-31). (b) Switch the ECM from normal mode to check mode using an intelligent tester (See page ES-35). (c) Perform a simulation test (See page IN-30). (d) Check and wiggle the harness(es), connector(s) and terminal(s) (See page IN-38). ES ES–10 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When a malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Carry out this check with the engine stopped and ignition switch OFF. Result ES NG Result Proceed to 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK WHETHER ENGINE CRANKS NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 3 CHECK WHETHER ENGINE STARTS NG GO TO STEP 6 OK 4 CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil. NG REPLACE AIR FILTER OK 5 CHECK IDLING SPEED (a) Check the idling speed (See page EM-2). 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–11 TROUBLESHOOT IDLING SPEED AND PROCEED TO NEXT STEP OK 6 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-4). NG TROUBLESHOOT FUEL PRESSURE AND PROCEED TO NEXT STEP OK 7 ES CHECK FOR SPARK (a) Check for spark (See page IG-1). NG OK PROCEED TO PROBLEM SYMPTOMS TABLE TROUBLESHOOT SPARK AND PROCEED TO NEXT STEP ES–56 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: The parameters listed in the chart are for reference only. Factors such as instrument type may cause readings to differ slightly from stated values. If any DTCs are displayed during a check mode DTC check, check the circuit for the DTCs listed in the table below. For details of each DTC, refer to the "See page" below. SFI SYSTEM: DTC Code Detection Item Trouble Areas MIL Memory See page P0010 Camshaft Position "A" Actuator Circuit (Bank 1) 1. Open or short in Oil Control Valve (OCV) circuit 2. OCV (bank 1) 3. ECM Come on DTC stored ES-59 P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) 1. Valve timing 2. OCV 3. OCV filter 4. Camshaft timing gear assembly 5. ECM Come on Does not come on DTC stored ES-64 P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) Same as DTC P0011 Come on Does not come on DTC stored ES-64 P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) 1. Mechanical system (Timing chain has jumped tooth or chain stretched) 2. ECM Come on DTC stored ES-70 P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) Same as DTC P0016 Come on DTC stored ES-70 P0020 Camshaft Position "A" Actuator Circuit (Bank 2) 1. Open or short in OCV circuit 2. OCV (bank 2) 3. ECM Come on DTC stored ES-59 P0021 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 2) Same as DTC P0011 Come on Does not come on DTC stored ES-64 P0022 Camshaft Position "A" - Timing Over-Retarded (Bank 2) Same as DTC P0011 Come on Does not come on DTC stored ES-64 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) 1. Open in Air-Fuel Ratio (A/F) sensor heater circuit 2. A/F sensor heater (bank 1 sensor 1) 3. A/F sensor heater relay 4. ECM Come on DTC stored ES-73 P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) 1. Short in A/F sensor heater circuit 2. A/F sensor heater (bank 1 sensor 1) 3. A/F sensor heater relay 4. ECM Come on DTC stored ES-73 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) 1. Open in Heated Oxygen (HO2) sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. EFI relay 4. ECM Come on DTC stored ES-78 P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. EFI relay 4. ECM Come on DTC stored ES-78 P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) 1. Open in A/F sensor heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F sensor heater relay 4. ECM Come on DTC stored ES-73 ES ES–57 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Memory See page P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) Detection Item 1. Short in A/F sensor heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F sensor heater relay 4. ECM Trouble Areas Come on MIL DTC stored ES-73 P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) 1. Open in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. EFI relay 4. ECM Come on DTC stored ES-78 P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. EFI relay 4. ECM Come on DTC stored ES-78 P0100 Mass or Volume Air Flow Circuit 1. Open or short in Mass Air Flow (MAF) meter circuit 2. MAF meter 3. ECM Come on DTC stored ES-85 ES P0101 Mass or Volume Air Flow Circuit Range / Performance Problem 1. MAF meter 2 Air induction system 3 PCV hose connections Come on DTC stored ES-92 P0102 Mass or Volume Air Flow Circuit Low Input 1. Open in MAF meter circuit 2. Short in ground circuit 3. MAF meter 4. ECM Come on DTC stored ES-85 P0103 Mass or Volume Air Flow Circuit High Input 1. Short in MAF meter circuit (+B circuit) 2. MAF meter 3. ECM Come on DTC stored ES-85 P0110 Intake Air Temperature Circuit 1. Open or short in Intake Air Temperature (IAT) sensor circuit 2. IAT sensor (built into Mass Air Flow [MAF] meter) 3. ECM Come on DTC stored ES-95 P0111 Intake Air Temperature Sensor Gradient Too High IAT sensor (built into MAF meter) Come on DTC stored ES-101 P0112 Intake Air Temperature Circuit Low Input 1. Short in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Come on DTC stored ES-95 P0113 Intake Air Temperature Circuit High Input 1. Open in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Come on DTC stored ES-95 P0115 Engine Coolant Temperature Circuit 1. Open or short in Engine Coolant Temperature (ECT) sensor circuit 2. ECT sensor 3. ECM Come on DTC stored ES-104 P0116 Engine Coolant Temperature Circuit Range / Performance Problem 1. Thermostat 2. ECT sensor Come on DTC stored ES-109 P0117 Engine Coolant Temperature Circuit Low Input 1. Short in ECT sensor circuit 2. ECT sensor 3. ECM Come on DTC stored ES-104 P0118 Engine Coolant Temperature Circuit High Input 1. Open in ECT sensor circuit 2. ECT sensor 3. ECM Come on DTC stored ES-104 P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit 1. Throttle Position (TP) sensor (built into throttle body) 2. ECM Come on DTC stored ES-112 P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem TP sensor (built into throttle body) Come on DTC stored ES-120 P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA1 circuit 3. Open in VC circuit 4. ECM Come on DTC stored ES-112 ES–58 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Memory See page P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA1 circuit 3. Open in E2 circuit 4. Short between VC and VTA1 circuits 5. ECM Come on DTC stored ES-112 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control 1. Cooling system 2. ECT sensor 3. Thermostat (water inlet) Come on DTC stored ES-122 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) 1. Thermostat (water inlet) 2. Cooling system 3. ECT sensor 4. ECM Come on DTC stored ES-125 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor circuit 2. HO2 sensor (bank 1 sensor 2) 3. HO2 sensor heater (bank 1 sensor 2) 4. A/F sensor (bank 1 sensor 1) 5. EFI relay 6. Gas leakage from exhaust system Come on DTC stored ES-128 P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) 1. Open in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. HO2 sensor heater (bank 1 sensor 2) 4. EFI relay 5. Gas leakage from exhaust system Come on DTC stored ES-128 P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) 1. Short in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. ECM internal circuit malfunction Come on DTC stored ES-128 P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor heater circuit 2. HO2 sensor heater 3. EFI relay 4. ECM Come on DTC stored ES-78 P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) 1. Open or short in HO2 sensor circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor 2) 4. A/F sensor (bank 2 sensor 1) 5. EFI relay 6. Gas leakage from exhaust system Come on DTC stored ES-128 P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) 1. Open in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor 2) 4. EFI relay 5. Gas leakage from exhaust system Come on DTC stored ES-128 P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) 1. Short in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. ECM internal circuit malfunction Come on DTC stored ES-128 P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) 1. Open or short in HO2 sensor heater circuit 2. HO2 sensor heater 3. EFI relay 4. ECM Come on DTC stored ES-78 P0171 System Too Lean (Bank 1) 1. Air induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in A/F sensor (bank 1 sensor 1) circuit 8. A/F sensor (bank 1 sensor 1) 9. A/F sensor heater (bank 1 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. PCV hose connections 13. PCV valve and hose 14. ECM Come on DTC stored ES-148 ES Trouble Areas MIL ES–59 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Memory See page P0172 System Too Rich (Bank 1) Detection Item 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in A/F sensor (bank 1 sensor 1) circuit 8. A/F sensor (bank 1 sensor 1) 9. A/F sensor heater (bank 1 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. ECM Trouble Areas Come on MIL DTC stored ES-148 P0174 System Too Lean (Bank 2) 1. Air induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in A/F sensor (bank 2 sensor 1) circuit 8. A/F sensor (bank 2 sensor 1) 9. A/F sensor heater (bank 2 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. PCV hose connections 13. PCV valve and hose 14. ECM Come on DTC stored ES-148 P0175 System Too Rich (Bank 2) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in A/F sensor (bank 2 sensor 1) circuit 8. A/F sensor (bank 2 sensor 1) 9. A/F sensor heater (bank 2 sensor 1) 10. A/F sensor heater relay 11. A/F sensor heater and A/F sensor heater relay circuits 12. ECM Come on DTC stored ES-148 P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit 1. TP sensor (built into throttle body) 2. ECM Come on DTC stored ES-112 P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input 1. TP sensor (built into throttle body) 2. Short in VTA2 circuit 3. Open in VC circuit 4. ECM Come on DTC stored ES-112 P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input 1. TP sensor (built into throttle body) 2. Open in VTA2 circuit 3. Open in E2 circuit 4. Short between VC and VTA2 circuits 5. ECM Come on DTC stored ES-112 P0230 Fuel Pump Primary Circuit 1. Open or short in fuel pump relay circuit 2. Fuel pump relay 3. ECM Does not come on DTC stored ES-160 ES ES–60 DTC Code ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory See page P0300 Random / Multiple Cylinder Misfire Detected Detection Item 1. Open or short in engine wire harness 2. Connector connection 3. Vacuum hose connection 4. Ignition system 5. Injector 6. Fuel pressure 7. MAF meter 8. ECT sensor 9. Compression pressure 10. Valve clearance 11. Valve timing 12. PCV hose connection 13. PCV hose 14. ECM 15. Air induction system Trouble Areas Come on or flash DTC stored ES-165 P0301 Cylinder 1 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0302 Cylinder 2 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0303 Cylinder 3 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0304 Cylinder 4 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0305 Cylinder 5 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0306 Cylinder 6 Misfire Detected Same as DTC P0300 Come on or flash DTC stored ES-165 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) 1. Short in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Come on DTC stored ES-178 P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) 1. Open in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Come on DTC stored ES-178 P0332 Knock Sensor 2 Circuit Low Input (Bank 2) 1. Short in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Come on DTC stored ES-178 P0333 Knock Sensor 2 Circuit High Input (Bank 2) 1. Open in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Come on DTC stored ES-178 P0335 Crankshaft Position Sensor "A" Circuit 1. Open or short in Crankshaft Position Sensor (CKP) circuit 2. CKP sensor 3. Sensor plate (CKP sensor plate) 4. ECM Come on DTC stored ES-185 P0339 Crankshaft Position Sensor "A" Circuit Intermittent Same as DTC P0335 Does not come on DTC stored ES-185 P0340 Camshaft Position Sensor "A" Circuit (Bank 1 or Single Sensor) 1. Open or short in VVT sensor circuit 2. VVT sensor 3. Camshaft timing pulley 4. Jumped tooth of timing chain 5. ECM Come on DTC stored ES-190 P0342 Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) Sam as DTC P0340 Come on DTC stored ES-190 P0343 Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) Sam as DTC P0340 Come on DTC stored ES-190 P0345 Camshaft Position Sensor "A" Circuit (Bank 2) Sam as DTC P0340 Come on DTC stored ES-190 P0347 Camshaft Position Sensor "A" Circuit Low Input (Bank 2) Sam as DTC P0340 Come on DTC stored ES-190 ES–61 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Memory See page P0348 Camshaft Position Sensor "A" Circuit High Input (Bank 2) Detection Item Sam as DTC P0340 Trouble Areas Come on MIL DTC stored ES-190 P0351 Ignition Coil "A" Primary / Secondary Circuit 1. Ignition system 2. Open or short in IGF1 or IGT circuit (1 to 6) between ignition coil with igniter and ECM 3. No.1 to No.6 ignition coil with igniters 4. ECM Come on DTC stored ES-196 P0352 Ignition Coil "B" Primary / Secondary Circuit Same as DTC P0351 Come on DTC stored ES-196 P0353 Ignition Coil "C" Primary / Secondary Circuit Same as DTC P0351 Come on DTC stored ES-196 P0354 Ignition Coil "D" Primary / Secondary Circuit Same as DTC P0351 Come on DTC stored ES-196 P0355 Ignition Coil "E" Primary / Secondary Circuit Same as DTC P0351 Come on DTC stored ES-196 P0356 Ignition Coil "F" Primary / Secondary Circuit Same as DTC P0351 Come on DTC stored ES-196 P0420 Catalyst System Efficiency Below Threshold (Bank 1) 1. Gas leakage from exhaust system 2. A/F sensor (bank 1 sensor 1) 3. HO2 sensor (bank 1 sensor 2) 4. Exhaust manifold (Three-Way Catalytic Converter [TWC]) Come on DTC stored ES-205 P0430 Catalyst System Efficiency Below Threshold (Bank 2) 1. Gas leakage from exhaust system 2. A/F sensor (bank 2 sensor 1) 3. HO2 sensor (bank 2 sensor 2) 4. Exhaust manifold (Three-Way Catalytic Converter [TWC]) Come on DTC stored ES-205 P043E Evaporative Emission System Reference Orifice Clog Up 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM 4. Leakage from EVAP system Come on DTC stored ES-212 P043F Evaporative Emission System Reference Orifice High Flow 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM 4. Leakage from EVAP system Come on DTC stored ES-212 P0441 Evaporative Emission Control System Incorrect Purge Flow 1. Purge VSV 2. Connector/wire harness (Purge VSV-ECM) 3. ECM 4. Pump module 5. Leakage from EVAP system 6. Leakage from EVAP line (Purge VSV-Intake manifold) Come on DTC stored ES-218 P0450 Evaporative Emission Control System Pressure Sensor / Switch 1. Pump module (including pressure sensor) 2. ECM Come on DTC stored ES-224 P0451 Evaporative Emission Control System Pressure Sensor Range / Performance 1. Pump module (including pressure sensor) 2. Connector/Wire harness (between pump module and ECM) 3. ECM Come on DTC stored ES-224 P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input 1. Pump module (including pressure sensor) 2. Connector/Wire harness (between pump module and ECM) 3. ECM Come on DTC stored ES-224 P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input 1. Pump module (include pressure sensor) 2. Connector/Wire harness (between pump module and ECM) 3. ECM Come on DTC stored ES-224 ES ES–62 DTC Code ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Memory See page P0455 Evaporative Emission Control System Leak Detected (Gross Leak) Detection Item 1. Fuel tank cap (loose) 2. Leakage from EVAP line (between canister and fuel tank) 3. Leakage from EVAP line (between purge VSV and canister) 4. Leakage from pump module 5. Leakage from fuel tank 6. Leakage from canister Trouble Areas Come on MIL DTC stored ES-232 P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) Same as DTC P0455 Come on DTC stored ES-232 P0500 Vehicle Speed Sensor "A" 1. Open or short in speed sensor circuit 2. Combination meter 3. ECM 4. Skid control ECU Come on DTC stored ES-236 P0504 Brake Switch "A" / "B" Correlation 1. Short in stop light switch signal circuit 2. STOP fuse 3. Stop light switch 4. ECM Does not come on DTC stored ES-239 P0505 Idle Control System Malfunction 1. ETCS (Electronic Throttle Control System) 2. Air induction system 3. PCV hose connection 4. ECM Come on DTC stored ES-244 P050A Cold Start Idle Air Control System Performance 1. Throttle body assembly 2. MAF meter 3. Air induction system 4. PCV hose connections 5. VVT system 6. Air cleaner filter element 7. ECM Come on DTC stored ES-248 P050B Cold Start Ignition Timing Performance Same as DTC P050A Come on DTC stored ES-248 P0560 System Voltage 1. Open in back up power source circuit 2. EFI fuse 3. ECM Come on DTC stored ES-254 P0604 Internal Control Module Random Access Memory (RAM) Error ECM Come on DTC stored ES-258 P0606 ECM / PCM Processor 1. ECM 2. Heated Oxygen (HO2) sensor (bank 1, 2 sensor 2) Come on DTC stored ES-259 P0607 Control Module Performance ECM Come on DTC stored ES-262 P0617 Starter Relay Circuit High 1. Park/Neutral Position (PNP) switch 2. Starter relay circuit 3. Ignition switch 4. ECM Come on DTC stored ES-264 P0630 VIN not Programmed or Mismatch - ECM / PCM ECM Come on DTC stored ES-269 P0657 Actuator Supply Voltage Circuit / Open ECM Come on DTC stored ES-271 P2102 Throttle Actuator Control Motor Circuit Low 1. Open in throttle actuator circuit 2. Throttle actuator 3. ECM Come on DTC stored ES-272 P2103 Throttle Actuator Control Motor Circuit High 1. Short in throttle actuator circuit 2. Throttle actuator 3. Throttle valve 4. Throttle body 5. ECM Come on DTC stored ES-272 P2111 Throttle Actuator Control System - Stuck Open 1. Throttle actuator 2. Throttle body 3. Throttle valve Come on DTC stored ES-276 ES–63 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Memory See page P2112 Throttle Actuator Control System - Stuck Closed Same as DTC P2111 Trouble Areas Come on MIL DTC stored ES-276 P2118 Throttle Actuator Control Motor Current Range / Performance 1. Open in ETCS power source circuit 2. ETCS fuse 3. ECM Come on DTC stored ES-279 P2119 Throttle Actuator Control Throttle Body Range / Performance 1. ETCS 2. ECM Come on DTC stored ES-283 P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 1. Accelerator Pedal Position (APP) sensor 2. ECM Come on DTC stored ES-286 P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 1. APP sensor 2. ECM Come on DTC stored ES-294 P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 1. APP sensor 2. Open in VCP1 circuit 3. Open or ground short VPA circuit 4. ECM Come on DTC stored ES-286 P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 1. APP sensor 2. Open in EPA circuit 3. ECM Come on DTC stored ES-286 P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 1. APP sensor 2. ECM Come on DTC stored ES-286 P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 1. APP sensor 2. Open in VCP2 circuit 3. Open or ground short VPA2 circuit 4. ECM Come on DTC stored ES-286 P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 1. APP sensor 2. Open in EPA2 circuit 3. ECM Come on DTC stored ES-286 P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation 1. Short between VTA1 and VTA2 circuits 2. TP sensor (built into throttle body) 3. ECM Come on DTC stored ES-112 P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 1. Short between VPA and VPA2 circuits 2. APP sensor 3. ECM Come on DTC stored ES-286 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) 1. Open or short in A/F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank 1 sensor 1) 3. A/F sensor heater (bank 1 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Injector 9. ECM Come on DTC stored ES-298 P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Same as DTC P2195 Come on DTC stored ES-298 P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) 1. Open or short in A/F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Injector 9. ECM Come on DTC stored ES-298 P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) Same as DTC P2197 Come on DTC stored ES-298 ES ES–64 DTC Code 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Memory See page P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) Detection Item 1. Open or short in A/F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank 1 sensor 1) 3. A/F sensor heater (bank 1 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuit 6. ECM Come on DTC stored ES-313 P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Same as DTC P2238 Come on DTC stored ES-313 P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) 1. Open or short in A/F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F sensor heater relay 5. A/F sensor heater and relay circuit 6. ECM Come on DTC stored ES-313 P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) Same as DTC P2241 Come on DTC stored ES-313 P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Same as DTC P2238 Come on DTC stored ES-313 P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Same as DTC P2238 Come on DTC stored ES-313 P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) Same as DTC P2241 Come on DTC stored ES-313 P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) Same as DTC P2241 Come on DTC stored ES-313 P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM 4. Leakage from EVAP Come on DTC stored ES-320 P2402 Evaporative Emission System Leak Detection Pump Control Circuit High 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM Come on DTC stored ES-320 P2419 Evaporative Emission System Switching Valve Control Circuit Low 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM Come on DTC stored ES-326 P2420 Evaporative Emission System Switching Valve Control Circuit High 1. Pump module 2. Connector/Wire harness (between pump module and ECM) 3. ECM 4. Leakage from EVAP Come on DTC stored ES-326 P2610 ECM / PCM Internal Engine Off Timer Performance ECM Come on DTC stored ES-332 P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) 1. Open or short in A/F sensor circuit 2. A/F sensor 3. ECM Come on DTC stored ES-334 P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) 1. Open or short in A/F sensor circuit 2. A/F sensor 3. ECM Come on DTC stored ES-334 ES Trouble Areas MIL ES–65 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1) DTC P0020 Camshaft Position "A" Actuator Circuit (Bank 2) HINT: These DTCs relate to the Oil Control Valve (OCV). DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, OCV and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. Duty Control ECM Crankshaft Positon Sensor Target Valve Timing Mass Air Flow Meter Camshaft Timing OCV Throttle Position Sensor Feedback Actual Valve Timing Engine Coolant Temperature Sensor Correction Vehicle Speed Signal Camshaft Position Sensor A071007E09 DTC No. DTC Detection Conditions Trouble Areas P0010 Open or short in OCV circuit (1 trip detection logic) • • • Open or short in Oil Control Valve (OCV) circuit OCV ECM P0020 Open or short in OCV circuit (1 trip detection logic) • • • Open or short in Oil Control Valve (OCV) circuit OCV ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the VVT system to control the intake camshaft. The VVT system includes the ECM, the OCV and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake camshaft. After the ECM sends the target duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an actual duty-cycle. The ECM determines the existence of a malfunction and sets a DTC when the actual duty-cycle ratio varies from the target duty-cycle ratio. ES ES–66 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY ES Related DTCs P0010: VVT OCV (Bank 1) range check P0020: VVT OCV (Bank 2) range check Required sensors / components (Main) VVT OCV (Variable Valve Timing Oil Control Valve) Required sensors / components (Related) - Frequency of operation Continuous Duration 1 second MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Starter OFF Ignition switch ON Time after ignition switch OFF to ON 0.5 seconds or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition 1, 2 or 3 1. All of the following conditions are met: Condition (a), (b) and (c) (a) Battery voltage 11 to 13 V (b) Target duty ratio Less than 70 % (c) Output signal duty ratio 100 % or more 2. All of the following conditions are met: Condition (d), (e) and (f) (d) Battery voltage 13 V or more (e) Target duty ratio Less than 80 % (f) Output signal duty ratio 100 % or more 3. All of the following conditions are met: Condition (g) and (h) (g) Current cut status Not cut (h) Output signal duty ratio 3 % or less COMPONENT OPERATING RANGE OCV current 3 % to 100 % ES–67 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C3 ECM OCV (Bank 1) G-Y 17 OC1+ E6 L-B 16 OC1E6 1 2 ES C2 OCV (Bank 2) L-W 15 OC2+ E6 L-R 14 OC2E6 1 2 A086808E26 INSPECTION PROCEDURE HINT: • If DTC P0010 is displayed, check the bank 1 VVT system circuit. • Bank 1 refers to the bank that include cylinder No. 1. • If DTC P0020 is displayed, check the bank 2 VVT system circuit. • Bank 2 refers to the bank that does not includes cylinder No. 1. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine and idle it. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. ES–68 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard Tester Operations Specified Conditions OCV OFF Normal engine idle speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) OK CHECK FOR INTERMITTENT PROBLEMS NG 2 ES INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV SIGNAL) (a) Disconnect the C2 or C3 OCV connector. (b) While idling, check the waveform between the terminals of the C2 or C3 OCV connector using an oscilloscope. OK Wire Harness Side: OCV Connector C2 Bank 1 C3 Bank 2 + Front View Specified Conditions + (C2-1) - - (C2-2) Correct waveform appears + (C3-1) - - (C3-2) Correct waveform appears (c) Reconnect the OCV connector. OK OCV Signal Waveform 5 V/Division GND 1 msec./Division A094633E45 NG Tester Connections REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–69 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 INSPECT ECM (OCV SIGNAL) (a) Inspect the ECM using an oscilloscope. (b) While idling, check the waveform between the terminals of the E6 ECM connector. OK ECM: E6 OC1+ OC1- OC2+ OC2- Tester Connections Specified Conditions OC1+ (E6-17) - OC1- (E6-16) Correct waveform appears OC2+ (E6-15) - OC2- (E6-14) Correct waveform appears NG REPLACE ECM OCV Signal Waveform 5 V/Division GND 1 msec./Division G035623E09 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (OCV SIGNAL OPEN CIRCUIT) ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION 1. 2. INITIALIZATION NOTICE: • Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM (See page AT19). • Perform the REGISTRATION (VIN registration) when replacing the ECM (See page ES-9). HINT: RESET MEMORY can not be completed by only removing the battery. FOR USING INTELLIGENT TESTER NOTICE: Observe the following items for safety reasons: • Read its instruction books before using the tester. • Prevent the tester cable from being caught on the pedals, shift lever and steering wheel when driving with the tester connected to the vehicle. • When driving the vehicle for testing purposes using the tester, two persons are required. One is for driving the vehicle, and the other operates the tester. ES ES–2 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DEFINITION OF TERMS Terms ES Definitions Monitor Description Description of what ECM monitors and how to detect malfunctions (monitoring purpose and details). Related DTCs A group of diagnostic trouble codes that are output by ECM based on the same malfunction detection logic. Typical Enabling Conditions Preconditions that allow ECM to detect malfunction. With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s). Sequence of Operation Order of monitor priority, applied if multiple sensors and components involved in single malfunction detection process. Each sensor and component monitored in turn and not monitored until previous detection operation is completed. Required Sensors / Components Sensors and components used by ECM to detect each malfunction. Frequency of Operation Number of times ECM checks for each malfunction during each driving cycle. "Once per driving cycle" means ECM only performs checks for that malfunction once during single driving cycle. "Continuous" means ECM performs checks for that malfunction whenever enabling conditions are met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC. Timing begins when typical enabling conditions are met. Malfunction Thresholds Values, beyond which, ECM determines malfunctions exist and sets DTCs. MIL Operation Timing of MIL illumination after defect is detected. "Immediate" means ECM illuminates MIL as soon as malfunction is detected. "2 driving cycles" means ECM illuminates MIL if the same malfunction is detected twice during the next sequential driving cycle. ES–70 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) DTC P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) DTC P0021 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 2) DTC P0022 Camshaft Position "A" - Timing Over-Retarded (Bank 2) HINT: If DTC P0011, P0012, P0021 or P0022 is present, check the VVT (Variable Valve Timing) system. DESCRIPTION Refer to DTC P0010 (See page ES-59). DTC No. DTC Detection Conditions P0011 P0021 Advanced cam timing: With warm engine and engine speed of between 550 rpm and 4,000 rpm, all conditions (a), (b) and (c) are met (1 trip detection logic): (a) Difference between target and actual intake valve timings is more than 5° CA (Crankshaft Angle) for 4.5 seconds (b) Current intake valve timing is fixed (timing changes less than 5° CA in 5 seconds) (c) Variations in VVT controller timing are more than 19° CA of maximum delayed timing (advanced) Trouble Areas • • • • • Valve timing OCV OCV filter Intake camshaft timing gear assembly ECM P0012 P0022 Retarded cam timing: With warm engine and engine speed of between 550 rpm and 4,000 rpm, all conditions (a), (b) and (c) are met (2 trip detection logic): (a) Difference between target and actual intake valve is timings more than 5° CA (Crankshaft Angle) for 4.5 seconds (b) Current intake valve timing is fixed (timing changes less than 5° CA in 5 seconds) (c) Variations in VVT controller timing is 19° CA or less of maximum delayed timing (retarded) • • • • • Valve timing OCV OCV filter Camshaft timing gear assembly ECM MONITOR DESCRIPTION The ECM optimizes the intake valve timing using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake camshaft. If the difference between the target and actual intake valve timings is large, and changes in actual intake valve timing are small, the ECM interprets this as the VVT controller stuck malfunction and sets a DTC. Example: A DTC will be set when the following conditions 1), 2) and 3) are met: 1) The difference between the target and actual intake valve timings is more than 5° CA (Crankshaft Angle) and the condition continues for more than 4.5 seconds. 2) It takes 5 seconds or more to change the valve timing by 5° CA. ES–71 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3) After above conditions 1) and 2) are met, the OCV is forcibly activated 63 times or more. DTCs P0011 and P0021 (Advanced Cam Timing) are subject to 1 trip detection logic. DTCs P0012 and P0022 (Retarded Cam Timing) are subject to 2 trip detection logic. These DTCs indicate that the VVT controller cannot operate properly due to OCV malfunctions or the presence of foreign objects in the OCV. The monitor will not run unless the following conditions are met: - The engine is warm (the engine coolant temperature is 75°C [167°F] or more). - The vehicle has been driven at more than 40 mph (64 km/h) for 3 minutes. - The engine has idled for 3 minutes. MONITOR STRATEGY Related DTCs P0011: VVT system advance (Bank 1) P0012: VVT system retard (Bank 1) P0021: VVT system advance (Bank 2) P0022: VVT system retard (Bank 2) Required sensors / components (Main) VVT OCV, VVT Actuator Required sensors / components (Related) Crankshaft position sensor, Camshaft position sensor, ECT sensor Frequency of operation Once per driving cycles Duration Less than 10 seconds MIL operation P0011 and P0021: Immediate P0012 and P0022: 2 driving cycles Sequence operation None ES TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0100, P0101, P0102, P0103 (MAF Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0125 (Insufficient ECT for Closed Loop), P0335 (CKP Sensor), P0340 (VVT Sensor 1, 2), P0351, P0352, P0353, P0354, P0355, P0356 (Ignitor) Battery voltage 11 V or more Engine RPM 500 to 4,000 rpm ECT 75 to 100°C (167 to 212°F) TYPICAL MALFUNCTION THRESHOLDS P0011, P0021: Duration of actual valve timing and target valve timing More than 5° CA (Crankshaft angle) Valve timing No change at advanced valve timing P0012, P0022: Duration of actual valve timing and target valve timing More than 5° CA (Crankshaft angle) Valve timing No change at retarded valve timing If the difference between the target and actual camshaft timings is greater than the specified value, the ECM operates the VVT actuator. Then, the ECM monitors the camshaft timing change for 5 seconds. WIRING DIAGRAM Refer to DTC P0010 (See page ES-61). INSPECTION PROCEDURE Abnormal bank Advanced timing over (Valve timing is out of specified range) Retarded timing over (Valve timing is out of specified range) Bank 1 P0011 P0012 Bank 2 P0021 P0022 ES–72 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • If DTC P0011 or P0012 is displayed, check the bank 1 VVT system circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • If DTC P0021 or P0022 is displayed, check the bank 2 VVT system circuit. • Bank 2 refers to the bank that does not include cylinder No. 1. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 ES CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0011, P0012, P0021 OR P0022) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0011, P0012, P0021 or P0022 A P0011, P0012, P0021 or P0022 and other DTCs B HINT: If any DTCs other than P0011, P0012, P0021 or P0022 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operations Specified Conditions OCV OFF Normal engine idle speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG OK Go to step 4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P0011, P0012, P0021 OR P0022) (a) (b) (c) (d) (e) (f) (g) Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Clear DTCs (See page ES-31). Start the engine and warm it up. Select check mode using the tester (See page ES-35). Drive the vehicle for more than 10 minutes. Read DTCs using the tester. OK: No DTC output. NG OK END ES–73 Go to step 4 ES ES–74 4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TEETH ON TIMING CHAIN) Timing Mark ES Timing Mark Timing Mark (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft to align the matchmarks of the crankshaft. (c) Align the notch of the crankshaft pulley to the "0" position. (d) Check if the matchmarks of the camshaft pulley and camshaft bearing cap align. (e) Turn the crankshaft clockwise by 360° if the matchmarks do not align. Check if they align once again. OK: The matchmarks of the camshaft pulley and the camshaft bearing cap align when the notch of the crankshaft pulley is in the "0" position. NG ADJUST VALVE TIMING Timing Mark A135015E01 OK 5 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) Valve Moves A097066E08 (a) Remove the OCV. (b) Measure the resistance between the terminals of the OCV. Resistance: 6.9 to 7.9 Ω at 20°C (68°F) (c) Apply the positive battery voltage to terminal 1 and negative battery voltage to terminal 2. Check the valve operation. OK: Valve moves quickly. (d) Reinstall the OCV. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–75 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY OK 6 CHECK OIL PIPE AND OIL CONTROL VALVE FILTER OK: The filter is not clogged. NG REPLACE OIL PIPE OR OIL CONTROL VALVE FILTER ES OK 7 REPLACE CAMSHAFT TIMING GEAR ASSEMBLY NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on (IG) and turn the tester on. Clear DTCs (See page ES-31). Start the engine and warm it up. Select the check mode using the tester (See page ES35). (f) Drive the vehicle for more than 10 minutes. (g) Confirm that no DTC is set using the tester. OK: No DTC output. HINT: DTC P0011, P0012, P0021 or P0022 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay registered even if the system returns to normal after a short time. These foreign objects are then captured by the oil filter, thus eliminating the source of the problem. NG OK END REPLACE ECM ES–76 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) DTC P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) DESCRIPTION Refer to DTC P0335 (See page ES-185). DTC No. P0016 ES P0018 DTC Detection Conditions Deviations in crankshaft and camshaft position sensor (for intake camshaft) 1 signals (2 trip detection logic) Deviations in crankshaft and camshaft position sensor (for intake camshaft) 2 signals (2 trip detection logic) Trouble Areas • • • • Mechanical system (Timing chain has jumped tooth or chain stretched) ECM Mechanical system (Timing chain has jumped tooth or chain stretched) ECM MONITOR DESCRIPTION The ECM optimizes the valve timing by using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake camshaft. The ECM calibrates the intake valve timing by setting the intake camshaft to the most retarded angle while the engine is idling. The ECM closes the OCV to retard the cam. The ECM stores this value as the VVT learning value. When the difference between the target and actual intake valve timings is 5° CA (Crankshaft Angle) or less, the ECM stores it. If the VVT learning value matches the following conditions, the ECM determines the existence of a malfunction in the VVT system, and sets the DTC. • The VVT learning value: Less than 22.5° CA, or more than 45.2° CA. • The above condition continues for 18 seconds or more. This DTC indicates that the intake camshaft has been installed toward the crankshaft at an incorrect angle, caused by factors such as the timing chain having jumped a tooth. This monitor begins to run after the engine has idled for 5 minutes. MONITOR STRATEGY Related DTCs P0016: Deviation in crankshaft position sensor signal and camshaft position sensor signal (Bank 1) P0018: Deviation in crankshaft position sensor signal and camshaft position sensor signal (Bank 2) Required Sensors / Components (Main) VVT actuator Required Sensors / Components (Related) Camshaft position sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration Less than 60 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0011, P0012 (VVT System1-Advance, Retard), P0021, P0022 (VVT System2Adavance, Retard), P0115, P0116, P0117, P0118 (ECT Sensor), Engine RPM 500 to 1,400 rpm 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–77 TYPICAL MALFUNCTION THRESHOLDS P0016 and P0018: One of the following conditions is met - VVT learning value at maximum retarded valve timing (Bank 1) Less than 22.5° CA (crankshaft angle) VVT learning value at maximum retarded valve timing (Bank 1) Less than 22.5° CA (crankshaft angle) VVT learning value at maximum retarded valve timing (Bank 2) More than 45.2° CA (crankshaft angle) VVT learning value at maximum retarded valve timing (Bank 2) More than 45.2° CA (crankshaft angle) WIRING DIAGRAM Refer to DTC P0335 (See page ES-187). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES ES–78 1 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VALVE TIMING (CHECK FOR LOOSE AND A JUMPED TOOTH OF TIMING CHAIN) Timing Mark ES Timing Mark Timing Mark Timing Mark (a) Remove the cylinder head covers RH and LH. (b) Turn the crankshaft to align the matchmarks of the crankshaft. (c) Align the notch of the crankshaft pulley to the "0" position. (d) Check if the matchmarks of the camshaft pulley and camshaft bearing cap align. (e) Turn the crankshaft clockwise by 360° if the matchmarks do not align. Check if they align once again. OK: The matchmarks of the camshaft pulley and the camshaft bearing cap align when the notch of the crankshaft pulley is in the "0" position. NOTICE: After replacing the ECM or adjusting intake valve timing, confirm that the DTC output does not recur. (f) Confirm that the DTC output does not recur. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester on. (4) Clear DTCs (See page ES-31). (5) Select the check mode using the tester (See page ES-35). (6) Start the engine and warm it up. (7) Allow the engine to idle for 1 minute or more, and then drive the vehicle for 1 minute or more. (8) Confirm that no DTC is set, using the tester. NG A135015E01 OK REPLACE ECM ADJUST VALVE TIMING ES–79 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) DTC P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) DTC P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) ES HINT: • Although the DTC titles say the oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION Refer to DTC P2195 (See page ES-298). HINT: • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the A/F sensor heater in fail-safe mode. Fail-safe mode continues until the ignition switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The A/F sensor heater circuit uses a relay on the +B side of the circuit. Reference (System Diagram of Bank 1 Sensor 1): A/F Sensor Heater Relay From Battery From EFI Relay ECM A/F Sensor +B Heater HT HA1A AF- Sensor AF+ A1A+ A/F Heater Fuse EFI No. 2 A1A- Duty Control G035624E01 DTC No. DTC Detection Conditions Trouble Areas P0031 P0051 Air-Fuel Ratio (A/F) sensor heater current less than 0.8 A (1 trip detection logic) • • • • Open in A/F sensor heater circuit A/F sensor heater A/F sensor heater relay ECM P0032 P0052 Air-Fuel Ratio (A/F) sensor heater current more than 10 A (1 trip detection logic) • • • • Short in A/F sensor heater circuit A/F sensor heater A/F sensor heater relay ECM ES–80 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the closest sensor to the engine assembly. • Sensor 2 refers to the furthest sensor away from the engine assembly. MONITOR DESCRIPTION ES The ECM uses information from the Air-Fuel Ratio (A/F) sensor to regulate the air-fuel ratio and keep it close to the stoichiometric level. This maximizes the ability of the Three-Way Catalytic Converter (TWC) to purify the exhaust gas. The A/F sensor detects oxygen levels in the exhaust gas and transmits the information to the ECM. The inner surface of the sensor element is exposed to the outside air. The outer surface of the sensor element is exposed to the exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates small voltage when there is a large difference in the oxygen concentrations between the exhaust gas and outside air. The platinum coating amplifies this voltage generation. The A/F sensor is more efficient when heated. When the exhaust gas temperature is low, the sensor cannot generate useful voltage signals without supplementary heating. The ECM regulates the supplementary heating using a duty-cycle approach to adjust the average current in the sensor heater element. If the heater current is outside the normal range, the signal transmitted by the A/F sensor will be inaccurate, as a result, the ECM will be unable to regulate air-fuel ratio properly. When the current in the A/F sensor heater is outside the normal operating range, the ECM interprets this as a malfunction in the sensor heater and sets a DTC. Example: The ECM sets DTC P0032 or P0052 when the current in the A/F sensor heater is more than 10 A. Conversely, when the heater current is less than 0.8 A, DTC P0031 or P0051 is set. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater (Bank 1) range check (Low current) P0032: A/F sensor heater (Bank 1) range check (High current) P0051: A/F sensor heater (Bank 2) range check (Low current) P0052: A/F sensor heater (Bank 2) range check (High current) Required sensors / components (Main) A/F sensor heater Required sensors / components (Related) - Frequency of operation Continuous Duration 10 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None P0031 and P0051: Battery voltage 10.5 V or more A/F sensor heater duty ratio 50% or more Time after engine start 10 seconds or more P0032 and P0052: Time after engine start 10 seconds or more ES–81 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS P0031 and P0051: A/F sensor heater current Less than 0.8 A P0032 and P0052: A/F sensor heater current More than 10 A COMPONENT OPERATING RANGE 1.8 to 3.4 Ω at 20°C (68°F) A/F sensor heater resistance WIRING DIAGRAM ES Refer to DTC P2195 (See page ES-302). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance Component Side: A/F Sensor A12 Bank 1 A13 Bank 2 AF- +B Front View HT AF+ Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. A085152E62 NG REPLACE AIR FUEL RATIO SENSOR OK 2 INSPECT AIR FUEL RATIO SENSOR RELAY (a) Remove the A/F sensor heater relay from the engine room R/B. (b) Measure the A/F sensor heater relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F sensor heater relay. NG REPLACE AIR FUEL RATIO SENSOR RELAY ES–82 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 3 INSPECT ECM (HA1A OR HA2A VOLTAGE) (a) Turn the ignition switch on (IG). (b) Measure the voltage between the terminals of the E5 ECM connector. Standard voltage ECM: E5 ES E04 E05 HA1A HA2A A131509E32 Specified Conditions HA1A (E5-2) - E04 (E5-7) 9 to 14 V HA2A (E5-1) - E05 (E5-6) 9 to 14 V HINT: • The HA1A means the A/F sensor bank 1 sensor 1. • The HA2A means the A/F sensor bank 2 sensor 1. OK NG Tester Connections REPLACE ECM ES–83 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM, A/F SENSOR - A/F SENSOR HEATER RELAY) (a) Check the harness and the connector between the ECM and the A/F sensor. (1) Disconnect the A12 or A13 A/F sensor connector. (2) Disconnect the E5 ECM connector. (3) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: A/F Sensor Connector HT +B A12 Bank 1 A13 Bank 2 Front View Tester Connections Specified Conditions HT (A12-1) - HA1A (E5-2) Below 1 Ω HT (A13-1) - HA2A (E5-1) Below 1 Ω Standard resistance (Check for short) Tester Connections E5 Specified Conditions HT (A12-1) or HA1A (E5-2) - Body ground 10 kΩ or higher HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher (b) Check the harness and the connector between the A/F sensor and engine room junction block (A/F sensor heater relay). (1) Remove the engine room junction block. (2) Measure the resistance. Standard resistance (Check for open) HA2A HA1A ECM Connector Engine Room R/B Tester Connections Specified Conditions +B (A12-2) -A/F sensor heater relay (3) Below 1 Ω +B (A13-2) -A/F sensor heater relay (3) Below 1 Ω Standard resistance (Check for short) A/F Sensor Heater Relay A138714E01 Tester Connections Specified Conditions +B (A12-2) or A/F sensor heater relay (3) - Body ground 10 kΩ or higher +B (A13-2) or A/F sensor heater relay (3) - Body ground 10 kΩ or higher (3) Reconnect the A/F sensor connector. (4) Reconnect the ECM connector. (5) Reinstall the A/F sensor heater relay. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–84 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) DTC P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) DTC P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) DTC P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) HINT: Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located furthest from the engine assembly. DESCRIPTION Refer to DTC P0136 (See page ES-128). HINT: • When any of these DTCs are set, the ECM enters fail-safe mode. The ECM turns off the Heated Oxygen (HO2) sensor heater in fail-safe mode. Fail-safe mode continues until the ignition switch is turned off. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The HO2 sensor heater circuit uses a relay on the B+ side of the circuit. Reference (System Diagram of Bank 1 Sensor 2): Engine Room Junction Block EFI Relay From Battery EFI No. 2 Fuse ECM HO2 Sensor +B EFI No. 1 Fuse HT HT1B OX1B OX1B Heater E1 Duty Control Sensor Ground E2 MREL G042820E04 ES–85 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions Trouble Areas P0037 P0057 Heated Oxygen (HO2) sensor heater current is less than 0.3 A (1 trip detection logic) • • • • Open in HO2 sensor heater circuit HO2 sensor heater EFI relay ECM P0038 P0058 Heated Oxygen (HO2) sensor heater current is more than 2 A (1 trip detection logic) • • • • Short in HO2 sensor heater circuit HO2 sensor heater EFI relay ECM P0141 P0161 Cumulative heater resistance correction value exceeds the acceptable threshold. (2 trip detection logic) • • • • Open or short in HO2 sensor heater circuit HO2 sensor heater EFI relay ECM HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor furthest away from the engine assembly. MONITOR DESCRIPTION The sensing portion of the Heated Oxygen (HO2) sensor has a zirconia element which is used to detect the oxygen concentration in the exhaust gas. If the zirconia element is at the appropriate temperature, and the difference between the oxygen concentrations surrounding the inside and outside surfaces of the sensor is large, the zirconia element generates voltage signals. In order to increase the oxygen concentration detecting capacity of the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. Heated oxygen sensor heater range check (P0037, P0038, P0057 and P0058): The ECM monitors the current applied to the O2 sensor heater to check the heater for malfunctions. If the current is below the threshold value, the ECM will determine that there is an open circuit in the heater. If the current is above the threshold value, the ECM will determine that there is a short circuit in the heater. Example: The ECM sets DTC P0038 or P0058 when the current in the HO2 sensor heater is more than 2 A. Conversely, when the heater current is less than 0.3 A, DTC P0037 or P0057 is set. Heated oxygen sensor heater performance (P0141 and P0161): After the accumulated heater ON time exceeds 100 seconds, the ECM calculates the heater resistance using the battery voltage and the current applied to the heater. If the resistance is above the threshold value, the ECM will determine that there is a malfunction in the HO2S heater and set DTC P0141 and P0161. MONITOR STRATEGY Related DTCs P0037: Heated oxygen sensor heater (bank 1 sensor 2) open/short (Low electrical current) P0038: Heated oxygen sensor heater (bank 1 sensor 2) open/short (High electrical current) P0057: Heated oxygen sensor heater (bank 2 sensor 2) open/short (Low electrical current) P0058: Heated oxygen sensor heater (bank 2 sensor 2) open/short (High electrical current) Required Sensors / Components (Main) Heated oxygen sensor heater (bank 1 sensor 2) Heated oxygen sensor heater (bank 2 sensor 2) Required sensors / components (Sub) - Frequency of Operation Continuous: P0037, P0038, P0057, P0058 Once per driving cycle: P0141, P0161 Duration 0.5 seconds: P0037, P0057 Within 1 second: P0038, P0058 10 seconds: P0141 and P0161 ES ES–86 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation MIL operation Immediate: P0037, P0038, P0057 and P0058 2 driving cycles: P0141 and P0161 Sequence of Operation None TYPICAL ENABLING CONDITIONS P0037 and P0057 (Low current): 1. When all conditions below are met ES - Battery voltage 10.5 V or more to less than 20 V Learned heater current during heater OFF Completed Active heater OFF control Not operating Active heater ON control Not operating Duration of following conditions are met 0.5 seconds or more Heater OFF time Less than 0.1 seconds Heater current Less than 0.3 A 2. Heater OFF time 1 second or more 3. When all condition below are met - Learned heater OFF current operation Completed Active heater OFF control Not operating Active heater ON control Not operating Heater OFF time Less than 0.1 seconds P0038 and P0058 (High current): When one of following conditions is met: Condition 1, 2 or 3 1. When all conditions below are met - Battery voltage 10.5 V or more Engine Running Starter OFF Catalyst monitoring active A/F control Not operating Active heater OFF control Not operating Active heater ON control Not operating 2. When all conditions below are met: - Battery voltage 10.5 V or more to less than 20 V Learned heater current during heater OFF Completed Active heater OFF control Not operating Active heater ON control Not operating Heater OFF time Less than 0.1 seconds Heater current 2 A or more 3. Heater OFF time 1 second or more P0141 and P0161: When one of following conditions is met: Condition 1 or 2 1. All of the following conditions are met: - Battery voltage 10.5 V or more Fuel cut OFF Time after fuel cut ON to OFF 30 seconds or more Accumulated heater ON time 100 seconds or more Learned heater OFF current operation Completed 2. Duration that rear heated oxygen sensor impedance is less than 15 kΩ 2 seconds or more 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–87 TYPICAL MALFUNCTION THRESHOLDS P0037 and P0057 (Low current): Heater current Less than 0.3 A P0038 and P0058 (High current): When either condition below is met - Learned heater OFF current More than 2 A Heater current - Learned heater OFF current 2 A or more P0141 and P0161 (Heater performance monitor check): Accumulated heater resistance Varies with sensor element temperature (Example: More than 23 ohm) COMPONENT OPERATING RANGE Heated Oxygen (HO2) sensor heater current 0.4 to 1.0 A (when engine idles, HO2 sensor warmed up and battery voltage 11 to 14 V) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). WIRING DIAGRAM Refer to DTC P0136 (See page ES-135). INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES ES–88 1 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the H6 or H8 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance between the terminals of the HO2 sensor connector. Standard resistance: Bank 1 Component Side: HO2 Sensor H6 Bank 1 ES HT +B E OX HO2 Sensor +B Specified Conditions HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E (4) 10 kΩ or higher Bank 2 Front View H8 Bank 2 Tester Connections HT Tester Connections Specified Conditions HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E (4) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. NG E REPLACE HEATED OXYGEN SENSOR OX Front View A126268E03 OK 2 INSPECT EFI RELAY (a) Remove the EFI relay from the engine room R/B. (b) Measure the EFI relay heater relay resistance. Standard resistance Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2 (c) Reinstall the EFI relay. B016200 OK NG REPLACE EFI RELAY ES–89 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 INSPECT ECM (HT1B OR HT2B VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the E4, E5 and E6 ECM connector. Standard voltage ECM: E4 HT1B (+) E5 E6 HT2B (+) E1 (-) A131509E33 Specified Conditions 9 to 14 V HT2B (E5-5) - E1 (E6-1) 9 to 14 V HINT: • The HT1B means the heated oxygen sensor bank 1 sensor 2. • The HT2B means the heated oxygen sensor bank 2 sensor 2. OK NG Tester Connections HT1B (E4-1) - E1 (E6-1) REPLACE ECM ES ES–90 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM, HEATED OXYGEN SENSOR - EFI RELAY) (a) Check the harness and the connector between the ECM and the HO2 sensor. (1) Disconnect the H6 or H8 HO2 sensor connector. (2) Disconnect the E4 or E5 ECM connector. (3) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: HO2 Sensor Connector H6 Bank 1 H8 Bank 2 HT ES +B Front View Tester Connections Specified Conditions HT (H6-1) - HT1B (E4-1) Below 1 Ω HT (H8-1) - HT2B (E5-5) Below 1 Ω Standard resistance (Check for short) E4 Tester Connections Specified Conditions HT (H6-1) or HT1B (E4-1) - Body ground 10 kΩ or higher HT (H8-1) or HT2B (E5-5) - Body ground 10 kΩ or higher E5 (b) Check the harness and the connector between the HO2 sensor and EFI relay. (1) Inspect the EFI No. 2 fuse • Remove the EFI No. 2 fuse from engine room R/ B. • Check the EFI No. 2 fuse resistance. Standard resistance: Below 1 Ω (2) Measure the resistance. • Remove the engine room junction block. Standard resistance (Check for open): HT2B HT1B ECM Connector Engine Room R/B EFI Relay Tester Connections Specified Conditions +B (H6-2) - EFI relay (3) Below 1 Ω +B (H8-2) - EFI relay (3) Below 1 Ω Standard resistance (Check for short): A138715E01 Tester Connections Specified Conditions +B (H6-2) or EFI relay (3) - Body ground 10 kΩ or higher +B (H8-2) or EFI relay (3) - Body ground 10 kΩ or higher (3) Reconnect the HO2 sensor connector. (4) Reconnect the ECM connector. (5) Reinstall the EFI relay. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–91 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0100 Mass or Volume Air Flow Circuit DTC P0102 Mass or Volume Air Flow Circuit Low Input DTC P0103 Mass or Volume Air Flow Circuit High Input DESCRIPTION The Mass Air Flow (MAF) meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide appropriate airfuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air flow through the sensor, and the ECM uses it to calculate the intake air volume. The circuit is constructed so that the platinum hot wire and the temperature sensor provide a bridge circuit, and the power transistor is controlled so that the potentials of A and B remain equal to maintain the predetermined temperature. HINT: When any of these DTCs are set, the ECM enters fail-safe mode. During fail-safe mode, the ignition timing is calculated by the ECM, according to the engine RPM and throttle valve position. Fail-safe mode continues until a pass condition is detected. B+ Temperature Sensor (Thermistor) Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor (Thermistor) Platinum Hot Wire (Heater) A094565E04 DTC No. DTC Detection Conditions Trouble Areas P0100 Open or short in Mass Air Flow (MAF) meter circuit for 3 seconds • • • Open or short in MAF meter circuit MAF meter ECM P0102 Open in Mass Air Flow (MAF) meter circuit for 3 seconds • • • • Open in MAF meter circuit Short in ground circuit MAF meter ECM P0103 Short in Mass Air Flow (MAF) meter circuit for 3 seconds • • • Short in MAF meter circuit (+B circuit) MAF meter ECM HINT: When any of these DTCs are set, check the air-flow rate by selecting the following menu items on an intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. ES ES–92 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Mass Air Flow Rate (gm/s) Approximately 0.0 271.0 or more Malfunctions • • Open in Mass Air Flow (MAF) meter power source circuit Open or short in VG circuit Open in EVG circuit MONITOR DESCRIPTION ES If there is a defect in the MAF meter or an open or short circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets a DTC. Example: When the sensor voltage output remains less than 0.2 V, or more than 4.9 V, for more than 3 seconds, the ECM sets a DTC. If the malfunction is not repaired successfully, a DTC is set 3 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0100: Mass air flow meter range check (Fluctuating) P0102: Mass air flow meter range check (Low voltage) P0103: Mass air flow meter range check (High voltage) Required Sensors / Components (Main) MAF meter Required Sensors / Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate: Engine RPM less than 4,000 rpm 2 driving cycles: Engine RPM 4,000 rpm or more Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0100: Mass air flow meter voltage Less than 0.2 V, or more than 4.9 V P0102: Mass air flow meter voltage Less than 0.2 V P0103: Mass air flow meter voltage More than 4.9 V COMPONENT OPERATING RANGE Mass air flow meter voltage Between 0.4 V and 2.2 V ES–93 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Engine Room R/B Engine Room R/B EFI Relay 2 2 EFI No. 2 5 3 2 1 2 B 2 1 L-W 2 2 2 L 12 IM1 W-B 2 17 IC3 L-W A L-W 1 +B 2 EFI L-W J4 J/C Engine Room R/B ECM R-Y 30 E4 VG E2G 2 R-W 29 E4 E2G VG 3 1 2 M1 Mass Air Flow Meter B J2 B A J/C W-G B J3 35 IC4 W-G 8 MREL E8 W-B Battery EB G032680E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (MASS AIR FLOW RATE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (e) Read the values displayed on the tester. ES ES–94 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Mass Air Flow Rate (gm/s) Proceed to 0.0 A 271.0 or more B Between 1.0 and 270.0 (*1) C *1: The value must be changed when the throttle valve is open or closed. B C ES Go to step 6 CHECK FOR INTERMITTENT PROBLEMS A 2 INSPECT MASS AIR FLOW METER (POWER SOURCE VOLTAGE) (a) Disconnect the M1 Mass Air Flow (MAF) meter connector. (b) Turn the ignition switch on. (c) Measure the voltage between the terminal of the wire harness side connector and body ground. Standard voltage Wire Harness Side: MAF Meter Connector M1 +B (+) Front View A054396E81 Tester Connections Specified Conditions +B (M1-1) - Body ground 9 to 14 V (d) Reconnect the MAF meter connector. NG Go to step 5 OK 3 INSPECT ECM (VG VOLTAGE) (a) Start the engine. (b) Measure the voltage between the terminals of the E4 ECM connector. HINT: The transmission gear selector lever should be in the P or N position and the A/C switch should be turned off. Standard voltage ECM: E4 VG (+) E2G (-) A131509E36 Tester Connections Conditions Specified Conditions VG (E4-30) - E2G (E429) Engine idling 0.5 to 3.0 V OK NG REPLACE ECM ES–95 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the M1 MAF meter connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector M1 1 2 3 4 5 Specified Conditions Below 1 Ω E2G (M1-2) - E2G (E4-29) Below 1 Ω Standard resistance (Check for short) E2G VG Front View ECM: E4 Tester Connections Specified Conditions VG (M1-3) or VG (E4-30) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG VG Tester Connections VG (M1-3) - VG (E4-30) E2G A114604E04 OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–96 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - EFI RELAY) Wire Harness Side: Mass Air Flow Meter Connector M1 +B (+) ES Front View (a) Inspect the EFI No. 2 fuse. (1) Remove the EFI No. 2 fuse from the engine room R/ B. (2) Measure the EFI No. 2 fuse resistance. Standard resistance: Below 1 Ω (3) Reinstall the EFI No. 2 fuse. (b) Disconnect the M1 MAF meter connector. (c) Remove the EFI relay from the engine room R/B. (d) Measure the resistance. Standard resistance (Check for open) Engine Room R/B: Tester Connections Specified Conditions +B (M1-1) - EFI relay (3) Below 1 Ω Standard resistance (Check for short) Tester Connections Specified Conditions +B (M1-1) or EFI relay (3) - Body ground 10 kΩ or higher (e) Reconnect the MAF meter connector. (f) Reinstall the EFI relay. EFI Relay A138716E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK CHECK ECM POWER SOURCE CIRCUIT 6 INSPECT ECM (SENSOR GROUND) (a) Check the resistance. Standard resistance ECM: E4 Tester Connections Specified Conditions E2G (E4-29) - Body ground Below 1 Ω NG E2G A131509E37 OK REPLACE ECM ES–97 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the M1 MAF meter connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: MAF Meter Connector M1 1 2 3 4 5 E2G VG Front View Specified Conditions Below 1 Ω E2G (M1-2) - E2G (E4-29) Below 1 Ω Standard resistance (Check for short) ECM: E4 Tester Connections Specified Conditions VG (M1-3) or VG (E4-30) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. NG VG Tester Connections VG (M1-3) - VG (E4-30) E2G A114606E02 OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–98 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Mass or Volume Air Flow Circuit Range / Performance Problem P0101 DESCRIPTION Refer to DTC P0100 (See page ES-85). ES DTC No. DTC Detection Conditions P0101 Conditions (a), (b), (c), (d) and (e) are met (2 trip detection logic): (a) Engine running (b) Engine coolant temperature 70°C (158°F) or higher (c) Throttle Position (TP) sensor voltage 0.4 V or more (d) Average engine load value ratio less than 0.85, or more than 1.19 (varies with estimated engine load) Average engine load value ratio = Average engine load based on MAF meter output / Average engine load estimated from driving conditions (e) Average air-fuel ratio less than -20 %, or more than 20 % Trouble Areas • • • Mass Air Flow (MAF) meter Air induction system PCV hose connections MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The ECM monitors the average engine load value ratio to check the MAF meter for malfunctions. The average engine load value ratio is obtained by comparing the average engine load calculated from the MAF meter output to the average engine load estimated from the driving conditions, such as the engine speed and the throttle opening angle. If the average engine load value ratio is below the threshold value, the ECM determines that the intake air volume is low, and if the average engine load value ratio is above the threshold value, the ECM determines that the intake air volume is high. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0101: Mass air flow meter rationality Required Sensors / Components (Main) Mass air flow meter Required Sensors / Components (Related) Crankshaft Position (CKP) sensor, Engine Coolant Temperature (ECT) sensor and Throttle Position (TP) sensor Frequency of Operation Continuous Duration 20 seconds or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340 (CMP sensor) Throttle position (TP sensor voltage) 0.24 V or more Engine Running ES–99 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or more Engine coolant temperature 70°C (158°F) or more IAT sensor circuit OK ECT sensor circuit OK CKP sensor circuit OK TP sensor circuit OK Canister pressure sensor circuit OK EVAP leak detection pump OK EVAP vent valve OK TYPICAL MALFUNCTION THRESHOLDS Both of following conditions 1 and 2 met - 1. Averaged engine load value ratio Less than 0.85, or more than 1.19 (varies with estimated engine load) 2. Averaged air-fuel ratio Less than -20 %, or more than 20 % ES WIRING DIAGRAM Refer to DTC P0100 (See page ES-87). CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the mass air flow performance monitor. Vehicle Speed Approximately 100 km/h (62 mph) Idling Time Warming Up 20 seconds or more A112632E02 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3. Turn the ignition switch to ON. Turn the tester ON. Clear DTCs (See page ES-31). Start the engine, and warm it up until the engine coolant temperature reaches 70°C (158°F) or higher. Drive the vehicle at approximately 62 mph (100 km/h) for 20 seconds or more. ES–100 7. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0101) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0101 A P0101 and other DTCs B HINT: If any DTCs other than P0101 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 3 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE PCV HOSE 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0110 Intake Air Temperature Circuit DTC P0112 Intake Air Temperature Circuit Low Input DTC P0113 Intake Air Temperature Circuit High Input ES–101 DESCRIPTION The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT is low, the resistance of the thermistor increases. When the temperature is high, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (see Fig. 1). The IAT sensor is powered by a 5 V applied from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve drivability. (Figure 1) Resistance kΩ Acceptable Temperature °C (°F) A056276E06 HINT: When any of DTCs P0110, P0112 and P0113 are set, the ECM enters fail-safe mode. During fail-safe mode, the IAT is estimated to be 20°C (68°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. P0110 P0112 Proceed to DTC Detection Conditions Trouble Area Step 1 Open or short in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open or short in IAT sensor circuit IAT sensor (built into MAF meter) ECM Step 4 Short in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in IAT sensor circuit IAT sensor (built into MAF meter) ECM ES ES–102 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0113 Proceed to Step 2 DTC Detection Conditions Open in Intake Air Temperature (IAT) sensor circuit for 0.5 seconds (1 trip detection logic) Trouble Area • • • Open in IAT sensor circuit IAT sensor (built into MAF meter) ECM HINT: When any of these DTCs are set, check the IAT by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. ES Temperature Displayed Malfunctions -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the Intake Air Temperature (IAT). When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a malfunction in the IAT sensor and sets a DTC. Example: If the sensor voltage output is -40°C (-40°F) for 0.5 seconds or more, the ECM determines that there is an open in the IAT sensor circuit, and sets DTC P0113. Conversely, if the voltage output is more than 140°C (284°F) for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0112. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0110: IAT sensor range check (Fluttering) P0112: IAT sensor range check (Low voltage) P0113: IAT sensor range check (High voltage) Required Sensors / Components (Main) Intake Air Temperature (IAT) sensor Required sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0110: Intake air temperature sensor voltage Less than 0.18 V or more than 4.91 V [More than 140°C (284°F), or less than -40°C (-40°F)] P0112: Intake air temperature sensor voltage Less than 0.18 V [More than 140°C (284°F)] P0113: Intake air temperature sensor voltage More than 4.91 V [Less than -40°C (-40°F)] ES–103 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE Intake air temperature sensor voltage 0.18 V to 4.91 V [-40 to 140°C (-40 to 284°F)] WIRING DIAGRAM M1 Intake Air Temperature Sensor (Built into Mass Air Flow Meter) ECM 5V THA R-B 22 E4 BR 28 E4 4 THA R ES E2 5 E2 G035631E01 INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (INTAKE AIR TEMPERATURE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCEDOBD II / DATA LIST / PRIMARY / INTAKE AIR. (e) Read the value displayed on the tester. Standard: Same as actual Intake Air Temperature (IAT). Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Same as actual IAT C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). ES–104 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If there is a short circuit, the intelligent tester indicates140°C (284°F) or higher. B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 ES READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) ECM MAF Meter Connector THA E2 Wire Harness Side: MAF Meter Connector M1 OK 1 2 3 4 5 E2 THA Front View A114607E03 NG (a) Disconnect the M1 Mass Air Flow (MAF) meter connector. (b) Connect terminals THA and E2 of the MAF meter wire harness side connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (g) Read the value displayed on the tester. Standard: 140°C (284°F) or higher (h) Reconnect the MAF meter connector. CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE MASS AIR FLOW METER 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) MAF Meter Connector (a) Disconnect the M1 MAF meter connector. (b) Connect terminals THA and E2 of the B45 ECM connector. HINT: Before checking, do visual and contact pressure checks on the ECM connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (g) Read the value displayed on the tester. Standard: 140°C (284°F) or higher (h) Reconnect the MAF meter connector. ECM THA E2 ECM: E4 OK THA ES–105 REPAIR OR REPLACE HARNESS OR CONNECTOR E2 A114608E06 NG CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) MAF Meter Connector (a) (b) (c) (d) (e) ECM THA E2 A084869E47 Disconnect the M1 MAF meter connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) (g) Reconnect the MAF meter connector. OK NG CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE MASS AIR FLOW METER ES ES–106 5 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) MAF Meter Connector (a) (b) (c) (d) (e) Disconnect the E4 ECM connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) (g) Reconnect the ECM connector. ECM THA E2 ES ECM: OK E4 A114609E05 NG REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0111 ES–107 Intake Air Temperature Sensor Gradient Too High DESCRIPTION Fig. 1 Resistance (kΩ) Acceptable Temperature ES (°C) (°F) A067628E14 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT is low, the resistance of the thermistor increases. When the temperature is high, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (See Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, according to changes in the IAT, the voltage at terminal THA also varies. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. DTC No. DTC Detection Conditions P0111 When either of following conditions met (2 trip detection logic): • The intake air temperature rise is large from the previous trip warm-up to the following trip. • When the change in the intake air temperature after engine start is less than the threshold value. Trouble Areas IAT sensor (built into MAF meter) MONITOR DESCRIPTION The ECM performs OBD II monitoring based on the values from the intake air temperature sensor. If there is no change of the sensor value within the normal range, the ECM will not be able to perform OBD II monitoring or will misdiagnose that there is a malfunction in the sensor. The ECM detects the stuck intake air temperature sensor value by performing monitoring after the ignition switch is turned to OFF or START. MONITOR STRATEGY Related DTCs P0111: Intake air temperature sensor rationality (After engine stop) P0111: Intake air temperature sensor rationality (After cold engine start) ES–108 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) Engine Coolant Temperature (ECT) sensor and Mass Air Flow (MAF) meter Frequency of Operation Once per driving cycle Duration 10 seconds or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: ES Monitor runs whenever following DTCs are not present - Battery voltage 10.5 V or more After engine stop: Time after engine start 10 seconds or more ECT sensor circuit OK ECT in previous driving cycle 70°C (158°F) or more Accumulated MAF amount in previous driving cycle 3,070 g or more ECT when 30 minutes elapsed after engine stop 20°C (68°F) or more After cold engine start: Key-off duration 5 hours Time after engine start 10 seconds or more ECT sensor circuit OK ECT 70°C (158°F) or more Accumulated MAF amount 3,070 g or more One of the following conditions 1 or 2 is met: - 1. Duration while engine load is low 120 seconds or more 2. Duration while engine load is high 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS After engine stop: IAT change Less than 1°C (2°F) After cold engine start: IAT change Less than 1°C (2°F) WIRING DIAGRAM Refer to DTC P0110 (See page ES-97). INSPECTION PROCEDURE 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0111) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch ON. Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–109 Result Display (DTC Output) Proceed To P0111 and other DTCs A P0111 B HINT: If any DTCs other than P0111 are output, troubleshoot those DTCs first. B REPLACE MASS AIR FLOW METER A GO TO DTC CHART ES ES–12 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. The intelligent tester is required to register the VIN. 1. INPUT INSTRUCTIONS (a) Explains the general VIN input instructions using the intelligent tester. (b) Intelligent tester The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used to input the VIN. (c) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (d) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (e) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) After input, the cursor should move. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (f) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT buttons. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. (g) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. 2. READ VIN (Vehicle Identification Number) (a) Explains the VIN reading process in a flowchart. Reading the VIN stored in the ECM is necessary when comparing it to the VIN provided with the vehicle. (b) Read VIN using the intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the ignition switch to ON. (f) Turn the tester ON. ES ES–13 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / VIN. Menu Screen: Select VIN READ ES VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 3. WRITE VIN (a) Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and Vehicle VIN do not match, the VIN can be registered, or overwritten in the ECM by following this procedure. (b) Write VIN using the intelligent tester. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to ON. (e) Turn the tester ON. ES–14 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / VIN. Menu Screen: Select VIN WRITE ES VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 ES–15 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM New Registration Input Instructions [ENTER] ES [ENTER] [ENTER] [ENTER] Input Error [EXIT] Continue to next illustration A103814E03 ES–16 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES A103815 ES–110 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0115 Engine Coolant Temperature Circuit DTC P0117 Engine Coolant Temperature Circuit Low Input DTC P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION ES A thermistor is built into the Engine Coolant Temperature (ECT) sensor, of which the resistance value varies according to the ECT. The structure of the sensor and its connection to the ECM are the same as those of the Intake Air Temperature (IAT) sensor. HINT: When any of DTCs P0115, P0117 and P0118 are set, the ECM enters fail-safe mode. During fail-safe mode, the ECT is estimated to be 80°C (176°F) by the ECM. Fail-safe mode continues until a pass condition is detected. DTC No. P0115 P0117 P0118 DTC Detection Conditions Proceed to Trouble Areas Step 1 Open or short in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open or short in ECT sensor circuit ECT sensor ECM Step 4 Short in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Short in ECT sensor circuit ECT sensor ECM Step 2 Open in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds (1 trip detection logic) • • • Open in ECT sensor circuit ECT sensor ECM HINT: When any of these DTCs are set, check the ECT by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. Temperature Displayed Malfunctions -40°C (-40°F) Open circuit 140°C (284°F) or higher Short circuit MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the ECT. The ECT sensor has a thermistor with a resistance that varies according to the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. These variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the ECT. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: If the sensor voltage output is -40°C (-40°F) for 0.5 seconds or more, the ECM determines that there is an open in the ECT sensor circuit, and sets DTC P0118. Conversely, if the voltage output is more than 140°C (284°F) for 0.5 seconds or more, the ECM determines that there is a short in the sensor circuit, and sets DTC P0117. If the malfunction is not repaired successfully, a DTC is set 0.5 seconds after the engine is next started. ES–111 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY P0115: ECT sensor range check (Fluttering) P0117: ECT sensor range check (Low voltage) P0118: ECT sensor range check (High voltage) Related DTCs Required Sensors / Components (Main) Engine coolant temperature sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present ES None TYPICAL MALFUNCTION THRESHOLDS P0115: Less than 0.14 V or more than 4.91 V [More than 140°C (284°F), or less than -40°C (-40°F)] Engine coolant temperature sensor voltage P0117: Engine coolant temperature sensor voltage Less than 0.14 V [More than 140°C (284°F)] P0118: Engine coolant temperature sensor voltage More than 4.91 V [Less than -40°C (-40°F)] COMPONENT OPERATING RANGE Engine coolant temperature sensor voltage 0.14 V to 4.91 V [-40 to 140°C (-40 to 284°F)] WIRING DIAGRAM ECM E2 Engine Coolant Temperature Sensor B-L 21 E4 THW BR 28 E4 E2 2 1 G035631E02 ES–112 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE) ES (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the value displayed on the tester. Standard: Between 80°C and 97°C (176°F and 207°F) with warm engine. Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) or higher B Between 80°C and 97°C (176°F and 207°F) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or higher. B C A Go to step 4 CHECK FOR INTERMITTENT PROBLEMS 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–113 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) ECM ECT Sensor E2 THW E2 Wire Harness Side: ECT Sensor Connector (a) Disconnect the E2 Engine Coolant Temperature (ECT) sensor connector. (b) Connect terminals 1 and 2 of the ECT sensor connector on the wire harness side. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (g) Read the value displayed on the tester. Standard: 140°C (284°F) or higher (h) Reconnect the ECT sensor connector. OK E2 1 CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2 Front View A114610E03 NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) ECT Sensor (a) Disconnect the E4 ECT sensor connector. (b) Connect terminals THW and E2 of the E4 ECM connector. HINT: Before checking, do visual and contact pressure checks on the ECM connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch on. (e) Turn the tester on. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (g) Read the value displayed on the tester. Standard: 140°C (284°F) or higher (h) Reconnect the ECT sensor connector. ECM E2 THW E2 ECM: E4 OK THW E2 A114608E07 REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–114 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) ECT Sensor ES (a) (b) (c) (d) (e) ECM E2 THW E2 A084869E64 Disconnect the E2 ECT sensor connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) (g) Reconnect the ECT sensor connector. OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR NG 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) Disconnect the E4 ECM connector. Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (f) Read the value displayed on the tester. Standard: -40°C (-40°F) (g) Reconnect the ECM connector. ECM ECT Sensor E2 (a) (b) (c) (d) (e) THW E2 ECM: OK E4 A114609E06 NG REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–115 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Engine Coolant Temperature Circuit Range / Performance Problem P0116 DESCRIPTION Refer to DTC P0115 (See page ES-104). DTC No. DTC Detection Conditions P0116 When either of following conditions met (2 trip detection logic): • When cold engine started and engine warmed up, Engine Coolant Temperature (ECT) sensor value does not change. • After warmed up engine stopped and then next cold engine start performed, ECT sensor value does not change. Trouble Areas • • Thermostat ECT sensor MONITOR DESCRIPTION ECT sensor cold start monitor When a cold engine start is performed and then the engine is warmed up, if the ECT sensor value does not change, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. ECT sensor soak monitor If the ECT sensor value does not change after the warmed up engine is stopped and then the next cold engine start is performed, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0116: ECT sensor cold start monitor P0116: ECT sensor soak monitor Required Sensors / Components (Main) ECT sensor Required Sensors / Components (Related) Intake Air Temperature (IAT) sensor and Mass Air Flow (MAF) meter Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ECT sensor cold start monitor: Monitor runs whenever following DTCs not present P0100 to P0103: MAF meter P0110 to P0113: IAT sensor Battery voltage 10.5 V or more Time after engine start 1 second or more ECT at engine start Less than 60°C (140°F) IAT sensor circuit OK Soak time 0 seconds or more Accumulated MAF 1,484 g or more Engine Running Fuel cut OFF Difference between ECT at engine start and IAT Less than 40°C (72°F) ECT sensor soak monitor: Monitor runs whenever following DTCs not present P0100 to P0103: MAF meter P0110 to P0113: IAT sensor ES ES–116 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or more Engine Running Soak time 5 hours or more Either (a) or (b) condition met - (a) ECT 60°C (140°F) or more (b) Accumulated MAF 2,105 g or more TYPICAL MALFUNCTION THRESHOLDS ECT sensor cold start monitor: ECT sensor value change ES Less than 5°C (9°F) ECT sensor soak monitor: Difference between current ECT sensor value and previous ECT sensor value when engine stopped Less than 3°C (9°F) COMPONENT OPERATING RANGE ECT ECT sensor value changes in accordance with actual ECT INSPECTION PROCEDURE HINT: • If any of DTCs P0115, P0117, P0118 or P0125 are set simultaneously with DTC P0116, the ECT sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0116) (a) (b) (c) (d) Connect an intelligent tester to the DLC3. Turn the ignition switch ON. Turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (e) Read the DTC. Result Display (DTC Output) Proceed To P0116 A P0116 and other DTCs B B GO TO DTC CHART A 2 INSPECT WATER INLET WITH THERMOSTAT (a) Remove the water inlet with thermostat. (b) Check the valve opening temperature of the thermostat. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–117 Standard: 80°C to 84°C (176°F to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the water inlet with thermostat. NG REPLACE WATER INLET WITH THERMOSTAT OK REPLACE COOLANT TEMPERATURE SENSOR ES ES–399 1GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER MASS AIR FLOW METER ON-VEHICLE INSPECTION NOTICE: • Perform the MAF meter inspection according to the procedures below. • Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. Intelligent Tester 1. CAN VIM DLC3 G039021E01 CHECK MASS AIR FLOW METER (a) Perform confirmation driving pattern. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) Turn the tester ON. (4) Clear the DTCs (see page ES-31). (5) Start the engine and warm it up with all accessory switches OFF (until the engine coolant temperature is 75°C (167°F) or more). (6) Drive the vehicle at 50 km/h (31 mph) or more for 3 minutes or more *1. (7) Let the engine idle with the accelerator pedal fully released for 2 minutes or more *2. (8) Perform steps *1 and *2 at least 3 times. (Vehicle Speed) *1 *1 *1 50 km/h (31 mph) Idling Ignition Switch OFF *2 *2 *2 Warming up *1: 3 to 5 minutes *2: 2 minutes A116436E27 (b) Read the value the using intelligent tester (LONG FT#1). (1) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / LONG FT#1. ES ES–400 ES 1GR-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER (2) Read the values displayed on the tester. Standard value: Within -15 to +15 % If the result is not within the specified range, perform the inspection below. (c) Read the value the using intelligent tester (MAF). NOTICE: • Turn off the engine. • Perform the inspection with the vehicle indoors and on a level surface. • Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle). • During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn the ignition switch to ACC. (2) Turn the ignition switch ON (do not run the engine). (3) Turn the tester ON. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (5) Wait 30 seconds, and read the values on the intelligent tester. Standard condition: Less than 0.72 g/sec. • If the result is not as specified, replace the MAF meter. • If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (see page ES-73). ES–118 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit DTC P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input DTC P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input DTC P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit DTC P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input DTC P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input DTC P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation HINT: These DTCs relate to the Throttle Position (TP) sensor. DESCRIPTION HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Throttle Position (TP) sensor is mounted on the throttle body, and detects the opening angle of the throttle valve. This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The TP sensor has two sensor circuits which each transmit a signal, VTA1 and VTA2. VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1. The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle, and are transmitted to the VTA terminals of the ECM. As the valve closes, the sensor output voltage decreases and as the valve opens, the sensor output voltage increases. The ECM calculates the throttle valve opening angle according to these signals and controls the throttle actuator in response to driver inputs. These signals are also used in calculations such as air-fuel ratio correction, power increase correction and fuel-cut control. ES–119 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail-Safe Angle Throttle Position Sensor Output Voltage (V) 5 VTA2 Throttle Position Sensor 2.55 2.25 ECM Magnet VTA1 0.93 0.69 IC No. 1 ES 6 VC E2 84 Throttle Valve Opening Angle (degrees) VTA1 VTA2 Usable Range 0 Note: The throttle valve opening angle detected by the sensor terminal VTA1 is expressed as percentages. IC No. 2 Between 10% and 24%: Throttle valve fully closed Magnet Between 64% and 96%: Throttle valve fully open Approximately 19%: Fail-safe angle (6°) A019802E49 DTC No. DTC Detection Conditions P0120 Output voltage of VTA1 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds (1 trip detection logic) Trouble Areas • Throttle Position (TP) sensor (built into throttle body) ECM Output voltage of VTA1 is 0.2 V or less for 2 seconds (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA1 circuit Open in VC circuit ECM P0123 Output voltage of VTA1 is 4.8 V or more for 2 seconds (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA1 circuit Open in E2 circuit Short between VC and VTA1 circuits ECM P0220 Output voltage of VTA2 quickly fluctuates beyond lower and upper malfunction thresholds for 2 seconds (1 trip detection logic) • • TP sensor (built into throttle body) ECM P0222 Output voltage of VTA2 is 1.75 V or less for 2 seconds (1 trip detection logic) • • • • TP sensor (built into throttle body) Short in VTA2 circuit Open in VC circuit ECM P0223 Output voltage of VTA2 is 4.8 V or more, and VTA1 is between 0.2 V and 2.02 V, for 2 seconds (1 trip detection logic) • • • • • TP sensor (built into throttle body) Open in VTA2 circuit Open in E2 circuit Short between VC and VTA2 circuits ECM P0122 • ES–120 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions P2135 Either condition (a) or (b) met (1 trip detection logic): (a) Difference between output voltages of VTA1 and VTA2 is 0.02 V or less for 0.5 seconds or more (b) Output voltage of VTA1 is 0.2 V or less, and VTA2 is 1.75 V or less, for 0.4 seconds or more Trouble Areas • • • Short between VTA1 and VTA2 circuits TP sensor (built into throttle body) ECM HINT: • When any of these DTCs are set, check the throttle valve opening angle by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS AND THROTTLE POS #2. • THROTTLE POS denotes the VTA1 signal (expressed in percentages), and THROTTLE POS #2 denotes the VTA2 signal (expressed in voltages). Reference (Normal Condition) ES Tester Display Accelerator Pedal Fully Released Accelerator Pedal Fully Depressed THROTTLE POS 10 to 24% 64 to 96% THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.0 V MONITOR DESCRIPTION The ECM uses the Throttle Position (TP) sensor to monitor the throttle valve opening angle. There are several checks that the ECM performs to confirm the proper operation of the TP sensor. • A specific voltage difference is expected between the sensor terminals, VTA1 and VTA2, for each throttle valve opening angle. If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 each have a specific voltage range. If VTA1 or VTA2 is outside the normal operating range, the ECM interprets this as a malfunction in the sensor, and sets a DTC. • VTA1 and VTA2 should never be close to the same voltage level. If VTA1 is within 0.02 V of VTA2, the ECM determines that there is a short circuit in the sensor, and sets a DTC. If the malfunction is not repaired successfully, a DTC is set 2 seconds after the engine is next started. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the ignition switch is turned to OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0120: Throttle position sensor 1 range check (Fluctuating) P0122: Throttle position sensor 1 range check (Low voltage) P0123: Throttle position sensor 1 range check (High voltage) P0220: Throttle position sensor 2 range check (Fluctuating) P0222: Throttle position sensor 2 range check (Low voltage) P0223: Throttle position sensor 2 range check (High voltage) P2135: Throttle position sensor range check (Correlation) Required Sensors / Components (Main) Throttle position sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration Accelerator pedal ON: 2 seconds Accelerator pedal OFF: 10 seconds P2135: 0.5 seconds or 0.4 seconds MIL Operation Immediate 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence of Operation ES–121 None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Ignition switch ON Throttle control motor power ON TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less, or 4.535 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4,535 V or more P0220: VTA2 voltage 1.75 V or less, or 4.8 V or more P0222: VTA2 voltage 1.75 V or less P0223: Both of the following conditions are met for 2 seconds or more: Condition 1 and 2 1. VTA1 voltage 0.2 to 2.02 V 2. VTA2 voltage 4.8 V or more P2135: Either of the following conditions is met: Condition 1 or 2 1. Difference between VTA1 and VTA2 voltage 0.02 V or less 2. Both of the following conditions are met: Condition (a) and (b) (a) VTA1 voltage 0.2 V or less (b) VTA2 voltage 1.75 V or less COMPONENT OPERATING RANGE VTA1 voltage 0.69 to 3.96 V VTA2 voltage 2.25 to 4.8 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is fully depressed slowly, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is turned to OFF. ES ES–122 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM T2 Throttle Position Sensor (Built into Throttle with motor Body) VC VTA1 ES VTA2 E2 5 19 E4 G-W W 23 VC E4 20 E4 G-B 4 3 L-R R 6 ECM BR VTA1 VTA2 28 E4 E2 G032681E02 INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (THROTTLE POS AND THROTTLE POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the intelligent tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS and THROTTLE POS #2. (d) Check the values displayed on the tester. Result TP#1 (VTA1) When AP Released TP#2 (VTA2) When AP Released TP#1 (VTA1) When AP Depressed TP#2 (VTA2) When AP Depressed Trouble Areas Proceed to 0% Between 0 V and 0.2 V 0% Between 0 V and 0.2 V VC circuit open A 100% Between 4.5 V and 5.0 V 100 % Between 4.5 V and 5.0 V E2 circuit open A 0% or 100% Between 2.1 V and 3.1 V (Fail-safe) 0% or 100% Between 2.1 V and 3.1 V (Fail-safe) VTA1 circuit open or ground short A ES–123 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TP#1 (VTA1) When AP Released TP#2 (VTA2) When AP Released TP#1 (VTA1) When AP Depressed TP#2 (VTA2) When AP Depressed Trouble Areas Proceed to Approx. 19% (Fail-safe) Between 0 V and 0.2 V, or 4.5 V and 5.0 V Between 10% and 24% (Fail-safe) Between 0 V and 0.2 V, or 4.5 V and 5.0 V VTA2 circuit open or ground short A Between 10% and 24% Between 2.1 V and 3.1 V Between 64% and 96% (Not fail-safe) Between 4.5 V and 5.0 V (Not fail-safe) TP sensor circuit normal B HINT: • TP#1 denotes THROTTLE POS, and TP#2 denotes THROTTLE POS#2. • AP denotes Accelerator Pedal. • VTA1 is expressed as percentage, and VTA2 is expressed as voltage. B Go to step 5 A 2 CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) (a) Disconnect the T2 throttle with motor body connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Throttle with Motor Body Connector T2 Tester Connections 1 E2 2 3 4 5 6 VTA2 VC Front View VTA1 ECM: Below 1 Ω Below 1 Ω VTA2 (T2-4) - VTA2 (E4-19) Below 1 Ω E2 (T2-3) - E2 (E4-28) Below 1 Ω Tester Connections Specified Conditions VC (T2-5) or VC (E4-23) - Body ground 10 kΩ or higher VTA1 (T2-6) or VTA1 (E4-20) - Body ground 10 kΩ or higher VTA2 (T2-4) or VTA2 (E4-19) - Body ground 10 kΩ or higher (d) Reconnect the throttle with motor body connector. (e) Reconnect the ECM connector. VTA2 E2 NG VTA1 A114611E03 OK VC (T2-5) - VC (E4-23) VTA1 (T2-6) - VTA1 (E4-20) Standard resistance (Check for short) E4 VC Specified Conditions REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–124 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (VC VOLTAGE) (a) Disconnect the T2 throttle with motor body connector. (b) Turn the ignition switch on. (c) Measure the voltage between the terminals of the E4 ECM connector. Standard voltage Wire Harness Side: Throttle with Motor Body Connector T2 1 E2 ES 2 3 4 VTA2 5 6 VC VTA Tester Connections Specified Conditions VC (T2-23) - E2 (E4-28) 4.5 to 5.0 V (d) Reconnect the throttle with motor body connector. Front View NG REPLACE ECM ECM: E4 VC (+) E2 (-) A114612E03 OK 4 REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY (a) Replace the throttle with motor body assembly (See page ES-413). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (THROTTLE POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Clear DTCs (See page ES-31). Start the engine. Allow the engine to idle for 15 seconds or more. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read DTCs. Result Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 A No output B B SYSTEM OK 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–125 A REPLACE ECM ES ES–126 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem P0121 HINT: This DTC relates to the Throttle Position (TP) sensor. DESCRIPTION Refer to DTC P0120 (See page ES-112). DTC No. DTC Detection Conditions P0121 Difference between VTA1 and VTA2 voltages less than 0.8 V, or more than 1.6 V for 2 seconds (1 trip detection logic) ES Trouble Areas TP sensor (built into throttle body) MONITOR DESCRIPTION The ECM uses the TP sensor to monitor the throttle valve opening angle. This sensor transmits two signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. The ECM performs several checks to confirm the proper operation of the TP sensor and VTA1. For each throttle opening angle, a specific voltage difference is expected between the outputs of VTA1 and VTA2. If the voltage output difference between the two signals deviates from the normal operating range, the ECM interprets this as a malfunction of the TP sensor. The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P0121: TP sensor rationality Required Sensors / Components (Main) TP sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 2 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Either of following conditions A or B is met - A. Ignition switch ON B. Electric throttle motor power ON TP sensor malfunction (P0120, P0122, P0123, P0220, P0222, P0223, P02135) Not detected TYPICAL MALFUNCTION THRESHOLDS Either of following conditions is met - "Difference of TP sensor voltage between VTA1 and VTA2 x 0.8" Higher than 1.6 V "Difference of TP sensor voltage between VTA1 and VTA2 x 0.8" Lower than 0.8 V 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–127 FAIL-SAFE When this DTC, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, is set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is fully depressed slowly, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 REPLACE THROTTLE BODY ASSEMBLY (a) Replace the throttle body assembly (See page ES-412). NEXT END ES ES–128 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Insufficient Coolant Temperature for Closed Loop Fuel Control P0125 DESCRIPTION Refer to DTC P0115 (See page ES-104). DTC No. DTC Detection Conditions • ES • P0125 • Case 1: Engine Coolant Temperature (ECT) less than 19.45°C (-3°F) at engine start and following conditions met (2 trip detection logic): (a) 20 minutes elapsed since engine start (b) ECT sensor value remains below closed-loop fuel control enabling temperature Case 2: ECT between -19.45°C and -8.34°C (-3°F and 17°F) at engine start and following conditions met (2 trip detection logic): (a) 105 seconds elapsed since engine start (b) ECT sensor value remains below closed-loop fuel control enabling temperature Case 3: ECT above -8.34°C (17°F) at engine start and following conditions met (2 trip detection logic): (a) 61 seconds elapsed since engine start (b) ECT sensor value remains below closed-loop fuel control enabling temperature Trouble Areas • • • Cooling system ECT sensor Thermostat (water inlet) MONITOR DESCRIPTION The resistance of the ECT sensor varies in proportion to the actual ECT. The ECM supplies a constant voltage to the sensor and monitors the signal output voltage of the sensor. The signal voltage output varies according to the changing resistance of the sensor. After the engine is started, the ECT is monitored through this signal. If the ECT sensor indicates that the engine is not yet warm enough for closed-loop fuel control, despite a specified period of time having elapsed since the engine was started, the ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. Example: The ECT is 0°C (32°F) at engine start. After 5 minutes running time, the ECT sensor still indicates that the engine is not warm enough to begin closed-loop fuel (air-fuel ratio feedback) control. The ECM interprets this as a malfunction in the sensor or cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient engine coolant temperature for closed-loop fuel control Required Sensors / Components (Main) Thermostat, Cooling system, ECT sensor Required Sensors / Components (Related) Engine coolant temperature sensor and mass air flow meter Frequency of Operation MAF meter Duration 61 seconds: Engine coolant temperature at engine start -8.34°C (17°F) or more 105 seconds: Engine coolant temperature at engine start -19.45 to -8.34°C (-3 to 17°F) 20 minutes: Engine coolant temperature at engine start less than -19.45°C (-3°F) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0100, P0101, P0102, P0103 (MAF meter), P0110, P0112, P0113 (IAT sensor), P0115, P0116, P0117, P0118 (ECT sensor) Thermostat fail Not detected ES–129 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Time until "engine coolant temperature" detection temperature reaches feedback start temperature - When the temperature at the time of engine starting is 8.34°C (17°F) or more Engine coolant temperature is less than "closed-loop enable temperature" when 61 seconds or more after engine start When the temperature at the time of engine starting is 19.45 to -8.34°C (-3 to 17°F) Engine coolant temperature is less than "closed-loop enable temperature" when 105 seconds or more after engine start When the temperature at the time of engine starting is 19.45°C (-3°F) or less Engine coolant temperature is less than "closed-loop enable temperature" when 20 minutes. or more after engine start WIRING DIAGRAM ES Refer to DTC P0115 (See page ES-105). INSPECTION PROCEDURE HINT: • If any of DTCs P0115, P0116, P0117 or P0118 are set simultaneously with DTC P0125, the Engine Coolant Temperature (ECT) sensor may have an open or a short circuit. Troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0125) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0125 A P0125 and other DTCs B HINT: If any DTCs other than P0125 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-14). (b) Check the valve opening temperature of the thermostat (See page CO-14). Standard: 80° to 84°C (176° to 183°F) ES–130 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-15). NG REPLACE THERMOSTAT OK 3 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as abnormal radiator fan operation or any modifications. ES NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES–131 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) P0128 HINT: This DTC relates to the thermostat. DESCRIPTION This DTC is set when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. DTC No. DTC Detection Conditions P0128 Conditions (a), (b) and (c) are met for 5 seconds (2 trip detection logic): (a) Cold start (b) Engine warmed up (c) ECT less than 75°C (167°F) Trouble Areas • • • • Thermostat Cooling system ECT sensor ECM ES MONITOR DESCRIPTION Estimated ECT 5 Seconds Threshold (75°C (167 °F)) Indicated ECT reading ECT Time DTC set (after 2 driving cycle) A082385E14 The ECM estimates the ECT based on the starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated ECT reaches 75°C (167°F), the ECM checks the actual ECT. If the actual ECT is less than 75°C (167°F), the ECM interprets this as a malfunction in the thermostat or the engine cooling system and sets the DTC. MONITOR STRATEGY Related DTCs P0128: Coolant Thermostat Required Sensors / Components (Main) Engine Coolant Temperature (ECT) sensor, Thermostat ES–132 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors / Components (Related) Intake Air Temperature (IAT) sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 900 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ES The monitor will run whenever these DTCs are not present P0010, P0020 (VVT VSV 1, 2), P0011, P0012 (VVT System1-Advance, Retard), P0021, P0022 (VVT System2-Adavance, Retard), P0031, P0032, P0051, P0052 (A/ F Sensor heater Sensor 1), P0100, P0101, P0102, P0103 (MAF Meter), P0110, P0112, P0113 (IAT Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0125 (Insufficient ECT for Closed Loop), P0171,P0172 (Fuel System), P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Misfire), P0335 (CKP Sensor), P0340 (CMP Sensor), P0340, P0342, P0343, P0345 (VVT Sensor1, 2), P0351, P0352, P0353, P0354, P0355, P0356 (Ignitor), P0500 (VSS), P2196, P2198(A/F Sensor (Rationality)), P2A00, P2A03 (A/F Sensor (Slow Response)) Battery voltage 11 V or more Either of following conditions met: Condition 1 or 2 1. All of following conditions met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine starts -15° to 7°C (5° to 45°F) (b) ECT at engine start -10° to 56°C (14° to 133°F) (c) IAT at engine start -10° to 56°C (14° to 133°F) 2. All of following conditions met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine start More than 7°C (45°F) (b) ECT at engine start 56°C (133°F) or less (c) IAT at engine start -10°C (14°F) or more Accumulated time that vehicle speed is 80 mph (128km/h) or more Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS Duration that all of following conditions 1 and 2 met 5 seconds or more 1. Estimated ECT 75°C (167°F) or more 2. ECT sensor output Below 75°C (167°F) MONITOR RESULT Refer to Checking Monitor Status (See page ES-14). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0128) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (c) Turn the tester on. ES–133 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0128 A P0128 and other DTCs B HINT: If any DTCs other than P0128 are output, troubleshoot those DTCs first. B GO TO DTC CHART ES A 2 CHECK COOLING SYSTEM (a) Check that there is no defect in the cooling system which causes overcool, such as abnormal radiator fan operation, modified cooling system and so on. NG REPAIR OR REPLACE COOLING SYSTEM OK 3 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-14). (b) Check the valve opening temperature of the thermostat (See page CO-14). Standard: 80° to 84°C (176° to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-15). NG OK REPLACE ECM REPLACE THERMOSTAT ES–134 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) DTC P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) DTC P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) DTC P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) DTC P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) DTC P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) HINT: Sensor 2 refers to the sensor mounted behind the Three-Way Catalytic Converter (TWC) and located far from the engine assembly. DESCRIPTION In order to obtain a high purification rate of the carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxide (NOx) components in the exhaust gas, a TWC (Three-Way Catalytic Converter) is used. For the most efficient use of the TWC, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel level. For helping the ECM to deliver accurate air-fuel ratio control, a Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air-fuel ratio becomes lean, the oxygen concentration in the exhaust gas is rich. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air-fuel ratio is richer than the stoichiometric air-fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor informs the ECM that the post-TWC air-fuel ratio is rich (high voltage, i.e. more than 0.45 V). The HO2 sensor has the property of changing its output voltage drastically when the air-fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air-fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air-fuel ratio control. ES–135 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmospheric Air Ideal Air-Fuel Mixture Housing Output Voltage Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover ES Richer - Air-Fuel Ratio - Leaner Exhaust Gas A088111E10 DTC No. DTC Detection Conditions • P0136 P0156 • • P0137 P0157 • • P0138 P0158 • Abnormal voltage output: During active air-fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) Heated Oxygen (HO2) sensor voltage does not decrease to less than 0.21 V (b) HO2 sensor voltage does not increase to more than 0.6 V Low impedance: Sensor impedance less than 5 Ω for more than 30 seconds when ECM presumes sensor to being warmed up and operating normally (2 trip detection logic) Trouble Areas • • • • • • Open or short in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) HO2 sensor heater (bank 1, 2 sensor 2) Air-Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) EFI relay Gas leakage from exhaust system Low voltage (open): During active air-fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) HO2 sensor voltage output less than 0.21 V (b) Target air-fuel ratio rich High impedance: Sensor impedance 15 kΩ or more for more than 90 seconds when ECM presumes sensor to being warmed up and operating normally (2 trip detection logic) • • • • • Open in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) HO2 sensor heater (bank 1, 2 sensor 2) EFI relay Gas leakage from exhaust system High voltage (short): During active air-fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) HO2 sensor voltage output 0.59 V or more (b) Target air-fuel ratio lean Extremely high voltage (short): HO2 sensor voltage output exceeds 1.2 V for more than 30 seconds (2 trip detection logic) • • • • Short in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) Air-Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) ECM internal circuit malfunction MONITOR DESCRIPTION Active Air-Fuel Ratio Control The ECM usually performs air-fuel ratio feedback control so that the Air-Fuel Ratio (A/F) sensor output indicates a near stoichiometric air-fuel level. This vehicle includes active air-fuel ratio control in addition to regular air-fuel ratio control. The ECM performs active air-fuel ratio control to detect any deterioration in the Three-Way Catalytic Converter (TWC) and Heated Oxygen (HO2) sensor malfunctions (refer to the diagram below). ES–136 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Active air-fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine. During active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become lean or rich by the ECM. If the ECM detects a malfunction, one of the following DTCs is set: DTC P0136 or P0156 (abnormal voltage output), P0137 or P0157 (open circuit) or P0138 or P0158 (short circuit). Abnormal Voltage Output of HO2 Sensor (DTCs P0136 and P0156) While the ECM is performing active air-fuel ratio control, the air-fuel ratio is forcibly regulated to become rich or lean. If the sensor is not functioning properly, the voltage output variation is small. For example, when the HO2 sensor voltage does not decrease to less than 0.21 V or does not increase to more than 0.59 V during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormal and sets DTCs P0136 and P0156. HO2 SENSOR CIRCUIT MALFUNCTION ) ES 15 to 20 seconds (P0136 and P0156: ABNORMAL VOLTAGE) Operation Active air-fuel ratio control Off Normal 0.59 V HO2 sensor voltage Abnormal 0.21 V A076837E08 Open or Short in Heated Oxygen (HO2) Sensor Circuit (DTCs P0137 and P0157 or P0138 and P0158) During active air-fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the ThreeWay Catalytic Converter (TWC) by forcibly regulating the air-fuel ratio to become rich or lean. If the HO2 sensor has an open or short, or the voltage output of the sensor noticeably decreases, the OSC indicates an extraordinarily high value. Even if the ECM attempts to continue regulating the air-fuel ratio to become rich or lean, the HO2 sensor output does not change. While performing active air-fuel ratio control, when the target air-fuel ratio is rich and the HO2 sensor voltage output is 0.21 V or less (lean), the ECM interprets this as an abnormally low sensor output voltage and sets DTC P0137 or P0157. When the target air-fuel ratio is lean and the voltage output is 0.59 V or more (rich) during active air-fuel ratio control, the ECM determines that the sensor voltage output is abnormally high, and sets DTC P0138 or P0158. HINT: DTC P0138 or P0158 is also set if the HO2 sensor voltage output is more than 1.2 V for 30 seconds or more. *: The TWC has the capability to store oxygen. The OSC and the emission purification capacity of the TWC are mutually related. The ECM determines whether the catalyst has deteriorated, based on the calculated OSC value (See page ES-205). 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HO2 SENSOR CIRCUIT LOW VOLTAGE (P0137 and P0157: OPEN) Active air-fuel ratio control Target air-fuel ratio Off 15 to 20 seconds Operation Abnormal Normal Stoichiometric Air-Fuel Level Rich HO2 sensor voltage ES–137 Normal ES 0.21 V Abnormal HO2 SENSOR CIRCUIT HIGH VOLTAGE (P0138 and P0158: SHORT) Operation Active air-fuel ratio control Target air-fuel ratio HO2 sensor voltage Off Lean Stoichiometric Air-Fuel Level Abnormal 0.59 V A080024E08 ES–138 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM High or Low Impedance of Heated Oxygen (HO2) Sensor (DTCs P0136 and P0156 or P0137 and P0157) During normal air-fuel ratio feedback control, there are small variations in the exhaust gas oxygen concentration. In order to continuously monitor the slight variation of the HO2 sensor signal while the engine is running, the impedance* of the sensor is measured by the ECM. The ECM determines that there is a malfunction in the sensor when the measured impedance deviates from the standard range. *: The effective resistance in an alternating current electrical circuit. Interrelation between temperature of element and impedance: Impedance Ω ES DTC Detection Area 15,000 1,000 100 10 5 300 400 500 600 700 800 (572) (752) (932) (1,112) (1,292) (1,472) Temperature °C (°F) A076841E08 HINT: • The impedance cannot be measured using an ohmmeter. • DTCs P0136 and P0156 indicate the deterioration of the HO2 sensor. The ECM sets the DTCs by calculating the impedance of the sensor when the typical enabling conditions are satisfied (1 driving cycle). • DTCs P0137 and P0157 indicate an open or short circuit in the HO2 sensor (1 driving cycle). The ECM sets the DTCs when the impedance of the sensor exceeds the threshold 15 kΩ. MONITOR STRATEGY Related DTCs P0136: Heated oxygen sensor output voltage (Output voltage) (bank 1) P0136: Heated oxygen sensor impedance (Low) (bank 1) P0137: Heated oxygen sensor output voltage (Low voltage) (bank 1) P0137: Heated oxygen sensor impedance (High) (bank 1) P0138: Heated oxygen sensor output voltage (High voltage) (bank 1) P0138: Heated oxygen sensor output voltage (Extremely high) (bank 1) P0156: Heated oxygen sensor output voltage (Output voltage) (bank 2) P0156: Heated oxygen sensor impedance (Low) (bank 2) P0157: Heated oxygen sensor output voltage (Low voltage) (bank 2) P0157: Heated oxygen sensor impedance (High) (bank 2) P0158: Heated oxygen sensor output voltage (High voltage) (bank 2) P0158: Heated oxygen sensor impedance (Extremely high) (bank 2) Required Sensors / Components (Main) Heated oxygen sensor Required Sensors / Components (Related) Crankshaft position sensor, Engine coolant temperature sensor, Mass air flow meter, Throttle position sensor Frequency of Operation Once per driving cycle: Active air-fuel ratio control detection Continuous: Others Duration 20 seconds.: Heated oxygen sensor output (Output voltage, High voltage, Low voltage) 30 seconds.: Heated oxygen sensor impedance (Low) 90 seconds.: Heated oxygen sensor impedance (High) 10 seconds.: Heated oxygen sensor impedance (Stuck high) MIL Operation 2 driving cycles Sequence of Operation None 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–139 TYPICAL ENABLING CONDITIONS All: Monitor runs whenever DTCs not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172, P0174, P0175 (Fuel system) P0300 - P0306 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0450 - P0456 (EVAP System) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2A00, P2A03 (A/F sensor - slow response) Heated oxygen sensor output voltage (Output voltage, High voltage and Low voltage): Active air-fuel ratio control Performing Active air-fuel ratio control begins when all of following conditions met: - Battery voltage 11 V or more Engine coolant temperature 75°C (167°F) or more Idle OFF Engine RPM Less than 3,200 rpm A/F sensor status Activated Fuel system status Closed loop Fuel-cut OFF Engine load 10 to 70% Shift position 4th or more Heated oxygen sensor impedance (Low): Battery voltage 11 V or more Estimated HO2S temperature Less than 700°C (1,292°F) ECM monitor Completed DTC P0606 Not set Heated oxygen sensor impedance (High): Battery voltage 11 V or more Estimated HO2S temperature 520 to 750°C (968 to 1,382°F) DTC P0606 Not present Heated oxygen sensor output voltage (Extremely high): Battery voltage 11 V or more Time after engine start 2 seconds or more TYPICAL MALFUNCTION THRESHOLDS Heated oxygen sensor output voltage (Output voltage): Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions (a), (b) and (c) are met - (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2 sensor voltage 0.21 to 0.59 V (c) OSC (Oxygen Storage Capacity of Catalyst) 2.5 g or more 2. All of the following conditions (d), (e) and (f) are met. - (d) Commanded air-fuel ratio 14.9 or more ES ES–140 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Rear HO2 sensor voltage 0.21 to 0.59 V (f) OSC 2.5 g or more Heated oxygen sensor output voltage (Low output voltage): All of the following conditions (a), (b) and (c) are met. - (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2 sensor voltage Less than 0.21 V (c) OSC (Oxygen Storage Capacity of Catalyst) 2.5 g or more Heated oxygen sensor output voltage (High output voltage): ES All of the following conditions (a), (b) and (c) are met. - (a) Commanded air-fuel ratio 14.3 or more (b) Rear HO2 sensor voltage More than 0.59 V (c) OSC (Oxygen Storage Capacity of Catalyst) 2.5 g or more Heated oxygen sensor impedance (Low): Duration of following condition 30 seconds or more Rear heated oxygen sensor impedance Less than 5 Ω Heated oxygen sensor impedance (High): Duration of following condition 90 seconds or more Rear heated oxygen sensor impedance 15 kΩ or more Heated oxygen sensor impedance (Extremely high): Duration of following condition 10 seconds or more Rear heated oxygen sensor voltage 1.2 V or more COMPONENT OPERATING RANGE Heated oxygen sensor voltage Varies between 0.1 and 0.9 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES–141 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM H6 Heated Oxygen Sensor (Bank 1 Sensor 2) 17 IC3 L-W 12 IM1 L-W L-W A BR J4 J/C L-W A L-W 2 2 L-W EFI No. 2 Engine Room R/B ECM 2 +B HT 1 G 1 HT1B E4 4 E1 OX 3 W 18 E4 OX1B H8 Heated Oxygen Sensor (Bank 2 Sensor 2) 2 +B HT 1 BR 4 E1 OX 3 (*1) 5 HT2B E5 L 33 E5 OX2B B 1 ES (*1) 2 W-G B 2 2 3 35 IC4 W-G 28 E4 BR 1 EFI Relay 8 MREL E8 E2 Engine Room R/B 2 5 2 2 *1: Shielded W-B L E 2 E Engine Room R/B 2 J28 J/C B J2 EFI 1 E J/C B J3 BR 2 W-B B Battery EB EE G032682E01 ES–142 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN HINT: • This confirmation driving pattern is used in steps 5, 8 and 11 of the following diagnostic troubleshooting procedure when using the intelligent tester. • Performing this confirmation pattern will activate the Heated Oxygen (HO2) sensor monitor. (The catalyst monitor is performed simultaneously.) This is very useful for verifying the completion of a repair. Engine Speed NOTICE: “H” This test will not be completed if the vehicle is driven under absolutely constant speed condition such as with cruise control activated. Between 40 mph and 70 mph (64 km/h and 113 km/h) ES Idling Ignition Switch off “G” Warm up 10 minutes Time (Note: Even when vehicle stops during driving pattern, the test can be resumed) A079199E76 1. Connect the intelligent tester to the DLC3 (Procedure A). A098191E04 2. 3. 4. 5. 6. 7. 8. Turn the ignition switch on (Procedure B). Turn the tester on (Procedure C). Clear DTCs (See page ES-31) (Procedure D). Select the following menu items: DIAGNOSIS / CARB OBD II / READINESS TESTS (Procedure E). Check that O2S EVAL is INCMPL (incomplete) (Procedure F). Start the engine and warm it up (Procedure G). Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes (Procedure H). 9. Note the state of the Readiness Tests items. Those items will change to COMPL (complete) as O2S EVAL monitor operates (Procedure I). 10.On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set (Procedure J). HINT: If O2S EVAL does not change to COMPL, and any pending DTCs fail to set, extend the driving time. ES–143 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: For use of the intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Main Suspected Trouble Area - 1 2 3 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit ES ES–144 Case 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection volume +25 % -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area • • • 4 ES Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) – Following the A/F CONTROL procedure enables technicians to check the graph of the voltage outputs of both the A/F and HO2 sensors. – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Press the YES button and then the ENTER button. Then press the F4 button. HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • If the OX1B wire from the ECM connector is short-circuited to the +B wire, DTC P0136 will be set. • If the OX2B wire from the ECM connector is short-circuited to the +B wire, DTC P0156 will be set. 1 READ DTC OUTPUT (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0138 or P0158 A P0137 or P0157 B P0136 or P0156 C B Go to step 13 C Go to step 6 A 2 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. ES–145 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / O2S B1S2 or O2S B2S2. (d) Allow the engine to idle. (e) Read the Heated Oxygen (HO2) sensor output voltage while idling. Result HO2 Sensor Output Voltages Proceed to More than 1.2 V A Less than 1.0 V B B Go to step 5 ES A 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT) (a) Turn the ignition switch off and wait for 5 minutes. (b) Disconnect the E4 or E5 ECM connector. (c) Measure the resistance. Standard resistance ECM: E4 HT1B E5 OX2B OX1B Specified Conditions HT1B (E4-1) - OX1B (E4-18) 10 kΩ or higher HT2B (E5-5) - OX2B (E5-33) 10 kΩ or higher (d) Reconnect the ECM connector. HT2B G035620E13 OK NG Tester Connections REPLACE ECM ES–146 4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) Disconnect the H6 or H8 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance between the terminals of the HO2 sensor connector. Standard resistance: Bank 1 Component Side: HO2 Sensor H6 Bank 1 ES HT +B E1 OX HO2 Sensor +B Specified Conditions +B (2) - E1 (4) 10 kΩ or higher +B (2) - OX (3) 10 kΩ or higher Tester Connections Specified Conditions +B (2) - E1 (4) 10 kΩ or higher +B (2) - OX (3) 10 kΩ or higher Bank 2: Front View H8 Bank 2 Tester Connections HT (c) Reconnect the HO2 sensor connector. NG REPLACE HEATED OXYGEN SENSOR OX E1 Front View A126268E04 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK AIR FUEL RATIO SENSOR HINT: This A/F sensor test is to check the A/F sensor current during the fuel-cut. When the sensor is normal, the sensor current will indicate below 3 mA in this test. (a) Clear DTC. (b) Drive the vehicle by the drive pattern as listed below: (1) Warm up the engine. (2) Drive the vehicle at 60 km/h (40 mph) or more for 10 minutes or more. (3) Stop the vehicle. (4) Accelerator the vehicle until 60 km/h (40 mph) or more and decelerate for 3 seconds or more. Perform this three times. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–147 Drive Pattern: 40 mph (60 km/h) 0 mph (0 km/h) ES 10 minutes or more 3 seconds or more 3 seconds or more 3 seconds or more A152792E01 (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR RESULT. (d) Confirm that RANGE B1S1 is either PASS or FAIL. (e) Select RANGE B1S1 an press ENTER. (f) Read the test value. Standard: Less than 3.0 mA NOTICE: Do not turn the engine switch Off during this step because the test results will be lost. OK Go to step 9 NG REPLACE AIR FUEL RATIO SENSOR 6 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Start the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2 or O2S B1S2. (e) After warming up the engine, run the engine at an engine speed of 2,500 rpm for 3 minutes. (f) Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased. ES–148 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Quickly accelerate the engine to 4,000 rpm 3 times using the accelerator pedal. Standard: Fluctuates between 0.4 V or less and 0.5 V or more. NG Go to step 13 OK 7 ES PERFORM CONFIRMATION DRIVING PATTERN (a) Perform confirmation driving pattern (See page ES-17). NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P0136 OR P0156) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0136 or P0156 A No output B B CHECK FOR INTERMITTENT PROBLEMS A 9 REPLACE HEATED OXYGEN SENSOR (a) Replace the heated oxygen sensor (See page EX-2). NEXT 10 PERFORM CONFIRMATION DRIVING PATTERN (a) Perform confirmation driving pattern (See page ES-17). NEXT 11 CHECK WHETHER DTC OUTPUT RECURS (DTC P0136 OR P0156) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. ES–149 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P0136 or P0156 A No output B B REPAIR COMPLETED A 12 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTION VOLUME) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester on. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. (e) Change the fuel injection volume using the tester, monitoring the voltage output of Air-Fuel Ratio (A/F) and HO2 sensors displayed on the tester. HINT: • Change the fuel injection volume within the range of 12% and +12%. The injection volume can be changed in 1% graduations within the range. • The A/F sensor is displayed as AFS B1S1 or AFS B2S1, and the HO2 sensor is displayed as O2S B1S2 or O2S B2S2, on the intelligent tester. Result Tester Display (Sensor) Voltage Variations Proceed to AFS B1S1 (A/F) AFS B2S1 (A/F) Alternates between more and less than 3.3 V OK AFS B1S1 (A/F) AFS B2S1 (A/F) Remains at more than 3.3 V NG AFS B1S1 (A/F) AFS B2S1 (A/F) Remains at less than 3.3 V NG HINT: A normal HO2 sensor voltage (O2S B1S2 or O2S B2S2) reacts in accordance with increases and decreases in fuel injection volumes. When the A/F sensor voltage remains at either less or more than 3.3 V despite the HO2 sensor indicating a normal reaction, the A/F sensor is malfunctioning. ES ES–150 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Injection Volume +12% Malfunction -12% A/F Sensor Output Normal 3.3 V ES HO2 Sensor Output Malfunction 1V 0V A087979E15 NG REPLACE AIR FUEL RATIO SENSOR OK CHECK AND REPLACE EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (INJECTOR, FUEL PRESSURE, GAS LEAKAGE FROM EXHAUST SYSTEM,ETC) 13 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG OK REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT ES–151 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 14 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the H6 or H8 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance between the terminals of the HO2 sensor connector. Standard resistance: Bank 1 Component Side: HO2 Sensor H6 Bank 1 HT +B E1 OX HO2 Sensor +B Specified Conditions HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E1 (4) 10 kΩ or higher Bank 2 Front View H8 Bank 2 Tester Connections HT Tester Connections Specified Conditions HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E1 (4) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. NG REPLACE HEATED OXYGEN SENSOR OX E1 Front View A126268E05 OK 15 INSPECT EFI RELAY (a) Remove the EFI relay from the engine room R/B. (b) Measure the EFI relay resistance. Standard resistance Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the EFI relay. NG B016200 OK REPLACE EFI RELAY ES ES–152 16 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM) (a) Disconnect the H6 or H8 HO2 sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the +B terminal of the HO2 sensor connector and body ground. Standard voltage Wire Harness Side: HO2 Sensor Connector H6 Bank 1 HT +B 1 2 3 4 OX E1 Front View ES H8 Bank 2 HT 2 3 4 OX Specified Conditions +B (H6-2) - Body ground 9 V to 14 V +B (H8-2) - Body ground 9 V to 14 V (d) Turn the ignition switch off. (e) Disconnect the E4 and E5 ECM connectors. (f) Measure the resistance. Standard resistance (Check for open) +B 1 Tester Connections E1 Tester Connections ECM: E5 E4 Specified Conditions HT (H6-1) - HT1B (E4-1) Below 1 Ω OX (H6-3) - OX1B (E4-18) Below 1 Ω E1 (H6-4) - E2 (E4-28) Below 1 Ω HT (H8-1) - HT2B (E5-5) Below 1 Ω OX (H8-3) - OX2B (E5-33) Below 1 Ω E1 (H8-4) - E2 (E4-28) Below 1 Ω Standard resistance (Check for short) HT2B HT1B OX1B E2 OX2B A114613E03 Tester Connections Specified Conditions HT (H6-1) or HT1B (E4-1) - Body ground 10 kΩ or higher OX (H6-3) or OX1B (E4-18) - Body ground 10 kΩ or higher E1 (H6-4) or E2 (E4-28) - Body ground 10 kΩ or higher HT (H8-1) or HT2B (E5-5) - Body ground 10 kΩ or higher OX (H8-3) or OX2B (E5-33) - Body ground 10 kΩ or higher E1 (H8-4) or E2 (E4-28) - Body ground 10 kΩ or higher (g) Reconnect the HO2 sensor connector. (h) Reconnect the ECM connectors. Reference (System Diagram of Bank 1 Sensor 2): Engine Room Junction Block EFI Relay From Battery EFI No. 2 Fuse ECM HO2 Sensor +B EFI No. 1 Fuse HT HT1B OX1B OX1B Heater E1 Duty Control Sensor Ground E2 MREL G042820E04 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–153 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HEATED OXYGEN SENSOR ES ES–154 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0171 System Too Lean (Bank 1) DTC P0172 System Too Rich (Bank 1) DTC P0174 System Too Lean (Bank 2) DTC P0175 System Too Rich (Bank 2) DESCRIPTION ES The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim consists of both the short-term and long-term fuel trims. The short-term fuel trim is fuel compensation that is used to constantly maintain the air-fuel ratio at stoichiometric levels. The signal from the Air-Fuel Ratio (A/F) sensor indicates whether the air-fuel ratio is rich or lean compared to the stoichiometric ratio. This triggers a reduction in the fuel injection volume if the air-fuel ratio is rich and an increase in the fuel injection volume if it is lean. Factors such as individual engine differences, wear over time and changes in operating environment cause short-term fuel trim to vary from the central value. The long-term fuel trim, which controls overall fuel compensation, compensates for long-term deviations in the fuel trim from the central value caused by the short- term fuel trim compensation. If both the short-term and long-term fuel trims are lean or rich beyond predetermined values, it is interpreted as a malfunction, and the ECM illuminates the MIL and sets a DTC. DTC No. P0171 P0174 DTC Detection Conditions With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to lean side (2 trip detection logic) Trouble Areas • • • • • • • • • • • • • • P0172 P0175 With warm engine and stable air-fuel ratio feedback, fuel trim considerably in error to rich side (2 trip detection logic) • • • • • • • • • • • • Air induction system Injector blockage Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F sensor heater relay A/F sensor heater and A/F sensor heater relay circuits PCV valve and hose PCV hose connections ECM Injector leakage or blockage MAF meter ECT sensor Ignition system Fuel pressure Gas leakage from exhaust system Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F sensor heater relay A/F sensor heater and A/F sensor heater relay circuits ECM HINT: • When DTC P0171 or P0174 is set, the actual air-fuel ratio is on the lean side. When DTC P0172 P0175 is set, the actual air-fuel ratio is on the rich side. • If the vehicle runs out of fuel, the air-fuel ratio is lean and DTC P0171 or P0174 may be set. The MIL is then illuminated. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–155 • When the total of the short-term and long-term fuel trim values is within the malfunction threshold (and the engine coolant temperature is more than 75°C [167°F]), the system is functioning normally. MONITOR DESCRIPTION Under closed-loop fuel control, fuel injection volumes that deviate from those estimated by the ECM cause changes in the long-term fuel trim compensation value. The long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. Deviations from the ECM's estimated fuel injection volumes also affect the average fuel trim learning value, which is a combination of the average short-term fuel trim (fuel feedback compensation value) and the average long-term fuel trim (learning value of the air-fuel ratio). If the average fuel trim learning value exceeds the malfunction thresholds, the ECM interprets this a fault in the fuel system and sets a DTC. Example: The average fuel trim learning value is more than +35% or less than -35%, the ECM interprets this as a fuel system malfunction. Fuel Compensation Amount P0171 or P0174: 1.35 +35 (%) Lean Malfunction Threshold 1.0 P0172 or P0175: 0.65 -35 (%) Rich Malfunction Threshold A082386E30 MONITOR STRATEGY Related DTCs P0171: Fuel system Lean (Bank 1) P0172: Fuel system Rich (Bank 1) P0174: Fuel system Lean (Bank 2) P0175: Fuel system Rich (Bank 2) Required Sensors / Components (Main) Fuel system Required Sensors / Components (Related) A/F sensor, Mass air flow meter, Crankshaft position sensor Frequency of Operation Continuous Duration Within 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES ES–156 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present ES P0010, P0020 (VVT VSV1, 2), P0011, P0012 (VVT System-Advance, Retard), P0021, P0022(VVT System2-Adavance, Retard), P0031, P0032, P0051, P0052 (A/F Sensor heater Sensor 1), P0100, P0101, P0102, P0103 (MAF Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223 , P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0335 (CKP Sensor), P0340 (CMP Sensor), P0351, P0352, P0353, P0354, P0356 (Ignitor), P0500 (VSS), Battery voltage 11 V or more Fuel system status Closed-loop Either of following conditions is met Condition 1 or 2 1. Engine RPM Below 1,100 rpm 2. Intake air amount per revolution 0.22 g/rev or more Catalyst monitor No executed TYPICAL MALFUNCTION THRESHOLDS Purge-cut Executing Either of following conditions met Condition 1 or 2 1. Average between short-term fuel trim and long-term fuel trim 35% or more (varies with ECT) 2. Average between short-term fuel trim and long-term fuel trim -35% or less (varies with ECT) WIRING DIAGRAM Refer to DTC P2195 (See page ES-302). INSPECTION PROCEDURE HINT: For use of the intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3. 2. Start the engine and turn the tester on. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. Select the following menu items on the tester: DIAGNOSIS / ENHANCEDOBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 ES–157 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display (Sensor) Injection Volumes Status Voltages O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - 1 2 3 4 ES • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) – Following the A/F CONTROL procedure enables technicians to check the graph of the voltage outputs of both the A/F and HO2 sensors. – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Press the YES button and then the ENTER button. Then press the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. ES–158 1 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0171, P0172, P0174 OR P0175) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result ES Display (DTC Output) Proceed to P0171, P0172, P0174 or P0175 A P0171, P0172, P0174 or P0175 and other DTCs B HINT: If any DTCs other than P0171, P0172, P0174 or P0175 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). ES–159 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Monitor the voltage outputs of A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 Result Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 Lean/Rich Lean/Rich A/F Condition and A/F Sensor Condition Normal Misfires Lean Proceed to - C • • • • Lean Suspected Trouble Areas Actual air-fuel ratio lean May occur • • • • • • PCV valve and hose PCV hose connections Injector blockage Gas leakage from exhaust system Air induction system Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor A Injector leakage or blockage Gas leakage from exhaust system Ignition system Fuel pressure MAF meter ECT sensor A Rich Rich Actual air-fuel ratio rich - Lean Lean/Rich A/F sensor malfunction - A/F sensor B Rich Lean/Rich A/F sensor malfunction - A/F sensor B • • • • Lean: During A/F CONTROL, the A/F sensor output voltage (AFS) is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL of the ACTIVE TEST, the output voltage of the heated oxygen sensor alternates correctly. B Go to step 11 C Go to step 15 ES ES–160 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 5 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the COOLANT TEMP twice, when the engine is cold and also when warmed up. Standard: With cold engine: Same as ambient air temperature. With warm engine: Between 75°C and 95°C (167°F and 203°F) ES NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 6 READ VALUE OF INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (d) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (e) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF while engine idling: Between 3.2 g/s and 4.7 g/s (shift position: N, A/ C: OFF). MAF at engine speed of 2,500 rpm: Between 13.1 g/s and 18.9 g/s (shift position: N, A/C: OFF). NG REPLACE MASS AIR FLOW METER OK 7 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-4). NG OK REPAIR OR REPLACE FUEL SYSTEM 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–161 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST SYSTEM OK 9 CHECK FOR SPARKS AND IGNITION (a) Check for sparks and ignition (See page IG-1). HINT: If the spark plugs or ignition system malfunctions, engine misfire may occur. The misfire count can be read using the intelligent tester. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #6). NG REPAIR OR REPLACE IGNITION SYSTEM OK 10 INSPECT FUEL INJECTOR ASSEMBLY (INJECTION AND VOLUME) (a) Inspect the fuel injector assembly (See page FU-11). HINT: If the injectors malfunction, engine misfire may occur. The misfire count can be read using the intelligent tester. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #6). NG OK REPLACE FUEL INJECTOR ASSEMBLY ES ES–162 11 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance: Bank 1 Component Side: A12 Bank 1 ES +B HT AFAF+ A/F Sensor Front View A13 Bank 2 +B Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - A1A- (4) 10 kΩ or higher Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher Bank 2 HT (c) Reconnect the A/F sensor connector. NG REPLACE AIR FUEL RATIO SENSOR AFAF+ A/F Sensor Front View A126269E06 OK 12 INSPECT AIR FUEL RATIO SENSOR HEATER RELAY (a) Remove the A/F sensor heater relay from the engine room R/B. (b) Measure the A/F sensor heater relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F sensor heater relay. NG OK REPLACE AIR FUEL RATIO SENSOR HEATER RELAY ES–163 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) Wire Harness Side: A/F Sensor Connector A12 Bank 1 HT +B AF+ AF- A13 Bank 2 Front View HT +B AF+ AF- (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Tester Connections Specified Conditions +B (A12-2) - Body ground 9 to 14 V +B (A13-2) - Body ground 9 to 14 V ECM: E5 HA1A A2A+ A2A- ES (d) Turn the ignition switch off. (e) Disconnect the E5 ECM connector. (f) Measure the resistance. Standard resistance (Check for open) HA2A A1A+ A1A- Tester Connections Specified Conditions HT (A12-1) - HA1A (E5-2) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) Below 1 Ω AF- (A12-4) - A1A- (E5-30) Below 1 Ω HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A138717E01 Tester Connections Specified Conditions HT (A12-1) or HA1A (E5-2) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground 10 kΩ or higher HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. Reference (System Diagram of Bank 1 Sensor 1): A/F Sensor Heater Relay From Battery +B Heater HT HA1A AF+ A1A+ A/F Heater Fuse From EFI Relay ECM A/F Sensor AF- Sensor EFI No. 2 A1A- Duty Control G035624E01 ES–164 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 14 REPLACE AIR FUEL RATIO SENSOR NEXT 15 PERFORM CONFIRMATION DRIVING PATTERN ES (a) Connect the intelligent tester to the DLC3 (Procedure A). (b) Turn the ignition switch on and turn the tester on (Procedure B). (c) Clear DTCs (See page ES-31) (Procedure C). (d) Switch the ECM from normal mode to check mode using the tester (See page ES-35) (Procedure D). (e) Start the engine and warm it up with all the accessories switched off (Procedure E). (f) Drive the vehicle at between 38 mph and 75 mph (60 km/h and 120 km/h) and at an engine speed of between 1,400 rpm and 3,200 rpm for 3 to 5 minutes (Procedure F). Engine Speed “F” Between 1,400 rpm and 3,200 rpm Idling Ignition Switch off Between 38 mph and 75 mph (60 km/h and 120 km/h) “E” 2 minutes 3 to 5 minutes Time “A”, “B”, “C”, “D” A079199E68 HINT: If the system is still malfunctioning, the MIL will be illuminated during procedure "F". NOTICE: If the conditions in this test are not strictly followed, no malfunction will be detected. NEXT ES–165 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 16 CHECK WHETHER DTC OUTPUT RECURS (DTC P0171, P0172, P0174 OR P0175) (a) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (b) Read DTCs. Result Display (DTC Output) Proceed to No output A P0171, P0172, P0174 or P0175 B B A END Go to step 5 ES ES–166 DTC 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0230 Fuel Pump Primary Circuit DESCRIPTION ES In the diagram below, when the engine is cranked, current flows from terminal ST1 of the ignition switch into the ECM to the ST (starter) relay coil and also current flows to terminal STA of the ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr1 (power transistor 1) is turned ON, current flows to the coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump, and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps the Tr1 ON (circuit opening relay ON) and the fuel pump also keeps operating. The fuel pump speed is controlled at two levels (high speed or low speed) by engine condition (starting, light load, heavy load). When the engine starts (STA ON), Tr2 (power transistor 2) in the ECM is OFF, so the fuel pump relay closes and positive battery voltage is applied directly to the fuel pump. The fuel pump operates at high speed. During idling or under light loads, Tr2 goes ON, and then power is supplied to the fuel pump via the fuel pump resistor. The fuel pump operates at low speed. ES–167 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM EFI Relay EFI MREL Fuel Pump Resistor Circuit Opening Relay Fuel Pump Relay FPR Tr2 FC Tr1 IGN Ignition Switch Fuel Pump ALT AM1 AM1 IG1 ST1 STA AM2 IG2 AM2 ST2 P N ST Relay Park/Neutral Position Switch STA Starter Crankshaft Position Sensor (NE Signal) NE Battery A152362E01 DTC No. P0230 DTC Detection Condition Open or short in fuel pump relay circuit Trouble Area • • • Open or short in fuel pump relay circuit Fuel pump relay ECM ES ES–168 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Engine Room R/B EFI Relay L 2 5 3 2 2 1 W-B 2 IGN 1 5 6 2 3 2 IG2 I18 Ignition Switch GR-B B-W B-W 2 2 7 R 4 2 2 B J2 AM2 EFI J/C 1 1 B-R B J3 B Engine Room J/B W-B 2 IB1 B-R 5 F14 Fuel Pump EB Y-B IC4 5 1 19 Y-B IM2 F8 Fuel Pump Resistor Y-B BO 30 E6 FPR 2 W-B A J41 A J41 J/C W-B Battery B-Y B-R 4 2 2 2 B-R Fuel Engine Room Pump R/B Relay 1 5 2 33 10 GR-B E8 FC IC4 2 3 AM2 Engine Room C/OPN R/B Relay 2 6 2 MREL 23 Driver B-R Side J/B 2 8 E8 C 2 1D W-G B-O C 1E 35 IC4 W-G 2 J4 J/C B-O ES B 2 A J40 W-B BL G032683E02 HINT: This DTC chart is on the premise that the engine is started normally. If the engine is difficult to start, proceed to the problem symptoms table (See page ES-21). ES–169 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT ECM (FPR VOLTAGE) ECM Connector E6 FPR (+) (a) Measure the voltage of the ECM connector. Standard voltage Tester Connection Condition Specified Condition FPR (E6-30) - E1 (E6-1) STA signal ON 9 to 14 V FPR (E6-30) - E1 (E6-1) STA signal OFF 0 to 3 V NG E1 (-) REPLACE ECM E118245E32 OK 2 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay from the engine room R/B. (b) Measure the resistance of the fuel pump relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) A030519E02 NG OK REPLACE FUEL PUMP RELAY ES ES–170 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (FUEL PUMP RELAY - ECM) (a) Remove the fuel pump relay from the engine room R/B. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between wire harness side connectors. Standard resistance (Check for open) E6 FPR ES Tester Connections Specified Conditions Fuel pump relay (1) - FPR (E6-30) Below 1 Ω Standard resistance (Check for short) ECM Connector Tester Connections Specified Conditions Fuel pump relay (1) or FPR (E6-30) - Body ground 10 kΩ or higher Engine Room R/B: (d) Reconnect the ECM connector. (e) Reinstall the fuel pump relay. NG Fuel Pump Relay A138718E01 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–171 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0300 Random / Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected ES DESCRIPTION When the engine misfires, high concentrations of hydrocarbons (HC) enter the exhaust gas. Extremely high HC concentration levels can cause increase in exhaust emission levels. High concentrations of HC can also cause increases in the Three-Way Catalytic Converter (TWC) temperature, which may cause damage to the TWC. To prevent this increase in emissions and to limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the TWC reaches the point of thermal degradation, the ECM blinks the MIL. To monitor misfires, the ECM uses both the Camshaft Position (CMP) sensor and the Crankshaft Position (CKP) sensor. The CMP sensor is used to identify any misfiring cylinders and the CKP sensor is used to measure variations in the crankshaft rotation speed. Misfires are counted when the crankshaft rotation speed variations exceed predetermined thresholds. If the misfire exceeds the threshold levels, and could cause emission deterioration, the ECM illuminates the MIL and sets a DTC. DTC No. P0300 DTC Detection Conditions Simultaneous misfiring of several cylinders are detected (2 trip detection logic) Trouble Areas • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connections Vacuum hose connections Ignition system Injector Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Compression pressure Valve clearance Valve timing PCV hose PCV hose connection Air induction system ECM ES–172 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0301 P0302 P0303 P0304 P0305 P0306 ES DTC Detection Conditions Trouble Areas Misfiring of specific cylinder is detected (2 trip detection logic) • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connections Vacuum hose connections Ignition system Injector Fuel pressure MAF meter ECT sensor Compression pressure Valve clearance Valve timing PCV hose PCV hose connection Air induction system ECM HINT: When DTCs for misfiring cylinders are randomly set, but DTC P0300 is not set, it indicates that misfires have been detected in different cylinders at different times. DTC P0300 is only set when several misfiring cylinders are detected at the same time. Reference: Inspection using an oscilloscope With the engine idling, check the waveform between terminals #10 to #60 and E01 of the ECM connectors. 20 V/Division Items Contents Terminals #10 to #60 - E01 Equipment Settings 20 V/Division, 100 or 1 ms/Division Conditions Idling Injector Signal Waveform GND 20 V/Division (Magnification) GND 100 msec./Division (Idling) Injection Duration 1 msec./Division (Idling) A078423E24 ES–173 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Camshaft Position Sensor Crankshaft Position Sensor ECM (36-2 teeth) ES A082387E06 The ECM illuminates the MIL (2 trip detection logic) if: • The percent misfire exceeds the specified limit per 1,000 engine revolutions. One occurrence of excessive misfire during engine start will set the MIL. Four occurrences are required to set the MIL 1,000 revolutions after engine start. The ECM blinks the MIL (MIL blinks immediately) if: • The threshold for percent of misfire causing catalyst damage is reached 1 time within 200 engine revolutions at a high engine rpm. • The threshold for percent of misfire causing catalyst damage is reached 3 times within 200 engine revolutions at a normal engine rpm. MONITOR STRATEGY Related DTCs P0300: Random/multiple cylinder misfire detected P0301: Cylinder 1 misfire detected P0302: Cylinder 2 misfire detected P0303: Cylinder 3 misfire detected P0304: Cylinder 4 misfire detected P0305: Cylinder 5 misfire detected P0306: Cylinder 6 misfire detected Required Sensors / Components (Main) Crankshaft position sensor, Camshaft position sensor Required Sensors / Components (Related) ECT sensor, IAT sensor, MAF meter Frequency of Operation Continuous Duration Every 1,000 revolutions (soon after engine is started: 1 time, other: 4 times) (emission related misfire) Every 200 revolutions (1 or 3 times) (catalyst deteriorating misfire) MIL Operation 2 driving cycles: Emission related misfire MIL flashes immediately: Catalyst damaged misfire Sequence of Operation None TYPICAL ENABLING CONDITIONS Misfire: The monitor will run whenever these DTCs are not present P0100, P0101, P0102, P0103 (MAF Sensor), P0110, P0112, P0113 (IAT Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223 , P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0327, P0328, P0332, P0333 (Knock Sensor), P0335 (CKP Sensor), P0340 (CMP Sensor), P0500 (VSS) Battery voltage 8 V or more VVT system No operate by scan tool Engine RPM 450 to 5,400 rpm ES–174 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Either of the following conditions is met Condition (a) or (b) (a) ECT at engine start More than -7°C (19°F) (b) ECT More than 20°C (68°F) Fuel cut OFF Monitor period of emission-related-misfire: First 1,000 revolutions after engine start, or check mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions x 4 Monitor period of catalyst-damage-misfire (MIL blinks): ES All of following conditions 1, 2 and 3 are met Crankshaft 200 revolutions 1. Driving cycle 1st 2. Check mode OFF 3. Engine RPM Less than 2,800 rpm Except above Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Monitor period of emission-related-misfire: Misfire rate 2 % or more Monitor period of catalyst-damage-misfire (MIL blinks): Number of misfire per 200 revolutions 77 or more (varies with intake air amount and RPM) Paired cylinders misfire Detected MONITOR RESULT Refer to Checking Monitor Status (See page ES-14). WIRING DIAGRAM Refer to DTC P0351 for the wiring diagram of the ignition system (See page ES-200). ES–175 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Driver Side J/B To Combination Meter I9 Injector No. 1 6 1D 3 1H B-R 5 IM1 B-R B-R 2 B-R B-R B-R 6 IG2 I18 Ignition Switch I10 Injector No. 2 2 B-R R 2 B-R AM2 Engine Room R/B D J27 J/C B 3 #20 E6 1 R 4 #30 E6 1 G 5 #40 E6 Y 6 #50 E6 2 L 7 #60 E6 ES I13 Injector No. 5 B-R 2 1 I14 Injector No. 6 1 2 #10 E6 I12 Injector No. 4 B-R 2 2 1 R-L I11 Injector No. 3 B-R 2 AM2 7 B-R D 1 R-L D B-R 2 1 B Battery G032684E01 CONFIRMATION DRIVING PATTERN 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Record the DTC(s) and freeze frame data. Using the tester, switch the ECM from normal mode to check mode (See page ES-35). Read the misfire counts of each cylinder (CYL #1 to #6) with the engine in an idling condition. If any misfire count is displayed, skip the following confirmation driving pattern. 7. Drive the vehicle several times with the conditions, such as engine rpm and engine load, shown in MISFIRE RPM and MISFIRE LOAD in the DATA LIST. HINT: In order to store misfire DTCs, it is necessary to drive the vehicle for the period of time shown in the table below, with the MISFIRE RPM and MISFIRE LOAD in the DATA LIST. Engine RPM Duration Idling 3.5 minutes or more 1,000 3 minutes or more 2,000 1.5 minutes or more 3,000 1 minute or more ES–176 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8. Check whether misfires have occurred by checking DTCs and freeze frame data. HINT: Do not turn the ignition switch off until the stored DTC(s) and freeze frame data have been recorded. When the ECM returns to normal mode (default), the stored DTC(s), freeze frame data and other data will be erased. 9. Record the DTC(s), freeze frame data and misfire counts. 10.Turn the ignition switch off and wait for at least 5 seconds. INSPECTION PROCEDURE ES HINT: • If any DTCs other than the misfire DTCs are output, troubleshoot those DTCs first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • If the misfire does not recur when the vehicle is brought to the workshop, reproduce the conditions stored in the freeze frame data. • If the misfire still cannot be reproduced even though the conditions stored in the freeze frame data have been duplicated, one of the following factors is considered to be a possible cause of the problem: 1. The fuel tank is low full. 2. Improper fuel is used. 3. The spark plugs have been contaminated. 4. The problem is complex. • After finishing repairs, check the misfire counts of the cylinders (CYL #1, #2, #3, #4, #5 and #6). • Be sure to confirm that no misfiring cylinder DTCs are set again by conducting the confirmation driving pattern, after repairs. • For 6 and 8 cylinder engines, the ECM intentionally does not set the specific misfiring cylinder DTCs at high engine RPM. If misfires occur only in high engine RPM areas, only DTC P0300 is set. If the event of DTC P0300 being present, perform the following operations: 1. Clear the DTC (See page ES-31). 2. Start the engine and conduct the confirmation driving pattern. 3. Read the misfiring rates of each cylinder or DTC(s) using the tester. 4. Repair the cylinder(s) that has a high misfiring rate or is indicated by the DTC. 5. After finishing repairs, conduct the confirmation driving pattern again, in order to verify that DTC P0300 is not set. • When one of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is outside the range of +-20%, the air-fuel ratio may be rich (-20% or less) or lean (+20% or more). • When the COOLANT TEMP in the freeze frame data is less than 75°C (167°F), the misfires have occurred only while warming up the engine. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO MISFIRE TO DTCS) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 A P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 and other DTCs B 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–177 HINT: If any DTCs other than P0300, P0301, P0302, P0303, P0304, P0305 and P0306 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (MISFIRE RPM AND MISFIRE LOAD) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / MISFIRE RPM and MISFIRE LOAD. (d) Read and note the MISFIRE RPM and MISFIRE LOAD (engine load) values. HINT: The MISFIRE RPM and MISFIRE LOAD indicate the vehicle conditions under which the misfire occurred. NEXT 3 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 4 CHECK MISFIRE COUNT (CYL #1, #2, #3, #4, #5 AND #6) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Clear DTCs (See page ES-31). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / CYL #1, #2, #3, #4, #5 and #6 (Procedure "A"). (f) Allow the engine to idle. (g) Read each value of CYL #1 to #6 displayed on the tester (Procedure "B"). (1) Shift the gear selector lever to the D position. (2) Repeat procedures "A" to "B" above. (3) Check the CYL #1 to #6. (4) If misfire counts are still not displayed, perform procedures "C" and "D" and then check the misfire counts again. (h) Drive the vehicle with the MISFIRE RPM and MISFIRE LOAD noted in step 2 (Procedure "C"). ES ES–178 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (i) Read the CYL #1 to #6 or DTCs displayed on the tester (Procedure "D"). Result Misfire Count Proceed to One or two cylinders have misfire counts A Three cylinders or more have misfire counts B B Go to step 13 A ES 5 CHECK SPARK PLUG (a) Remove the ignition coil and the spark plug of the misfiring cylinder. (b) Measure the spark plug electrode gap. Standard: Between 1.0 mm and 1.1 mm (0.039 in. and 0.043 in.) (c) Check the electrode for carbon deposits. Require spark plug: Electrode Gap Manufacturers A088861E12 Products DENSO K20HR-U11 NGK LFR6C-11 NOTICE: If the electrode gap is larger than the standard, replace the spark plug. Do not adjust the electrode gap. NG REPLACE SPARK PLUG OK 6 CHECK FOR SPARKS AND IGNITION (a) Disconnect the injector connectors, in order to prevent the engine from starting. (b) Install the spark plug to the ignition coil, and connect the ignition coil connector. (c) Attach the spark plug assembly to the cylinder head cover. (d) Crank the engine for less than 2 seconds and check the spark. NOTICE: Do not crank the engine for more than 2 seconds. OK: Sparks jump across electrode gap (e) Reconnect the injector connectors. NG OK Go to step 8 ES–179 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER (a) Measure the cylinder compression pressure of the misfiring cylinder (See page EM-2). OK Go to step 9 NG CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION ES 8 CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER (a) Change the installed spark plug to a spark plug that functions normally. (b) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if sparks occur while the engine is being cranked. OK: Sparks jump across electrode gap. OK REPLACE SPARK PLUG NG REPLACE IGNITION COIL ASSEMBLY 9 INSPECT ECM TERMINAL OF MISFIRING CYLINDER (#10, #20, #30, #40, #50 AND/OR #60 VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the E4 and E6 ECM connector. Standard voltage ECM: E4 E01 (-) #60 (+) E6 #10 (+) #50 (+) #30 (+) #40 (+) #20 (+) A131509E38 Tester Connections Specified Conditions #10 (E6-2) - E01 (E4-7) 9 to 14 V #20 (E6-3) - E01 (E4-7) 9 to 14 V #30 (E6-4) - E01 (E4-7) 9 to 14 V #40 (E6-5) - E01 (E4-7) 9 to 14 V #50 (E6-6) - E01 (E4-7) 9 to 14 V #60 (E6-7) - E01 (E4-7) 9 to 14 V ES–180 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK Go to step 11 NG 10 CHECK HARNESS AND CONNECTOR (INJECTOR - ECM) (a) Disconnect the injector connector (of the misfiring cylinder). (b) Disconnect the E6 ECM connector. (c) Turn the ignition switch on. (d) Measure the resistance and voltage between the injector and the ECM connector terminals. Standard (Cylinder No. 1) Wire Harness Side: Injector Connector ES I9 I10 I11 I12 I13 I14 1 2 Tester Connections Front View ECM: E6 I9-1 - Ground 11 to 14 V I9-2 - Ground 10 kΩ or higher I9-2 - #10 (E6-2) Below 1 Ω Standard (Cylinder No. 2) Tester Connections #60 #50 #40 Specified Conditions #10 #20 #30 Specified Conditions I10-1 - Ground 11 to 14 V I10-2 - Ground 10 kΩ or higher I10-2 - #20 (E6-3) Below 1 Ω Standard (Cylinder No. 3) Tester Connections Specified Conditions A114616E03 I11-1 - Ground 11 to 14 V I11-2 - Ground 10 kΩ or higher I11-2 - #30 (E6-4) Below 1 Ω Standard (Cylinder No. 4) Tester Connections Specified Conditions I12-1 - Ground 11 to 14 V I12-2 - Ground 10 kΩ or higher I12-2 - #40 (E6-5) Below 1 Ω Standard (Cylinder No. 5) Tester Connections Specified Conditions I13-1 - Ground 11 to 14 V I13-2 - Ground 10 kΩ or higher I13-2 - #50 (E6-6) Below 1 Ω Standard (Cylinder No. 6) Tester Connections Specified Conditions I13-1 - Ground 11 to 14 V I13-2 - Ground 10 kΩ or higher I13-2 - #60 (E6-7) Below 1 Ω (e) Reconnect the injector connector. (f) Reconnect the ECM connector. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–181 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 11 CHECK FUEL INJECTOR OF MISFIRING CYLINDER (a) Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor) (See page IG-1). NG REPLACE FUEL INJECTOR ASSEMBLY ES OK 12 CHECK VALVE CLEARANCE (MISFIRING CYLINDER) NG ADJUST VALVE CLEARANCE OK 13 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 14 CHECK VALVE TIMING (a) Remove the cylinder head cover (See page EM-130). (b) Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover. (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration. If not, turn the crankshaft 1 revolution (360°), then align the marks as above. OK: Point marks on camshaft timing gears are aligned as shown in the illustration. (d) Reinstall the cylinder head cover (See page EM-195). NG OK ADJUST VALVE TIMING ES–182 15 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-4). NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER OK ES 16 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the COOLANT TEMP twice, when the engine is cold and also when warmed up. Standard: With cold engine: Same as ambient air temperature. With warm engine: Between 75°C and 95°C (167°F and 203°F). NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 17 READ VALUE OF INTELLIGENT TESTER (MAF) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (e) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (f) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF while engine idling: Between 3.2 g/s and 4.7 g/s (shift position: N, A/ C: OFF). MAF at engine speed of 2,500 rpm: Between 13.1 g/s and 18.9 g/s (shift position: N, A/C: OFF). NG REPLACE MASS AIR FLOW METER 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–183 OK CHECK FOR INTERMITTENT PROBLEMS ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–17 CHECKING MONITOR STATUS The purpose of the monitor result (mode 06) is to allow access to the results for on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalyst, evaporative emission (EVAP) and thermostat. The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction. When the component is not malfunctioning, if the difference of the test value and test limit is very small, the component will malfunction in the near future. Perform the following instruction to view the monitor status. Although this instruction reference the Lexus/Toyota diagnostic tester, it can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedures. 1. PERFORM MONITOR DRIVE PATTERN (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch ON and the tester ON. (c) Clear DTCs (See page ES-17). (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (See page ES-31). Do not turn the ignition switch OFF. NOTICE: The test results will be lost if the ignition switch is turned OFF. 2. ACCESS MONITOR RESULT (a) Select from the intelligent tester menus: DIAGNOSIS, ENHANCED OBD II, MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMP: The component has not been monitored yet. • PASS: The component is functioning normally. • FAIL: The component is malfunctioning. (b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The accuracy test value appears if the monitor status is either PASS or FAIL. 3. CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT). ES ES–18 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES 4. (b) If the test value is between the minimum test limit and maximum test limit, the component is functioning normally. If not, the component is malfunctioning. The test value is usually significantly higher or lower than the test limit. If the test value is on the borderline of the test limit, the component will malfunction in the near future. HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the value by the scaling value listed below. A/F Sensor Bank 1 Sensor 1 Monitor ID Test ID Scaling Unit $01 $8E Multiply by 0.001 V $01 $91 Multiply by 0.004 mA Description A/F sensor deterioration level A/F sensor current A/F Sensor Bank 2 Sensor 1 Monitor ID Test ID Scaling Unit $05 $8E Multiply by 0.001 V $05 $91 Multiply by 0.004 mA Description A/F sensor deterioration level A/F sensor current HO2 Sensor Bank 1 Sensor 2 Monitor ID Test ID Scaling Unit $02 $07 Multiply by 0.001 V Description Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.0003 g Maximum oxygen storage capacity HO2 Sensor Bank 2 Sensor 2 Monitor ID Test ID Scaling Unit $06 $07 Multiply by 0.001 V Description Minimum sensor voltage $06 $08 Multiply by 0.001 V Maximum sensor voltage $06 $8F Multiply by 0.0003 g Maximum oxygen storage capacity Catalyst - Bank 1 Monitor ID Test ID Scaling Unit $21 $A9 Multiply by 0.0003 No dimension Description Oxygen storage capacity of catalyst - Bank 1 Catalyst - Bank 2 Monitor ID Test ID Scaling Unit $22 $A9 Multiply by 0.0003 No dimension Description Oxygen storage capacity of catalyst - Bank 2 EVAP Monitor ID Test ID Scaling Unit $3D $C9 Multiply by 0.001 kPa Description $3D $CA Multiply by 0.001 kPa Test value for gross leak (P0455) $3D $CB Multiply by 0.001 kPa Test value for leak detection pump OFF stuck (P2401) $3D $CD Multiply by 0.001 kPa Test value for leak detection pump ON stuck (P2402) $3D $CE Multiply by 0.001 kPa Test value for vent valve OFF stuck (P2420) Test value for small leak (P0456) 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor ID Test ID Scaling Unit $3D $CF Multiply by 0.001 kPa ES–19 Description Test value for vent valve ON stuck (P2419) $3D $D0 Multiply by 0.001 kPa Test value for reference orifice low flow (P043E) $3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F) $3D $D4 Multiply by 0.001 kPa Test value for purge VSV close stuck (P0441) $3D $D5 Multiply by 0.001 kPa Test value for purge VSV open stuck (P0441) $3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441) Rear Oxygen Sensor Heater Monitor ID Test ID Scaling Unit $42 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 1 sensor 2 Description $46 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 2 sensor 2 ES Misfire Monitor ID Test ID Scaling Unit Description $A1 $0B Multiply by 1 Time Exponential Weighted Moving Average (EWMA) misfire for all cylinders: Misfire counts for last 10 driving cycles - Total $A1 $0C Multiply by 1 Time Misfire rate for all cylinders: Misfire counts for last/current driving cycles - Total $A2 $0B Multiply by 1 Time EWMA misfire for cylinder 1: Misfire counts for last 10 driving cycles - Total $A2 $0C Multiply by 1 Time Misfire rate for cylinder 1: Misfire counts for last/current driving cycles - Total $A3 $0B Multiply by 1 Time EWMA misfire for cylinder 2: Misfire counts for last 10 driving cycles - Total $A3 $0C Multiply by 1 Time Misfire rate for cylinder 2: Misfire counts for last/current driving cycles - Total $A4 $0B Multiply by 1 Time EWMA misfire for cylinder 3: Misfire counts for last 10 driving cycles - Total $A4 $0C Multiply by 1 Time Misfire rate for cylinder 3: Misfire counts for last/current driving cycles - Total $A5 $0B Multiply by 1 Time EWMA misfire for cylinder 4: Misfire counts for last 10 driving cycles - Total $A5 $0C Multiply by 1 Time Misfire rate for cylinder 4: Misfire counts for last/current driving cycles - Total $A6 $0B Multiply by 1 Time EWMA misfire for cylinder 5: Misfire counts for last 10 driving cycles - Total $A6 $0C Multiply by 1 Time Misfire rate for cylinder 5: Misfire counts for last/current driving cycles - Total $A7 $0B Multiply by 1 Time EWMA misfire for cylinder 6: Misfire counts for last 10 driving cycles - Total $A7 $0C Multiply by 1 Time Misfire rate for cylinder 6: Misfire counts for last/current driving cycles - Total ES–184 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) DTC P0332 Knock Sensor 2 Circuit Low Input (Bank 2) DTC P0333 Knock Sensor 2 Circuit High Input (Bank 2) DESCRIPTION A flat type knock sensor (non-resonant type) has a structure that can detect vibrations over a wide band of frequencies: between approximately 6 kHz and 15 kHz. Knock sensors are fitted onto the engine block to detect engine knocking. The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The voltage is generated when the engine block vibrates due to knocking. Any occurrence of engine knocking can be suppressed by delaying the ignition timing. DTC No. DTC Detection Conditions Trouble Areas P0327 P0332 Output voltage of knock sensor 1 or 2 is less than 0.5 V (1 trip detection logic) • • • Short in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM P0328 P0333 Output voltage of knock sensor 1 or 2 is more than 4.5 V (1 trip detection logic) • • • Open in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM HINT: When any of DTCs P0327, P0328, P0332 and P0333 are set, the ECM enters fail-safe mode. During failsafe mode, the ignition timing is delayed to its maximum retardation. Fail-safe mode continues until the ignition switch is turned off. Reference: Inspection using an oscilloscope KNK1 Signal Waveform 1 V/DIV GND 1 msec./Division A085286E31 The correct waveform is as shown. Items Contents Terminals KNK1 - EKNK or KNK2 - EKN2 Equipment Settings 0.01 to 10 V/Division, 0.01 to 10 msec./ Division Conditions Keep engine speed at 4,000 rpm with warm engine 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–185 MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When spark knock occurs, the piezoelectric element of the sensor vibrates. When the ECM detects the voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, and if the knock sensor output voltage is out of the normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. MONITOR STRATEGY Related DTCs P0327: Knock sensor (Bank 1) range check (Low voltage) P0328: Knock sensor (Bank 1) range check (High voltage) P0332: Knock sensor (Bank 2) range check (Low voltage) P0333: Knock sensor (Bank 2) range check (High voltage) Required Sensors / Components (Main) Knock sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Battery voltage 10.5 V or more Time after engine start 5 seconds or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Low voltage) P0327 and P0332: Knock sensor voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328 and P0333: Knock sensor voltage More than 4.5 V ES ES–186 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM K1 Knock Sensor (Bank 1) ECM 5V ES B 1 2 (*1) W K2 Knock Sensor (Bank 2) (*1) (*1) BR 2 ED1 B 5 ED1 W 1 ED1 (*1) BR (*1) 28 EKNK E5 (*1) 5V (*1) (*1) G 1 29 KNK1 E5 2 (*1) R 4 ED1 G 6 ED1 R 21 KNK2 E5 (*1) 20 EKN2 E5 BR EE *1: Shielded A130684E01 INSPECTION PROCEDURE HINT: • DTCs P0327 and P0328 are for the bank 1 knock sensor circuit. • DTCs P0332 and P0333 are for the bank 2 knock sensor circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–187 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ VALUE OF DTC OUTPUT (CHECK KNOCK SENSOR CIRCUIT) ED1 Knock Sensor 2 2 1 2 (a) Disconnect the ED1 connector. (b) Using lead wires, connect the connectors as follows. Male Connector - Female Connector 2 1 ECM 5 5 4 4 6 6 Male Connector 29 E5 28 E5 21 E5 20 E5 Terminal 2 - Terminal 4 KNK1 Terminal 5 - Terminal 6 EKNK Terminal 4 - Terminal 2 Terminal 6 - Terminal 5 KNK2 EKN2 Female Connector ED1 (c) (d) (e) (f) Warm up the engine. Run the engine at 3,000 rpm for 10 seconds or more. Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the intelligent tester on. (g) Select the item: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Read DTCs. Result Display Proceed to DTCs same as when vehicle brought in P0327, P0328 → P0327, P0328 or P0332, P0333 → P0332, P0333 A DTCs different from when vehicle brought in P0327, P0328 → P0332, P0333 or P0332, P0333 → P0327, P0328 B A073822E15 (i) B A Reconnect the ED1 connector. Go to step 4 ES ES–188 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS OR CONNECTOR (CONNECTOR - ECM) (a) Disconnect the ED1 connector. (b) Disconnect the E5 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Female Connector ED1 Front View ES Tester Connections Specified Conditions ED1 female connector 2 - KNK1 (E5-29) Below 1 Ω ED1 female connector 5 - EKNK (E5-28) Below 1 Ω ED1 female connector 4 - KNK2 (E5-21) Below 1 Ω ED1 female connector 6 - EKN2 (E5-20) Below 1 Ω Standard resistance (Check for short) E5 EKN2 KNK2 KNK1 EKNK ECM Connector A138719E01 Tester Connections Specified Conditions ED1 female connector 2 or KNK1 (E5-29) - Body ground 10 kΩ or higher ED1 female connector 5 or EKNK (E5-28) - Body ground 10 kΩ or higher ED1 female connector 4 or KNK2 (E5-21) - Body ground 10 kΩ or higher ED1 female connector 6 or EKN2 (E5-20) - Body ground 10 kΩ or higher (d) Reconnect the ED1 connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM ECM: KNK1 KNK2 (a) Disconnect the E5 ECM connector. (b) Turn the ignition switch on. (c) Measure the voltage between the ECM terminals. Standard voltage EKN2 EKNK E5 G035655E06 Tester Connections Specified Conditions KNK1 (E5-29) - EKNK (E5-28) 4.5 to 5.5 V KNK2 (E5-21) - EKN2 (E5-20) 4.5 to 5.5 V (d) Reconnect the ECM connector. NOTICE: Fault may be intermittent. Check the wire harness and connectors carefully and retest. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–189 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK KNOCK SENSOR (a) Check the knock sensor installation. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NG REPAIR OR REPLACE KNOCK SENSOR ES A076270 OK 5 INSPECT KNOCK SENSOR (a) Disconnect the ED1 connector. (b) Measure the resistance between the terminals of the ED1 male connector. Standard resistance Wire Harness Side: Male Connector ED1 Front View Tester Connections Specified Conditions ED1 male connector 2 - 5 120 to 280 kΩ ED1 male connector 4 - 6 120 to 280 kΩ (c) Reconnect the connector. A072922E17 OK CHECK FOR INTERMITTENT PROBLEMS NG 6 CHECK HARNESS AND CONNECTOR (CONNECTOR - KNOCK SENSOR) HINT: • If DTC P0327 or P0328 has changed to P0332 or P0333, check the knock sensor circuit on the right bank side. • If DTC P0332 or P0333 has changed to P0327 or P0328, check the knock sensor circuit on the left bank side. ES–190 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) Disconnect the ED1 connector. (b) Disconnect the K1 and K2 knock sensor connectors. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Male Connector ED1 Front View Wire Harness Side: K1 Bank 1 K2 Bank 2 A138720E01 REPLACE KNOCK SENSOR ED1 male connector 2 - K1-2 Below 1 Ω ED1 male connector 5 - K1-1 Below 1 Ω ED1 male connector 4 - K2-2 Below 1 Ω ED1 male connector 6 - K2-1 Below 1 Ω Tester Connections Specified Conditions ED1 male connector 2 or K1-2 - Body ground 10 kΩ or higher ED1 male connector 5 or K1-1 - Body ground 10 kΩ or higher ED1 male connector 4 or K2-2 - Body ground 10 kΩ or higher ED1 male connector 6 or K2-1 - Body ground 10 kΩ or higher (d) Reconnect the connector. (e) Reconnect the knock sensor connector. Front View OK Specified Conditions Standard resistance (Check for short) Knock Sensor Connector ES Tester Connections NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES–191 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0335 Crankshaft Position Sensor "A" Circuit DTC P0339 Crankshaft Position Sensor "A" Circuit Intermittent DESCRIPTION The Crankshaft Position (CKP) sensor system consists of a CKP sensor plate and a pickup coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of an iron core and a magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is created. The pickup coil generates 34 signals per engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. DTC No. DTC Detection Conditions P0335 • • • • Open or short in CKP sensor circuit CKP sensor Sensor plate (CKP sensor plate) ECM Under conditions (a), (b) and (c), no CKP sensor signal to ECM for 0.05 seconds or more (1 trip detection logic): (a) Engine speed 1,000 rpm or more (b) Starter signal OFF (c) 3 seconds or more has lapsed since starter signal switched from ON to OFF • • • • Open or short in CKP sensor circuit CKP sensor Sensor plate (CKP sensor plate) ECM • P0339 Trouble Areas No CKP sensor signal to ECM while cranking (1 trip detection logic) No CKP sensor signal to ECM at engine speed of 600 rpm or more (1 trip detection logic) • Reference: Inspection using an oscilloscope VV1, VV2 and NE Signal Waveforms NE 5 V/DIV GND VV1 GND VV2 GND G035795E19 HINT: • The correct waveform is shown on the illustration. • VV1+ and VV2+ stands for the VVT sensor signal, and NE+ stands for the CKP sensor signal. Items Contents Terminals VV1+ - VV1VV2+ - VV2NE+ - NE- Equipment Settings 5 V/Division, 20 ms/Division Conditions Cranking or idling MONITOR DESCRIPTION If there is no signal from the CKP sensor despite the engine revolving, the ECM interprets this as a malfunction of the sensor. If the malfunction is not repaired successfully, a DTC is set 10 seconds after the engine is next started. ES ES–192 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0335: Crankshaft position sensor range check or rationality Required Sensors / Components (Main) Crankshaft Position sensor Required Sensors / Components (Related) VVT sensor Frequency of Operation Continuous Duration Conditions met for 3 times MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: ES The monitor will run whenever these DTCs are not present None Case 1: Engine RPM 600 rpm or more Starter OFF Time after starter ON to OFF 3 seconds or more Case 2: Time after starter ON to OFF 0.3 seconds or more Number of camshaft position sensor signal pulse 6 times Ignition switch ON Battery voltage 7 V or more TYPICAL MALFUNCTION THRESHOLDS Case 1: Engine speed signal No signal Case 2: Number of crankshaft position sensor signal pulse 132 or less, or 174 or more COMPONENT OPERATING RANGE Crankshaft Position Sensor • • Crankshaft position sensor output voltage fluctuates while crankshaft revolving 34 crankshaft position sensor signals per crankshaft revolution ES–193 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM V4 VVT Sensor RH ECM 1 R 2 G 3 L-R 3 L-R L-R 19 E6 VV1+ 29 E6 VV123 E4 VC V3 VVT Sensor LH ES 1 Y 2 L C4 Crankshaft Position Sensor 18 E6 VV2+ 28 E6 VV2- Shielded 1 B 2 W 21 NE+ E6 20 NEE6 BR EE G039648E01 INSPECTION PROCEDURE HINT: • If no problem is found by this diagnostic troubleshooting procedure, troubleshoot the engine mechanical systems. • Check the engine speed. The engine speed can be checked by using the intelligent tester. To check, follow the operation below: (a)Connect the intelligent tester to the DLC3. (b)Start the engine. (c) Turn the tester on. (d)Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. The engine speed may be indicated as zero despite the engine revolving normally. This is caused by a lack of NE signals from the Crankshaft Position (CKP) sensor. Alternatively, the engine speed may be indicated as lower than the actual engine speed, if the CKP sensor voltage output is insufficient. ES–194 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE) (a) Disconnect the C4 Crankshaft Position (CKP) sensor connector. (b) Measure the resistance between terminals 1 and 2. Standard resistance Component Side: Crankshaft Position Sensor ES C4 Tester Connections Specified Conditions 1-2 1,630 Ω to 2,740 Ω at cold 1-2 2,065 Ω to 3,225 Ω at hot Front View A078431E20 HINT: Terms cold and hot refer to the temperature of the coils. Cold means approximately -10° to 50°C (14° to 122°F). Hot means approximately 50° to 100°C (122° to 212°F). (c) Reconnect the CKP sensor connector. NG REPLACE CRANKSHAFT POSITION SENSOR OK 2 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) Wire Harness Side: Crankshaft Position Sensor Connector (a) Disconnect the C4 CKP sensor connector. (b) Disconnect the E6 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) C4 1 2 NE+ NE- Tester Connections Specified Conditions NE+ (C4-1) - NE+ (E6-21) Below 1 Ω NE- (C4-2) - NE- (E6-20) Below 1 Ω Standard resistance (Check for short) Front View ECM: E6 Tester Connections Specified Conditions NE+ (C4-1) or NE+ (E6-21) - Body ground 10 kΩ or higher NE- (C4-2) or NE- (E6-20) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the CKP sensor connector. NG NE+ NEA114619E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 ES–195 CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) (a) Check the CKP sensor installation. OK: Sensor is installed correctly. NG REPAIR OR REPLACE CRANKSHAFT POSITION SENSOR Clearance Normal Abnormal ES BR03795E54 OK 4 CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE) (a) Check the teeth of the sensor plate. OK: Sensor plate does not have any cracks or deformation. NG OK REPLACE ECM REPAIR OR REPLACE CRANKSHAFT POSITION SENSOR PLATE 1GR-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Intelligent Tester ES–401 CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ON-VEHICLE INSPECTION 1. CAN VIM DLC3 G039021E01 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Check the operation. (1) Turn the ignition switch to ON. (2) Turn the intelligent tester ON. (3) Start the engine and warm it up. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (5) Operate the OCV using the intelligent tester, then check the engine speed. Standard Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Rough idling or engine stalls If the operation is not as specified, check the camshaft timing oil control valve, wire harness and ECM. INSPECTION 1. Ohmmeter A095415E01 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 1 (+B) - 2 (GND) 6.9 to 7.9 Ω at 20°C (68°F) If the result is not as specified, replace the camshaft timing oil control valve. Valve Battery A076909E04 (b) Check the operation. (1) Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, and check that the valve operates. NOTICE: Check that the spool valve is not stuck. HINT: The spool valve may not return if foreign objects are caught in it. This may cause subtle pressure leakage to the advance side, and a DTC may, be set. ES ES–196 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0340 Camshaft Position Sensor "A" Circuit (Bank 1 or Single Sensor) DTC P0342 Camshaft Position Sensor "A" Circuit Low Input (Bank 1 or Single Sensor) DTC P0343 Camshaft Position Sensor "A" Circuit High Input (Bank 1 or Single Sensor) DTC P0345 Camshaft Position Sensor "A" Circuit (Bank 2) DTC P0347 Camshaft Position Sensor "A" Circuit Low Input (Bank 2) DTC P0348 Camshaft Position Sensor "A" Circuit High Input (Bank 2) DESCRIPTION The variable valve timing (VVT) sensor (VV signal) consists of a magnet, iron core and pickup coil. The VV signal plate has 3 teeth on its outer circumference and is installed on the camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating a voltage in the pickup coil. This sensor monitors a timing rotor located on the camshaft and is used to detect a camshaft angle by the ECM. The camshaft rotation synchronizes with the crankshaft rotation, and this sensor communicates the rotation of the camshaft timing rotor as a pulse signal to the ECM. Based on the signal, the ECM controls fuel injection time and ignition timing. DTC No. DTC Detection Conditions • Open or short in VVT sensor circuit VVT sensor Camshaft timing pulley Jumped tooth of timing chain ECM Output voltage of VVT sensor is 0.3 V or less for 5 seconds (1 trip detection logic) • • • • • Open or short in VVT sensor circuit VVT sensor Camshaft timing pulley Jumped tooth of timing chain ECM Output voltage of VVT sensor is 4.7 V or more for 5 seconds (1 trip detection logic) • • • • • Open or short in VVT sensor circuit VVT sensor Camshaft timing pulley Jumped tooth of timing chain ECM • P0343 P0348 Trouble Areas • • • • • P0340 P0345 P0342 P0347 Input voltage to ECM remains 0.3 V or less, or 4.7 V or higher for more than 5 seconds, when 2 or more seconds have elapsed after turning the ignition switch ON (2 trip detection logic) No VVT sensor signal to ECM during cranking (1 trip detection logic) Reference: Inspection using an oscilloscope 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VV1, VV2 and NE Signal Waveforms ES–197 5 V/DIV. NE GND VV1 GND VV2 GND 20 ms/DIV. G035795E20 HINT: • The correct waveform is shown on the illustration. • VV1+ and VV2+ stands for the VVT sensor signal, and NE+ stands for the CKP sensor signal. Items Contents Terminals NE+ - NEVV1+ - VV1VV2+ - VV2- Equipment Settings 5V/Division, 20ms/Division Conditions Cranking or idling MONITOR DESCRIPTION If there is no signal from the VVT sensor even though the engine is turning, or if the rotation of the camshaft and crankshaft is not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0340: Camshaft position sensor range check P0340: Camshaft position/crankshaft position misalignment P0340: Camshaft position sensor range check (Chattering) P0342: Camshaft position sensor range check (Low voltage) P0343: Camshaft position sensor range check (High voltage) P0345: VVT sensor range check (While starting engine) P0345: VVT sensor range check (After starting engine) P0345: VVT sensor range check (Chattering) P0347: VVT sensor range check (Low voltage) P0348: VVT sensor range check (High voltage) Required Sensors / Components (Main) VVT sensor, Camshaft position sensor Required Sensors / Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 4 seconds: P0340 (Camshaft position sensor range check), P0345 (VVT sensor range check (While starting engine)) 5 seconds: Others MIL Operation 2 driving cycles: P0340 (Camshaft position sensor range check), P0345 (VVT sensor range check (While starting engine)) Immediate: Others Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None ES ES–198 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Camshaft Position Sensor Range Check: Starter ON and not starter ON again Minimal battery voltage while starter ON Less than 11 V Camshaft Position/Crankshaft Position Misalignment: Engine RPM 600 rpm or more Starter OFF Camshaft Position Sensor Range Check (Chattering, Low voltage, High voltage): ES Starter OFF Ignition switch ON and time after ignition switch is OFF to ON 2 seconds or more VVT sensor range check (While starting engine): Starter ON Battery voltage while starter ON once at least Less than 11 V VVT sensor range check (After starting engine): Engine RPM 600 rpm or more Starter OFF Battery voltage 8 V or more Ignition switch ON VVT sensor range check (Chattering, Low voltage, High voltage): Starter OFF Ignition switch ON and time after ignition switch is OFF to ON 2 seconds or more Battery voltage 8 V or more TYPICAL MALFUNCTION THRESHOLDS Camshaft Position Sensor Range Check: Camshaft position sensor signal No signal Camshaft Position/Crankshaft Position Misalignment: Camshaft position and crankshaft position phase Mis-aligned Camshaft Position Sensor Range Check (Chattering): Camshaft position sensor voltage Less than 0.3 V, or more than 4.7 V Camshaft Position Sensor Range Check (Low voltage): Camshaft position sensor voltage Less than 0.3 V Camshaft Position Sensor Range Check (High voltage): Camshaft position sensor voltage More than 4.7 V VVT sensor range check (While starting engine): VVT sensor signal No signal VVT sensor range check (After starting engine): VVT sensor signal No signal VVT sensor range check (Chattering): VVT sensor voltage Less than 0.3 V, or more than 4.7 V VVT sensor range check (Low voltage): VVT sensor voltage Less than 0.3 V 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–199 VVT sensor range check (High voltage): VVT sensor voltage More than 4.7 V COMPONENT OPERATING RANGE VVT sensor voltage 0.3 to 4.7 V WIRING DIAGRAM Refer to DTC P0335 (See page ES-187). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ECM TERMINAL VOLTAGE (a) Inspect the ECM using an oscilloscope. (1) While the engine is idling, check the waveform of the ECM connector. OK ECM: NE+ NE- E6 VV1+ VV2+ VV1- VV2- GND VV1 GND VV2 GND 20 ms/DIV. NG Specified Conditions VV1+ (E6-19) - VV1- (E6-29) Correct waveform shown VV2+ (E6-18) - VV2- (E6-28) Correct waveform shown NE+ (E6-21) - NE- (E6-20) Correct waveform shown OK VV1, VV2 and NE Signal Waveforms NE Tester Connections A114620E05 REPLACE ECM ES ES–200 2 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (VVT SENSOR - ECM) (a) Disconnect the V3 or V4 VVT sensor connector. (b) Disconnect the E6 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: V4 Bank 1 V3 Bank 2 1 2 3 VVT Sensor ES Tester Connections Specified Conditions VVT sensor (V4-1) - VV1+ (E6-19) Below 1 Ω VVT sensor (V3-1) - VV2+ (E6-18) Below 1 Ω VVT sensor (V3 or V4-3) - NE- (E6-20) Below 1 Ω Standard resistance (Check for short) ECM: E6 Tester Connections Specified Conditions VVT sensor (V4-1) or VV1+ (E6-19) - Body ground 10 kΩ or higher VVT sensor (V3-1) or VV2+ (E6-18) - Body ground 10 kΩ or higher VVT sensor (V3 or V4-3) or NE- (E6-20) - Body ground 10 kΩ or higher (d) Reconnect the VVT sensor connector. (e) Reconnect the ECM connector. VV2+ NE- VV1+ NG A114621E03 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK VVT SENSOR (SENSOR POWER SOURCE) (a) Disconnect the V3 or V4 VVT sensor connector. (b) Measure the voltage between the terminals of the VVT sensor. Standard voltage Wire Harness Side: V4 Bank 1 V3 Bank 2 Tester Connections Specified Conditions 3 - Body ground 4.5 to 5.0 V (c) Reconnect the VVT sensor connector. VVT Sensor G038815E05 NG REPAIR OR REPLACE ECM OK 4 CHECK SENSOR INSTALLATION (VVT SENSOR) (a) Check the VVT sensor installation. OK: Sensor is installed correctly. NG OK REPAIR OR REPLACE VVT SENSOR 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 ES–201 CHECK CAMSHAFT TIMING GEAR ASSEMBLY (TEETH OF PLATE) (a) Check the teeth of the signal plate. OK: Sensor plate teeth do not have any cracks or deformation. NG REPLACE CAMSHAFT TIMING GEAR ASSEMBLY OK REPLACE ECM ES ES–202 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0351 Ignition Coil "A" Primary / Secondary Circuit DTC P0352 Ignition Coil "B" Primary / Secondary Circuit DTC P0353 Ignition Coil "C" Primary / Secondary Circuit DTC P0354 Ignition Coil "D" Primary / Secondary Circuit DTC P0355 Ignition Coil "E" Primary / Secondary Circuit DTC P0356 Ignition Coil "F" Primary / Secondary Circuit HINT: • These DTCs indicate malfunctions relating to the primary circuit. • If DTC P0351 is set, check No. 1 ignition coil with igniter circuit. • If DTC P0352 is set, check No. 2 ignition coil with igniter circuit. • If DTC P0353 is set, check No. 3 ignition coil with igniter circuit. • If DTC P0354 is set, check No. 4 ignition coil with igniter circuit. • If DTC P0355 is set, check No. 5 ignition coil with igniter circuit. • If DTC P0356 is set, check No. 6 ignition coil with igniter circuit. DESCRIPTION A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system in which each cylinder is ignited by one ignition coil and one spark plug is connected to the end of each secondary wiring. A powerful voltage, generated in the secondary wiring, is applied directly to each spark plug. The sparks of the spark plugs pass from the center electrodes to the ground electrodes. The ECM determines the ignition timing and transmits the ignition (IGT) signals to each cylinder. Using the IGT signal, the ECM turns the power transistor inside the igniter on and off. The power transistor, in turn, switches on and off the current to the primary coil. When the current to the primary coil is cut off, a powerful voltage is generated in the secondary coil. This voltage is applied to the spark plugs, causing them to spark inside the cylinders. As the ECM cuts the current to the primary coil, the igniter sends back an ignition confirmation (IGF) signal to the ECM, for each cylinder ignition. ES–203 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM From Battery ECM Igniter No. 1 Ignition Coil with Igniter IGT1 No. 1 Cylinder IGF1 Crankshaft Position Sensor VVT Sensor Ignition Coil IGT2 No. 2 Ignition Coil with Igniter IGT3 No. 3 Ignition Coil with Igniter IGT4 No. 4 Ignition Coil with Igniter IGT5 No. 5 Ignition Coil with Igniter IGT6 No. 6 Ignition Coil with Igniter Spark Plug No. 2 Cylinder ES No. 3 Cylinder No. 4 Cylinder Other Sensor (Engine Coolant Temperature. Sensor, Mass Air Flow Meter, Throttle Position Sensor, etc.) No. 5 Cylinder No. 6 Cylinder TACH To Tachometer A082677E06 DTC No. P0351 P0352 P0353 P0354 P0355 P0356 DTC Detection Conditions No IGF signal to ECM while engine running (1 trip detection logic) Trouble Areas • • • • Ignition system Open or short in IGF1 or IGT circuit (1 to 6) between ignition coil with igniter and ECM No. 1 to No. 6 ignition coils with igniters ECM Reference: Inspection using an oscilloscope IGT and IGF Signal Waveform 2 V/Division CH1 GND CH2 GND 20 msec./Division G042403E01 ES–204 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM While cranking or idling, check the waveform between terminals IGT (1 to 6) and E1, and IGF1 and E1 of the ECM connector. Items Contents Terminals CH1: IGT1, IGT2, IGT3, IGT4, IGT5, IGT6 - E1 CH2: IGF1 - E1 Equipment Settings 2 V/Division, 20 ms/Division Conditions Cranking or idling MONITOR DESCRIPTION Ignition Coil with Igniter ES IGT ECM Ignition Coil Igniter IGF Ignition Signal (IGT) Normal Ignition Confirmation Signal (IGF) Malfunction Circuit Open Time A082388E23 If the EMC does not receive the ignition confirmation (IGF) signal after sending the ignition (IGT) signal, it interprets as a fault in the igniter and sets a DTC. MONITOR STRATEGY Related DTCs P0351: No.1 ignition coil with igniter circuit malfunction P0352: No.2 ignition coil with igniter circuit malfunction P0353: No.3 ignition coil with igniter circuit malfunction P0354: No.4 ignition coil with igniter circuit malfunction P0355: No.5 ignition coil with igniter circuit malfunction P0356: No.6 ignition coil with igniter circuit malfunction Required Sensors / Components (Main) Igniter Required Sensors / Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 0.256 seconds +4 sparks MIL Operation Immediate Sequence of Operation None 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–205 TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Engine speed 1,500 rpm or less Spark cut Not operating Either of the following conditions is met: Condition 1 or 2 1. Following conditions are met: Condition (a) and (b) (a) Engine RPM 500 rpm or less (b) Battery voltage 6 V or more 2. Following conditions are met: Condition (c), (d) and (e) (c) Engine RPM More than 500 rpm (d) Battery voltage 10 V or more (e) Number of sparks after CPU is reset 5 sparks or more TYPICAL MALFUNCTION THRESHOLDS Ignition signal fail count More than 2 Ignition signal fail count is on the right: When IGF does not return despite sending IGT. COMPONENT OPERATING RANGE IGF signal Igniter outputs IGF signal when it receives IGT signal from ECM ES ES–206 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM I1 Ignition Coil Assembly (with Igniter No. 1) 13 IM1 B-R B-R B-R B-R B-R ES 1H 4 4 2 W-B W-R B-R B-R W-B 1 3 4 2 7 R W-B 1 3 4 2 Engine Room R/B 2 W-B 1 3 4 2 IGT3 W-R IGT4 I5 Ignition Coil Assembly (with Igniter No. 5) GR 1 1 3 4 2 W-B B-R W-B W-B W-R 12 E4 IGT5 W-R I6 Ignition Coil Assembly (with Igniter No. 6) L B W-B 11 E4 W-R B-R 2 10 E4 LG-B B-R AM2 W-R I4 Ignition Coil Assembly (with Igniter No. 4) W-B 2 IGT2 W-R B-R 1 9 E4 LG B-R 2 N1 Noise Filter W-R I3 Ignition Coil Assembly (with Igniter No. 3) W-B AM2 IGT1 24 IGF1 E4 W-R B-R I18 Ignition Switch W-R P-L W-B B-R IG2 3 B-R 1D 6 6 1 I2 Ignition Coil Assembly (with Igniter No. 2) Driver Side J/B 8 E4 Y-R 1 3 4 2 W-B 13 E4 IGT6 W-R Battery EF G032686E02 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–207 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK WHETHER DTC OUTPUT RECURS (DTC P0351, P0352, P0353, P0354, P0355 OR P0356) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch to ON. Turn the tester ON. Clear DTCs (See page ES-31). Shuffle arrangement of the ignition coils with igniters (among No. 1 to No. 6 cylinders). NOTICE: Do not shuffle the connectors. (f) Perform a simulation test. (g) Check DTCs displayed on the tester. Result Display (DTC Output) Proceed to P0351, P0352, P0353, P0354, P0355 or P0356 A Any other DTCs B B A REPLACE IGNITION COIL ASSEMBLY ES ES–208 2 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (IGT1, IGT2, IGT3, IGT4, IGT5 IGT6 AND IGF1 SIGNAL) (a) Inspect the ECM using an oscilloscope. (b) While cranking or idling, check the waveform between the terminals of the E4 and E6 ECM connector. Standard IGT2 (+) IGT1 (+) E4 ES E1 (-) E6 IGF1 (+) IGT5 (+) IGT3 (+) IGT4 (+) ECM Connector IGT6 (+) IGT and IGF Signal Waveform 2 V/ Division 20 msec./Division NG Tester Connections Specified Conditions IGT1 (E4-8) - E1 (E6-1) Correct waveform shown IGT2 (E4-9) - E1 (E6-1) Correct waveform shown IGT3 (E4-10) - E1 (E6-1) Correct waveform shown IGT4 (E4-11) - E1 (E6-1) Correct waveform shown IGT5 (E4-12) - E1 (E6-1) Correct waveform shown IGT6 (E4-13) - E1 (E6-1) Correct waveform shown IGF1 (E4-24) - E1 (E6-1) Correct waveform shown REPLACE ECM A138721E01 OK 3 CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM) (a) Disconnect the I1, I2, I3, I4, I5 or I6 ignition coil with igniter connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) ECM: E4 IGT5 IGT3 Tester Connections Specified Conditions IGF (I1-2) - IGF1 (E4-24) Below 1 Ω IGT1 IGT2 IGT4 IGT6 IGF (I2-2) - IGF1 (E4-24) Below 1 Ω IGF (I3-2) - IGF1 (E4-24) Below 1 Ω IGF (I4-2) - IGF1 (E4-24) Below 1 Ω IGF (I5-2) - IGF1 (E4-24) Below 1 Ω Wire Harness Side: IGF (I6-2) - IGF1 (E4-24) Below 1 Ω IGF1 Ignition Coil with Igniter Connector I1 I2 I3 I4 I5 I6 1 2 3 Standard resistance (Check for open) Tester Connections Specified Conditions IGT (I1-3) - IGT1 (E4-8) Below 1 Ω 4 IGF IGT Front View A114622E05 IGT (I2-3) - IGT2 (E4-9) Below 1 Ω IGT (I3-3) - IGT3 (E4-10) Below 1 Ω IGT (I4-3) - IGT4 (E4-11) Below 1 Ω IGT (I5-3) - IGT5 (E4-12) Below 1 Ω IGT (I6-3) - IGT6 (E4-13) Below 1 Ω ES–209 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard resistance (Check for short) Tester Connections Specified Conditions IGF (I1-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I2-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I3-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I4-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I5-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I6-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher Standard resistance (Check for short) Tester Connections Specified Conditions IGT (I1-3) or IGT1 (E4-8) - Body ground 10 kΩ or higher IGT (I2-3) or IGT2 (E4-9) - Body ground 10 kΩ or higher IGT (I3-3) or IGT3 (E4-10) - Body ground 10 kΩ or higher IGT (I4-3) or IGT4 (E4-11) - Body ground 10 kΩ or higher IGT (I5-3) or IGT5 (E4-12) - Body ground 10 kΩ or higher IGT (I6-3) or IGT6 (E4-13) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the ignition coil with igniter connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT IGNITION COIL ASSEMBLY (POWER SOURCE) (a) Disconnect the I1, I2, I3, I4, I5 or I6 ignition coil with igniter connector. (b) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Ignition Coil with Igniter Connector I1 I2 I3 I4 I5 I6 +B (+) GND (-) Front View A054393E73 Tester Connections Specified Conditions GND (I1-4) - Body ground Below 1 Ω GND (I2-4) - Body ground Below 1 Ω GND (I3-4) - Body ground Below 1 Ω GND (I4-4) - Body ground Below 1 Ω GND (I5-4) - Body ground Below 1 Ω GND (I6-4) - Body ground Below 1 Ω (c) Turn the ignition switch on. (d) Measure the voltage between the terminals of the wire harness side connector. Standard voltage Tester Connections Specified Conditions +B (I1-1) - GND (I1-4) 9 to 14 V +B (I2-1) - GND (I2-4) 9 to 14 V +B (I3-1) - GND (I3-4) 9 to 14 V +B (I4-1) - GND (I4-4) 9 to 14 V +B (I5-1) - GND (I5-4) 9 to 14 V +B (I6-1) - GND (I6-4) 9 to 14 V (e) Reconnect the ignition coil with igniter connector. ES ES–210 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Go to step 5 OK REPLACE IGNITION COIL ASSEMBLY 5 CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - IGNITION SWITCH) Wire Harness Side: ES Ignition Coil with Igniter Connector I1 I2 I3 I4 I5 1 2 3 (a) Disconnect the I1, I2, I3, I4, I5 or I6 ignition coil with igniter connector. (b) Disconnect the I18 ignition switch connector. (c) Measure the resistance. Standard resistance (Check for open) 4 I6 +B Front View Ignition Switch Connector Tester Connections Specified Conditions +B (I1-1) - IG2 (I18-6) Below 1 Ω +B (I2-1) - IG2 (I18-6) Below 1 Ω +B (I3-1) - IG2 (I18-6) Below 1 Ω +B (I4-1) - IG2 (I18-6) Below 1 Ω +B (I5-1) - IG2 (I18-6) Below 1 Ω +B (I6-1) - IG2 (I18-6) Below 1 Ω Standard resistance (Check for short) I18 IG2 1 2 3 4 5 6 7 8 Front View A114624E03 Tester Connections Specified Conditions +B (I1-1) or IG2 (I18-6) - Body ground 10 kΩ or higher +B (I2-1) or IG2 (I18-6) - Body ground 10 kΩ or higher +B (I3-1) or IG2 (I18-6) - Body ground 10 kΩ or higher +B (I4-1) or IG2 (I18-6) - Body ground 10 kΩ or higher +B (I5-1) or IG2 (I18-6) - Body ground 10 kΩ or higher +B (I6-1) or IG2 (I18-6) - Body ground 10 kΩ or higher (d) Reconnect the ignition coil with igniter connector. (e) Reconnect the ignition switch connector. NG OK REPLACE IGNITION COIL ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR ES–211 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) MONITOR DESCRIPTION The ECM uses sensors mounted in front of and behind the Three-Way Catalytic Converter (TWC) to monitor its efficiency. The first sensor, the Air-Fuel Ratio (A/F) sensor, sends pre-catalyst information to the ECM. The second sensor, the Heated Oxygen (HO2) sensor, sends post-catalyst information to the ECM. In order to detect any deterioration in the TWC, the ECM calculates the Oxygen Storage Capacity (OSC) of the TWC. This calculation is based on the voltage output of the HO2 sensor while performing active airfuel ratio control, rather than the conventional detecting method, which uses the locus ratio. The OSC value is an indication of the oxygen storage capacity of the TWC. When the vehicle is being driven with a warm engine, active air-fuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the ECM deliberately sets the air-fuel ratio to lean or rich levels. If a rich-lean cycle of the HO2 sensor is long, the OSC becomes greater. There is a direct correlation between the OSCs of the HO2 sensor and the TWC. The ECM uses the OSC value to determine the state of the TWC. If any deterioration has occurred, it illuminates the MIL and sets the DTC. DTC No. DTC Detection Conditions Trouble Areas P0420 OSC value smaller than standard value under active air-fuel ratio control (2 trip detection logic) • • • • P0430 OSC value smaller than standard value under active air-fuel ratio control (2 trip detection logic) • • • • Gas leakage from exhaust system A/F sensor (bank 1 sensor 1) HO2 sensor (bank 1 sensor 2) Exhaust manifold (TWC) Gas leakage from exhaust system A/F sensor (bank 2 sensor 1) HO2 sensor (bank 2 sensor 2) Exhaust manifold (TWC) HINT: • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that does not include cylinder No. 1. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Catalyst (Bank 1) Deterioration P0430: Catalyst (Bank 2) Deterioration Required Sensors / Components (Main) A/F sensor, Rear HO2S Required Sensors / Components (Related) Rear HO2S, IAT sensor, MAF meter, Crankshaft position sensor, ECT sensor Frequency of Operation Once per driving cycle Duration 30 seconds MIL Operation 2 driving cycles Sequence of Operation None ES ES–212 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS ES The monitor will run whenever these DTCs are not present P0011, P0012 (VVT System1-Advance, Retard), P0021, P0022 (VVT System2Adavance, Retard), P0031, P0032, P0051, P0052 (A/F Sensor Heater Sensor 1), P0037, P0038, P0057, P0058 (O2 Sensor heater Sensor 2), P0100, P0101, P0102, P0103 (MAF Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223 , P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0136, P0156 (O2 Sensor 2), P0171,P0172 (Fuel System), P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Misfire), P0335 (CKP Sensor), P0340 (CMP Sensor), P0351, P0352, P0353, P0354, P0355, P0356 (Ignitor), P0500 (VSS), P2196, P2198 (A/F Sensor (Rationality)), P2A00, P2A03 (A/ F Sensor (Slow Response)) Battery voltage 11 V or more IAT -10°C (14°F) or more ECT 75°C (167°F) or more Atmospheric pressure coefficient 76 kPa (570 mmHg) or more Idle OFF Engine RPM Less than 3.200 rpm A/F sensor Activated Fuel system status Closed loop Engine load 10 to 70% All of the following conditions are met Condition 1, 2 and 3 1. MAF 5 to 70 g/sec. 2. Front catalyst temperature (estimated) 650 to 720°C (1,202 to 1,328°F) 3. Rear catalyst temperature (estimated) 100 to 900°C (212 to 1,652°F) A/F sensor Completed Rear HO2S Completed Shift position 4th or higher TYPICAL MALFUNCTION THRESHOLDS Oxygen Storage Capacity (OSC) of catalyst Less than 0.08 g MONITOR RESULT Refer to Checking Monitor Status (See page ES-14). CONDITIONING FOR SENSOR TESTING HINT: Perform the operation with the engine speeds and time durations described below prior to check the waveforms of the A/F and HO2 sensors. This is in order to activate the sensors sufficiently to obtain the appropriate inspection results. ES–213 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Speed “C” 3,000 rpm “D” “D” 2,000 rpm Idling “B” “A” Time Ignition Switch OFF Warming up At least 3 minutes 2 seconds ES 2 seconds A093766E19 1. Connect the intelligent tester to the DLC3 (Procedure "A"). 2. Start the engine and warm it up with all the accessories switched off, until the engine coolant temperature stabilizes (Procedure "B"). 3. Run the engine at an engine speed of between 2,500 rpm and 3,000 rpm for at least 3 minutes (Procedure "C"). 4. While running the engine at 3,000 rpm for 2 seconds and 2,000 rpm for 2 seconds, check the waveforms of the A/F and HO2 sensors using the tester (Procedure "D"). HINT: • If either of the voltage outputs of the Air-Fuel Ratio (A/F) or Heated Oxygen (HO2) sensor does not fluctuate, or either of the sensors makes a noise, the sensor may be malfunctioning. • If the voltage outputs of both the sensors remain lean or rich, the air-fuel ratio may be extremely lean or rich. In such cases, perform the following A/F CONTROL using the intelligent tester. • If the Three-Way Catalytic Converter (TWC) has deteriorated, the HO2 sensor (located behind the TWC) voltage output fluctuates up and down frequently, even under normal driving conditions (active air-fuel ratio control is not performed). Voltage output when active air-fuel ratio control not performed: Normal Catalyst Waveform of A/F Sensor in front of TWC Deteriorated Catalyst 3.5 V 3.0 V Waveform of HO2 Sensor behind TWC 1.0 V 0V 10 seconds 10 seconds A076893E08 ES–214 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. ES A/F CONTROL HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using an intelligent tester. (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Main Suspected Trouble Area - 1 2 3 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit ES–215 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area • • • 4 Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check the graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2, press the YES button and then the ENTER button followed by the F4 button. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0420 AND/OR P0430) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0420 and/or P0430 A P0420 and/or P0430 and other DTCs B HINT: If any DTCs other than P0420 or P0430 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3. (b) Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. ES ES–216 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. ES Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 Result Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F and HO2 Sensor Conditions Misfires Suspected Trouble Areas • Lean/Rich Lean/Rich Normal - Lean Lean/Rich A/F sensor malfunction - Rich Lean/Rich A/F sensor malfunction • Three-Way Catalytic Converter (TWC) Gas leakage from exhaust system Proceed to A A/F sensor B - A/F sensor B HO2 sensor Gas leakage from exhaust system C Lean/Rich Lean HO2 sensor malfunction - • • Lean/Rich Rich HO2 sensor malfunction - • • HO2 sensor Gas leakage from exhaust system C • Extremely rich or lean actual air-fuel ratio Gas leakage from exhaust system A Extremely rich or lean actual air-fuel ratio Gas leakage from exhaust system A Lean Lean Actual air-fuel ratio lean May occur • • Rich Rich Actual air-fuel ratio rich - • Lean: During A/F CONTROL, the A/F sensor output voltage (AFS) is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL of the ACTIVE TEST, the output voltage of the HO2 sensor alternates correctly. B CHECK AND REPLACE AIR FUEL RATIO SENSOR 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C ES–217 CHECK AND REPLACE HEATED OXYGEN SENSOR, AND CHECK AND REPAIR EXHAUST GAS LEAKAGE A 3 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK REPLACE THREE-WAY CATALYTIC CONVERTER (FRONT EXHAUST PIPE) ES ES–218 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P043E Evaporative Emission System Reference Orifice Clog Up DTC P043F Evaporative Emission System Reference Orifice High Flow DTC SUMMARY DTCs Monitoring Items Malfunction Detection Conditions Trouble Areas • ES P043E P043F 0.02 inch orifice clogged 0.02 inch orifice high-flow P043E, P043F, P2401, P2402 and P2419 present when one of following conditions met during key-off EVAP monitor: • EVAP pressure just after reference pressure measurement greater than -1 kPa-g (-7.5 mmHg-g) • Reference pressure less than -4.85 kPa-g (-36.4 mmHg-g) • Reference pressure greater than 1.057 kPa-g (-7.93 mmHg-g) • Reference pressure not saturated • Reference pressure difference between first and second 0.7 kPa-g (5.25 mmHg-g) or more HINT: Typical example values • • • • • • • Detection Timings Detection Logic Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM While ignition switch OFF 2 trip Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM While ignition switch OFF 2 trip * : The threshold values vary according to the atmospheric pressure measured at the EVAP monitor beginning. The values described in the table above are based on an atmospheric pressure of 100 kPa (750.1 mmHg) (absolute pressure). HINT: The 0.02 inch orifice is located inside the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-349). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned to off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–219 HINT: *1: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence *2 Operations Descriptions Duration - ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. - ES - : If there is only a small amount of fuel in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–220 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter ON Vacuum Pump: OFF ES Pump Module Operation D: Purge VSV Monitor Operation C: EVAP System Pressure Measurement OFF ON (closed) ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E18 ES–221 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P043E: 0.02 inch orifice clogged In operation B, the vacuum pump creates negative pressure (vacuum) through the 0.02 inch orifice. The EVAP system pressure is then measured by the ECM, using the pressure sensor, to determine the 0.02 inch leak pressure standard. If the pressure is lower than -4.3 kPa (-36.4 mmHg)*, the ECM interprets this as a clog malfunction in the 0.02 inch orifice, and stops the EVAP (Evaporative Emission) system monitor. The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when 0.02 Inch Orifice Clogged: ON: Open OFF: Closed ON Purge VSV ON: Closed ON Vent Valve OFF: Vent ON Vacuum Pump EVAP Pressure Positive Negative OK First 0.02 Inch Leak Pressure Standard Malfunction Sequence Time A B C 10 seconds 60 seconds With 15 minutes D E 60 seconds 10 seconds F G036773E07 ES ES–222 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P043F: 0.02 inch orifice high-flow In operation B, the vacuum pump creates negative pressure (vacuum) through the 0.02 inch orifice. The EVAP system pressure is then measured by the ECM using the pressure sensor to determine the 0.02 inch leak pressure standard. If the pressure is higher than -1.057 kPa (-7.93 mmHg)*, the ECM interprets this as a high-flow malfunction in the 0.02 inch orifice, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). * : The threshold varies according to the atmospheric pressure measured in operation A. The value described above is based on a atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when 0.02 Inch Orifice High-flow Malfunction: ES ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure Malfunction Positive Negative OK First 0.02 Inch Leak Pressure Standard Sequence Time A B C 10 seconds 60 seconds With 15 minutes D E 60 seconds 10 seconds MONITOR STRATEGY Related DTCs P043E: 0.02 inch orifice clog (built-in pump module) P043F: 0.02 inch orifice high-flow (built-in pump module) Required Sensors / Components Pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool F G036774E07 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–223 TYPICAL MALFUNCTION THRESHOLDS One of following conditions met Condition 1, 2, 3, 4 or 5 1. EVAP pressure just after reference pressure measurement start More than -1 kPa (-7.93 mmHg) 2. Reference pressure Less than -4.85 kPa (-36.4 mmHg) 3. Reference pressure -1.057 kPa (-7.93 mmHg) or more 4. Reference pressure Not saturated within 60 seconds 5. Difference between first reference pressure and second reference pressure 0.7 kPa (5..25 mmHg) or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES ES–224 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Evaporative Emission Control System Incorrect Purge Flow P0441 DTC SUMMARY DTCs P0441 Monitoring Items Purge VSV (Vacuum Switching Valve) stuck open Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure is measured. The 0.02 inch leak pressure standard is measured at the start and end of the leak check. If stabilized pressure is higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that purge VSV is stuck open Purge VSV stuck closed After EVAP leak check performed, purge VSV turned ON (open), and atmospheric air is introduced into EVAP system. 0.02 inch leak pressure standard is measured at the start and end of leak check. If pressure does not return to near atmospheric pressure, ECM determines that purge valve is stuck closed Purge flow While engine running, the following conditions successively met: • Negative pressure is not created in EVAP system when purge VSV is turned ON (open) • EVAP system pressure change is less than 1 kPa (7.5 mmHg) when vent valve is turned ON (closed) • Atmospheric pressure change before and after purge flow monitor is less than 1 kPa (0.75 mmHg) ES P0441 P0441 Malfunction Detection Conditions Trouble Areas • • • • • • • • • • • • • • Detection Timings Detection Logic Purge VSV Connector/wire harness (Purge VSV - ECM) ECM Pump module Leakage from EVAP system While ignition Switch OFF 2 trip Purge VSV Connector/wire harness (Purge VSV - ECM) ECM Pump module Leakage from EVAP system While ignition Switch OFF 2 trip Purge VSV Connector/wire harness (Purge VSV - ECM) Leakage from EVAP line (Purge VSV - Intake manifold) ECM While engine running 2 trip DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-349). MONITOR DESCRIPTION The two monitors, Key-Off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The Key-Off monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours*1 after the ignition switch is turned to off. The purge flow monitor runs while the engine is running. 1. KEY-OFF MONITOR 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *1: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations ECM activation Descriptions Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. Duration - ES–225 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operations Descriptions Duration 10 seconds A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. *2: - If only a small amount of fuel in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter ON Vacuum Pump: OFF Pump Module Operation D: Purge VSV Monitor Operation C: EVAP System Pressure Measurement OFF ON (closed) ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E18 ES ES–226 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) Purge VSV stuck open In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The EVAP system pressure is then measured by the ECM using the pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2], the ECM interprets this as the purge VSV (Vacuum Switching Valve) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Open: ON: Closed ON Vent Valve ES ON: Open OFF: Closed ON Purge VSV OFF: Vent ON Vacuum Pump EVAP Pressure Malfunction Positive Negative First 0.02 Inch Leak Pressure Standard [Second 0.02 lnch Leak Pressure Standard] x 0.2 OK Sequence A Time 10 seconds B 60 seconds C Within 15 minutes D E 10 60 seconds seconds G036775E08 ES–227 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Purge VSV stuck closed In operation D, the pressure sensor measures the EVAP (Evaporative Emission) system pressure. The pressure measurement for purge VSV monitor is begun when the purge VSV is turned on (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Closed: ON: Open OFF: Closed ON Purge VSV ON: Closed ON Vent Valve ES ON: Vent ON Vacuum Pump EVAP Pressure OK Positive Negative Malfunction First 0.02 Inch Leak Pressure Standard Sequence Time A B 10 seconds C 60 seconds Within 15 minutes D E 60 seconds 10 seconds G036776E14 2. EVAP Pressure During Purge Flow Monitor: Open Purge VSV ON (Closed) Vent Valve Malfunction 0.1 kPa EVAP Pressure OK 1st Monitor 0.5 kPa OK 2nd Monitor A071563E10 PURGE FLOW MONITOR The purge flow monitor consists of the two step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is on (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned on (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 1 kPa (7.5 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. ES–228 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY ES Related DTCs P0441: Purge VSV stuck open P0441: Purge VSV stuck closed P0441: Purge flow Required Sensors / Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Purge VSV stuck open and closed: Within 15 minutes. (varies with amount of fuel in tank) Purge flow: Within 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor is run whenever this DTC is not present P0011, P0012 (VVT System-Advance, Retard), P0021, P0022 (VVT System2Adavance, Retard), P0100, P0101, P0102, P0103 (MAF Sensor), P0110, P0112, P0113 (IAT Sensor),P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223 , P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0171,P0172 (Fuel System), P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Misfire), P0335 (CKP Sensor), P0340 (CMP sensor), P0351, P0352, P0353, P0354, P0355, P0356 (Ignitor), P0450, P0451, P0452, P0453 (EVAP pressure Sensor), P0500 (VSS) Purge VSV stuck open and closed: Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key-off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) Purge flow: Engine Running ECT 4.4°C (40°F) or more IAT 4.4°C (40°F) or more EVAP pressure sensor Not detected EVAP canister purge valve Not operated by scan tool EVAP system check Not operated by scan tool Battery voltage 10 V or more Purge duty cycle 8% or more TYPICAL MALFUNCTION THRESHOLDS Purge flow: Both of the following conditions are met Condition (a) and (b) 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) EVAP pressure change when purge flow is started Less than 0.1 kPa (0.75 mmHg) (b) EVAP pressure change during purge flow when EVAP pressure switching valve ON (closed) Less than 0.5 kPa (3.75 mmHg) ES–229 EVAP VSV stuck open: EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 EVAP VSV stuck closed: EVAP pressure change after EVAP canister purge valve is open Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES ES–230 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0450 Evaporative Emission Control System Pressure Sensor / Switch DTC P0451 Evaporative Emission Control System Pressure Sensor Range / Performance DTC P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input DTC P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input DTC SUMMARY DTCs Monitoring Items P0450 Pressure sensor abnormal voltage fluctuation P0451 Pressure sensor noising Malfunction Detection Conditions Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 seconds. Sensor output voltage fluctuates frequently in certain time period. • • • Pressure sensor stuck Sensor output voltage does vary in certain time period. • • • • • P0452 Pressure sensor voltage low Sensor output voltage is less than 0.45 V for 0.5 seconds. • • • P0453 Pressure sensor voltage high Sensor output voltage is more than 4.9 V for 0.5 seconds. Pump module ECM • • P0451 Detection Timings Trouble Areas • • • Pump module Connector/wire harness (Pump module - ECM) ECM Pump module Connector/wire harness (Pump module - ECM) ECM Pump module Connector/wire harness (Pump module - ECM) ECM Pump module Connector/wire harness (Pump module - ECM) ECM • • Detection Logic EVAP monitoring (ignition OFF) Ignition ON 1 trip EVAP monitoring (ignition OFF) Engine running 2 trip EVAP monitoring (ignition OFF) 2 trip • • Ignition ON EVAP monitoring (ignition OFF) 1 trip • • Ignition ON EVAP monitoring (ignition OFF) 1 trip HINT: The pressure sensor is built into the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–231 MONITOR DESCRIPTION Pressure Sensor Specification: Output Voltage Malfunction Area 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V Pressure 60 kPa 110 kPa HINT: Standard Atmospheric Pressure is 101.3 kPa A071562E16 1. DTC P0450: Pressure sensor abnormal voltage fluctuation If the pressure sensor voltage output rapidly fluctuates between less than 0.45 V and more than 4.9 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP (Evaporative Emission) system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 2. DTC P0451: Pressure sensor noising or stuck If the pressure sensor voltage output fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor voltage output does not change for 10 seconds, the ECM interprets this as the sensor being stuck, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both the malfunctions are detected by 2 trip detection logic) 3. DTC P0452: Pressure sensor voltage low If the pressure sensor voltage output is below 0.45 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 4. DTC P0453: Pressure sensor voltage high If the pressure sensor voltage output is 4.9 V or more, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). MONITOR STRATEGY Related DTCs P0450: Evaporative emission control system pressure sensor/switch chattering P0451: Evaporative emission control system pressure sensor noise P0451: Evaporative emission control system pressure sensor stuck P0452: Evaporative emission control system pressure sensor/switch low input P0453: Evaporative emission control system pressure sensor/switch high input Required Sensors / Components Pump module Frequency of Operation Once pre driving cycle Duration 0.5 seconds: P0450, P0452, P0453 Within 15 seconds: P0451 MIL Operation Immediate: P0450, P0452, P0453 2 driving cycles: P0451 Sequence of Operation None ES ES–232 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None Pressure sensor noise: ES Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more IAT 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Either of the following conditions is met Condition 1 or 2 1. Time after key off 5 or 7 or 9.5 hours 2. Engine condition Running Pressure sensor stuck Battery voltage 10.5 V or more IAT 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Time after key off 5 or 7 or 9.5 hours Pressure sensor chattering, low/high voltage Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Pressure sensor noise: Frequency that EVAP pressure change is 0.3 kPa (2.25 mmHg) or more 10 times or more in 10 seconds Pressure sensor stuck: EVAP pressure change during reference pressure measurement Less than 1 kPa (0.75 mmHg) Pressure sensor chattering: EVAP pressure Less than 42.11 kPa (315.82mmHg), or more than 123.761 kPa (928.207 mmHg) Pressure sensor low pressure: EVAP pressure Less than 42.11 kPa (315.82 mmHg) Pressure sensor high pressure: EVAP pressure More than 123.761 kPa (928.207 mmHg) ES–233 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM L4 Canister Pump Module Pressure Sensor 42 IE1 L-R R 17 IE1 R BR 43 IE1 BR O 28 IE1 O 6 E8 MPMP 11 IE1 R-G 5 E8 VPMP L-R 4 3 Vacuum Pump 2 6 1 R-G 8 W-B ECM Vent Valve L-W 9 1 IB2 7 IM2 22 BR IM2 L-W G-Y A J4 J/C A 9 IE1 A L-W L EFI 1 W-B 12 IM1 L-W 8 E8 MREL 2 1 2 B W-G EFI Relay 2 34 E4 PRG EFI No. 2 2 W-B 2 2 ES 1 L-W Engine Room R/B 2 17 IM2 28 E2 E4 V2 2 Purge VSV 17 IC3 Engine Room R/B 23 VC E4 22 PPMP E8 L-W W-B L-R 5 3 2 1 B J2 B J3 IC4 35 2 2 W-G 2 B W-B J/C EF Battery EB G032687E01 ES–234 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel tank cap. • Do not disassemble the pump module. • The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1 CONFIRM DTC AND EVAP PRESSURE (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on (do not start the engine). Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / VAPOR PRESS. (g) Read the EVAP (Evaporative Emission) pressure displayed on the tester. ES Result Display (DTC Output) Test Results P0451 - Suspected Trouble Areas Pressure sensor • P0452 Less than 45 kpa (338 mmHg) • • • P0453 More than 120 kPa (900 mmHg) B C • • Proceed to C Wire harness/connector (ECM - pressure sensor) Pressure sensor Short in ECM circuit A Wire harness/connector (ECM - pressure sensor) Pressure sensor Open in ECM circuit B Go to step 4 GO TO EVAP SYSTEM A 2 CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM) ECM: (a) Turn the ignition switch off. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between PPMP terminal of the ECM connector and the body ground. E8 PPMP G035619E14 ES–235 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas • 10 Ω or less • • 10 Ω or more • Proceed to Wire harness/connector (ECM - pressure sensor) Short in pressure sensor circuit A Wire harness/connector (ECM - pressure sensor) Short in ECM circuit B (d) Reconnect the ECM connector. B Go to step 8 A ES 3 CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM) (a) Disconnect the L4 canister connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between PPMP terminal of the ECM connector and the body ground. L4 ECM: E8 PPMP A138722E01 Result Test Results Suspected Trouble Areas Proceed to 10 kΩ or more Short in pressure sensor circuit A 10 kΩ or less Short in wire harness/connector (ECM - pressure sensor) B (d) Reconnect the canister connector. (e) Reconnect the ECM connector. B Go to step 6 A 4 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace charcoal canister assembly (See page EC-6). (b) Connect the intelligent tester to the DLC3. ES–236 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Turn the ignition switch on and turn the tester on. (d) Wait for at least 60 seconds. (e) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. NEXT COMPLETED ES 5 CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM) (a) Disconnect the L4 canister connector. (b) Turn the ignition switch on. (c) Measure the voltage and resistance of the L4 canister connector. Standard L4 Tester Connections Specified Conditions L4-4 - Body ground Between 4.5 V and 5.5 V L4-3 - Body ground Between 4.5 V and 5.5 V L4-2 - Body ground 100 Ω or less Wire Harness Side: Canister Connector L4 Front View A138723E01 Result Test Results Suspected Trouble Areas Proceed to Voltage and resistance is within standard ranges Open in pressure sensor circuit A Voltage and resistance is outside standard ranges Open in wire harness/connector (ECM - pressure sensor) B (d) Reconnect the canister connector. B Go to step 7 A 6 REPLACE CHARCOAL CANISTER ASSEMBLY (a) Replace charcoal canister assembly (See page EC-6). (b) Connect the intelligent tester to the DLC3. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–237 (c) Turn the ignition switch on and turn the tester on. (d) Wait for at least 60 seconds. (e) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. NEXT COMPLETED ES 7 REPAIR OR REPLACE WIRE HARNESS OR CONNECTORS (a) (b) (c) (d) (e) Repair or replace wire harness or connectors. Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Wait for at least 60 seconds. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. (a) (b) (c) (d) (e) Replace the ECM (See page ES-434). Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Wait for at least 60 seconds. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. NEXT COMPLETED 8 REPLACE ECM NEXT COMPLETED ES–238 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0455 Evaporative Emission Control System Leak Detected (Gross Leak) DTC P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY DTCs ES P0455 P0456 Malfunction Detection Conditions Monitoring Items EVAP gross leak EVAP small leak Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure is measured. The 0.02 inch leak pressure standard is measured at the start and end of the leak check. If stabilized pressure is higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that EVAP system has large leakage. Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. The 0.02 inch leak pressure standard measured at the start and end of the leak check. If stabilized pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system has small leakage. Trouble Areas • • • • • • Fuel tank cap (loose) Leakage from EVAP line (Canister - Fuel tank) Leakage from EVAP line (Purge VSV Canister) Leakage from pump module Leakage from fuel tank Leakage from canister Same above Detection Timings Detection Logic While ignition switch OFF 2 trip While ignition switch OFF 2 trip DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-349). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *1: If the engine coolant temperature is not below 35°C (95°F) after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence Operations Descriptions - ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. Duration - 10 seconds ES–239 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence Operations Descriptions Duration First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. B ES - *2 : If only a small amount of fuel in the fuel tank, it take longer for the EVAP pressure to stabilize. Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter ON Vacuum Pump: OFF Operation C: EVAP System Pressure Measurement OFF Pump Module ON (closed) Operation D: Purge VSV Monitor ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E18 1. P0455: EVAP (Evaporative Emission) gross leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic). ES–240 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P0456: EVAP very small leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than second 0.02 inch leak pressure standard, the ECM determines that the EVAP system has a small leakage, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP System Leaks: ON: Open ON Purge VSV OFF: Closed ES Vent Valve ON Vacuum Pump ON EVAP Pressure ON: Closed OFF: Vent P0455 Positive Negative P0456 First 0.02 Inch Leak Pressure Standard OK Sequence Time A B 10 seconds 60 seconds C With 15 minutes [Second 0.02 Inch Leak Pressure Standard] x 0.2 D 60 seconds 10 seconds MONITOR STRATEGY Related DTCs P0455: Gross leak detected P0456: Very small leak (0.020 inch hole) detected Required Sensors / Components Purge VSV, pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key-off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more E F G038299E06 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–241 TYPICAL MALFUNCTION THRESHOLDS Small leak (0.020 inch) malfunction detection: EVAP pressure when vacuum introduction is complete Between reference pressure and reference pressure x 0.2 Gross leak detection: EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES ES–242 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0500 Vehicle Speed Sensor "A" DESCRIPTION Vehicles, which are equipped with ABS (Anti-lock Brake System), detect the vehicle speed using the skid control ECU and wheel speed sensor. The wheel speed sensor monitors the wheel rotation speed and sends a signal to the skid control ECU. The skid control ECU converts the wheel speed signal into a 4pulse signal and transmits it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of the pulse signal. 4-Pulse ES From Speed Sensor 4-Pulse Skid Control ECU ECM Combination Mater A079413E17 DTC No. P0500 DTC Detection Conditions The ECM detects following conditions simultaneously 500 times (2 trip detection logic) • No SP1 (speed sensor) signal while ECM detects SP2 (No. 2 speed sensor) signal • Vehicle speed is 6 mph (9 km/h) or more for 4 seconds • Park/Neutral position switch is OFF (shift lever other than P and N positions) • Transfer lever is in other than N position (4WD) Trouble Areas • • • • Open or short in speed signal circuit Combination meter ECM Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is being driven, the vehicle speed sensor signal is being transmitted by the combination meter. If there is no signal from combination meter, despite the ECM detects the speed signal from speed sensor No. 2, the ECM interprets this as a malfunction in the speed signal circuit. The ECM then illuminates the MIL and sets the DTC. MONITOR STRATEGY Related DTCs P0500: Vehicle speed sensor "A" pulse input error Required Sensors / Components (Main) Vehicle Speed Sensor Required Sensors / Components (Related) Park/neutral Position switch, Engine Coolant Temperature sensor, Combination meter Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None ES–243 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present - Vehicle speed is 5.59 mph (9 km/h) or more 4 seconds or more Park/neutral position switch OFF Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS 2WD: Sensor signal No input 4WD: Either of following conditions is met Condition 1 or 2 1. All of following conditions (a), (b) and (c) met - (a) Sensor signal No input (b) Output speed sensor input 16 pulse (c) Transfer L4 Switch OFF 2. All of following conditions (a), (b) and (c) met - (a) Sensor signal No input (b) Output speed sensor input 41 pulse (c) Transfer L4 Switch ON ES WIRING DIAGRAM C9 Combination Meter 5 V-R ECM Driver Side J/B 1 1G 11 1K Center J/B V-R B 3D B 3D V-R G J29 J/C G J30 V-R 8 E7 SPD G032688E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–244 1 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is operating normally if the speedometer reading is normal. NG ES CHECK SPEEDOMETER CIRCUIT OK 2 INSPECT ECM (SPD VOLTAGE) (a) (b) (c) (d) ECM: E6 E1 (-) E7 Shift the shift lever to the neutral position. Jack up the vehicle. Turn the ignition switch on. Check the voltage between the terminals of the E6 and E7 ECM connectors as the wheel is turned slowly. OK NG Turn Wheel A114628E03 OK REPLACE ECM Specified Conditions Voltage generated intermittently HINT: The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly. SPD (+) 4.5 to 14 V 0V Tester Connections SPD (E7-8) - E1 (E6-1) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–245 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0504 Brake Switch "A" / "B" Correlation DESCRIPTION The stop light switch is a duplex system that transmits two signals: STP and ST1-. These two signals are used by the ECM to monitor whether or not the brake system is working properly. If the signals, which indicate the brake pedal is being depressed or released, are detected simultaneously, the ECM interprets this as a malfunction in the stop light switch and sets the DTC. HINT: The normal conditions are as shown in the table below. The signals can be read using the intelligent tester. Signals Brake Pedal Released In Transition Brake Pedal Depressed STP OFF ON ON ST1- ON ON OFF DTC No. P0504 DTC Detection Conditions Conditions (a), (b) and (c) continue for 0.5 seconds or more (1 trip detection logic): (a) Ignition switch on (b) Brake pedal released (c) STP signal OFF when ST1- signal OFF Trouble Areas • • • • Short in stop light switch signal circuit STOP fuse Stop light switch ECM ES ES–246 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM G-Y 15 E8 STP R-L 16 E8 ST1- B-R Driver Side J/B ES To Towing Brake Controller 11 IC3 J/C H J31 IGN 6 1D E J32 12 1J 24 1E S12 Stop Light SW 3 4 G-W Center J/B E 3C J4 J/C B-O R-L G-Y 23 1E B-O C C G-Y 1 2 E 3C G-Y 15 IC3 G-B S28 Skid Control ECU with Actuator B G-Y B G-Y G-Y B B Engine Room R/B 45 STP2 2 E 4 2 G-W 5 3 1 2 2 G-B 2 1 2 1 2 7 16 2 2 E LG 2 ALT STOP G-B E STP STPO From IG1 Fuse B I18 Ignition SW 2 B AM2 2 1 2 2 R 7 AM2 IG2 6 Battery G032694E01 ES–247 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK OPERATION OF STOP LIGHT (a) Check whether the stop lights turn on and off normally when the brake pedal is depressed and released. OK: Stop lights turn on when brake pedal is depressed. NG REPAIR OR REPLACE STOP LIGHT SWITCH CIRCUIT OK 2 Free INSPECT STOP LIGHT SWITCH ASSEMBLY Pushed in 2 4 1 3 A072924E24 (a) Remove the stop light switch assembly. (b) Measure the resistance. Standard resistance Switch Positions Tester Connections Specified Conditions Switch pin free 1-2 Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω (c) Reinstall the stop light switch assembly. NG OK REPLACE STOP LIGHT SWITCH ASSEMBLY ES ES–248 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (STP SIGNAL AND ST1 - VOLTAGE) Brake Pedal Depressed (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STOP LIGHT SW. (d) Check the STP signal when the brake pedal is depressed and released. Standard Brake Pedal Released ES ECM: E6 Specified Conditions Depressed STP signal ON Released STP signal OFF (e) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage E8 E1 (-) Brake Pedal Operations ST1- (+) G035663E06 Tester Connections Brake Pedal Operations Specified Conditions ST1- (E8-16) - E1 (E6-1) Depressed Below 1.5 V ST1- (E8-16) - E1 (E6-1) Released 7.5 to 14 V OK CHECK FOR INTERMITTENT PROBLEMS NG 4 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH - ECM) (a) Disconnect the S12 stop light switch connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) Wire Harness Side: Stop Light Switch Connector S12 1 3 2 Tester Connections Specified Conditions Stop light switch (S12-1) - STP (E8-15) Below 1 Ω Stop light switch (S12-4) - ST1- (E8-16) Below 1 Ω Standard resistance (Check for short) 4 Tester Connections Specified Conditions Stop light switch (S12-1) or STP (E8-15) - Body ground 10 kΩ or higher Stop light switch (S12-4) or ST1- (E8-16) - Body ground 10 kΩ or higher Front View ECM: E8 (d) Reconnect the stop light switch connector. (e) Reconnect the ECM connector. NG ST1STP A114629E03 REPAIR OR REPLACE HARNESS OR CONNECTOR 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–249 OK REPLACE ECM ES ES–250 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0505 Idle Control System Malfunction DESCRIPTION The idling speed is controlled by the ETCS (Electronic Throttle Control System). The ETCS is comprised of: 1) the one valve type throttle body; 2) the throttle actuator, which operates the throttle valve; 3) the Throttle Position (TP) sensor, which detects the opening angle of the throttle valve; 4) the Accelerator Pedal Position (APP) sensor, which detects the accelerator pedal position; and 5) the ECM, which controls the ETCS. Based on the target idling speed, the ECM controls the throttle actuator to provide the proper throttle valve opening angle. DTC No. ES P0505 DTC Detection Conditions Idling speed continues to vary greatly from target idling speed (2 trip detection logic) Trouble Areas • • • • ETCS Air induction system PCV hose connection ECM MONITOR DESCRIPTION The ECM monitors the idling speed and idling air flow volume to conduct Idle Speed Control (ISC). The ECM determines that the ISC system is malfunctioning if the following conditions apply: • The learned idling air flow volume remains at the maximum or minimum volume 5 times or more during a drive cycle. • While driving at 6 mph (10 km/h) or more, the actual engine idling speed varies from the target idling speed by between 100 rpm and 200 rpm, 5 times or more during a drive cycle. ES–251 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Example: If the actual idling speed varies from the target idling speed by more than 200 rpm* 5 times during a drive cycle, the ECM illuminates the MIL and sets the DTC. *: Threshold idling speed varies with engine load. Example: Idling Speed Learned Idling Air Volume Maximum ES Large Target Speed 0 Minimum Actual Idling Speed Small Time Time A082389E22 MONITOR STRATEGY Related DTCs P0505: Idle air control malfunction Required Sensors / Components (Main) ETCS Required Sensors / Components (Related) Engine coolant temperature sensor, Vehicle speed sensor, Crankshaft position sensor Frequency of Operation Continuous Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTC is not present None Engine Running TYPICAL MALFUNCTION THRESHOLDS Either of following conditions is met Condition 1 or 2 1. Frequency that both of following conditions (a) and (b) are met 5 times or more (a) Engine RPM - Target engine RPM Less than -100 rpm, or more than 150 rpm ES–252 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Vehicle condition Stop after vehicle was driven by 6.25 mph (10 km/h) or more 2. Frequency that both of following conditions (a) and (b) are met Once (a) Engine RPM - Target engine RPM Below -100 rpm, 150 rpm or more (b) IAC flow rate learning valve 1.3 L/sec. or less, or 8.5 L/sec. or more INSPECTION PROCEDURE ES HINT: • The following conditions may also cause DTC P0505 to be set: (a)The floor carpet overlapping slightly onto the accelerator pedal, causing the accelerator pedal to be slightly depressed and therefore the throttle valve position to be slightly open. (b)The accelerator pedal being not fully released. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0505) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0505 A P0505 and other DTCs B HINT: If any DTCs other than P0505 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–253 REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 CHECK THROTTLE VALVE (a) Check the throttle valve condition. OK: Normal NG OK REPLACE ECM REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY ES ES–20 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READINESS MONITOR DRIVE PATTERN 1. ES PURPOSE OF READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission related components, and indicate any detected abnormalities with DTCs (Diagnostic Trouble Codes). Since various components need to be monitored during different driving conditions, the OBD II system is designed to run separate monitoring programs called Readiness Monitors. • The intelligent tester's software must be version 9.0 or newer to view the Readiness Monitor status. To view the status, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. • When the Readiness Monitor status reads COMPL (complete), the necessary conditions have been met for running the performance tests for that Readiness Monitor. • A generic OBD II scan tool can also be used to view the Readiness Monitor status. HINT: Many Inspection and Maintenance (I/M) programs require a vehicle's Readiness Monitor status to show COMPL before beginning emission tests. The Readiness Monitor will be reset to INCMPL (incomplete) if: • The ECM has lost battery power or broken a fuse. • DTCs have been cleared. • The conditions for running the Readiness Monitor have not been met. If the Readiness Monitor status shows INCMPL, follow the appropriate Readiness Monitor Drive Pattern to change the status to COMPL. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: These drive patterns represent the fastest method of satisfying all conditions necessary to achieve complete status for each specific Readiness Monitor. In the event of a drive pattern being interrupted (possibly due to factors such as traffic conditions), the drive pattern can be resumed. In most cases, the Readiness Monitor will still achieve complete status upon completion of the drive pattern. To ensure completion of the Readiness Monitors, avoid sudden changes in vehicle load and speed (driving up and down hills and / or sudden acceleration). 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–21 Contents: Steps Section Titles 1 Catalyst Monitor (Active Air-Fuel Ratio Control Type) 2 EVAP System Monitor (Key-Off Type) 3 Air-Fuel Ratio (A/F) and Heated Oxygen (HO2) Sensor Monitors (Active Air-Fuel Ratio Control Type) 4 Air-Fuel Ratio (A/F) and Heated Oxygen (HO2) Sensor Heater Monitors (Front A/F and Rear HO2 Sensor Type) 2. CATALYST MONITOR (ACTIVE AIR-FUEL RATIO CONTROL TYPE) Vehicle Speed NOTICE: “F” Between 40 mph and 70 mph (64 km/h and 113 km/h) Idling Ignition Switch off This test will not be completed if the vehicle is driven under absolute constant speed condition such as with cruise control activated. “E” Warm up 10 minutes Time (Note: Even when vehicle stops during driving pattern, the test can be resumed) A079199E66 3. (a) Preconditions The monitor will not run unless: • The MIL is OFF (b) Drive Pattern (1) Connect an intelligent tester or OBDII scan tool to the DLC3 (Procedure "A"). (2) Turn the ignition switch on (IG) (Procedure "B"). (3) Turn the tester or scan tool ON (Procedure "C"). (4) Clear DTCs (where set) (See page ES-31) (Procedure "D"). (5) Start the engine and warm it up (Procedure "E"). (6) Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes (Procedure "F"). (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester or scan tool. (2) If the status does not switch to COMPL (complete), extend the driving time. EVAP SYSTEM MONITOR (KEY-OFF TYPE) (a) Preconditions The monitor will not run unless: • The fuel tank is less than 90% full. • The altitude is less than 8,000 ft (2,450 m). • The vehicle is stationary. • The engine coolant temperature is between 4.4°C and 35°C (40°F to 95°F). ES ES–22 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES 4. • The intake air temperature is between 4.4°C and 35°C (40°F to 95°F). • Vehicle was driven in the city area (or on freeway) for 10 minutes or more. (b) Monitor Conditions (1) Turn the ignition switch off and wait for 6 hours. HINT: Do not start the engine until checking Readiness Monitor status. If the engine is started, the step described above must be repeated. (c) Monitor Status (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on (IG). (3) Turn the tester or scan tool ON. (4) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), restart the engine, make sure that the preconditions have been met, and then perform the Monitor Conditions again. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR MONITORS (ACTIVE AIR-FUEL RATIO CONTROL TYPE) (a) Preconditions The monitor will not run unless: • 2 minutes or more have elapsed since the engine was started. • The Engine Coolant Temperature (ECT) is 75°C (167°F) or more. • Cumulative driving time at a vehicle speed of 30 mph (48 km/h) or more exceeds 6 minutes. • Air-fuel ratio feedback control is performed. • Fuel-cut control is performed for 8 seconds or more (for the Rear HO2 Sensor Monitor) (b) Drive Pattern for front A/F sensor and HO2 sensor (1) Connect an intelligent tester to the DLC3 (Procedure "A"). (2) Turn the ignition switch on (IG) (Procedure "B"). (3) Turn the tester ON (Procedure "C"). (4) Clear DTCs (See page ES-31) (Procedure "D"). (5) Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher (Procedure "E"). (6) Drive the vehicle at 38 mph (60 km/h) or more for at least 10 minutes (Procedure "F"). (7) Change the transmission to 2nd gear (Procedure "G"). (8) Accelerate the vehicle to 40 mph (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds (Procedure "H"). (9) Soon after performing procedure "H" above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control (Procedure "I"). ES–23 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (10)Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) (Procedure "J"). (11)Repeat procedures from "H" through "J" above at least 3 times in one driving cycle (Procedure "K"). (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and then perform procedures from "E" through "K" in Drive Pattern above. Monitor Drive Pattern Accelerator Pedal Released (Fuel-cut) Accelerator Pedal Depressed ECT: 75°C (167°F) or more At Least 3 times Vehicle Speed “F” 38 to 75 mph (60 to 120 km/h) Idling 40 mph (64 km/h) or more “E” “H” “I” “J” 6 mph (10 km/h) “G” Time 10 minutes or more Warming up 10 seconds or more 4 seconds or more G039003E08 5. AIR-FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR HEATER MONITORS (FRONT A/F AND REAR HO2 SENSOR TYPE) Vehicle Speed “G” 25 mph (40 km/h) Idling “F” Ignition Switch off 10 minutes or more 2 minutes or more A078886E21 ES ES–24 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) Preconditions The monitor will not run unless: • The MIL is OFF (b) Drive Pattern (1) Connect an intelligent tester to the DLC3 (Procedure "A"). (2) Turn the ignition switch on (IG) (Procedure "B"). (3) Turn the tester or scan tool ON (Procedure "C"). (4) Clear DTCs (where set) (See page ES-31) (Procedure "D"). (5) Start the engine (Procedure "E"). (6) Allow the engine to idle for 10 minutes or more (Procedure "F"). (7) Drive the vehicle at 25 mph (40 km/h) or more for at least 2 minutes (Procedure "G"). (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and repeat procedures through "E" to "G" described in the Drive Pattern above. ES–254 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P050A Cold Start Idle Air Control System Performance DTC P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed. In addition, the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly increase the catalyst temperature at cold start to reduce emissions. DTC No. DTC Detection Conditions Trouble Areas ES P050A P050B Accumulated intake air amount during 10 seconds of idling after cold start, less than threshold (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM Ignition timing retard value insufficient for 5 seconds or more during 10 seconds of P050A monitoring duration at cold start (2 trip detection logic) • • • • • • • Throttle body assembly Mass air flow meter Air induction system PCV hose connections VVT system Air cleaner filter element ECM MONITOR DESCRIPTION Ignition Timing Accumulated Intake Air Value P050B Detected Pass Detected (g) Advanced 5 or more P050A Detected Threshold Threshold Pass Detected 0 Retarded 10 3 (Second) 3 (Second) Time Time Engine Start 10 Engine Start A112588E01 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–255 The ECM monitors the intake air amount during idling and the ignition timing. When the Engine Coolant Temperature (ECT) is between -10°C and 50 °C (14°F and 122°F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start. The ECM also monitors the ignition timing at cold start, and judges it to be incorrect when it is advanced to the same value for a warm engine for 5 seconds or more of the 10 second monitoring period. Example: P050A is detected when all conditions below are met (2 trip detection logic). 1. The ECT is between -10°C and 50 °C (14°F and 122°F) when the engine starts. 2. The engine idles for 13 seconds after engine start. 3. The accumulated intake air amount is below the threshold. The ECM sets the DTC and illuminates the MIL 13 seconds after the engine is next started. NOTICE: When the negative battery terminal is disconnected during inspection or repairs, the ISC learning values are cleared. The ISC learning must be performed by warming up the engine and idling for 5 minutes with the ECT at 75°C (167°F) or more because DTCs cannot be detected with the ISC learning values cleared. MONITOR STRATEGY Related DTCs P050A: Idle speed control problem at cold P050B: Idle ignition timing problem at cold Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Related) Engine Coolant Temperature (ECT) sensor, Throttle position sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P050A: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) Time after shift position changed 1 second or more Atmospheric pressure 76 kPa (570 mmHg) or more P050B: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.875 mph (3 km/h) ES ES–256 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmospheric pressure 76 kPa (570 mmHg) or more TYPICAL MALFUNCTION THRESHOLDS P050A: Accumulated air flow amount (Neutral position) Varies with ECT (Example: Less than 42.5 g) Accumulated air flow amount (Driving position) Varies with ECT (Example: Less than 47.5 g) P050B: Accumulated time when ignition timing retard value insufficient 5 seconds or more INSPECTION PROCEDURE ES HINT: Read freeze frame data using an intelligent tester. Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data, from the time the malfunction occurred. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P050A AND/OR P050B) (a) (b) (c) (d) Connect an intelligent tester to the DLC3. Turn the ignition switch ON. Turn the tester ON. Select the following the menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed To P050A and/or P050B A P050A and/or P050B and other DTCs B HINT: If any DTCs other than P050A and P050B are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE USING INTELLIGENT TESTER (FUEL TRIM) HINT: Calculate the total fuel trim values to check the characteristic deviation of the mass air flow meter. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / SHORT FT #1 and LONG FT #1, or SHORT FT #2 and LONG FT #2. (e) Read the values displayed on the tester. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) ES–257 Add together the SHORT FT #1 and LONG FT #1, or SHORT FT #2 and LONG FT #2 values to obtain the total FUEL TRIM. OK: Total of SHORT FT #1 and LONG FT #1, or SHORT FT #2 and LONG FT #2 values is between -20 % and 20 %. OK Go to step 12 NG 3 PERFORM ACTIVE TEST USING INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 and VVT CTRL B2. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operations Specified Conditions OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 8 OK 4 CHECK PCV HOSE CONNECTIONS OK: PCV hose is connected correctly and is not damaged. NG Go to step 9 OK 5 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG OK Go to step 10 ES ES–258 6 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (a) Visually check that the air cleaner filter element is not excessively contaminated with dirt or oil. OK: Air cleaner filter element is not excessively contaminated with dirt or oil. NG Go to step 11 OK ES 7 REPLACE MASS AIR FLOW METER Replace the mass air flow meter. NEXT 8 9 10 CHECK AND REPAIR VVT SYSTEM NEXT Go to step 15 NEXT Go to step 15 REPAIR OR REPLACE PCV HOSE REPAIR OR REPLACE AIR INDUCTION SYSTEM NEXT 11 Go to step 15 REPLACE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY NEXT 12 Go to step 15 Go to step 15 CHECK THROTTLE VALVE (a) Check for deposits around the throttle valve and throttle valve condition. OK: No deposits around throttle valve and throttle valve moves smoothly. NG OK Go to step 14 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 ES–259 REPLACE ECM Replace the ECM (See page ES-434). NEXT 14 REPAIR OR REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY NEXT 15 Go to step 15 Go to step 15 CHECK WHETHER DTC OUTPUT RECURS (DTC P050A AND/OR P050B) NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data). (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Clear DTCs (See page ES-31). (e) Switch the ECM from normal mode to check mode using the tester (See page ES-35). (f) Start the engine to idle for a minute. OK: Stable fast idling. (g) Read DTCs. OK: No DTC output. NEXT END ES ES–260 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0560 System Voltage MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is in the off position. This power allows the ECM to store data such as DTC history, freeze frame data and fuel trim values. If the battery voltage falls below a minimum level, these memories are cleared and the ECM determines that there is a malfunction in the power supply circuit. When the engine is next started, the ECM illuminates the MIL and sets the DTC. DTC No. P0560 ES DTC Detection Conditions Open in ECM back up power source circuit (1 trip detection logic) Trouble Areas • • • Open in back up power source circuit EFI fuse ECM HINT: If DTC P0560 is set, the ECM does not store other DTCs. MONITOR STRATEGY Related DTCs P0560: ECM system voltage Required Sensors / Components (Main) ECM Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate (MIL will illuminate after next engine start) Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS Battery voltage Less than 3.5 V ES–261 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Engine Room R/B 2 1 ECM EFI 2 2 12 IC4 L L 3 E8 BATT ES BR 1 E6 E1 B Battery EE G035643E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–262 1 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FUSE (EFI FUSE) Engine Room R/B: EFI Fuse (a) Remove the EFI fuse from the engine room R/B and J/B. (b) Measure the resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI fuse. NG ES CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE, AND REPLACE FUSE A072881E02 OK 2 INSPECT ECM (BATT VOLTAGE) (a) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage ECM: E6 E8 NG E1 (-) BATT (+) A131509E44 OK REPLACE ECM Tester Connections Specified Conditions BATT (E8-3) - E1 (E6-1) 9 to 14 V Go to step 3 ES–263 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (ECM - EFI FUSE, EFI FUSE - BATTERY) ECM: E8 (a) Check the harness and the connector between the EFI fuse and ECM. (1) Remove the EFI fuse from the engine room R/B. (2) Disconnect the E8 ECM connector. (3) Measure the resistance. Standard resistance (Check for open) BATT Tester Connections Specified Conditions EFI fuse (2) - BATT (E8-3) Below 1 Ω Standard resistance (Check for short) Tester Connections Specified Conditions EFI fuse (2) or BATT (E8-3) - Body ground 10 kΩ or higher Engine Room R/B: EFI Fuse A138724E01 (4) Reconnect the ECM connector. (5) Reinstall the EFI fuse. (b) Check the harness and the connector between the EFI fuse and battery. (1) Remove the EFI fuse from the engine room R/B. (2) Disconnect the negative battery terminal. (3) Measure the resistance. Standard resistance (Check for open) Tester Connections Specified Conditions Battery positive terminal - EFI fuse (1) Below 1 Ω Standard resistance (Check for short) Tester Connections Specified Conditions Battery positive terminal or EFI fuse (1) - Body ground 10 kΩ or higher (4) Reconnect the negative battery cable. (5) Reinstall the EFI No. 1 fuse. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT BATTERY (a) Check that the battery is not depleted. NG REPLACE BATTERY OK CHECK AND REPLACE ENGINE ROOM RELAY BLOCK ES ES–402 1GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR VVT SENSOR 1GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (76, 66 in.*lbf) V-BANK COVER ES 8.0 (82, 71 in.*lbf) VENTILATION HOSE NO.2 AIR CLEANER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A119786E01 1GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–403 ES 8.0 (82, 71 in.*lbf) VVT SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque A119791E01 ES–264 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Internal Control Module Random Access Memory (RAM) Error P0604 MONITOR DESCRIPTION The ECM continuously monitors its internal memory status. This self-check ensures that the ECM functioning properly. It is diagnosed by internal "mirroring" of the main CPU and sub CPU to detect the Random Access Memory (RAM) errors. If outputs from these CPUs are different and deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. DTC No. P0604 ES DTC Detection Conditions ECM RAM errors) Trouble Areas ECM MONITOR STRATEGY Related DTCs None Required Sensors / Components (Main) ECM Required Sensors / Components (Related) None Frequency of Operation Continuous Duration 16 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS None - TYPICAL MALFUNCTION THRESHOLDS RAM mirror check Fail INSPECTION PROCEDURE 1 REPLACE ECM (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the battery negative terminal and wait for 1 minutes. (d) Connect the battery negative terminal. (e) Turn the ignition switch ON. (f) Check DTC. OK: P0604 is not present. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–265 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0606 ECM / PCM Processor MONITOR DESCRIPTION The ECM continuously monitors its internal processors (CPUs), A/F sensor transistors and heated oxygen sensor (HO2S) transistors. This self-check ensures that the ECM functioning properly. These are diagnosed by internal "mirroring" of the main and sub CPUs to detect the processors error. If outputs from the processors deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. DTC No. P0606 DTC Setting Condition • • • ECM CPUs malfunction A/F sensor transistors malfunction HO2S transistors malfunction Trouble Area • • • Exhaust gas leak HO2S ECM ES MONITOR STRATEGY Related DTCs None Required sensors/Components (main) ECM Required sensors/Components (sub) APP sensor, TP sensor, Brake switch, Cruise control, A/F sensor, HO2S Frequency of operation Continuous Duration 60 seconds MIL operation immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Engine Running Estimated A/F sensor temperature 450 - 800°C (842 - 1,472°F) Estimated HO2S temperature 450 - 800°C (842 - 1,472°F) TYPICAL MALFUNCTION THRESHOLDS Difference of main APP and sub APP 0.3 V or more Difference of main TP and sub TP 0.3 V or more Difference of main brake switch signal and sub brake switch signal Different Cruise control Fail A/F sensor transistors Fail HO2S transistors Fail INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data, from the time the malfunction occurred. 1 CHECK FOR EXHAUST GAS LEAK (a) Allow the engine to idle. (b) Check for exhaust gas leak around the HO2S. OK: No leak from the HO2S. ES–266 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR LEAK OK 2 CHECK HEATED OXYGEN SENSOR (a) Warm up the engine. Fuel-Trim and Rear HO2S Voltage Cross-reference Fuel-Trim ES 25% -12.5% HO2S Voltage 0.8 V 0.2 V A144391E01 (b) Allow the engine to idle. (c) Select the tester menus: ENHANCED OBDII, ACTIVE TEST AND A/F CONTROL. (d) Check the O2S B1S2 (O2S B2S2) values when the A/F CONTROL is -12.5% (Lean fuel-trim). (e) Check the O2S B1S2 (O2S B2S2) values when the A/F CONTROL is 25% (Rich fuel-trim). Standard A/F CONTROL O2S B1S2 (O2S B2S2) -12.5% Less than 0.2 V 25% More than 0.8 V NG REPLACE HEATED OXYGEN SENSOR OK 3 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the battery negative terminal and wait for 1 minute. (d) Connect the battery negative terminal. ES–267 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Start the engine. Monitor Drive Pattern for P0606 Engine Coolant Temperature: 75°C (167°F) or more km/h (mph) 5 Minutes 80 (50) 60 (35) ES Time 0 A144392E01 (f) Perform the drive pattern. (1) Warm up the engine. (2) Accelerate the vehicle until 80 km/h (50 mph) and stop the vehicle. (3) Drive the vehicle by 60 to 80 km/h (35 to 50 mph) for 5 minutes or more. (g) Check DTC. OK: P0606 is not present. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–268 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0607 Control Module Performance MONITOR DESCRIPTION The ECM continuously monitors its main and sub CPUs. This self-check ensures that the ECM functioning properly. If output from the CPUs are different and deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. The ECM also monitors the cruise control cancel circuit. If this circuit malfunctions, the ECM will set a DTC immediately (MIL is not illuminated). DTC No. P0607 ES DTC Detection Conditions • • • Trouble Area ECM main CPU error ECM sub CPU error Cruise control cancel circuit malfunction ECM MONITOR STRATEGY Related DTCs None Required sensors / components (main) ECM Required sensors / components (sub) Throttle actuator (throttle body) Frequency of operation Once per driving cycle Duration 16 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS CPU reset Occurred TYPICAL MALFUNCTION THRESHOLDS When either condition below is met: Condition 1 or 2 1. When all conditions below are met: - - CPU reset 1 time or more - Learned TP - Learned APP 0.4 V or more - Electronic throttle actuator OFF 2. CPU reset 2 time or more INSPECTION PROCEDURE 1 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the battery negative terminal and wait for 1 minute. (d) Connect the battery negative terminal. (e) Turn the ignition switch ON. (f) Check DTC. OK: P0607 is not present. NG REPLACE ECM 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–269 OK CHECK FOR INTERMITTENT PROBLEMS ES ES–270 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0617 Starter Relay Circuit High MONITOR DESCRIPTION While the engine is being cranked, the positive battery voltage is applied to terminal STA of the ECM. If the ECM detects the Starter Control (STA) signal while the vehicle is being driven, it determines that there is a malfunction in the STA circuit. The ECM then illuminates the MIL and sets the DTC. This monitor runs when the vehicle is driven at 12.4 mph (20 km/h) for over 20 seconds. DTC No. P0617 ES DTC Detection Conditions When conditions (a), (b) and (c) met, when positive (+B) battery voltage 10.5 V or more is applied to ECM for 20 seconds (1 trip detection logic): (a) Vehicle speed more than 12.43 mph (20 km/h) (b) Engine speed more than 1,000 rpm (c) STA signal ON Trouble Areas • • • • Park/Neutral Position (PNP) switch Starter relay circuit Ignition switch ECM MONITOR STRATEGY Related DTCs P0617: Starter signal Required Sensors / Components (Main) STARTER relay, PNP switch Required Sensors / Components (Related) Vehicle Speed Sensor, Crankshaft Position sensor Frequency of Operation Continuous Duration 20 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Battery voltage 10.5 V or more Vehicle speed 12.43 mph (20 km/h) or more Engine speed 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON ES–271 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 8 STAR/ E5 NSW 11 E6 STA P P1 Park/Neutral Position SW B-Y B J27 J/C B-Y B 5 B P L-Y 4 IM2 B-Y 11 IM1 12 E6 L-Y STSW B-Y Driver Side J/B N 4 Center J/B 38 IC4 P F 3E F 3E 2 1K STA No. 2 8 1K ACC ES 3 1D G-B 5 1D W-G Engine Room R/B P From A/C System ACC CUT Relay 2 To EFI Fuse 2 2 4 3 2 2 1 16 IC3 W-G 17 E8 W-G ACCR I18 Ignition SW AM1 ALT 2 1 B 2 B 1 2 2 1 2 W-L 2 AM1 ACC 3 2 5 B-L(*1) W (*2) R 2 R 2 1 Y R 7 AM2 ST2 8 2 IC4 B-Y B J3 W-B 4 EA2 2 STA Relay 3 2 Battery 2 AM2 2 Y-G 2 J/C G B-Y G J35 J/C B J3 1 S3 1 S2 Starter W-B *1: Cold Area Spec. EB *2: Except Cold Area Spec. G032693E01 ES–272 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If the engine will not crank, proceed to the problem symptoms table (See page ES-21). • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) ES (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on and START positions. OK Ignition Switch Positions STARTER SIG ON OFF START ON OK REPLACE ECM NG 2 INSPECT PARK/NEUTRAL POSITION SWITCH (a) Inspect the Park/Neutral Position (PNP) switch. (1) Disconnect the P1 PNP switch connector. (2) Measure the resistance when the transmission gear selector lever is moved to each position. Standard resistance Component Side: P1 Gear Selector Lever Positions Tester Connections Specified Conditions P 2 - 6, 4 - 5 Below 1 Ω PNP Switch A093221E13 R 1-2 Below 1 Ω N 2 - 9, 4 - 5 Below 1 Ω D 2-7 Below 1 Ω 2 2-3 Below 1 Ω L 2-8 Below 1 Ω (3) Reconnect the PNP switch connector. NG OK REPLACE PARK/NEUTRAL POSITION SWITCH ES–273 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on and START positions. OK Ignition Switch Positions STARTER SIG ON OFF START ON OK ES SYSTEM OK NG 4 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY Component Side: Ignition Switch I18 (a) Disconnect the I18 ignition switch connector. (b) Check the resistance. Standard resistance Ignition Switch Positions Tester Conditions Specified Condition LOCK All Terminals 10 kΩ or higher ACC 2-4 Below 1 Ω ON 1-2, 1-4, 5-6 Below 1 Ω START 1-3, 1-4, 3-4, 5-6, 5-7, 6-7 Below 1 Ω A056879E39 (c) Reconnect the ignition switch connector. NG REPLACE IGNITION OR STARTER SWITCH ASSEMBLY OK 5 READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STARTER SIG. (d) Check the value displayed on the tester when the ignition switch is turned on and START positions. OK Ignition Switch Positions STARTER SIG ON OFF START ON OK SYSTEM OK ES–274 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–275 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0630 VIN not Programmed or Mismatch - ECM / PCM DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is not accurate. Input the VIN with the intelligent tester. DTC No. P0630 DTC Detection Conditions • • VIN not stored in ECM Input VIN in ECM not accurate Trouble Areas ECM MONITOR STRATEGY Related DTCs P0630: VIN not programmed Required Sensors / Components (Main) ECM Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None ES TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Battery voltage 8 V or more Ignition switch ON Ignition switch OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE 1 READ CURRENT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0630 A P0630 and other DTCs B If any DTCs other than P0630 are output, troubleshoot those DTCs first. ES–276 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: If P0630 is set, the VIN must be input to the ECM using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are set, check them first. B GO TO DTC CHART A 2 INPUT VIN WITH INTELLIGENT TESTER ES HINT: Refer to "REGISTRATION" (See page ES-9). NEXT 3 READ CURRENT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTC again. Result: DTC is not output (P0630). NG OK END REPLACE ECM ES–277 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0657 Actuator Supply Voltage Circuit / Open MONITOR DESCRIPTION The ECM monitors the output voltage to the throttle actuator. This self-check ensures that the ECM functioning properly. The output voltage usually is 0 V when the ignition switch is turned OFF. If the output voltage is higher than 7 volts when the ignition switch is turned OFF, the ECM will illuminate the MIL and set a DTC when the ignition switch is turned ON. DTC P0657 DTC Detection Condition Trouble Area Throttle actuator power supply error ECM MONITOR STRATEGY ES Related DTCs ES None Required sensors / components (main) ECM Required sensors / components (sub) Throttle actuator Frequency of operation Once per driving cycle Duration Within 1 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Ignition switch From ON to OFF TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage 7 V or more INSPECTION PROCEDURE 1 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the battery negative terminal and wait for 1 minute. (d) Connect the battery terminal. (e) Turn the ignition switch ON for 10 seconds. (f) Turn the ignition switch OFF. (g) Turn the ignition switch ON. (h) Check DTC. OK: P0657 is not present. NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–278 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2102 Throttle Actuator Control Motor Circuit Low DTC P2103 Throttle Actuator Control Motor Circuit High DESCRIPTION ES The throttle actuator is operated by the ECM and opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body. The TP sensor provides feedback to the ECM. This feedback allows the ECM to appropriately control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. DTC Detection Conditions Trouble Areas P2102 Conditions (a) and (b) continue for 2.0 seconds (1 trip detection logic): (a) Throttle actuator duty ratio 80% or more (b) Throttle actuator current is 0.5 A or less • • • Open in throttle actuator circuit Throttle actuator ECM P2103 Either of following conditions met: • Hybrid IC diagnosis signal fail • Hybrid IC current limiter port fail • • • • • Short in throttle actuator circuit Throttle actuator Throttle valve Throttle body ECM MONITOR DESCRIPTION The ECM monitors the electrical current through the electronic actuator, and detects malfunctions and open circuits in the throttle actuator based on this value. If the current is outside the standard range, the ECM determines that there is a malfunction in the throttle actuator. In addition, if the throttle valve does not function properly (for example, stuck on), the ECM determines that there is a malfunction. The ECM then illuminates the MIL and sets a DTC. Example: When the electrical current is more than 10 A, or less than 0.5 A and the throttle actuator duty ratio exceeds 80%, the ECM interprets this as the current being outside the standard range, and illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the engine is quickly revved to a high rpm several times after the engine has idled for 5 seconds after engine start. MONITOR STRATEGY Related DTCs P2102: Throttle actuator control motor current (low current) P2103: Throttle actuator control motor current (high current) Required Sensors / Components (Main) Throttle actuator (throttle body) Required Sensors / Components (Related) - Frequency of Operation Continuous Duration P2102: 2 seconds P2103: 0.6 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–279 P2102: Throttle motor ON Duty-cycle ratio to open throttle actuator 80 % or more Throttle actuator power supply 8 V or more Current motor current - Motor current at 0.016 sec. before Less than 0.2 A P2103: Throttle motor ON Either of the following conditions is met: Condition 1 or 2 1. Throttle actuator power supply 8 V or more 2. Throttle actuator power ON Battery voltage 8 V or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current Less than 0.5 A (when motor drive duty 80 % or more) P2103: Either of the following conditions is met Condition 1 or 2 1. Hybrid IC diagnosis signal Fail 2. Hybrid IC current limiter port Fail FAIL-SAFE When either of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned to off. ES ES–280 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM T2 Throttle Control Motor (Built in Throttle w/ Motor Body) ECM (Shielded) M+ 2 P 5 M+ E4 1 L 4 ME4 M- ES 17 E4 GE01 A087825E09 INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • The throttle actuator current (THROTTLE MOT) and the throttle actuator duty ratio (THROTTLE OPN / THROTTLE CLS) can be read using the intelligent tester. However the ECM shuts off the throttle actuator current when the ETCS malfunctions. 1 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (RESISTANCE OF THROTTLE CONTROL MOTOR) (a) Disconnect the T2 throttle with motor body connector. (b) Measure the resistance between the terminals of the throttle control motor. Standard resistance Component Side: T2 Throttle with Motor Body Assembly Tester Connections Specified Conditions M+ (T2-2) - M- (T2-1) 0.3 to 100 Ω at 20°C (68°F) (c) Reconnect the throttle with motor body connector. M+ MA059778E38 OK NG REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY ES–281 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (THROTTLE CONTROL MOTOR - ECM) Wire Harness Side: Throttle with Motor Body Connector T2 1 M- M+ 2 3 4 5 (a) Disconnect the T2 throttle with motor body connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) 6 Tester Connections Specified Conditions M+ (T2-2) - M+ (E4-5) Below 1 Ω M- (T2-1) - M- (E4-4) Below 1 Ω Standard resistance (Check for short) Front View ECM: E4 Tester Connections Specified Conditions M+ (T2-2) or M+ (E4-5) - Body ground 10 kΩ or higher M- (T2-1) or M- (E4-4) - Body ground 10 kΩ or higher (d) Reconnect the throttle with motor body connector. (e) Reconnect the ECM connector. NG M+ REPAIR OR REPLACE HARNESS OR CONNECTOR MA114631E03 OK 3 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) Check for foreign objects between the throttle valve and the housing. OK: Normal NG REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY OK 4 INSPECT THROTTLE VALVE (a) Check if the throttle valve opens and closes smoothly. OK: The throttle valve opens and closes smoothly. NG OK REPLACE ECM REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY ES ES–282 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2111 Throttle Actuator Control System - Stuck Open DTC P2112 Throttle Actuator Control System - Stuck Closed DESCRIPTION ES The throttle actuator is operated by the ECM, and opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the Throttle Position (TP) sensor, which is mounted on the throttle body. The TP sensor provides feedback to the ECM in order that it can control the throttle actuator, and the throttle valve, appropriately in response to driver inputs. HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. DTC No. DTC Detection Conditions Trouble Areas P2111 ECM signals throttle actuator to close, but stuck (1 trip detection logic) • • • Throttle actuator Throttle body Throttle valve P2112 ECM signals throttle actuator to open, but stuck (1 trip detection logic) • • • Throttle actuator Throttle body Throttle valve MONITOR DESCRIPTION The ECM determines that there is a malfunction in the ETCS when the throttle valve remains at the fixed angle despite a high drive current from the ECM. The ECM illuminates the MIL and sets a DTC. If the malfunction is not repaired successfully, a DTC is set when the accelerator pedal is fully depressed and released quickly (to fully open and close the throttle valve) after the engine is next started. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required Sensors / Components (Main) Throttle actuator (throttle body) Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None P2111: System guard* ON Throttle actuator current 2 A or more Duty cycle to close throttle 80 % or more P2112: System guard* ON Throttle actuator current 2 A or more Duty cycle to open throttle 80 % or more ES–283 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM *: System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS P2111: TP sensor voltage change for 0.016 seconds Less than 0.1 V for 0.5 seconds or more ES P2112: TP sensor voltage change for 0.016 seconds Less than 0.1 V for 0.5 seconds or more FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-274). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2111 OR P2112) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B ES–284 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If any DTCs other than P2111 or P2112 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: Throttle valve is not contaminated with foreign objects and moves smoothly. ES NG REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P2111 OR P2112) (a) (b) (c) (d) (e) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Clear DTCs (See page ES-31). Start the engine, and fully depress and release the accelerator pedal quickly (to fully open and close the throttle valve). (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read DTCs. Result Display (DTC Output) Proceed to No DTC A P2111 or P2112 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–285 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle Actuator Control Motor Current Range / Performance P2118 DESCRIPTION The ETCS (Electronic Throttle Control System) has a dedicated power supply circuit. The voltage (+BM) is monitored and when it is low (less than 4 V), the ECM determines that there is a malfunction in the ETCS and cuts off the current to the throttle actuator. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the throttle actuator is cut. If repairs are made and the system returns to normal, turn the ignition switch off. The ECM then allows the current to flow to the throttle actuator so that it can be restarted. HINT: The ETCS does not use a throttle cable. ECM ETCS Fuse From Battery +BM Throttle Control Motor +M Motor Control Circuit -M ME01 A085832E19 DTC No. P2118 DTC Detection Conditions Open in ETCS power source (+BM) circuit (1 trip detection logic) Trouble Areas • • • Open in ETCS power source circuit ETCS fuse ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the throttle actuator. When the power supply voltage (+BM) drops below 4 V for 0.8 seconds or more, the ECM interprets this as an open in the power supply circuit (+BM). The ECM illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, a DTC is set 5 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P2118: Throttle actuator motor power supply line range check (Low voltage) Required Sensors / Components (Main) Throttle actuator, throttle valve, ETCS fuse Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.8 seconds ES ES–286 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Electronic throttle actuator power ON Battery voltage More than 8 V TYPICAL MALFUNCTION THRESHOLDS ES Throttle actuator power supply voltage Less than 4 V COMPONENT OPERATING RANGE Throttle actuator power supply voltage 11 to 14 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM ECM GR 13 IC4 GR 7 E8 +BM 2 2 ETCS Engine Room R/B 1 2 B Battery A074728E03 ES–287 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK FUSE (ETCS FUSE) Engine Room R/B: ETCS Fuse (a) Remove the ETCS fuse from the engine room R/B. (b) Check the ETCS fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the ETCS fuse. NG CHECK FOR SHORTS IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE A072882E01 OK 2 INSPECT ECM (+BM VOLTAGE) (a) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage ECM: E6 E8 OK E1 (-) +BM (+) A131509E47 NG Tester Connections Specified Conditions +BM (E8-7) - E1 (E6-1) 9 to 14 V CHECK FOR INTERMITTENT PROBLEMS ES ES–288 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) Engine Room R/B: ETCS Fuse (a) Check the harness and connector between the ETCS fuse and ECM. (1) Remove the ETCS fuse from the engine room R/B. (2) Disconnect the E8 ECM connector. (3) Check the resistance. Standard resistance (Check for open) Tester Connections Specified Conditions ETCS fuse (2) - +BM (E8-7) Below 1 Ω Standard resistance (Check for short) ES Tester Connections Specified Conditions ETCS fuse (2) or +BM (E8-7) - Body ground 10 kΩ or higher ECM: E8 +BM (4) Reconnect the ECM connector. (b) Check the harness and connector between the ETCS fuse and positive battery cable. (1) Disconnect the negative battery cable. (2) Check the resistance. Standard resistance (Check for open) A138725E01 Tester Connections Specified Conditions Positive battery cable - ETCS fuse (1) Below 1 Ω Standard resistance (Check for short) Tester Connections Specified Conditions Positive battery cable or ETCS fuse (1) - Body ground 10 kΩ or higher (3) Reinstall the ETCS fuse. (4) Reconnect the negative battery cable. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–289 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle Actuator Control Throttle Body Range / Performance P2119 DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of the throttle actuator, Throttle Position (TP) sensor, Accelerator Pedal Position (APP) sensor, and ECM. The ECM operates the throttle actuator to regulate the throttle valve in response to driver inputs. The TP sensor detects the opening angle of the throttle valve, and provides the ECM with feedback so that the throttle valve can be appropriately controlled by the ECM. DTC No. P2119 DTC Detection Conditions Throttle valve opening angle continues to vary greatly from target opening angle (1 trip detection logic) Trouble Areas • • ETCS ECM MONITOR DESCRIPTION The ECM determines the actual opening angle of the throttle valve from the TP sensor signal. The actual opening angle is compared to the target opening angle commanded by the ECM. If the difference between these two values is outside the standard range, the ECM interprets this as a malfunction in the ETCS. The ECM then illuminates the MIL and sets the DTC. If the malfunction is not repaired successfully, the DTC is set when the accelerator pedal is quickly released (to close the throttle valve) after the engine speed reaches 5,000 rpm by the accelerator pedal being fully depressed (fully open the throttle valve). MONITOR STRATEGY Related DTCs P2119: Electronic throttle control system failure Required Sensors / Components (Main) Throttle actuator (throttle body) Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None System guard* ON *System guard is ON when following conditions are set: - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is set: Condition 1 or 2 1. Commanded closed throttle position - current closed throttle position 0.3 V or more for 1 second 2. Commanded open throttle position - current open throttle position 0.3 V or more for 0.6 second ES ES–290 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When any of these DTCs, as well as other DTCs relating to ETCS (Electronic Throttle Control System) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 6° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned off. WIRING DIAGRAM Refer to DTC P2102 (See page ES-274). ES INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2119) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2119 A P2119 and other DTCs B HINT: If any DTCs other than P2119 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK WHETHER DTC OUTPUT RECURS (DTC P2119) (a) Connect the intelligent tester to the DLC3 (Procedure "A"). (b) Turn the ignition switch on (Procedure "B"). (c) Turn the tester on (Procedure "C"). (d) Clear DTCs (See page ES-31) (Procedure "D"). (e) Allow the engine to idle for 15 seconds (Procedure "E"). 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–291 CAUTION: Exercise extreme care and take precautions at procedure "F" and "G" below. Failure to do so may result in the vehicle unexpectedly rolling away. (f) Securely apply the parking brake and move the gear selector lever to the D position (Procedure "F"). (g) While depressing the brake pedal securely, fully depress the accelerator pedal for 5 seconds (Procedure "G"). (h) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (Procedure "H"). (i) Read DTCs (Procedure "I"). HINT: The voltage output of the throttle position sensor can be checked during procedure "G" using the intelligent tester. Variations in the voltage output indicate that the throttle actuator is in operation. To check the voltage output using the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / THROTTLE POS #1. OK: No DTC output. NG OK NORMAL REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY ES ES–25 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE HINT: When a malfunction is not confirmed by a DTC (Diagnostic Trouble Code) check and the cause of problem cannot be identified through a basic inspection, troubleshoot according to the priority order indicated in the table below. SFI SYSTEM Symptom Suspected Area 1. Immobilizer system Engine does not crank (Does not start) Engine cranks normally but difficult to start Difficult to start with cold engine Difficult to start with warm engine High engine idling speed (Poor idling) Low engine idling speed (Poor idling) ST-13 3. Starter (for Cold Area) ST-30 ST-37 1. ECM power source circuit ES-372 2. Fuel pump control circuit ES-381 3. VC output circuit ES-377 4. ECM ES-434 1. Fuel pump control circuit ES-381 2. Compression EM-2 1. Starter signal circuit ES-264 2. Fuel pump control circuit ES-381 3. Spark plug IG-1 4. Ignition system ES-196 5. Injector ES-165 1. Starter signal circuit ES-264 2. Fuel pump control circuit ES-381 3. Spark plug IG-1 4. Ignition system ES-196 5. Injector ES-165 1. A/C signal circuit (compressor circuit) AC-82 2. ECM power source circuit ES-372 3. Electronic throttle control system ES-112 4. Air induction system - 5. PCV hose - 1. A/C signal circuit (compressor circuit) AC-82 2. Fuel pump control circuit ES-381 3. Electronic throttle control system ES-112 4. Air induction system 5. PCV hose 1. Compression Rough idling (Poor idling) EI-2 2. Starter (for Standard) 4. STARTER relay No initial combustion (Does not start) See page EM-2 2. Fuel pump control circuit ES-381 3. Electronic throttle control system ES-112 4. Air induction system - 5. PCV hose - ES ES–26 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symptom Suspected Area ES-372 2. Fuel pump control circuit ES-381 3. Spark plug Hunting (Poor idling) 4. Ignition system ES-196 ES-165 6. Electronic throttle control system ES-112 8. PCV hose 1. Fuel pump control circuit ES Engine stalls soon after starting Engine stalls during A/C operation Unable/difficult to refuel ES-381 2. A/T faulty (A750F) AT-9 2. A/T faulty (A750E) AT-9 3. Spark plug 4. Ignition system Surging (Poor driveability) IG-1 5. Injector 7. Air induction system Hesitation/Poor acceleration (Poor driveability) See page 1. ECM power source circuit IG-1 ES-196 5. Injector ES-165 1. Fuel pump control circuit ES-381 2. Spark plug 3. Ignition system IG-1 ES-196 4. Injector ES-165 1. Fuel pump control circuit ES-381 2. Spark plug IG-1 3. Ignition system ES-196 4. Injector ES-165 1. A/C signal circuit (Compressor circuit) AC-82 2. ECM ES-434 Refueling valve (canister) - ES–292 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DTC P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation HINT: These DTCs relate to the Accelerator Pedal Position (APP) sensor. DESCRIPTION HINT: This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA (main) and VPA2 (sub). This sensor is a non-contact type, and uses Hall-effect elements, in order to yield accurate signals, even in extreme driving conditions, such as at high speeds as well as very low speeds. The voltage, which is applied to terminals VPA and VPA2 of the ECM, varies between 0 V and 5 V in proportion to the operating angle of the accelerator pedal (throttle valve). A signal from VPA indicates the actual accelerator pedal opening angle (throttle valve opening angle) and is used for engine control. A signal from VPA2 conveys the status of the VPA circuit and is used to check the APP sensor itself. The ECM monitors the actual accelerator pedal opening angle (throttle valve opening angle) through the signals from VPA and VPA2, and controls the throttle actuator according to these signals. ES–293 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Accelerator Pedal Position Sensor Output Voltage (V) Accelerator Pedal Position Sensor *1 *2 ECM 5 Magnet IC No. 1 VPA 3.4 to 5.0 2.6 to 4.5 EPA ES 1.6 VCPA 0.8 VPA2 EPA2 IC No. 2 25 0 VCP2 Usable Range Accelerator Pedal Turning Angle (deg) Magnet *1: Accelerator Pedal Fully Released *2: Accelerator Pedal Fully Depressed A019803E29 DTC No. DTC Detection Conditions Trouble Areas P2120 VPA fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • Accelerator Pedal Position (APP) sensor ECM P2122 VPA 0.4 V or less for 0.5 seconds or more when accelerator pedal is fully released (1 trip detection logic) • • • • APP sensor Open in VCP1 circuit Open or ground short in VPA circuit ECM P2123 VPA 4.8 V or more for 2.0 seconds or more (1 trip detection logic) • • • APP sensor Open in EPA circuit ECM P2125 VPA2 fluctuates rapidly beyond upper and lower malfunction thresholds for 0.5 seconds or more (1 trip detection logic) • • APP sensor ECM P2127 VPA2 is 1.2 V or less for 0.5 seconds or more when accelerator pedal is fully released (1 trip detection logic) • • • • APP sensor Open in VCP2 circuit Open or ground short in VPA2 circuit ECM P2128 Conditions (a) and (b) continue for 2.0 seconds or more (1 trip detection logic): (a) VPA2 is 4.8 V or more (b) VPA between 0.4 V and 3.45 V • • • APP sensor Open in EPA2 circuit ECM ES–294 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions P2138 Condition (a) or (b) continues for 2.0 seconds or more (1 trip detection logic): (a) Difference between VPA and VPA2 is 0.02 V or less (b) VPA is 0.4 V or less and VPA2 is 1.2 V or less Trouble Areas • • • Short between VPA and VPA2 circuits APP sensor ECM HINT: When any of these DTCs are set, check the APP sensor voltage by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1 and ACCEL POS #2. Trouble Areas ES ACCEL POS #1 When AP Released ACCEL POS #2 When AP Released ACCEL POS #1 When AP Depressed ACCEL POS #2 When AP Depressed VCP circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open or ground short in VPA circuit 0 to 0.2 V 1.2 to 2.0 V 0 to 0.2 V 3.4 to 5.0 V Open or ground short in VPA2 circuit 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V EPA circuit open 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V Normal condition 0.5 to 1.1 V 1.2 to 2.0 V 2.6 to 4.5 V 3.4 to 5.0 V HINT: • Accelerator pedal positions are expressed as voltages. • AP denotes for Accelerator Pedal. MONITOR DESCRIPTION When either of the voltage outputs of VPA or VPA2 deviates from the standard range, or the difference between the voltage outputs of the 2 sensor circuits is less than the threshold, the ECM determines that there is a malfunction in the APP sensor. The ECM then illuminates the MIL and sets a DTC. Example: When the voltage output of VPA drops below 0.2 V for more than 0.5 seconds when the accelerator pedal is fully depressed, DTC P2122 is set. If the malfunction is not repaired successfully, a DTC is set 2 seconds after the engine is next started. MONITOR STRATEGY Related DTCs P2120: Accelerator position sensor 1 (VPA) range check (Fluttering) P2122: Accelerator position sensor 1 (VPA) range check (Low voltage) P2123: Accelerator position sensor 1 (VPA) range check (High voltage) P2125: Accelerator position sensor 2 (VPA2) range check (Fluttering) P2127: Accelerator position sensor 2 (VPA2) range check (Low voltage) P2128: Accelerator position sensor 2 (VPA2) range check (High voltage) P2138: Accelerator position sensor correlation range check Required Sensors / Components (Main) Accelerator position sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds: P2120, P2122, P2125 and P2127 2.0 seconds: P2123, P2128 and P2138 MIL Operation Immediate Sequence Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Ignition switch ON Throttle control motor power ON 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–295 TYPICAL MALFUNCTION THRESHOLDS P2120: Either of the following conditions is met Condition 1 or 2 1. VPA voltage when VPA2 is 0.04 V or more 0.4 V or less 2. VPA voltage 4.8 or more P2122: VPA1 voltage when VPA2 is 0.04 V or more 0.4 V or less P2123: VPA1 voltage 4.8 V or more P2125: Either of the following conditions is met Condition 1 or 2 1. VPA2 voltage when VPA is 0.04 V or more 1.2 V or less 2. VPA2 voltage when VPA is 0.4 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA1 is 0.04 V or more 1.2 V or less P2128: VPA2 voltage when VPA1 is 0.4 to 3.45 V 4.8 V or more P2138: Either of the following conditions is met: Condition 1 or 2 1. Difference between VPA 1 and VPA2 voltage 0.02 V or less 2. Both of the following conditions are met: Condition (a) and (b) (a) VPA1 voltage 0.4 V or less (b) VPA2 voltage 1.2 V or less FAIL-SAFE When any of DTCs P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 are set, the ECM enters fail-safe mode. If either of the 2 sensor circuit malfunctions, the ECM uses the remaining circuit to calculate the accelerator pedal position to allow the vehicle to continue driving. If both of the circuits malfunction, the ECM regards the accelerator pedal as being released. As a result, the throttle valve is closed and the engine idles. Fail-safe mode continues until a pass condition is detected, and the ignition switch is turned off. ES ES–296 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A24 Accelerator Pedal Position Sensor 6 W-R 34 IC4 W-R 18 VPA E8 5 LG-B 29 IC4 LG-B 20 E8 VCP1 4 B-Y 26 IC4 B-Y 26 E8 3 R-B 31 IC4 R-B 19 VPA2 E8 2 V-W 8 IC3 V-W 21 E8 W-L 9 IC3 W-L VPA1 EP1 ES ECM VPA2 EP2 VCP2 1 EPA VCPA EPA2 27 VCP2 E8 A074729E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester ON. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1 and ACCEL POS #2. (d) Read the values displayed on the tester. Standard voltage Depressed Released Accelerator Pedal Operations ACCEL POS #1 (AP#1) ACCEL POS #2 (AP#2) Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.0 V FI07052E14 OK NG Go to step 5 ES–297 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) Wire Harness Side: VPA2 VCPA EPA EPA2 VCP2 VPA 1 A24 2 3 4 5 (a) Disconnect the A24 Accelerator Pedal Position (APP) sensor connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) 6 Accelerator Pedal Position Sensor Connector ECM: EPA VPA2 E8 VPA Tester Connections Specified Conditions VPA (A24-6) - VPA (E8-18) Below 1 Ω EPA (A24-5) - EPA (E8-20) Below 1 Ω VCPA (A24-4) - VCPA (E8-26) Below 1 Ω VPA2 (A24-3) - VPA2 (E8-19) Below 1 Ω EPA2 (A24-2) - EPA2 (E8-21) Below 1 Ω VCP2 (A24-1) - VCP2 (E8-27) Below 1 Ω Standard resistance (Check for short) Tester Connections EPA2 VCP2 VCPA A114633E03 Specified Conditions VPA (A24-6) or VPA (E8-18) - Body ground 10 kΩ or higher EPA (A24-5) or EPA (E8-20) - Body ground 10 kΩ or higher VCPA (A24-4) or VCPA (E8-26) - Body ground 10 kΩ or higher VPA2 (A24-3) or VPA2 (E8-19) - Body ground 10 kΩ or higher EPA2 (A24-2) or EPA2 (E8-21) - Body ground 10 kΩ or higher VCP2 (A24-1) or VCP2 (E8-27) - Body ground 10 kΩ or higher (d) Reconnect the APP sensor connector. (e) Reconnect the ECM connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–298 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) Disconnect the A24 APP sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the terminals of the E8 ECM connector. Standard voltage A24 Accelerator Pedal Position Sensor Connector ES Tester Connections Specified Conditions VCPA (E8-26) - EPA (E8-20) 4.5 to 5.0 V VCP2 (E8-27) - EPA2 (E8-21) 4.5 to 5.0 V (d) Reconnect the APP sensor connector. NG ECM: EPA2 (-) REPLACE ECM E8 EPA (-) VCPA (+) VCP2 (+) A114634E03 OK 4 REPLACE ACCELERATOR PEDAL ROD ASSEMBLY (a) Replace the accelerator pedal rod assembly (See page ES-436). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Clear DTCs (See page ES-31). Start the engine. Allow the engine to idle for 15 seconds. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read DTCs. Result Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 and/or P2138 A No output B B SYSTEM OK 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–299 A REPLACE ECM ES ES–300 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance P2121 HINT: This DTC relates to the Accelerator Pedal Position (APP) sensor. DESCRIPTION Refer to DTC P2120 (See page ES-286). DTC No. DTC Detection Conditions P2121 Difference between VPA and VPA2 is less than 0.4 V, or more than 1.2 V for 0.5 second (1 trip detection logic) Trouble Areas • • APP sensor ECM ES MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has 2 sensor elements and 2 signal outputs: VPA1 and VPA2. VPA1 is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA1. When the difference between the voltage outputs of VPA1 and VPA2 deviates from the standard, the ECM concludes the accelerator pedal position sensor has a malfunction. The ECM turns on the MIL and a DTC is set. MONITOR STRATEGY Related DTCs P2121: Accelerator pedal position (APP) sensor (rationality) Required Sensors / Components (Main) Accelerator position sensor Required Sensors / Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Either of the following conditions is met Condition 1 or 2 1. Ignition switch ON 2. Throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS Difference between VPA1 voltage (learned value) and VPA2 voltage (learned value) Less than 0.4 V, or more than 1.2 V FAIL-SAFE The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and switches to limp mode. In limp mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. ES–301 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM If a "pass" condition is detected and then the ignition switch is turned off, the fail-safe operation will stop and the system returns to a normal condition. WIRING DIAGRAM Refer to DTC P2120 (See page ES-290). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ACCEL POS #1 and ACCEL POS #2. (d) Read the values displayed on the tester. Standard voltage Depressed Released Accelerator Pedal Operations ACCEL POS #1 (AP#1) ACCEL POS #2 (AP#2) Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.0 V FI07052E14 OK NG Go to step 4 ES ES–302 2 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) Wire Harness Side: VPA2 VCP2 EP1 VPA1 1 ES A24 VCP1 EP2 2 3 4 5 (a) Disconnect the A24 Accelerator Pedal Position (APP) sensor connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance. Standard resistance (Check for open) 6 Accelerator Pedal Position Sensor Connector ECM: EPA VPA2 E8 VPA Tester Connections Specified Conditions VPA1 (A24-6) - VPA (E8-18) Below 1 Ω EP1 (A24-5) - EPA (E8-20) Below 1 Ω VCP1(A24-4) - VCPA (E8-26) Below 1 Ω VPA2 (A24-3) - VPA2 (E8-19) Below 1 Ω EP2 (A24-2) - EPA2 (E8-21) Below 1 Ω VCP2 (A24-1) - VCP2 (E8-27) Below 1 Ω Standard resistance (Check for short) Tester Connections EPA2 VCP2 VCPA Specified Conditions VPA1 (A24-6) or VPA (E8-18) - Body ground 10 kΩ or higher EP1 (A24-5) or EPA (A24E8-20) - Body ground 10 kΩ or higher VCP1 (A24-4) or VCPA (E8-26) - Body ground 10 kΩ or higher VPA2 (A24-3) or VPA2 (E8-19) - Body ground 10 kΩ or higher A114633E04 EP2 (A24-2) or EPA2 (E84-21) - Body ground 10 kΩ or higher VCP2 (A24-1) or VCP2 (E8-27) - Body ground 10 kΩ or higher (d) Reconnect the APP sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 REPLACE ACCELERATOR PEDAL ROD ASSEMBLY (a) Replace the accelerator pedal rod assembly (See page ES-436). NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Clear DTCs (See page ES-31). Start the engine. Allow the engine to idle for 15 seconds. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Read DTCs. ES–303 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2121 A No output B B SYSTEM OK A REPLACE ECM ES ES–406 1GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR 1GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES GENERATOR ASSEMBLY 9.8 (100, 7) TERMINAL CAP 43 (438, 32) GENERATOR WIRE GENERATOR CONNECTOR 43 (438, 32) 8.0 (82, 71 in.*lbf) COOLER COMPRESSOR ASSEMBLY WIRE HARNESS CLAMP BRACKET 25 (255, 18) 8.0 (82, 71 in.*lbf) COOLER COMPRESSOR CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque A119918E01 1GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–407 ES CRANKSHAFT POSITION SENSOR 10 (102, 7) N*m (kgf*cm, ft.*lbf) : Specified torque A119792E01 ES–304 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) DTC P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) DTC P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) HINT: • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION The A/F sensor generates a voltage* that corresponds to the actual air-fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air-fuel ratio. The ECM determines the deviation from the stoichiometric air-fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air-fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte though the alumina, therefore the sensor activation is accelerated. In order to obtain a high purification rate of the carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxide (NOx) components in the exhaust gas, a TWC is used. For the most efficient use of the TWC, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric level. *: Value changes inside the ECM. Since the A/F sensor is the current output element, a current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. Solid Electrolyte (Zirconia Element) ECM Monitored A/F Sensor Voltage Alumina Heater Platinum Electrode Cover Element Exhaust Gas A A Atmospheric Air A-A Cross Section Air-fuel Ratio A073819E03 ES–305 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions Trouble Areas • P2195 P2197 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) Air-Fuel Ratio (A/F) sensor voltage is more than 3.8 V (b) Heated Oxygen (HO2) sensor voltage is 0.15 V or more P2195 P2197 While fuel-cut operation is performed (during vehicle deceleration), air-furl ratio (A/F) sensor current is 3.6 mA or more for 3 seconds P2196 P2198 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) A/F sensor voltage is less than 2.8 V (b) HO2 sensor voltage is less than 0.6 V P2196 P2198 While fuel-cut operation is performed (during vehicle deceleration), air-furl ratio (A/F) sensor current less than 1.4 mA for 3 seconds (2 trip detection logic) • • • • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor (bank 1, 2 sensor 1) heater A/F sensor heater relay A/F sensor heater and relay circuits Air induction system Fuel pressure Injector ECM • • A/F sensor ECM • • • • • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor (bank 1, 2 sensor 1) heater A/F sensor heater relay A/F sensor heater and relay circuits Air induction system Fuel pressure Injector ECM • • A/F sensor ECM HINT: • DTCs P2195 and P2196 means malfunctions related to bank 1 A/F sensor circuit. • DTCs P2197 and P2198 means malfunctions related to bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. • When any of these DTCs are set, check the A/F sensor voltage output by selecting the following menu items on the intelligent tester: DIAGNOSIS / ENHANCED OBDII / DATA LIST / PRIMARY / AFS B1S1. • Short-term fuel trim values can also be read using the intelligent tester. • The ECM regulates the voltage at the A1A+, A2A+, A1A- and A2A- terminals of the ECM at a constant level. Therefore, the A/F sensor voltage output cannot be confirmed without using the intelligent tester. • If a A/F sensor malfunction is detected, the ECM sets a DTC. MONITOR DESCRIPTION Sensor voltage detection monitor Under the air-fuel ratio feedback control, if the A/F sensor voltage output indicates rich or lean for a certain period of time, the ECM determines that there is a malfunction in the A/F sensor. The ECM illuminates the MIL and sets a DTC. Example: If the A/F sensor voltage output is less than 2.8 V (very rich condition) for 10 seconds, despite the HO2 sensor voltage output being less than 0.85 V, the ECM sets DTC P2196. Alternatively, if the A/F sensor voltage output is more than 3.8 V (very lean condition) for 10 seconds, despite the HO2 sensor voltage output being 0.15 V or more, DTC P2195 is set. Sensor current detection monitor A rich air-fuel mixture causes a low air-fuel ratio sensor current, and a lean air-fuel mixture causes a high air-fuel ratio sensor current. Therefore, the sensor output becomes high during acceleration, and the sensor becomes low during deceleration with the throttle valve fully closed. The ECM monitors the air-fuel ratio sensor current during fuel-cut and detects an unusual current value. If the cumulative time the sensor output is 3.6mAor more (P2195: high-side stuck) or 1.4 mA or less (P2196: low-side stuck) exceeds more than 3 seconds, the ECM interprets a malfunction in the air-fuel ratio sensor and sets a DTC. ES ES–306 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air-fuel Ratio Sensor Current Monitor: Fuel-Cut Cumulative Time “t” = t1 + t2 = 3 seconds or more ON OFF Delay Delay Delay (3 seconds) (3 seconds) (3 seconds) Sensor Current (mA) High Side Threshold ES Low Side Threshold 3 seconds or more Normal Sensor Output t1 t2 Abnormal Sensor Output Time G034989E04 MONITOR STRATEGY Related DTCs P2195: A/F sensor (Bank 1) signal stuck lean P2196: A/F sensor (Bank 1) signal stuck rich P2197: A/F sensor (Bank 2) signal stuck lean P2198: A/F sensor (Bank 2) signal stuck rich Required Sensors / Components (Main) A/F sensor Required Sensors / Components (Related) HO2 sensor Frequency of Operation Continuous Duration 10 seconds: A/F sensor signal stuck lean/rich 3 seconds: A/F sensor current (high/low side) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present P0031, P0032, P0051, P0052 (A/F Sensor heater Sensor 1), P0037, P0038, P0057, P0058 (O2 Sensor heater Sensor 2), P0100, P0101, P0102, P0103 (MAF Sensor), P0110, P0112, P0113 (IAT Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223, P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0136, P0156 (O2 Sensor 2), P0171, P0172 (Fuel System), P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Misfire), P0335 (CKP Sensor), P0340 (CMP Sensor), P0450, P0451, P0452, P0453, P0455, P0456 (EVAP System), P0500 (VSS) P2195, P2197 (A/F sensor signal stuck lean): Duration while all of the following conditions met 2 seconds or more Rear HO2S voltage 0.15 V or more Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–307 P2196, P2198 (A/F sensor signal stuck rich): Duration while all of the following conditions met 2 seconds or more Rear HO2S voltage Less than 0.6 V Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running P2195, P2197 (A/F sensor signal (High side)): Battery voltage 11 V or more ECT 75°C (167°F) or more Atmospheric pressure 76 kPa (570 mmHg) or higher A/F sensor status Activated Continuous time of fuel-cut 3 to 10 seconds. P2196, P2198 (A/F sensor signal (Low side)): Battery voltage 11 V or more ECT 75°C (167°F) or more Atmospheric pressure 76 kPa (570 mmHg) or higher A/F sensor status Activated Continuous time of fuel-cut 3 to 10 seconds. TYPICAL MALFUNCTION THRESHOLDS P2195, P2197 (A/F sensor signal stuck lean): A/F sensor voltage More than 3.8 V for 10 seconds P2196, P2198 (A/F sensor signal stuck rich): A/F sensor voltage Less than 2.8 V P2195, P2197 (A/F sensor signal (High side)): A/F sensor current 3.6 mA or more for 10 seconds P2196, P2198 (A/F sensor signal (Low side)): A/F sensor current Less than 1.4 mA MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES ES–308 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A12 Air Fuel Ratio Sensor (Bank 1 Sensor 1) W W-B 2 ECM 2 3 A/F Heater Relay 2 IC4 9 Engine Room R/B W 5 1 2 2 HT 1 4 AF- AF+ 3 R-L (*1) P 2 HA1A E5 22 A1A+ E5 W ES L IM1 4 J27 W J/C A B-R 2 +B (*1) A13 Air Fuel Ratio Sensor (Bank 2 Sensor 1) A B 30 A1AE5 A W Engine Room R/B W-G 2 1 5 2 2 4 AF- AF+ 3 35 IC4 W-B B J2 2 2 2 A/F HEATER EFI 1 E5 HA2A (*1) Y 23 E5 A2A+ BR 31 E5 A2A- W-G 8 E8 B-W (*1) EFI Relay 2 L B J2 E MREL E J/C J28 J/C E 1 1 2 B HT 1 2 3 2 2 +B Engine Room R/B Battery B J3 BR *1: Shielded W-B EB EE G032689E02 CONFIRMATION DRIVING PATTERN This confirmation driving pattern is used in steps 4, 7, 17, and 21 of the following diagnostic troubleshooting procedure when using the intelligent tester. ES–309 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HO2S Monitor Drive Pattern ECT: 75°C (167°F) or more Vehicle Speed Acceletor Pedal Depressed “G” At Least 3 times “I” “J” 40 mph (64 km/h) Acceletor Pedal Released (Fuel-cut) “K” 6 mph (10 km/h) “H” “E” Idling Time 10 minutes or more Warning up ES 10 seconds 4 seconds or more or more G039659E01 Cumulative Detection Period “t” = t1 + t2 + t3 = 3 seconds or more Driving Pattern Detail for “H” through “K” “I” Engine RPM “J” “K” 2,500 rpm 1,000 rpm Idling “H” Idling Delay t2 t3 Time 4 seconds or more Detection Period t1 4 seconds or more 4 seconds or more G034990E04 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3 (Procedure "A"). Turn the ignition switch on (Procedure "B"). Turn the tester on (Procedure "C"). Clear DTCs (See page ES-31) (Procedure "D"). Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher (Procedure "E"). Select the following menu items on the tester to check the fuel-cut status: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / FC IDLE (Procedure "F"). 7. Drive the vehicle at between 40 mph (64 km/h) or more for at least 10 minutes. (Procedure "G"). 8. Change the transmission to 2nd gear (Procedure "H"). 9. Drive the vehicle at proper vehicle speed to perform fuel-cut operation (refer to the following HINT) (Procedure "I"). HINT: Fuel-cut is performed when the following conditions are met: • Accelerator pedal is fully released. • Engine speed is 2,500 rpm or more (fuel injection returns at 1,000 rpm). 10.Accelerate the vehicle to 30 mph (48 km/h) or more by depressing the accelerator pedal for at least 10 seconds (Procedure "J"). 11.Soon after performing procedure "J" above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control (Procedure "K"). 12.Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) (Procedure "L"). ES–310 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13.Repeat procedures from "H" through "K" above at least 3 times in one driving cycle (Procedure "M"). HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. CAUTION: Strictly observe of posted speed limits, traffic laws, and road conditions when performing these drive patterns. INSPECTION PROCEDURE ES HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using an intelligent tester. (a)Connect the intelligent tester to the DLC3. (b)Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d)Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e)Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - 1 2 • • • A/F sensor A/F sensor heater A/F sensor circuit ES–311 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area 3 • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) 4 – Following the A/F CONTROL procedure enables technicians to check the graph of the voltage outputs of both the A/F and HO2 sensors. – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2, and press the YES button and then the ENTER button. Then press the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P2195, P2196, P2197 OR P2198) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2195, P2196, P2197 or P2198 A P2195, P2196, P2197 or P2198 and other DTCs B HINT: If any DTCs other than P2195, P2196, P2197 or P2198 are output, troubleshoot those DTCs first. B A GO TO DTC CHART ES ES–312 2 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine. Turn the tester on. Warm up the Air-Fuel Ratio (A/F) sensor at an engine speed of 2,500 rpm for 90 seconds. (e) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA / AFS B1S1 or AFS B2S1 and ENGINE SPD. (f) Check the A/F sensor voltage 3 times, when the engine is in each of the following conditions: (1) While idling (check for at least 30 seconds) (Step (1)) (2) At an engine speed of approximately 2,500 rpm (without any sudden changes in engine speed) (Step (2)) (3) Raise the engine speed to 4,000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed (Step (3)). ES Standard voltage Conditions A/F Sensor Voltage Variations Steps (1) and (2) Step (3) Reference Changes at approximately 3.3 V 3.1 to 3.5 V Increases to 3.8 V or more This occurs during engine deceleration (when fuel-cut performed) HINT: For more information, see the diagrams below. Malfunction Conditon: Normal Conditon: (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) idling Engine RPM (2) Approximately 2,500 rpm (1) idling (1) idling Engine RPM “Condition (3)” 3.8 V or More A/F Sensor Voltage A/F Sensor Voltage Fuel Cut Fuel Cut “Condition (1), (2)” Change at approximately 3.3 V ( ): Step No. (1) idling When A/F sensor circuit is malfunctioning, voltage output does not change ( ): Step No. A072304E14 ES–313 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • If the output voltage of the A/F sensor remains at approximately 3.3 V (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have an open circuit. (This will also happen if the A/F sensor heater has an open circuit.) • If the output voltage of the A/F sensor remains at either approximately 3.8 V or more, or 2.8 V or less (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have a short circuit. • The ECM stops fuel injection (fuel cut) during engine deceleration. This causes a lean condition and results in a momentary increase in the A/F sensor output voltage. • The ECM must establish a closed throttle valve position learning value to perform fuel cut. If the battery terminal has been reconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle valve position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally. • The A/F sensor is a current output element; therefore, the current is converted into a voltage inside the ECM. Measuring the voltage at the connectors of the A/F sensor or ECM will show a constant voltage result. NG Go to step 9 OK 3 PERFORM CONFIRMATION DRIVING PATTERN NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to P2195, P2196, P2197 or P2198 A No output B ES ES–314 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 8 A 5 REPLACE AIR FUEL RATIO SENSOR NEXT 6 ES PERFORM CONFIRMATION DRIVING PATTERN NEXT 7 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197 or P2198 B B REPLACE ECM A 8 CONFIRM WHETHER VEHICLE HAS RUN OUT OF FUEL IN PAST NO YES DTC CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS AND PERFORM CONFIRMATION DIVING PATTERN ES–315 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 INSPECT AIR FUEL RATIO SENSOR (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance: Bank 1 Component Side: A12 Bank 1 +B HT +B Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher ES Bank 2 AFAF+ A/F Sensor Front View A13 Bank 2 Tester Connections HT Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG REPLACE AIR FUEL RATIO SENSOR AFAF+ A/F Sensor Front View A126269E08 OK 10 INSPECT AIR FUEL RATIO SENSOR HEATER RELAY (a) Remove the A/F sensor heater relay from the engine room R/B. (b) Check the A/F sensor heater relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F sensor heater relay. NG OK REPLACE AIR FUEL RATIO SENSOR HEATER RELAY ES–316 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side: A/F Sensor Connector A12 Bank 1 +B HT 1 2 3 4 AF+ AFFront View ES A13 Bank 2 HT 2 3 4 AF+ Specified Conditions +B (A12-2) - Body ground 9 to 14 V +B (A13-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the E5 ECM connector. (f) Measure the resistance between the terminals of A/F sensor connector and ECM connector. Standard resistance (Check for open) +B 1 Tester Connections AF- ECM: E5 HA1A A2A+ A2A- HA2A A1A+ A1A- Tester Connections Specified Conditions HT (A12-1) - HA1A (E5-2) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) Below 1 Ω AF- (A12-4) - A1A- (E5-30) Below 1 Ω HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A114635E02 Tester Connections Specified Conditions HT (A12-1) or HA1A (E5-2) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground 10 kΩ or higher HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. Reference (System Diagram of Bank 1 Sensor 1): A/F Sensor Heater Relay From Battery ECM A/F Sensor +B A/F Heater Fuse AFFrom EFI Relay Heater Sensor HT HA1A AF+ A1A+ EFI No. 2 A1A- Duty Control G035624E02 ES–317 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 12 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 13 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-4). NG REPAIR OR REPLACE FUEL SYSTEM OK 14 INSPECT FUEL INJECTOR ASSEMBLY (a) Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor) (See page FU-11). NG REPLACE FUEL INJECTOR ASSEMBLY OK 15 REPLACE AIR FUEL RATIO SENSOR NEXT 16 PERFORM CONFIRMATION DRIVING PATTERN NEXT 17 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRET CODES. Result Display (DTC Output) Proceed to No output A ES ES–318 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC Output) Proceed to P2195, P2196, P2197 or P2198 B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 18 CONFIRM WHETHER VEHICLE HAS RUN OUT OF FUEL IN PAST NO ES YES DTC CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS ES–319 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) DTC P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) DTC P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) DTC P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) DTC P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) DTC P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) DTC P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) DTC P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) HINT: • Although the DTC titles say oxygen sensor, these DTCs relate to the Air-Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION Refer to DTC P2195 (See page ES-298). DTC No. DTC Detection Conditions • P2238 P2241 • Case 1: Condition (a) or (b) continues for 5.0 seconds or more (1 trip detection logic): (a) AF+ voltage is 0.5 V or less (b) (AF+) - (AF-) = 0.1 V or less Case 2: A/F sensor admittance: Less than 0.022 1/Ω (2 trip detection logic) Trouble Areas • • • • • • • P2239 P2242 AF+ voltage is more than 4.5 V for 5.0 seconds or more (2 trip detection logic) • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM ES ES–320 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Conditions Trouble Areas • P2252 P2255 AF- voltage is 0.5 V or less for 5.0 seconds or more (2 trip detection logic) • • • • • • P2253 P2256 ES AF- voltage is more than 4.5 V for 5.0 seconds or more (1 trip detection logic) • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater A/F sensor heater relay A/F sensor heater and relay circuits ECM HINT: • DTC P2238, P2239, P2252 and P2253 means malfunction related to the bank 1 A/F sensor circuit. • DTC P2241, P2242, P2255 and P2256 means malfunction related to the bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. MONITOR DESCRIPTION The Air-Fuel Ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. If the A/F sensor impedance (alternating current resistance) or voltage output deviates greatly from the standard range, the ECM determines that there is an open or short malfunction in the A/F sensor circuit. MONITOR STRATEGY Related DTCs P2238: A/F sensor (Bank 1) open circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and GND P2239: A/F sensor (Bank 1) short circuit between AF+ and +B P2241: A/F sensor (Bank 2) open circuit between AF+ and AFP2241: A/F sensor (Bank 2) short circuit between AF+ and AFP2241: A/F sensor (Bank 2) short circuit between AF+ and GND P2242: A/F sensor (Bank 2) short circuit between AF+ and +B P2252: A/F sensor (Bank 1) short circuit between AF- and GND P2253: A/F sensor (Bank 1) short circuit between AF- and +B P2255: A/F sensor (Bank 2) short circuit between AF- and GND P2256: A/F sensor (Bank 2) short circuit between AF- and +B Required Sensors / Components (Main) A/F sensor Required Sensors / Components (Related) ECT sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 seconds: A/F sensor open circuit between AF+ and AF5 seconds: Others MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None P2238 and P2241 (open circuit between AF+ and AF-): AF+ terminal voltage 0.5 to 4.5 V AF- terminal voltage 0.5 to 4.5 V Difference between AF+ terminal and AF- terminal voltages 0.1 to 0.8 V ECT 5°C (41°F) or more 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Running Fuel-cut OFF Time after fuel-cut OFF 5 seconds or more A/F sensor heater ON Battery voltage 11 V or more Ignition switch ON Time after ignition switch is OFF to ON 5 seconds or more ES–321 Others: Battery voltage 11 V or more Ignition switch ON Time after ignition switch is OFF to ON 5 seconds or more TYPICAL MALFUNCTION THRESHOLDS P2238, P2241 (Open circuit between AF+ and AF-): A/F sensor admittance Below 0.022 1/Ω P2238, P2241 (Short circuit between AF+ and GND): AF+ terminal voltage 0.5 V or less P2238, P2241 (Short circuit between AF+ and AF-): Difference between AF+ and AF- terminal voltages 0.1 V or less P2239, P2242 (Short circuit between AF+ and +B): AF+ terminal voltage More than 4.5 V P2252, P2255 (Short circuit between AF- and GND): AF- terminal voltage 0.5 V or less P2253, P2256 (Short circuit between AF- and +B): AF- terminal voltage More than 4.5 V WIRING DIAGRAM Refer to DTC P2195 (See page ES-302). INSPECTION PROCEDURE HINT: For use the intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. (a)Connect the intelligent tester to the DLC3. (b)Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d)Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e)Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). ES ES–322 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 ES NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - 1 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) – Following the A/F CONTROL procedure enables technicians to check the graph of the voltage outputs of both the A/F and HO2 sensors. ES–323 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance: Bank 1 Component Side: A12 Bank 1 +B HT +B Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT(1) - AF- (4) 10 kΩ or higher Bank 2 AFAF+ A/F Sensor Front View A13 Bank 2 Tester Connections HT Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG REPLACE AIR FUEL RATIO SENSOR AFAF+ A/F Sensor Front View A126269E08 OK 2 INSPECT AIR FUEL RATIO SENSOR HEATER RELAY (a) Remove the A/F sensor heater relay from the engine room R/B. (b) Check the A/F sensor heater relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F sensor heater relay. NG REPLACE AIR FUEL RATIO SENSOR HEATER RELAY ES ES–324 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side: A/F Sensor Connector A12 Bank 1 HT ES +B 1 2 Tester Connections Specified Conditions 3 4 +B (A12-2) - Body ground 9 to 14 V +B (A13-2) - Body ground 9 to 14 V AF+ AFFront View A13 Bank 2 HA2A AF+ (d) Turn the ignition switch off. (e) Disconnect the B46 ECM connector. (f) Measure the resistance between the terminals of A/F sensor connector and ECM connector. Standard resistance (Check for open) +B 1 2 3 4 AF- Tester Connections ECM: E5 HA1A A2A+ A2A- HA2A A1A+ A1A- Specified Conditions HT (A12-1) - HA1A (E5-2) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) Below 1 Ω AF- (A12-4) - A1A- (E5-30) Below 1 Ω HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A114635E04 Tester Connections Specified Conditions HT (A12-1) or HA1A (E5-2) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground 10 kΩ or higher HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. ES–325 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (System Diagram of Bank 1 Sensor 1): A/F Sensor Heater Relay From Battery From EFI Relay ECM A/F Sensor +B A/F Heater Fuse AF- Heater Sensor HT HA1A AF+ A1A+ EFI No. 2 A1A- Duty Control ES G035624E02 NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–326 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low DTC P2402 Evaporative Emission System Leak Detection Pump Control Circuit High DTC SUMMARY DTCs Monitoring Items Malfunction Detection Conditions Trouble Areas • ES P2401 P2402 Vacuum pump stuck OFF Vacuum pump stuck ON P043E, P043F, P2401, P2402 and P2419 present when one of following conditions met during key-off EVAP monitor: • EVAP pressure just after reference pressure measurement greater than -1 kPa-g (-7.5 mmHg-g) • Reference pressure less than -4.85 kPa-g (-36.4 mmHg-g) • Reference pressure greater than 1.057 kPa-g (-7.93 mmHg-g) • Reference pressure not saturated • Reference pressure difference between first and second 0.7 kPa-g (5.25 mmHg-g) or more HINT: Typical example values • • • • • • • Detection Timings Detection Logic Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM While ignition switch off 2 trip Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM While ignition switch off 2 trip * : The threshold values vary according to the atmospheric pressure measured in operation A. The values described in the table above are based on an atmospheric pressure of 100 kPa (750.1 mmHg). HINT: The vacuum pump is built into the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP System (See page ES-349). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–327 HINT: *1: If the engine coolant temperature is not below 35°C (95°F) after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence *2 Operations Descriptions Duration - ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. - ES - : If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–328 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter ON Vacuum Pump: OFF ES Operation C: EVAP System Pressure Measurement OFF Pump Module ON (closed) Operation D: Purge VSV Monitor ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E18 ES–329 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P2401: Vacuum pump stuck OFF In operation B, the vacuum pump creates negative pressure (a vacuum) through the 0.02 inch orifice. The EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to determine the 0.02 inch leak pressure standard. If the pressure is higher than -1.2 kPa (-7.5 mmHg)*, or lower than -4.3 kPa (-32.25 mmHg)*, the ECM interprets this as the vacuum pump being stuck OFF (not operating). The ECM illuminates the MIL and sets the DTC (2 trip detection logic). * : The thresholds vary according to the atmospheric pressure measured in operation A. The values described above are based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Vacuum Pump Stuck OFF: ON: Open OFF: Closed ON Purge VSV ON: Closed OFF: Vent ON Vent Valve ON Vacuum Pump Malfunction EVAP Pressure Positive Negative OK First 0.02 Inch Leak Pressure Standard Sequence Time A B C 10 seconds 60 seconds With 15 minutes D E 60 seconds 10 seconds F G036777E07 ES ES–330 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P2402: Vacuum pump stuck ON In operation B, the vacuum pump creates negative pressure (a vacuum) through the 0.02 inch orifice. The EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to determine the 0.02 inch leak pressure standard. If the pressure is higher than -1.2 kPa (-7.5 mmHg)*, or lower than -4.3 kPa (-32.25 mmHg)*, the ECM interprets this as the vacuum pump being stuck ON (remaining ON all the time). The ECM illuminates the MIL and sets the DTC (2 trip detection logic). *: The thresholds vary according to the atmospheric pressure measured in operation A. The values described above are based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Vacuum Pump Stuck ON: ES ON Purge VSV ON: Open OFF: Closed ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump OK EVAP Pressure Positive Negative Malfunction First 0.02 Inch Leak Pressure Standard Sequence Time A 10 seconds B C With 15 minutes 60 seconds D E 10 seconds 60 seconds G036778E09 HINT: The detection logic of DTCs P2401 and P2402 is the same because in both cases the 0.02 inch leak pressure standard measured in operation B is compared to the atmospheric pressure registered in operation A. The ECM calculates the difference between these pressures by deducting [the 0.02 inch leak pressure standard] from [the stored atmospheric pressure], and uses this to monitor the EVAP system pressure change. MONITOR STRATEGY Related DTCs P2401: Vacuum pump stuck OFF P2402: Vacuum pump stuck ON Required Sensors / Components Pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Vehicle speed Less than 2.5 mph (4km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 or 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met Condition 1, 2, 3, 4 or 5 1. EVAP pressure just after reference pressure measurement start More than -1 kPa (-7.5 mmHg) 2. Reference pressure Less than -1.85 kPa (-36.4 mmHg) 3. Reference pressure -1.057 kPa (-7.93 mmHg) or more 4. Reference pressure Not saturated within 60 seconds 5. Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES–331 ES ES–332 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2419 Evaporative Emission System Switching Valve Control Circuit Low DTC P2420 Evaporative Emission System Switching Valve Control Circuit High DTC SUMMARY DTCs Monitoring Items ES P2419 Vent valve stuck closed Malfunction Detection Conditions P043E, P043F, P2401, P2402 and P2419 present when one of following conditions met during key-off EVAP monitor: • EVAP pressure just after reference pressure measurement greater than -1 kPa-g (-7.5 mmHg-g) • Reference pressure less than -4.85 kPa-g (-36.4 mmHg-g) • Reference pressure greater than 1.057 kPa-g (-7.93 mmHg-g) • Reference pressure not saturated • Reference pressure difference between first and second 0.7 kPa-g (5.25 mmHg-g) or more HINT: Typical example values Trouble Areas • • • • • P2420 Vent valve stuck open (vent) Following condition met during key-off EVAP monitor: • EVAP pressure change when vent valve closed (ON) less than 0.3 kPag (2.25 mmHg-g) • • Detection Timings Detection Logic Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM While ignition switch OFF 2 trip Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) ECM While ignition switch OFF 2 trip * : The threshold value varies according to the atmospheric pressure measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. HINT: The vent valve is built into the pump module. DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) System (See page ES-346). INSPECTION PROCEDURE Refer to the EVAP (Evaporative Emission) System (See page ES-349). MONITOR DESCRIPTION 5 hours*1 after the ignition switch is turned off, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–333 HINT: *1: If the engine coolant temperature is not below 35°C (95°F) after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence *2 Operations Descriptions Duration - ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned off. - A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve is turned ON (closed) to shut EVAP system. Negative pressure (vacuum) is created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes*2 D Purge VSV monitor Purge VSV is opened and then EVAP system pressure is measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement After second 0.02 inch leak pressure measurement, leak check is performed by comparing first and second 0.02 inch leak pressure standards. If stabilized system pressure is higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure is measured and then monitoring result is recorded by ECM. ES - : If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–334 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Operation B, E: Atmospheric Pressure Measurement 0.02 Inch Leak Pressure Measurement Canister Fuel Tank Purge VSV: OFF Vent Valve: OFF (vent) OFF OFF (vent) 0.02 Inch Orifice Pressure Sensor Air Filter ON Vacuum Pump: OFF ES Operation C: EVAP System Pressure Measurement OFF Pump Module ON (closed) Operation D: Purge VSV Monitor ON Atmospheric Pressure ON Negative Pressure ON (closed) ON A096746E18 ES–335 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P2419: Vent valve stuck closed In operation B, the vacuum pump creates negative pressure (a vacuum) through the 0.02 inch orifice. The EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to determine the 0.02 inch leak pressure standard. If the pressure exceeds -1.0578 kPa (-7.93 mmHg)* 4 seconds after the vacuum pump is turned ON, the ECM interprets this as the vent valve being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). * : The threshold varies according to the atmospheric pressure measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Vent Valve Stuck ON: ON Purge VSV ON: Open OFF: Closed ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure Malfunction Positive Negative OK First 0.02 Inch Leak Pressure Standard 4 seconds Sequence Time A B C 10 seconds 60 seconds With 15 minutes D E 60 seconds 10 seconds G036779E08 ES ES–336 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P2420: Vent valve stuck open (vent) In operation C, the vent valve turns ON (closes) and the EVAP (Evaporative Emission) system pressure is then measured by the ECM, using the pressure sensor, to conduct an EVAP leak check. If the pressure does not increase when the vent valve is open, the ECM interprets this as the vent valve being stuck open. The ECM illuminates the MIL and sets the DTC. EVAP Pressure when Vent Valve Stuck OFF: ON: Open OFF: Closed ON Purge VSV ON: Closed ON Vent Valve OFF: Vent ES ON Vacuum Pump EVAP Pressure Positive OK Negative First 0.02 Inch Leak Pressure Standard Malfunction Sequence Time A B C 10 seconds 60 seconds With 15 minutes D E 10 60 seconds seconds G036780E09 MONITOR STRATEGY Related DTCs P2419: Vent valve stuck open P2420: Vent valve stuck closed Required sensors / components Vent valve Frequency of operation Once per driving cycle Duration P2419: 2 seconds P2420: 10 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 or 2 1. Duration that vehicle has been driven 5 minutes or more 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–337 TYPICAL MALFUNCTION THRESHOLDS Vent value stuck closed: One of the following conditions is met Condition 1, 2, 3, 4 or 5 1. EVAP pressure just after reference pressure measurement start More than -1 kPa (-7.5 mmHg) 2. Reference pressure Less than -4.85 kPa (-36.4 mmHg) 3. Reference pressure -1.057 kPa (-7.93 mmHg) or more 4. Reference pressure Not saturated 5. Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) or more Vent value stuck open: EVAP pressure change after EVAP canister vent valve is ON Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-14). ES ES–338 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2610 ECM / PCM Internal Engine Off Timer Performance DTC SUMMARY DTC P2610 Monitoring Items Malfunction Detection Conditions Soak timer (built into ECM) ECM internal malfunction Trouble Areas ECM Detection Timings Engine running Detection Logic 2 trip DESCRIPTION ES To ensure the accuracy of the EVAP (Evaporative Emission) monitor values, the soak timer, which is built into the ECM, measures 5 hours (+- 15 minutes) from when the ignition switch is turned off, before the monitor is run. This allows the fuel to cool down, which stabilizes the Fuel Tank Pressure (FTP). When 5 hours have elapsed, the ECM turns on. Soak Timer Circuit: Ignition Switch ECM IGSW EFI Relay +B Power Source IC 15 A MREL Battery Main Relay Control IC Soak Timer IC A133262E02 MONITOR DESCRIPTION 5 hours after the ignition switch is turned off, the soak timer activates the ECM to begin the EVAP system monitor. While the engine is running, the ECM monitors the synchronization of the soak timer and the CPU clock. If these two are not synchronized, the ECM interprets this as a malfunction, illuminates the MIL and sets the DTC (2 trip detection logic). MONITOR STRATEGY Related DTCs P2610: Soak timer (bulit into ECM) Required sensors / components ECM Frequency of operation Once per driving cycles Duration 10 minutes MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Battery voltage 8 V or more Ignition switch ON 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Starter OFF Engine Running ES–339 TYPICAL MALFUNCTION THRESHOLDS Soak timer measurement when ECM CPU clock counts 10 minutes Less than 7 minutes or more than 13 minutes INSPECTION PROCEDURE HINT: • DTC P2610 is set if an internal ECM problem is detected. Diagnostic procedures are not required. ECM replacement is required. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 REPLACE ECM (a) Replace the ECM (See page ES-434). NEXT 2 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Clear DTCs (See page ES-31). Start the engine and wait for 10 minutes or more. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. If no pending DTC is displayed, the repair has been successfully completed. OK: No DTC output. NG OK END CHECK FOR INTERMITTENT PROBLEMS ES ES–340 ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) DTC P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) HINT: • DTC P2A00 means malfunctions related to the bank 1 A/F sensor. • DTC P2A03 means malfunctions related to the bank 2 A/F sensor. • Bank 1 refers to the bank that includes cylinder No. 1. • Bank 2 refers to the bank that includes cylinder No. 2. • Sensor 1 refers to the sensor mounted of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. DESCRIPTION Refer to DTC P2195 (See page ES-298). DTC No. P2A00 P2A03 DTC Detection Conditions Calculated value for air-fuel ratio (A/F) sensor response rate deterioration level is less than threshold Trouble Areas • • • Open or short in A/F sensor circuit A/F sensor ECM MONITOR DESCRIPTION After engine is warmed up, the ECM performs air-fuel ratio feedback control to regulate the air-fuel ratio at stoichiometric ratio. In addition, this vehicle performs Active A/F Ratio Control for approximately 10 seconds after preconditions met in order to measure the A/F sensor response rate. During active air-fuel ratio control, the ECM forcibly increases and decreases the injection volume for certain amount based on learned stoichiometric air-fuel ratio during usual air-fuel feedback control, and measures the A/F sensor response rate. The ECM calculates the signal from the A/F sensor while performing the active A/F ratio control and interprets the calculated value as an test value for A/F sensor response rate deterioration level. If the test value for A/F sensor response rate deterioration level is less than threshold, ECM interprets this as a malfunction, and sets the DTC. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Air-fuel Ratio Sensor Output: ES–341 Approximately 10 seconds OFF ON Active A/F Control Normal Malfunction A/F Sensor Output ES Increase Fuel Injection Volume Decrease G034991E08 CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the A/F sensor response monitor. Engine Speed “H” Between 25 mph and 75 mph (40 km/h and 120 km/h) Idling Between 38 mph and 75 mph (60 km/h and 120 km/h) “G” Ignition Switch off Time Warming up 3 minutes A079199E78 1. Connect the intelligent tester to the DLC3 (Procedure "A"). Tester Display G034992E04 ES–342 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. 3. 4. 5. ES Turn the ignition switch on (Procedure "B"). Turn the tester on (Procedure "C"). Clear DTCs (Procedure "D"). Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR RESULT (Procedure "E"). 6. Check that AFS B1 is INCOMPL (Procedure "F"). 7. Start the engine and warm it up (Procedure "G"). 8. Drive the vehicle at between 25 mph and 75 mph (40 km/h and 120 km/h) for 3 minutes. However, the vehicle should be driven at a constant speed (Procedure "H"). 9. Check the monitor result values on the intelligent tester by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT (Procedure "I"). HINT: The test values changes after monitor completed. 10.If the values indicated on the tester does not change, perform READINESS MONITOR DRIVE PATTERN for the A/F sensor and the heated oxygen sensor (See page ES-17) (Procedure "J"). HINT: Completion of all A/F sensor monitors are required to change the value in TEST RESULT. 11.Note the value of the Monitor Result (Procedure "K"). 12.Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES (Procedure "L"). 13.Check if any DTCs (any pending DTCs) are set (Procedure "M"). MONITOR STRATEGY Related DTCs P2A00: A/F sensor (Bank 1) slow response P2A03: A/F sensor (Bank 2) slow response Required Sensors / Components (Main) A/F sensor Required Sensors / Components (Related) Vehicle speed sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 to 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0031, P0032, P0051, P0052 (A/F Sensor heater Sensor 1), P0100, P0101, P0102, P0103 (MAF Sensor), P0110, P0112, P0113 (IAT Sensor), P0115, P0116, P0117, P0118 (ECT Sensor), P0120, P0121, P0122, P0123, P0220, P0222, P0223, P2135 (TP Sensor), P0125 (Insufficient ECT for Closed Loop), P0171, P0172 (Fuel System), P0300, P0301, P0302, P0303, P0304, P0305, P0306 (Misfire), P0335 (CKP Sensor), P0340 (CMP sensor), P0450, P0451, P0452, P0453, P0455, P0456 (EVAP System), P0500 (VSS), P2196, P2198 (A/F Sensor (Rationality)) Active A/F control Performing Active A/F control is performed when the following conditions are met - Battery voltage 11 V or more Engine coolant temperature 75°C (167°F) or more Idle OFF Engine RPM Less than 4,000 rpm A/F sensor status Activated Fuel cut OFF Engine load 10 to 70% Shift position 2 or more Catalyst monitor Not yet Intake air amount 3.0 to 10.5 g/s ES–343 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level Less than 0.2 V WIRING DIAGRAM Refer to DTC P2195 (See page ES-302). INSPECTION PROCEDURE HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air-Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using an intelligent tester. (a)Connect the intelligent tester to the DLC3. (b)Start the engine and turn the tester on. (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d)Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e)Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). (f) Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volumes Status Voltages AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 NOTICE: The Air-Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - 1 2 • • • A/F sensor A/F sensor heater A/F sensor circuit ES ES–344 Case 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area 3 • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Injector Fuel pressure Gas leakage from exhaust system (Air-fuel ratio extremely lean or rich) 4 ES – Following the A/F CONTROL procedure enables technicians to check the graph the voltage outputs of both the A/F and HO2 sensors. – To display the graph, select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2, and press the YES button and then the ENTER button followed by the F4 button. HINT: • DTC P2A00 or P2A03 may be also set, when the air-fuel ratio is stuck rich or lean. • A low A/F sensor voltage could be caused by a rich air-fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air-fuel mixture. Check for conditions that would cause the engine to run lean. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2A00 AND/OR P2A03) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch on. Turn the tester on. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A P2A00 and/or P2A03 and other DTCs B HINT: If any DTCs other than P2A00 or P2A03 are output, troubleshoot those DTCs first. B A GO TO DTC CHART ES–345 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance between the terminals of the A/ sensor connector. Standard resistance: Bank 1 Component Side: A12 Bank 1 +B HT +B HT HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher ES Tester Connections Specified Conditions HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. NG AFAF+ A/F Sensor Front View A126269E08 OK Specified Conditions Bank 2 AFAF+ A/F Sensor Front View A13 Bank 2 Tester Connections REPLACE AIR FUEL RATIO SENSOR ES–346 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch on. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side: A/F Sensor Connector A12 Bank 1 +B HT 1 2 3 4 AF+ AFFront View ES A13 Bank 2 HA2A 2 3 4 AF+ Specified Conditions +B (A12-2) - Body ground 9 to 14 V +B (A13-2) - Body ground 9 to 14 V (d) Turn the ignition switch off. (e) Disconnect the B46 ECM connector. (f) Measure the resistance between the terminals of the A/F sensor connector and ECM connector. Standard resistance (Check for open) +B 1 Tester Connections AF- ECM: E5 HA1A A2A+ A2A- HA2A A1A+ A1A- Tester Connections Specified Conditions HT (A12-1) - HA1A (E5-2) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) Below 1 Ω AF- (A12-4) - A1A- (E5-30) Below 1 Ω HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A114635E04 Tester Connections Specified Conditions HT (A12-1) or HA1A (E5-2) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground 10 kΩ or higher HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. Reference (System Diagram of Bank 1 Sensor 1): A/F Sensor Heater Relay From Battery ECM A/F Sensor +B A/F Heater Fuse AFFrom EFI Relay Heater Sensor HT HA1A AF+ A1A+ EFI No. 2 A1A- Duty Control G035624E02 ES–347 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A No output B B CHECK FOR INTERMITTENT PROBLEMS A 6 REPLACE AIR FUEL RATIO SENSOR NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read DTCs using the intelligent tester. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to No output A P2A00 and/or P2A03 B B CHECK EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (REFER TO DTC P0171 PROCEDURE) ES ES–348 A END ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–349 EVAP System RELATED DTCS DTCs Monitoring Items P043E 0.02 inch orifice clogged (built into pump module) P043F 0.02 inch orifice high-flow (built into pump module) P0441 • • • P0450 Pressure sensor (built into pump module) voltage abnormal fluctuation P0451 • • P0452 Pressure sensor (built into pump module) voltage low P0453 Pressure sensor (built into pump module) voltage high P0455 EVAP gross leak P0456 EVAP small leak Purge VSV (Vacuum Switching Valve) stuck closed Purge VSV stuck open Purge flow Pressure sensor (built into pump module) noise Pressure sensor (built into pump module) signal becomes fixed/flat P2401 Vacuum pump stuck OFF (built into pump module) P2402 Vacuum pump stuck ON (built into pump module) P2419 Vent valve stuck ON (closed) (built into pump module) P2420 Vent valve stuck OFF (vent) (built into pump module) P2610 Soak timer (built into ECM) See procedure ES-212 ES-218 ES-224 ES-232 ES-320 ES-326 ES-332 If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. ES ES–350 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas P043E P0441 P0450 P0451 P0452 P0453 P0455 P0456 P043F P2401 P2419 P2420 P2402 0.02 inch orifice clogged 0.02 inch orifice high-flow Purge VSV stuck open Purge VSV stuck closed ES Pressure sensor stuck Pressure sensor noise Pressure sensor low output Pressure sensor high output Gross leak Small leak Vacuum pump stuck OFF Vacuum pump stuck ON Vent valve stuck ON (closed) Vent valve stuck OFF (vent) A106731E15 NOTICE: If the 0.02 inch reference pressure difference between the first and second checks is greater than the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455, P0456, P2401, P2420) will be all stored. CONFIRMATION DRIVING PATTERN HINT: After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor Confirmation described below. 1. KEY-OFF MONITOR CONFIRMATION (a) Preconditions The monitor will not run unless: (1) The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) (2) The fuel tank is less than 90% full (3) The altitude is less than 8,000 ft (2,400 m) (4) The Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F) (5) The Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F) (6) The vehicle remains stationary (the vehicle speed is 0 mph [0 km/h]) (b) Monitor Conditions (1) Allow the engine to idle for at least 5 minutes. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. ES–351 (2) Turn the ignition switch off and wait for 6 hours (8 or 10.5 hours). HINT: Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above must be repeated. (c) Monitor Status (1) Connect an intelligent tester to the DLC3. (2) Turn the ignition switch on and turn the tester on. (3) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (4) Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again. PURGE FLOW MONITOR CONFIRMATION (P0441) HINT: Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete). (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The ECT is between 4.4°C and 35°C (40°F and 95°F) • The IAT is between 4.4°C and 35°C (40°F and 95°F) (b) Monitor Conditions (1) Release the pressure from the fuel tank by removing and reinstalling the fuel tank cap. (2) Warm the engine up until the ECT reaches more than 75°C (167°F). (3) Increase the engine speed to 3,000 rpm once. (4) Allow the engine to idle and turn the A/C ON for 1 minute. (c) Monitor Status (1) Turn the ignition switch off. (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch to on and turn the tester on. (4) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (5) Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again. MONITOR RESULT Refer to Checking Monitor Status (See page ES-14). ES ES–352 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION Location of EVAP (Evaporative Emission) System: EVAP Hose (To Throttle Body) Purge VSV (Vacuum Switching value) Canister Refueling Valve Fuel Tank Pump Module ES Pressure Sensor Vacuum Pump Vent Value Breeding Pipe Air Inlet Port Air Filter Fuel Tank Cap EVAP Hose (From Canister) Purge Line A130687E01 HINT: The canister is located near the fuel tank, underneath the body. EVAP System Circuit: Throttle Valve Air Cleaner ECM Intake Manifold Soak Timer Pump Module Fuel Tank Cap Purge VSV Canister Air Filter Refueling Valve Resistance (0.08 inch) Cut-off Valve Fuel Tank A126270E01 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–353 While the engine is running, if a predetermined condition (closed- loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. The following two monitors run to confirm appropriate EVAP system operation. 1. Key-off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned off. More than 5 hours are required to enough time the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The electric vacuum pump creates negative pressure (vacuum) in the EVAP system, and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. 2. Purge flow monitor The purge flow monitor consists of the two monitors. The 1st monitor is always conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned OFF (open) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa (3.75 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. ES ES–354 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP Purge Flow: Fuel Tank Cap Refueling Valve To Atmosphere Purge VSV (ON) Fuel Tank 0.02 Inch Orifice Canister Pressure Sensor ES To Intake Manifold Vent Valve (OFF) Air Filter ECM Vacuum Pump (OFF) Pump Module Soak Timer A126271E01 Components Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank is 100% full. Purge VSV (Vacuum Switching Valve) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold is controlled by purge VSV duty cycle ratio (current-carrying time). (Open: ON, Close: OFF) Refueling valve Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08 inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP is purged, valve closes and restrictor prevents a large amount of vacuum from affecting pressure in fuel tank. Valve is opened while refueling. When valve is open, adding fuel into fuel tank is possible. Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Service port Used for connecting vacuum gauge for inspecting EVAP system. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+- 15 min.) after ignition switch turned off. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approx 5 hours elapsed, ECM activates. Pump module Consists of (a) to (d) below. Pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system is vented. Negative pressure (vacuum) is created in EVAP system to check for EVAP leaks by closing purge VSV, turning on vent valve (closed) and operating vacuum pump. (refer to fig. 1). (b) Pressure sensor Indicates pressure as voltages. ECM supplies regulated 5 V to pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig 2). (c) Vacuum pump Creates negative pressure (vacuum) in EVAP system for leak check. (d) 0.02 inch orifice Has an opening with 0.02 inch diameter. Vacuum is produced through orifice by closing purge VSV, turning off vent valve and operating vacuum pump, to monitor 0.02 inch leak pressure. 0.02 inch leak pressure indicates a small leak of EVAP. ES–355 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Pump Module (fig. 1): Condition: Purge Flow : Airflow Condition: Leak Check Vent Valve: ON (closed) Vent Valve: OFF (vent) To Air Filter (Atmosphere) Canister 0.02 Inch Orifice From Refueling Valve Pressure Sensor ES Vacuum Pump: OFF Pressure Sensor Specification (fig. 2): Output Voltage Vacuum Pump: ON Soak Timer Circuit (fig. 3): Malfunction Area ECM Ignition Switch IGSW 4.900 V Engine Room Junction Block +B 15 A 4.150 V MREL Usable Range Power Source IC Main Relay Control IC EFI Relay 1.425 V Malfunction Area Soak Timer IC 0.450 V HINT: 60 kPa 110 kPa Pressure Battery Standard atmospheric pressure is 101.3 kpa (760 mm Hg) A118976E02 WIRING DIAGRAM Refer to DTC P0450 (See page ES-227). INSPECTION PROCEDURE NOTICE: An intelligent tester is required to conduct the following diagnostic troubleshooting procedure. HINT: • Using intelligent tester monitor results enables the EVAP (Evaporative Emission) system to be confirmed. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CONFIRM DTC (a) Turn the ignition switch OFF and wait for 10 seconds. (b) Turn the ignition switch on. ES–356 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) (d) (e) (f) Turn the ignition switch off and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the ignition switch on and turn the tester on. Select the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Confirm DTCs and freeze frame data. If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. DTCs Malfunctioning Areas ES P043E P043F P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2401 P2419 P2420 P2402 0.02 inch orifice clogged 0.02 inch orifice high-flow Purge VSV stuck open Purge VSV stuck closed Pressure sensor signal becomes fixed/flax Pressure sensor noise Pressure sensor voltage low Pressure sensor voltage high Gross leak Small leak Vacuum pump stuck OFF Vacuum pump stuck ON Vent valve stuck ON (closed) Vent valve stuck OFF (vent) A106731E16 NOTICE: If the 0.02 inch reference pressure difference between the first and second checks is greater than the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored. NEXT 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 ES–357 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed automatically by the intelligent tester. It takes a maximum of approximately 15 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Connect the intelligent tester to the DLC3. (b) Clear DTCs (See page ES-31). (c) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed, perform the Monitor Confirmation after this repair is completed. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal. NEXT ES ES–358 3 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) EVAP SYSTEM CHECK ON: Open ON Purge VSV OFF: Closed ES Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Gross Leak Positive Negative [Second 0.02 Inch Leak Pressure Standard] x 0.2 Small Leak First 0.02 Inch Leak Pressure Standard No Leak Normal Pressure Steps Time (Reference) 1/5 10 seconds 2/5 3/5 60 seconds Within 15 minutes 4/5 5/5 10 60 seconds seconds G036782E08 NOTICE: • In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed manually by the intelligent tester. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Connect the intelligent tester to the DLC3. (b) Clear DTCs (See page ES-31). (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION. NEXT 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–359 PERFORM EVAP SYSTEM CHECK (STEP 1/5) ON Purge VSV ON: Open OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent Pressure Sensor Noise EVAP Pressure ES Positive Negative First 0.02 Inch Leak Pressure Standard Steps Time (Reference) OK 1/5 10 seconds G036783E04 (a) Check the EVAP pressure in step 1/5. Result DTCs* P0451 Test Results Suspected Trouble Areas Proceed to Virtually no variation in EVAP pressure Not yet determined A EVAP pressure fluctuates by +-0.3 kPa (2.25 mmHg) or more Pressure sensor noising B *: The DTCs relating to the EVAP system displayed on the intelligent tester when checking. B A Go to step 30 ES–360 5 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) ON Purge VSV ON: Open OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent ES EVAP Pressure Positive Negative Vacuum Pump Stuck ON First 0.02 Inch Leak Pressure Standard Steps Time (Reference) 1/5 2/5 10 seconds 60 seconds G036784E04 (a) Check the EVAP pressure in step 1/5 and 2/5. Result DTCs* Test Results - Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 inch leak pressure standard* Not yet determined A Small difference between EVAP pressures during steps 1/5 and 2/5 Vacuum pump stuck ON B P2402 Suspected Trouble Areas Proceed to *: The DTCs relating to the EVAP system are displayed on the intelligent tester when checking. HINT: The first 0.02 inch leak pressure standard is the value determined in step 2/5. B A Go to step 23 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–361 PERFORM EVAP SYSTEM CHECK (STEP 2/5) ON Purge VSV ON: Open OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Vacuum Pump Stuck OFF 0.02 Inch Orifice High-flow 4 sec Positive Negative ES Vent Valve Stuck Closed First 0.02 Inch Leak Pressure Standard OK 0.02 Inch Orifice Clogged Steps Time (Reference) 3/5 Within 15 minutes 2/5 60 seconds G036785E06 HINT: Make a note of the pressures checked steps (a) and (b) below. (a) Check the EVAP pressure 4 seconds after the vacuum pump is activated*1 (Step (a)). (b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak pressure standard (Step (b)). *1: The vacuum pump begins to operate as step 1/5 is proceeded to step 2/5. Result DTCs*2 Test Results Suspected Trouble Areas Proceed to EVAP pressure in step (b) is between -4.85 kPa and -1.06 kPa (-36.38 mmHg and -7.95 mmHg) Not yet determined A P043F and P2401 EVAP pressure in step (b) is -1.06 kPa (-7.95 mmHg) or more • • B P043E EVAP pressure in step (b) is below -4.85 kPa (-36.38 mmHg) 0.02 inch orifice clogged C P2419 EVAP pressure in step (a) is more than -1.06 kPa (-7.95 mmHg) Vent valve stuck closed D - 0.02 inch orifice high-flow Vacuum pump stuck OFF *2: The DTCs related to the EVAP system displayed on the intelligent tester when checking. B Go to step 11 C Go to step 30 D Go to step 19 ES–362 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 7 PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) ON Purge VSV ON: Open OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent ES EVAP Pressure Positive Negative Vent Valve Stuck Open (vent) First 0.02 Inch Leak Pressure Standard Steps 2/5 3/5 Within 15 minutes Time (Reference) G036786E05 (a) Check the EVAP pressure increase in step 3/5. Result DTCs* Test Results Suspected Trouble Areas Proceed to EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 2/5 to step 3/5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/5 through 3/5 Pressure sensor malfunction C - *: The DTCs relating to the EVAP system displayed on the intelligent tester when checking. A B Go to step 20 C Go to step 30 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–363 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Open OFF: Closed ON: Closed OFF: Vent ES EVAP Pressure Positive Negative First 0.02 Inch Leak Pressure Standard Steps Time (Reference) 3/5 Within 15 minutes G038126E06 (a) Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds. (b) Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes. NEXT ES–364 9 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 4/5) ON Purge VSV ON: Closed ON Vent Valve ON: Open OFF: Closed OFF: Vent ON Vacuum Pump ES EVAP Pressure OK Positive Negative First 0.02 Inch Leak Pressure Standard Purge VSV Stuck Closed Steps 4/5 Time (Reference) 10 seconds G036776E10 (a) Check the EVAP pressure in step 4/5. Result DTCs* Test Results Suspected Trouble Areas Proceed to - EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Not yet determined A P0441 EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Problems in EVAP hose between pure VSV and intake manifold B P0441 Variation in EVAP pressure less than 0.3 kPa (2.25 mmHg) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C *: The DTCs relating to the EVAP system displayed on an intelligent tester when checking. A B Go to step 15 C Go to step 12 ES–365 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10 PERFORM EVAP SYSTEM CHECK (STEP 5/5) ON: Open ON Purge VSV OFF: Closed Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent ES EVAP Pressure Gross Leak Positive Negative [Second 0.02 Inch Leak Pressure Standard] x 0.2 Small Leak First 0.02 Inch Leak Pressure Standard No Leak Steps 5/5 Time (Reference) [Second 0.02 Inch Leak Pressure Standard] 60 seconds G036782E09 (a) Check the EVAP pressure in step 5/5. (b) Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak pressure standard (step 5/5). Result DTCs* Test Results - EVAP pressure (step 3/5) lower than second 0.02 inch leak pressure standard (step 5/5) Not yet determined (no leafage from EVAP system) A EVAP pressure (step 3/5) higher than [second 0.02 inch leak pressure standard (step 5/5) x 0.2] • • B EVAP pressure (step 3/5) higher than second 0.02 inch leak pressure standard (step 5/5) EVAP small leak P0441 and P0455 P0456 Suspected Trouble Areas Purge VSV stuck open EVAP gross leak Proceed to C *: The DTCs relating to the EVAP system are displayed on the intelligent tester when checking. A Go to step 36 B Go to step 12 ES–366 11 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON Purge VSV ES Vent Valve ON Vacuum Pump ON EVAP Pressure 0.02 Inch Orifice High-flow First 0.02 Inch Leak Pressure Standard Time (Reference) ON: Closed OFF: Vent Vacuum Pump Stuck OFF Positive Negative Steps ON: Open OFF: Closed 2/5 3/5 Within 15 minutes 60 seconds G036788E06 (a) Check the EVAP pressure in step 3/5. Result DTCs* Test Results Suspected Trouble Areas Proceed to P043F EVAP pressure is less than [0.02 inch leak pressure standard] measured in step 2/5 0.02 inch orifice high-flow A P2401 EVAP pressure is almost the same as [0.02 inch leak pressure standard] measure in step 2/5 Vacuum pump stuck OFF B *: The DTCs related to the EVAP system are displayed on the intelligent tester when checking. HINT: The first 0.02 inch leak pressure standard is the value determined in step 2/5. A Go to step 30 B Go to step 23 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 ES–367 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (PURGE VSV) Purge VSV Hose G035659E03 (a) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV (ALONE). (b) Disconnect the hose (connected to the canister) from the purge VSV. (c) Start the engine. (d) On the tester, turn off the purge VSV (EVAP VSV: OFF). (e) Use your finger to confirm that the purge VSV has no suction. (f) Using the tester, turn on the purge VSV (EVAP VSV: ON). (g) Use you finger to confirm that the purge VSV has suction. Result Test Results Suspected Trouble Areas Proceed to No suction when purge VSV turned OFF, and suction applied when turned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suction when purge VSV turned ON • • Purge VSV stuck closed Problems with EVAP hose between purge VSV and throttle body C (h) Reconnect the hose. B Go to step 14 C Go to step 15 A 13 CHECK FUEL TANK CAP ASSEMBLY (a) Check that the fuel tank cap is correctly installed and confirm the fuel tank cap meets OEM specification. HINT: If an EVAP tester is available, check the fuel tank cap using the tester. (1) Tighten the fuel tank cap. (2) Remove the fuel tank cap and install it onto a fuel tank cap adaptor. (3) Connect an EVAP tester pump hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump. (4) Seal the adaptor and wait for 2 minutes. (5) Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal. ES ES–368 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to - A Fuel tank cap correctly installed • • • Fuel tank cap loose Fuel tank cap improperly installed Defective fuel tank cap Fuel tank cap does not meet OEM specifications No fuel tank cap - ES 14 B C A Go to step 29 B Go to step 27 C Go to step 28 INSPECT NO. 1 VACUUM SWITCHING VALVE Purge VSV Hose (a) Turn the ignition switch off. (b) Disconnect the B19 purge VSV connector. (c) Disconnect the hose (connected to the canister) from the purge VSV. (d) Start the engine. (e) Use your finger to confirm that the purge VSV has no suction. Result Test Results G035660E03 Suspected Trouble Areas Proceed to No suction ECM A Suction applied Purge VSV B (f) Reconnect the purge VSV connector. (g) Reconnect the hose. 15 A Go to step 35 B Go to step 31 CHECK EVAP HOSE (PURGE VSV - THROTTLE BODY) Purge VSV (a) Disconnect the hose (connected to the throttle body) from the purge VSV. (b) Start the engine. (c) Use your finger to confirm that the hose has suction. Result Test Results Suction applied Hose (Connected to the throttle body) G035661E04 No suction Suspected Trouble Areas Proceed to EVAP hose between purge VSV and throttle body normal A • • Throttle body EVAP hose between purge VSV and throttle body (d) Reconnect the hose. B Go to step 26 B 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–369 A 16 INSPECT NO. 1 VACUUM SWITCHING VALVE (PURGE VSV) (a) Remove the purge VSV. (b) Apply battery voltage to the terminals of the purge VSV. (c) Using compressed air, confirm that air flows from port A to port B. Result Purge VSV: Port A Test Results Suspected Trouble Area Proceed to Air flowed Purge VSV normal A No air flow Purge VSV B Port B G035662E02 (d) Install the purge VSV. B Go to step 31 A 17 CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) (a) Disconnect the V2 purge VSV connector. (b) Turn the ignition switch on. (c) Measure the voltage between terminal 1 of the purge VSV connector and the body ground. Result Wire Harness Side: Purge VSV Connector V2 Test Results Front View Suspected Trouble Areas Normal A Other than result above Wire harness or connectors between purge VSV and ECM B A052933E31 (d) Reconnect the purge VSV connector. B A Proceed to Between 11 V and 14 V Go to step 32 ES ES–370 18 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the E4 ECM connector and the V2 purge VSV connector. (b) Measure the resistance between the terminals of the purge VSV connector and ECM connector. Standard resistance ECM: E4 Tester Connections ES Specified Conditions E4-34 (PRG) - V2-2 Below 1 Ω E4-34 (PRG) - Body ground 10 kΩ or higher V2-1 - Body ground 10 kΩ or higher (c) Reconnect the purge VSV connector. (d) Reconnect the ECM connector. PRG Wire Harness Side: Purge VSV Connector OK Go to step 35 NG Go to step 32 V2 1 2 Front View A114636E03 19 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE) ECM: E8 VPMP (a) Turn the ignition switch on. (b) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE). (c) Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. Result A131509E54 Test Results Suspected Trouble Areas Proceed to Between 9 V and 14 V when OFF Below 3 V when ON Vent valve A Below 3 V when OFF and ON ECM B A Go to step 22 B Go to step 35 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 20 ES–371 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE) ECM: A24 VPMP (a) Turn the ignition switch on (IG). (b) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE). (c) Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. Result A131509E15 Test Results Suspected Trouble Areas Proceed to Between 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF Below 3 V when ON Vent valve B Between 9 V and 14 V when OFF and ON ECM C B Go to step 22 C Go to step 35 A 21 INSPECT PUMP MODULE (POWER SOURCE FOR VENT VALVE) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the L4 canister connector. Turn the ignition switch on. Measure the voltage between terminal 9 of the canister connector and the body ground. Result Test Results L4 Wire Harness Side: Normal A Between 0 V and 3 V Power source wire harness of vent valve B B L4 Front View A138726E01 Proceed to Between 9 V and 14 V (e) Reconnect the canister connector. Canister Connector A Suspected Trouble Areas Go to step 32 ES ES–372 22 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT PUMP MODULE (VENT VALVE OPERATION) Charcoal Canister Assembly: (a) Turn the ignition switch to off. (b) Disconnect the L4 canister connector. (c) Apply the battery voltage to terminals 9 and 8 of the pump module. (d) Touch the pump module to confirm the vent valve operation. Result 8 (-) 9 (+) Test Results ES A096743E08 Suspected Trouble Areas Proceed to Operating Wire harness between vent valve and ECM A Not operating Vent valve B (e) Reconnect the canister connector. 23 A Go to step 32 B Go to step 30 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR PUMP MODULE (VACUUM PUMP)) (a) Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). (b) Measure the voltage between terminal MPMP of the ECM connector and the body ground when the vacuum pump is turned ON and OFF using the tester. Result ECM: E8 MPMP A131509E55 Test Results Proceed to Between 0 V and 3 V when OFF Between 9 V and 14 V when ON ECM normal A Between 9 V and 14 V when OFF Between 0 V and 3 V when ON ECM B B A Suspected Trouble Areas Go to step 35 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 24 ES–373 CHECK HARNESS AND CONNECTOR (PUMP MODULE - ECM) (a) (b) (c) (d) Turn the ignition switch off. Disconnect the L4 canister connector. Turn the ignition switch on. Select the following menu items on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). (e) Turn the vacuum pump ON. (f) Measure the voltage between terminal 1 of the canister connector and the body ground. Result L4 Test Results Wire Harness Side: Canister Connector L4 Suspected Trouble Areas Proceed to Between 9 V and 14 V Normal A Between 0 V and 3 V Wire harness between ECM and vacuum pump B (g) Reconnect the canister connector. B Go to step 32 Front View A138726E01 A 25 CHECK HARNESS AND CONNECTOR (PUMP MODULE - GROUND) (a) Disconnect the L4 canister connector. (b) Turn the ignition switch to off. (c) Check the resistance between terminal 6 of the canister connector and the body ground. Result Wire Harness Side: Canister Connector L4 Test Results Suspected Trouble Areas Proceed to Below 1 Ω Vacuum Pump A 10 kΩ or higher Wire harness between vacuum pump and body ground B Front View A085258E54 (d) Reconnect the canister connector. 26 A Go to step 30 B Go to step 32 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) (b) (c) (d) Stop the engine. Disconnect the EVAP hose from the throttle body. Start the engine. Use your finger to confirm that the port of the throttle body has suction. ES ES–374 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to Suction applied EVAP hose between throttle body and purge VSV A No suction Throttle body B (e) Reconnect the EVAP hose. ES 27 A Go to step 33 B Go to step 34 CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP HINT: • When reinstalling the fuel tank cap, tighten it until a few click sounds are heard. • When replacing the fuel tank cap, use a fuel tank cap that meets OEM specifications, and install it until a few click sounds are heard. NEXT 28 Go to step 37 REPLACE FUEL TANK CAP ASSEMBLY HINT: When installing the fuel tank cap, tighten it until a few click sounds are heard. NEXT 29 Go to step 37 LOCATE EVAP LEAK (a) Disconnect the vent hose. ES–375 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Air Filter ES Disconnect the Vent Hose here. Fuel Cap A130688E02 (b) Connect the EVAP pressure tester tool to the canister with the adapter. Canister Pressure Gauge Air Filter Adapter A130689E02 (c) Pressurize the EVAP system by 3.2 to 3.7 kPa (24 to 28 mmHg). (d) Apply soapy water to the piping and the connecting parts of the EVAP system. (e) Look for areas where bubbles appear. This indicates leak point. (f) Repair or replace the leak point. NEXT Go to step 37 ES–376 30 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE CHARCOAL CANISTER ASSEMBLY NEXT 31 Go to step 37 REPLACE NO. 1 VACUUM SWITCHING VALVE (PURGE VSV) Purge VSV ES (a) Disconnect the connector and 2 hoses from the purge VSV. (b) Remove the purge VSV. (c) Install a new purge VSV. (d) Reconnect the connector and 2 hoses. NEXT Go to step 37 A130690E01 32 REPAIR OR REPLACE HARNESS OR CONNECTOR NEXT 33 REPLACE EVAP HOSE (THROTTLE BODY - PURGE VSV) NEXT 34 Go to step 37 Go to step 37 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) Remove the throttle body (See page ES-412). (b) Check that the EVAP purge port of the throttle body is not clogged. If necessary, replace the throttle body. NEXT 35 Go to step 37 REPLACE ECM (a) Replace the ECM (See page ES-434). NEXT 36 Go to step 37 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS (a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–377 NEXT 37 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed automatically by the intelligent tester. It takes a maximum of approximately 15 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-31). (b) On the intelligent tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is found, the repair has been successfully completed. NEXT COMPLETED ES ES–378 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Power Source Circuit DESCRIPTION When the ignition switch is turned on, the battery voltage is applied to terminal IGSW of the ECM. The ECM MREL output signal causes a current to flow to the coil, closing the contacts of the EFI relay and supplying power to terminal +B of the ECM. If the ignition switch is turned off, the ECM holds the EFI relay ON for a maximum of 2 seconds to allow for the initial setting of the throttle valve. WIRING DIAGRAM Driver Side J/B ES B-R IGN 6 1D ECM J8 J/C 11 1J B-O B-O B B J/C B J31 B J32 B-O 9 E8 IGSW I18 Ignition Switch 6 IG2 AM2 7 Engine Room R/B R AM2 B 2 L 1 2 2 EFI 2 2 1 EFI Relay 2 W-B 2 5 3 1 2 B J2 J/C B 2 W-G 2 35 IC4 B C J31 J/C A J32 B 1 E8 +B A J32 B 2 E8 +B2 8 E8 MREL 1 E6 E1 W-G B J3 W-B Battery 11 IC4 EB BR EE G032692E02 ES–379 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 INSPECT ECM (+B VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the A24 and B47 ECM connectors. Standard voltage ECM: E6 E8 E1 OK +B A131509E56 Tester Connections Specified Conditions +B (E8-1) - E1 (E6-1) 9 to 14 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 ECM: CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the E6 ECM connector. (b) Measure the resistance between the terminal of the ECM connector and body ground. Standard resistance (Check for open) E6 E1 Tester Connections Specified Conditions E1 (E6-1) - Body ground Below 1 Ω (c) Reconnect the ECM connector. NG G035617E15 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM (IGSW VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage ECM: E6 E1 E8 IGSW A131509E57 NG OK Tester Connections Specified Conditions IGSW (E8-9) - E1 (E6-1) 9 to 14 V Go to step 6 ES ES–380 4 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FUSE (IGN FUSE) (a) Remove the IGN fuse from the driver side J/B. (b) Measure the IGN fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the IGN fuse. Driver Side J/B: NG IGN Fuse ES CHECK FOR SHORTS IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE A072891E02 OK 5 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY Component Side: Ignition Switch (a) Disconnect the I18 ignition switch connector. (b) Check the resistance. Standard resistance I18 Ignition Switch Positions Tester Conditions Specified Conditions LOCK All Terminals 10 kΩ or higher ACC 2-4 Below 1 Ω ON 1-2, 1-4, 5-6 Below 1 Ω START 1-3, 1-4, 3-4, 5-6, 5-7, 6-7 Below 1 Ω A056879E39 (c) Reconnect the ignition switch connector. NG REPLACE IGNITION OR STARTER SWITCH ASSEMBLY OK CHECK HARNESS AND CONNECTOR (BATTERY - IGNITION SWITCH, IGNITION SWITCH - ECM) 6 INSPECT ECM (MREL VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage ECM: E6 E1 (-) E8 MREL (+) A131509E58 NG Tester Connections Specified Conditions MREL (E8-8) - E1 (E6-1) 9 to 14 V REPLACE ECM ES–381 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 7 CHECK FUSE (EFI FUSE) Engine Room R/B: EFI Fuse (a) Remove the EFI fuse from the engine room R/B. (b) Measure the EFI fuse resistance. Standard resistance: Below 1 Ω (c) Reinstall the EFI fuse. NG CHECK FOR SHORTS IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE A072881E02 OK 8 INSPECT EFI RELAY (EFI RELAY) (a) Remove the EFI relay from the engine room R/B. (b) Check the EFI relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the EFI relay. NG OK REPLACE EFI RELAY ES ES–382 9 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (EFI RELAY - ECM, EFI RELAY - BODY GROUND) (a) Check the harness and connector between the EFI relay and ECM. (1) Remove the EFI relay from the engine room R/B. (2) Disconnect the E8 ECM connector. (3) Measure the resistance between the terminals of the ECM connector and EFI relay terminal. Standard resistance (Check for open) Engine Room R/B: ES Tester Connections Specified Conditions EFI relay (1)- MREL (E8-8) Below 1 Ω EFI Relay Standard resistance (Check for short) E8 Tester Connections Specified Conditions EFI relay (1) or MREL (E8-8) - Body ground 10 kΩ or higher (b) Check the harness and connector between the EFI relay and body ground. (1) Measure the resistance between the terminal of the EFI relay and body ground. Standard resistance (Check for open) MREL ECM Connector A138728E01 Tester Connections Specified Conditions EFI relay (2) - Body ground Below 1 Ω (2) Reinstall the EFI relay. (3) Reconnect the ECM connector. OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG CHECK AND REPLACE HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POSITIVE TERMINAL) 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–383 VC Output Circuit DESCRIPTION The ECM constantly generates 5 V power from the battery voltage supplied to the +B (BATT) terminal to operate the microprocessor. The ECM also provides this power to the sensors through the VC output circuit. ECM From EFI Fuse From EFI Relay Throttle Position Sensor, Accelerator Pedal Position Sensor, etc. (Sensors which have ICs) ES BATT 5 V Constant Voltage Circuit +B VC, VCPA, VCP2 Engine Coolant Temperature Sensor, Intake Air Temperature Sensor, etc. Microprocessor R A116143E24 When the VC circuit is short-circuited, the microprocessor in the ECM and sensors that are supplied power through the VC circuit are inactivated because the power is not supplied from the VC circuit. Under this condition, the system does not start up and the MIL does not illuminate even if the system malfunctions. HINT: Under normal conditions, the MIL is illuminated for several seconds when the ignition switch is first turned ON. The MIL goes off when the engine is started. WIRING DIAGRAM Refer to the following pages. • Throttle position sensor circuit (See page ES-116). • Accelerator pedal position sensor circuit (See page ES-290). • Canister pump module circuit (See page ES-227). • VVT sensor circuit (See page ES-187). INSPECTION PROCEDURE 1 CHECK MIL (a) Check that the Malfunction Indicator Lamp (MIL) lights up when turning the ignition switch ON. OK: MIL lights up OK SYSTEM OK ES–384 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 2 CHECK COMMUNICATION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Check the communication between an intelligent tester and ECM. Result ES Result Proceed to Communication is possible A Communication is not possible B A GO TO MIL CIRCUIT B 3 CHECK MIL (THROTTLE BODY) (a) Disconnect the throttle body connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the throttle body connector. A REPLACE THROTTLE WITH MOTOR BODY ASSEMBLY B 4 CHECK MIL (ACCELERATOR PEDAL) (a) Disconnect the accelerator pedal connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the accelerator pedal connector. A B REPLACE ACCELERATOR PEDAL ROD ASSEMBLY ES–385 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 CHECK MIL (CANISTER PUMP MODULE) (a) Disconnect the canister pump module connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the canister pump module connector. A REPLACE CHARCOAL CANISTER ASSEMBLY B 6 CHECK MIL (VVT SENSOR FOR BANK 1) (a) Disconnect the VVT sensor (bank 1) connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor (bank 1) connector. A REPLACE VVT SENSOR FOR BANK 1 B 7 CHECK MIL (VVT SENSOR FOR BANK 2) (a) Disconnect the VVT sensor (bank 2) connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Result Proceed to MIL illuminates A MIL does not illuminate B (d) Reconnect the VVT sensor (bank 2) connector. A REPLACE VVT SENSOR FOR BANK 2 B 8 CHECK HARNESS AND CONNECTOR (VC OUTPUT CIRCUIT) (a) Disconnect the throttle body connector. ES ES–386 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) (c) (d) (e) (f) (g) ECM Connector B1 Disconnect the accelerator pedal connector. Disconnect the canister pump module connector. Disconnect the VVT sensor (bank 1) connector. Disconnect the VVT sensor (bank 2) connector. Disconnect the ECM connector. Check the resistance. Standard Resistance (Check for short) Tester Connections E47 Specified Conditions VC (E4-23) - Body ground VCPA (E8-26) - Body ground VCP2 ES VC VCPA A115981E02 (h) (i) (j) (k) (l) (m) Reconnect the throttle body connector. Reconnect the accelerator pedal connector. Reconnect the canister pump module connector. Reconnect the VVT sensor (bank 1) connector. Reconnect the VVT sensor (bank 2) connector. Reconnect the ECM connector. NG OK REPLACE ECM 10 kΩ or higher VCP2 (E8-27) - Body ground REPAIR OR REPLACE HARNESS OR CONNECTOR ES–27 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM E4 7 6 5 4 E6 E5 3 2 17 16 15 14 13 12 11 10 9 1 8 7 6 5 4 3 2 19 18 17 16 15 14 13 12 11 10 9 1 8 7 6 5 4 E8 E7 3 6 1 2 17 16 15 14 13 12 11 10 9 5 4 3 16 15 14 13 12 11 10 9 8 2 1 8 7 7 6 5 4 3 1 2 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18 34 33 35 34 33 32 31 30 29 28 32 31 35 34 33 32 31 31 30 29 28 32 31 30 29 28 30 29 28 30 29 28 27 26 ES A121603E06 HINT: The standard normal voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard normal voltage for that pair of terminals, displayed in the Specified Condition column. The illustration above can be used as a reference to identify the ECM terminal locations. Symbols (Terminal No.) Wiring Color Terminal Description BATT (E8-3) - E1 (E6-1) L - BR Battery (for measuring the battery voltage and for the ECM memory) Always 9 to 14 V +BM (E8-7) - E1 (E6-1) GR - BR Power source of throttle motor Always 9 to 14 V IGSW (E8-9) - E1 (E6-1) B-O - BR +B (E8-1) - E1 (E6-1) B - BR +B2 (E8-2) - E1 (E6-1) B - BR Condition Specified Condition Ignition switch Ignition switch ON 9 to 14 V Power source of ECM Ignition switch ON 9 to 14 V Power source of ECM Ignition switch ON 9 to 14 V Ignition switch ON Pulse generation (see waveform 1) OC1+ (E6-17) - OC1- (E6-16) G-Y - L-B Camshaft timing oil control valve (OCV) OC2+ (E6-15) - OC2- (E6-14) L-W - L-R Camshaft timing oil control valve (OCV) Ignition switch ON Pulse generation (see waveform 1) MREL (E8-8) - E1 (E6-1) W-G - BR EFI relay Ignition switch ON 9 to 14 V VC (E4-23) - E2 (E4-28) L-R - BR Power source for sensors (specific voltage) Ignition switch ON 4.5 to 5.0 V Mass air flow meter Idling, Shift lever position P or N, A/C switch OFF 0.5 to 3.0 V VG (E4-30) - E2G (E4-29) R-Y - R-W THA (E4-22) - E2 (E4-28) R-B - BR Intake air temperature sensor Idling, Intake air temperature 20°C (68°F) 0.5 to 3.4 V THW (E4-21) - E2 (E4-28) B-L - BR Engine coolant temperature sensor Idling, Engine coolant temperature 80°C (176°F) 0.2 to 1.0 V VTA1 (E4-20) - E2 (E4-28) G-B - BR Throttle position sensor (for engine control) Ignition switch ON, Throttle valve fully closed 0.5 to 1.2 V VTA1 (E4-20) - E2 (E4-28) G-B - BR Throttle position sensor (for engine control) Ignition switch ON, Throttle valve fully open 3.2 to 4.8 V VTA2 (E4-19) - E2 (E4-28) G-W - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, Accelerator pedal released 2.1 to 3.1 V ES–28 Symbols (Terminal No.) ES 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Color Terminal Description VTA2 (E4-19) - E2 (E4-28) G-W - BR Throttle position sensor (for sensor malfunction detection) Condition Specified Condition Ignition switch ON, Accelerator pedal depressed 4.5 to 5.0 V VPA (E8-18) - EPA (E8-20) W-R - LG-B Accelerator pedal position sensor (for engine control) Ignition switch ON, Accelerator pedal released 0.5 to 1.1 V VPA (E8-18) - EPA (E8-20) W-R - LG-B Accelerator pedal position sensor (for engine control) Ignition switch ON, Accelerator pedal depressed 2.6 to 4.5 V VPA2 (E8-19) - EPA2 (E8-21) R-B - V-W Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, Accelerator pedal released 1.2 to 2.0 V VPA2 (E8-19) - EPA2 (E8-21) R-B - V-W Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, Accelerator pedal depressed 3.4 to 5.0 V VCPA (E8-26) - EPA (E8-20) B-Y - LG-B Power source of accelerator pedal position sensor (for VPA) Ignition switch ON 4.5 to 5.0 V VCP2 (E8-27) - EPA2 (E8-21) W-L - V-W Power source of accelerator pedal position sensor (for VPA2) Ignition switch ON 4.5 to 5.0 V HA1A (E5-2) - E04 (E5-7) HA2A (E5-1) - E05 (E5-6) R-L - W-B B-W - W-B A/F sensor heater Idling Below 3.0 V HA1A (E5-2) - E04 (E5-7) HA2A (E5-1) - E05 (E5-6) R-L - W-B B-W - W-B A/F sensor heater Ignition switch ON 9 to 14 V A1A+ (E5-22) - E1 (E6-1) P - BR A/F sensor Ignition switch ON 3.3 V*1 A1A+ (E5-22) - E1 (E6-1) P - BR A/F sensor Ignition switch ON 3.0 V*1 A2A+ (E5-23) - E1 (E6-1) Y - BR A/F sensor Ignition switch ON 3.3 V*1 A2A+ (E5-23) - E1 (E6-1) Y - BR A/F sensor Ignition switch ON 3.0 V*1 A1A- (E5-30) - E1 (E6-1) L - BR A/F sensor Ignition switch ON 3.3 V*1 A1A- (E5-30) - E1 (E6-1) L - BR A/F sensor Ignition switch ON 3.0 V*1 A2A- (E5-31) - E1 (E6-1) BR - BR A/F sensor Ignition switch ON 3.3 V*1 A2A- (E5-31) - E1 (E6-1) BR - BR A/F sensor Ignition switch ON 3.0 V*1 HT1B (E4-1) - E1 (E6-1) HT2B (E5-5) - E1 (E6-1) G - BR L - BR Heated oxygen sensor heater Idling HT1B (E4-1) - E1 (E6-1) HT2B (E5-5) - E1 (E6-1) G - BR L - BR Heated oxygen sensor heater Ignition switch ON OX1B (E4-18) - E2 (E4-28) OX2B (E5-33) - E2 (E4-28) W - BR B - BR Heated oxygen sensor Maintain engine speed at 2,500 rpm for 2 minutes after warming up Below 3.0 V 9 to 14 V Pulse generation (see waveform 2) #10 (E6-2) - E01 (E4-7) #20 (E6-3) - E01 (E4-7) #30 (E6-4) - E01 (E4-7) #40 (E6-5) - E01 (E4-7) #50 (E6-6) - E01 (E4-7) #60 (E6-7) - E01 (E4-7) R-L - BR B - BR R - BR G - BR Y - BR L - BR Injector Ignition switch ON #10 (E6-2) - E01 (E4-7) #20 (E6-3) - E01 (E4-7) #30 (E6-4) - E01 (E4-7) #40 (E6-5) - E01 (E4-7) #50 (E6-6) - E01 (E4-7) #60 (E6-7) - E01 (E4-7) R-L - BR B - BR R - BR G - BR Y - BR L - BR Injector Idling Pulse generation (see waveform 3) Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (see waveform 4) KNK1 (E5-29) - EKNK (E5-28) B -W 9 to 14 V 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition ES–29 Specified Condition KNK2 (E5-21) - EKN2 (E5-20) G-R Knock sensor Maintain engine speed at 4,000 rpm after warming up VV1+ (E6-19) - VV1- (E6-29) R-G Variable valve timing (VVT) sensor Idling Pulse generation (see waveform 5) VV2+ (E6-18) - VV2+ (E6-28) Y-L Variable valve timing (VVT) sensor Idling Pulse generation (see waveform 5) NE+ (E6-21) - NE- (E6-20) B -W Crankshaft position sensor Idling Pulse generation (see waveform 5) Y-R - BR P-L - BR LG - BR LG-B - BR GR - BR L - BR Ignition coil with igniter (ignition signal) Idling Pulse generation (see waveform 6) IGF1 (E4-24) - E1 (E6-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) Ignition switch ON IGF1 (E4-24) - E1 (E6-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) Idling PRG (E4-34) - E1 (E6-1) G-Y - BR EVAP VSV Ignition switch ON PRG (E4-34) - E1 (E6-1) G-Y - BR EVAP VSV Idling Pulse generation (see waveform 7) SPD (E7-8) - E1 (E6-1) V-R - BR Speed signal from combination meter Ignition switch ON, Rotate driving wheel slowly Pulse generation (see waveform 8) STA (E6-11) - E1 (E6-1) B-Y - BR Starter signal Cranking 9 to 14 V Ignition switch ON, Other shift position in P, N 9 to 14 V IGT1 (E4-8) - E1 (E6-1) IGT2 (E4-9) - E1 (E6-1) IGT3 (E4-10) - E1 (E6-1) IGT4 (E4-11) - E1 (E6-1) IGT5 (E4-12) - E1 (E6-1) IGT6 (E4-13) - E1 (E6-1) Pulse generation (see waveform 4) ES 4.5 to 5.0 V Pulse generation (see waveform 6) 9 to 14 V STAR/NSW (E5-8) - E1 (E6-1) P - BR Park/neutral position switch signal STAR/NSW (E5-8) - E1 (E6-1) P - BR Park/neutral position switch signal Ignition switch ON, Shift position in P, N 0 to 3.0 V STSW (E6-12) - E1 (E6-1) L-Y - BR Ignition switch signal Shift lever position P or N, ignition switch START 6.0 V or more STP (E8-15) - E1 (E6-1) G-Y - BR Stop light switch Brake pedal depressed 7.5 to 14 V STP (E8-15) - E1 (E6-1) G-Y - BR Stop light switch Brake pedal released Below 1.5 V ST1- (E8-16) - E1 (E6-1) R-L - BR Stop light switch (opposite to STP terminal) Ignition switch ON, Brake pedal depressed Below 1.5 V ST1- (E8-16) - E1 (E6-1) R-L - BR Stop light switch (opposite and STP terminal) Ignition switch ON, Brake pedal released 7.5 to 14 V M+ (E4-5) - ME01 (E5-3) P -W-B Throttle motor Idling with warm engine Pulse generation (see waveform 9) M- (E4-4) - ME01 (E5-3) L - W-B Throttle motor Idling with warm engine Pulse generation (see waveform 10) GR-B - BR Fuel pump control Ignition switch ON FPR (E6-30) - E1 (E6-1) Y-B - BR Fuel pump control Ignition switch ON 9 to 14 V W (E7-30) - E1 (E6-1) R-B - BR MIL Ignition switch ON Below 3.0 V W (E7-30) - E1 (E6-1) R-B - BR MIL Idling 9 to 14 V ELS1 (E7-13) - E1 (E6-1) Y-G - BR Electric load Defogger switch OFF 0 to 1.5 V ELS1 (E7-13) - E1 (E6-1) Y-G - BR Electric load Defogger switch ON 7.5 to 14 V ELS2 (E7-12) - E1 (E6-1) G - BR Electric load Taillight switch OFF 0 to 1.5 V 7.5 to 14 V FC (E8-10) - E1 (E6-1) ELS2 (E7-12) - E1 (E6-1) Electric load Taillight switch ON TC (E8-23) - E1 (E6-1) P-L - BR G - BR Terminal TC of DLC 3 Defogger switch ON TACH (E7-1) - E1 (E6-1) B-W - BR Engine speed Idling 9 to 14 V 9 to 14 V Pulse generation see waveform 11) ACIS (E4-33) - E1 (E6-1) W-L - BR VSV for ACIS Ignition switch ON 9 to 14 V PSW (E6-10) - E1 (E6-1) G-W - BR P/S pressure switch Ignition switch ON 9 to 14 V ES–30 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) ES Wiring Color Terminal Description Condition Specified Condition VPMP (E8-5) - E1 (E6-1) R-G - BR Vent valve (built into pump module) MPMP (E8-6) - E1 (E6-1) O - BR Vacuum pump (built into pump module) Vacuum pump OFF 0 to 3 V MPMP (E8-6) - E1 (E6-1) O - BR Vacuum pump (built into pump module) Vacuum pump ON 9 to 14 V PPMP (E8-22) - E2 (E4-28) R - BR Pressure sensor (built into pump module) Ignition switch ON 3 to 3.6 V F/PS (E7-32) - E1 (E6-1) L - BR Airbag sensor assembly Idling with warm engine Ignition switch ON 9 to 14 V Pulse generation (see waveform 12) HINT: *1: The ECM terminal voltage is constant regardless of the output voltage from the sensor. 1. 5 V/DIV WAVEFORM 1 Camshaft timing oil control valve (OCV) ECM Terminal Names Between OC1+ and OC1- or OC2+ and OC2- Tester Ranges 5 V/DIV, 1 msec./DIV Conditions Idling Ground HINT: The wavelength becomes shorter as the engine rpm increases. 1 msec./DIV A093229E18 2. 0.2 V/DIV WAVEFORM 2 Heated oxygen sensor ECM Terminal Names 200 msec./DIV A088863E20 3. Ground Tester Ranges 0.2 V/DIV, 200 msec./DIV Conditions Engine speed maintained 2,500 rpm for 2 minutes after warming up sensor HINT: In the DATA LIST, item O2S B1S2 shows the ECM input values from the heated oxygen sensor. Ground 30 V/DIV Between OX1B and E2 or OX2B and E2 WAVEFORM 3 Fuel injector ECM Terminal Names Between #10 (to 60) and E01 Tester Ranges 30 V/DIV, 20 msec./DIV Conditions Idling HINT: The wavelength becomes shorter as the engine rpm increases. 20 msec./DIV G035622E05 ES–31 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. KNK1 Signal Waveform 1 V/DIV ECM Terminal Names Between KNK1 and EKNK or KNK2 and EKN2 Tester Ranges 0.01 to 10 V/DIV, 0.01 to 10 msec./DIV Conditions Maintain engine speed 4,000 rpm after warming up engine Ground HINT: • The wavelength becomes shorter as the engine rpm increases. • The waveforms and amplitudes displayed differ slightly depending on the vehicle. 1 msec./DIV A085286E40 VV1, VV2 and NE Signal Waveforms 5. 2 V/DIV (a) NE WAVEFORM 4 Knock sensor WAVEFORM 5 (a) VVT sensor (b) Crankshaft position sensor GND (b) VV1 ECM Terminal Names (a) Between NE+ and NE(b) Between VV1+ and VV1- or VV2+ and VV2- Tester Ranges 2 V/DIV, 20 msec./DIV Conditions Idling GND VV2 GND HINT: The wavelength becomes shorter as the engine rpm increases. 20 msec./DIV (Idling) G035795E21 6. IGT and IGF Signal Waveform 2 V/DIV (a) (a) Between IGT (1 to 6) and E1 (b) Between IGF1 and E1 Tester Ranges 2 V/DIV, 20 msec./DIV Conditions Idling (b) HINT: The wavelength becomes shorter as the engine rpm increases. Ground G035664E07 7. 5 V/DIV Ground 50 msec./DIV A093230E11 WAVEFORM 6 (a) Igniter IGT signal (from ECM to igniter) (b) Igniter IGF signal (from igniter to ECM) ECM Terminal Names Ground 20 msec./DIV ES WAVEFORM 7 EVAP VSV ECM Terminal Names Between PRG and E01 Tester Ranges 5 V/DIV, 50 msec./DIV Conditions Idling HINT: If the waveform is not similar to the illustration, check the waveform again after idling for 10 minutes or more. ES–32 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8. 5 V/DIV WAVEFORM 8 Vehicle speed signal ECM Terminal Names Between SPD and E1 Tester Ranges 5 V/DIV, 20 msec./DIV Conditions Ground HINT: The wavelength becomes shorter as the vehicle speed increases. 20 msec./DIV A093224E19 9. ES Driving at 12 mph (20 km/h) 5 V/DIV WAVEFORM 9 Throttle actuator positive terminal ECM Terminal Names Tester Ranges Conditions Between M+ and ME01 5 V/DIV, 1 msec./DIV Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation. Ground 1 msec./DIV A093274E19 10. WAVEFORM 10 Throttle actuator negative terminal 5 V/DIV ECM Terminal Names Tester Ranges Conditions Between M- and ME01 5 V/DIV, 1 msec./DIV Idling with warm engine HINT: The duty ratio varies depending on the throttle actuator operation. Ground 1 msec./DIV A093275E19 11. WAVEFORM 11 Engine speed signal 5 V/DIV ECM Terminal Names Tester Ranges Conditions Ground Between TACH and E1 5 V/DIV, 10 msec./DIV Idling HINT: The wavelength becomes shorter as the engine rpm increases. 10 msec./DIV A093225E17 12. WAVEFORM 12 Airbag sensor assembly 5 V/DIV ECM Terminal Names Ground 500 msec./DIV A093227E08 Between F/PS and E1 Tester Ranges 5 V/DIV, 500 msec./DIV Conditions Idling with warm engine ES–387 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel Pump Control Circuit DESCRIPTION Refer to DTC P0230 (See page ES-160) WIRING DIAGRAM Refer to DTC O0230 (See page ES-162) INSPECTION PROCEDURE 1 CHECK FUEL PUMP OPERATION (a) Check if there is pressure in the fuel inlet hose (See page FU-4). HINT: If there is fuel pressure, you will hear the sound of fuel flowing sound. OK Go to step 10 NG 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATION OF CIRCUIT OPENING RELAY) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP/ SPD. (d) Check whether operating sounds can be heard while operating the relay using the tester. OK: Operating sounds can be heard from the relay. OK Go to step 5 NG 3 INSPECT CIRCUIT OPENING RELAY (a) Remove the circuit opening relay from the engine room R/B. (b) Check the circuit opening relay resistance. Standard resistance B016200 Tester Connections Specified Conditions 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the circuit opening relay. ES ES–388 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE CIRCUIT OPENING RELAY OK 4 INSPECT ECM (FC VOLTAGE) (a) Turn the ignition switch on. (b) Measure the voltage between the terminals of the E6 and E8 ECM connectors. Standard voltage ECM: E6 E8 ES E1 (-) FC (+) Tester Connections Specified Conditions FC (E8-10) - E1 (E6-1) 9 to 14 V OK REPLACE ECM A131509E59 NG CHECK AND REPLACE HARNESS OR CONNECTOR (ECM - IGNITION SWITCH) 5 INSPECT ECM POWER SOURCE CIRCUIT HINT: Refer to "ECM POWER SOURCE CIRCUIT" (See page ES372). NG REPAIR OR REPLACE ECM POWER SOURCE CIRCUIT OK 6 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay the engine room R/B. (b) Check the fuel pump relay resistance. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω A030519 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage applied to terminal 1 and 2) 3-5 Below 1 Ω (when battery voltage applied to terminal 1 and 2) (c) Reinstall the fuel pump relay. NG OK REPLACE FUEL PUMP RELAY ES–389 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 INSPECT FUEL PUMP ASSEMBLY Component Side: F14 (-) (+) Fuel Pump A074356E25 (a) Inspect fuel pump resistance. (1) Disconnect the F14 fuel pump connector. (2) Measure the resistance between terminals 4 and 5. Standard resistance: 0.2 to 3.0 Ω at 20°C (68°F) (b) Inspect fuel pump operation. (1) Apply battery voltage to both terminals. Check that the fuel pump operates. NOTICE: • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. • Keep the fuel pump as far away from the battery as possible. • Always switch at the battery side. NG REPLACE FUEL PUMP ASSEMBLY OK 8 CHECK HARNESS AND CONNECTOR (FUEL PUMP - FUEL PUMP RELAY RELAY, FUEL PUMP - BODY GROUND) (a) Check the harness and connector between the fuel pump and circuit opening relay. (1) Disconnect the F14 fuel pump connector. (2) Remove the Fuel pump relay from the engine room R/B. (3) Measure the resistance between the terminals of the fuel pump relay and fuel pump connector. Standard resistance (Check for open) Wire Harness Side: F14 Fuel Pump Connector Engine Room R/B: Tester Connections Specified Conditions Fuel pump (F14-4) - Fuel pump relay (4) Below 1 Ω Standard resistance (Check for short) Fuel Pump Relay A138729E01 Tester Connections Specified Conditions Fuel pump (F14-4) or Fuel pump relay (4) - Body ground 10 kΩ or higher (4) Reconnect the fuel pump connector. (5) Reinstall the engine room junction block. (b) Check the harness and connector between the fuel pump and body ground. (1) Disconnect the fuel pump connector. (2) Measure the resistance between the terminal of the fuel pump connector and body ground. Standard resistance (Check for open) Tester Connections Specified Conditions Fuel pump (F14-5) - Body ground Below 1 Ω (3) Reconnect the fuel pump connector. ES ES–390 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 9 CHECK HARNESS AND CONNECTOR (CIRCUIT OPENING RELAY - FUEL PUMP RELAY) Engine Room R/B: Fuel Pump Relay ES Circuit Opening Relay (a) Remove the circuit opening relay from the engine room R/B. (b) Remove the fuel pump relay from the engine room R/B. (c) Check the resistance. Standard resistance (Check for open) Tester Connections Specified Conditions Circuit opening relay (3) - Fuel pump relay (3) Below 1 Ω Standard resistance (Check for short) A079233E01 Tester Connections Specified Conditions Circuit opening relay (3) or Fuel pump relay (3) Body ground 10 kΩ or higher (d) Reinstall the circuit opening relay. (e) Reinstall the fuel pump relay. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK CHECK AND REPLACE HARNESS OR CONNECTOR (EFI RELAY - CIRCUIT OPENING RELAY) 10 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay from the engine room R/B. (b) Check the fuel pump relay resistance. Standard resistance Tester Connections Specified Conditions 3-4 Below 1 Ω A030519 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage applied to terminal 1 and 2) 3-5 Below 1 Ω (when battery voltage applied to terminal 1 and 2) (c) Reinstall the fuel pump relay. NG OK REPLACE FUEL PUMP RELAY ES–391 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 INSPECT FUEL PUMP RESISTOR (RESISTANCE) (a) Inspect the fuel pump resistor resistance. (1) Measure the resistance. Standard resistance: 0.70 to 0.76 Ω at 20°C (68°F) Ohmmeter NG REPLACE FUEL PUMP RESISTOR ES G035666E02 OK 12 CHECK HARNESS AND CONNECTOR (FUEL PUMP RELAY - FUEL PUMP) (a) Check the harness and connector between the fuel pump relay and fuel pump resistor. (1) Remove the fuel pump relay from the engine room R/B. (2) Disconnect the F8 fuel pump resistor connector. (3) Check the resistance. Standard resistance (Check for open) Engine Room R/B: Fuel Pump Relay Tester Connections Specified Conditions Fuel pump relay (5) - Fuel pump relay resistor (F81) Below 1 Ω Standard resistance (Check for short) Wire Harness Side: F8 Tester Connections Specified Conditions Fuel pump relay (5) - or Fuel pump resistor (F8-1) - Body ground 10 kΩ or higher (4) Reinstall the fuel pump relay (5) Reconnect the fuel pump resistor connector. (b) Check the harness and connector between the fuel pump resistor and fuel pump. (1) Disconnect the F18 fuel pump resistor connector. (2) Disconnect the F14 fuel pump connector. (3) Check the resistance. Standard resistance (Check for open) Fuel Pump Resistor Connector Wire Harness Side: F14 Tester Connections Specified Conditions Fuel pump resistor (F8-2) - Fuel pump (F14-4) Below 1 Ω Standard resistance (Check for short) Fuel Pump Connector A138730E01 Tester Connections Specified Conditions Fuel pump resistor (F8-2) or Fuel pump (F14-4) Body ground 10 kΩ or higher (4) Reconnect the fuel pump resistor connector. (5) Reconnect the fuel pump connector. ES–392 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE ES–393 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Cranking Holding Function Circuit DESCRIPTION The starter is controlled by the ECM, when the ECM detects a start signal (STSW) from the ignition switch, this system monitors the engine speed (NE) and continues to operate the starter until it has determined that the engine has started (engine speed reaches approximately 500 rpm). If the engine is already running and the ignition switch is turned to START, the ECM will not operate the starter. STA Relay EFI ACC CUT Relay Ignition SW STSW ACC AM2 ACCR Park/Neutral Position SW ST2 P STAR/ NSW N ACCR STA NO. 2 Starter ENG rpm ECM Battery STAR/NSW STA STSW A074731E05 WIRING DIAGRAM Refer to DTC P0617 (See page ES-265). INSPECTION PROCEDURE 1 CHECK OPERATION OF ENGINE CRANKING (a) When turning the ignition switch to the ST position, check whether the starter motor starts. OK CHECK FOR INTERMITTENT PROBLEMS NG 2 READ VALUE OF INTELLIGENT TESTER (STA SIGNAL) (a) Connect the intelligent tester to the DLC3. (b) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (c) Read the values. ES ES–394 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard STARTER SIG Ignition Switch Position OFF ON ON START OK Go to step 5 NG 3 ES INSPECT ECM (STAR AND STSW VOLTAGE) (a) Measure the voltage between the terminals of the E5 and E6 ECM connectors, while cranking the engine. Standard voltage ECM: E1 (-) E5 E6 Tester Connection Specified Condition STAR/NSW (E5-8) - E1 (E6-1) 9 to 14 V STSW (E5-12) - E1 (E6-1) 9 to 14 V Result STAR/NSW (+) STSW (+) Terminal STAR Terminal STSW Proceed to 9 to 14 V 9 to 14 V A 0V 9 to 14 V B 0V 0V C A131509E61 B REPLACE ECM C Go to step 9 A 4 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Disconnect the P1 park/neutral position switch connector. (b) Check for continuity between each terminal shown below when the shift lever is moved to each position. Standard Component Side P1 Park/Neutral Position Switch Shift Position Tester Connection P 1-3 6-9 R 2-3 N 3-5 6-9 D 3-7 3 3-4 2, L 3-8 Specified Condition Continuity A137885E01 NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY ES–395 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK CHECK AND REPLACE HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH ECM) 5 INSPECT STARTER RELAY (a) Remove the starter relay from the engine room R/B. (b) Inspect the starter relay. Standard Tester Connection Specified Condition 1-2 Continuity No continuity 3-5 A060553 Continuity (Apply battery voltage to terminals 1 and 2) (c) Reinstall the starter relay. NG REPLACE STARTER RELAY OK 6 CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - BODY GROUND) (a) Check the harness and connector between the park/ neutral position switch and starter relay. (1) Disconnect the P1 park/neutral position switch connector. (2) Remove the starter relay from the engine room R/B. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: P1 Park/Neutral Position Switch Connector Engine Room R/B: Tester Connections Specified Conditions Park/neutral position switch (P1-6) - Starter relay (1) Below 1 Ω Standard resistance (Check for short) Starter Relay A138731E01 Tester Connections Specified Conditions Park/neutral position switch (P1-6) or Starter relay (1) - Body ground 10 kΩ or higher (4) Reconnect the park/neutral position switch connector. (5) Reinstall the starter relay. (b) Check the harness and connector between the starter relay, and body ground. (1) Measure the resistance between each relay and body ground. Standard resistance (Check for open) Tester Connections Specified Conditions Starter relay (2) - Body ground Below 1 Ω ES ES–396 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (2) Reinstall the starter relay. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 7 INSPECT ENGINE ROOM RELAY BLOCK (STARTER RELAY VOLTAGE) (a) Remove the starter relay from the engine room R/B. (b) Measure the voltage between the terminal of the engine room R/B and body ground. Standard voltage Engine Room R/B: ES Tester Connections Specified Conditions Starter relay (5) - Body ground 9 to 14 V (c) Reinstall the starter relay. Starter Relay A072892E02 NG CHECK AND REPLACE HARNESS AND CONNECTOR (STARTER RELAY - BATTERY) OK 8 INSPECT STARTER ASSEMBLY (a) Inspect the starter assembly (See page ST-13 for Standard, ST-30 for Cold area). NG REPAIR OR REPLACE STARTER ASSEMBLY OK CHECK AND REPLACE HARNESS AND CONNECTOR (STARTER RELAY - STARTER, STARTER BATTERY) 9 CHECK FUSE (STA NO. 2) (a) Remove the STA No. 2 fuse from the driver side J/B. (b) Check for continuity in the STA No. 2 fuse. Standard: Continuity (c) Reinstall the STA No. 2 fuse. Driver Side J/B: STA No. 2 Fuse NG A072893E01 OK CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED NO. 2 STA FUSE AND REPLACE NO. 2 STA FUSE ES–397 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY Component Side: ACC IG1 AM1 (a) Disconnect the I18 ignition switch connector. (b) Check for continuity between the terminals shown in the chart below. Standard ST1 I18 ST2 AM2 Switch Position Tester Connection Specified Condition LOCK All terminal to terminal No continuity ACC 2-3 Continuity ON 2 - 3, 2 - 4, 3 - 4, 6 - 7 Continuity START 1 - 2, 1 - 4, 2 - 4, 6 - 7, 6 8, 7 - 8 Continuity IG2 A056879E40 (c) Reconnect the ignition switch connector. NG REPLACE IGNITION OR STARTER SWITCH ASSEMBLY OK CHECK AND REPLACE HARNESS AND CONNECTOR (ECM-BATTERT) ES ES–410 1GR-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR INSPECTION 1. Acceptable INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection ES RESISTANCE kΩ TEMPERATURE °C (°F) Z017274E14 Specified Condition 1-2 2.32 to 2.59 kΩ at 20°C (68°F) 1-2 0.310 to 0.326 kΩ at 80°C (176°F) NOTICE: If checking the engine coolant temperature sensor in water, be careful not to allow water to enter the terminals. After checking, wipe the water off the engine coolant temperature sensor. If the result is not as specified, replace the engine coolant temperature sensor. ES–398 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ACIS Control Circuit DESCRIPTION This circuit opens and closes the Intake Air Control Valve (IACV) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is between 2,200 and 4,100 rpm and the throttle valve opening angle is 60° or more, the ECM supplies current to the VSV (ON status), so the IACV will close. Besides that condition, the VSV is usually OFF and the IACV is open. IACV closed (VSV: ON) 6 ES 4 Throttle Valve opening angle 2 IACV 60° Throttle Valve 5 3 1 2,200 4,100 Engine speed (rpm) A078424E01 ES–399 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM B 35 IC4 W-G 2 2 3 2 1 1 2 5 2 EFI No. 2 ES 2 A L-W 2 V1 ACIS VSV J4 J/C W-B A L-W 2 Engine Room R/B 1 Engine Room R/B 2 2 EFI 8 MREL E8 W-G 17 IC3 L-W 12 IM1 L-W W-L 1 2 33 ACIS E4 J2 B J/C 2 J3 B B W-B Battery EB G032690E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE VSV FOR ACIS) VSV is ON Air VSV is OFF Air Air Filter Port F Port E Port F Port E A067588E06 (a) Disconnect the vacuum hose. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to ON and turn the intelligent tester ON. (d) Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1. Operate the VSV for AICS. (e) Check the VSV operation when it is operated using the intelligent tester. Standard Tester Operation Specified Condition VSV is ON Air from port E flows out through port F VSV is OFF Air from port E flows out through the air filter ES–400 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) Reconnect the vacuum hose. OK Go to step 4 NG 2 CHECK VACUUM SWITCHING VALVE (OPERATION) (a) (a) Check that air flows from port E to the air filter. Air Air Filter ES Port E A054315E04 (b) (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to port F. Air NG Port E Port F Battery A054316E04 OK REPLACE VACUUM SWITCHING VALVE ES–401 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (VSV FOR ACIS - ECM, VSV FOR ACIS - EFI RELAY) (a) Check the wire harness and connectors between the VSV for ACIS and ECM. (1) Disconnect the V1 VSV for ACIS connector. (2) Disconnect the E4 ECM connector. (3) Measure the resistance between the terminals of the VSV for ACIS connector and ECM connector. Standard resistance (Check for open) Wire Harness Side: VSV for ACIS connector V1 Front View Tester Connections Specified Conditions VSV for ACIS (V1-1) - ACIS (E4-33) Below 1 Ω Standard resistance (Check for short) E6 Tester Connections Specified Conditions VSV for ACIS (V1-1) or ACIS (E4-33) - E1 (E6-1) 10 kΩ or higher (4) Reconnect the VSV for ACIS connector. (5) Reconnect the ECM connector. (b) Check the wire harness between the VSV for ACIS and EFI relay. (1) Disconnect the V1 VSV for ACIS connector. (2) Remove the EFI fuse from the engine room R/B and J/B. (3) Measure the resistance of the VSV for ACIS connector and engine room R/B (EFI fuse). Standard resistance (Check for open) E4 E1 ACIS Engine Room R/B: Tester Connections Specified Conditions VSV for ACIS (V1-1) - EFI relay (3) Below 1 Ω (4) Reconnect the VSV for ACIS connector. (5) Reinstall the EFI fuse. NG EFI Relay REPAIR OR REPLACE HARNESS OR CONNECTOR A138727E01 OK 4 CHECK VACUUM HOSES (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, holes and damage. NG OK REPAIR OR REPLACE VACUUM HOSES ES ES–402 5 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT INTAKE AIR CONTROL VALVE (INTAKE AIR SURGE TANK) NG OK REPLACE ECM ES REPLACE INTAKE AIR SURGE TANK ES–403 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Circuit DESCRIPTION The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detections by the ECM. By turning the ignition switch on, power is supplied to the MIL circuit, and the ECM provides the circuit ground, which illuminates the MIL. The MIL operation can be checked visually: When the ignition switch is first turned on, the MIL should be illuminated and should then turn off. If the MIL remains illuminated or is not illuminated, conduct the following troubleshooting procedure using the intelligent tester. WIRING DIAGRAM ES ECM R 7 2 Engine Room R/B 2 AM2 6 2 I18 Ignition Switch 30 E7 W IG2 AM2 1 R-B 17 C8 B-R Driver Side J/B 6 1D B Malfunction Combination Indicator Meter Lamp GAUGE Battery 15 C10 4 1G R-L G032691E01 INSPECTION PROCEDURE HINT: Troubleshoot each trouble symptom in accordance with the table below. MIL remains illuminated Start inspection from step 1 MIL not illuminated Start inspection from step 3 1 CHECK WHETHER MIL TURNS OFF (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (c) Turn the tester on. ES–404 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Check whether any DTCs have been stored (See page ES-31). Note them down if necessary. (e) Clear the DTCs (See page ES-31). (f) Check if the MIL turns off. OK: MIL should turn off. OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC NG ES 2 ECM: CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the E7 ECM connector. (b) Turn the ignition switch on. (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. (d) Reconnect the ECM connector. E7 OK REPLACE ECM G035618E25 NG CHECK AND REPLACE HARNESS AND CONNECTOR (COMBINATION METER - ECM) 3 CHECK THAT MIL IS ILLUMINATED (a) Check if the MIL is illuminated when the ignition switch is turned on. OK: MIL should be illuminated. OK SYSTEM OK NG 4 INSPECT COMBINATION METER ASSEMBLY (MIL CIRCUIT) (a) See the combination meter troubleshooting procedure (See page ME-4). NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY OK CHECK AND REPLACE HARNESS AND CONNECTOR (COMBINATION METER - ECM) ES–404 1GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ON-VEHICLE INSPECTION 1. ES INSPECT VVT SENSOR (a) Turn the ignition switch to the ON position. (b) Check that the voltage between terminal VC1 and ground is 5 V. HINT: For the terminal arrangement of the engine ECU (See page ES-23). (c) While turning the crankshaft pulley by hand, measure the voltage between each terminal. Check that the voltage changes between the Hi range and Lo range shown in the table below. HINT: For the terminal arrangement of the ECM (See page ES-23). Sensor position Terminal No. Voltage (Hi) Voltage (Lo) Bank 1 VV1+ ←→ VV1- 3.375 to 4.950 0.450 to 1.375 Bank 2 VV2+ ←→ VV2- 3.375 to 4.950 0.450 to 1.375 1GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–405 REMOVAL 1. DRAIN ENGINE COOLANT (See page CO-3) 2. REMOVE V-BANK COVER (See page ES-413) 3. DISCONNECT VENTILATION HOSE NO.2 4. REMOVE AIR CLEANER ASSEMBLY (See page ES413) 5. REMOVE VVT SENSOR (a) RH bank side VVT sensor. (1) Disconnect the VVT sensor connector. (2) Remove the bolt and the VVT sensor. ES G038105 (b) LH bank side VVT sensor. (1) Disconnect the water by-pass hoses No. 4 and No. 5. (2) Disconnect the VVT sensor connector. A076414 (3) Remove the bolt and the VVT sensor. G038106 INSTALLATION 1. G038106 INSTALL VVT SENSOR (a) LH bank side VVT sensor. (1) Apply a light coat of engine oil to an O-ring of the VVT sensor. (2) Install the VVT sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (3) Connect the VVT sensor connector. ES–406 1GR-FE ENGINE CONTROL SYSTEM – VVT SENSOR (4) Connect the water by-pass hoses No. 4 and No. 5. A076414 (b) RH bank side VVT sensor. (1) Apply a light coat of engine oil to an O-ring of the VVT sensor. (2) Install the VVT sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (3) Connect the VVT sensor connector. ES G038105 2. INSTALL AIR CLEANER ASSEMBLY (See page ES415) 3. CONNECT VENTILATION HOSE NO.2 4. ADD ENGINE COOLANT (See page CO-3) 5. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 6. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) ES–408 1GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR REMOVAL 1. REMOVE GENERATOR ASSEMBLY (See page CH-10) 2. REMOVE ENGINE UNDER COVER ASSEMBLY REAR (a) Remove the 4 bolts and the engine under cover assembly rear. 3. SEPARATE COOLER COMPRESSOR ASSEMBLY (a) Remove the bolt and separate the suction hose subassembly. (b) Disconnect the cooler compressor assembly connector. (c) Remove the 4 bolts and separate cooler compressor assembly from the V-ribbed belt tensioner assembly. 4. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crankshaft position sensor connector. (b) Remove the bolt and the crankshaft position sensor. ES A076416 A076417 1GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–409 INSPECTION 1. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. RESISTANCE: Cold: 1,630 to 2,740 Ω Hot: 2,065 to 3,225 Ω NOTICE: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). ES ES–410 1GR-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to an O-ring of the crankshaft position sensor. (b) Install the crankshaft position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (c) Connect the crankshaft position sensor connector. 2. ES INSTALL COOLER COMPRESSOR ASSEMBLY (a) Install the cooler compressor assembly with the 4 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Connect the cooler compressor assembly connector. A076417 (c) Install the suction hose sub-assembly with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A076416 3. INSTALL ENGINE UNDER COVER ASSEMBLY REAR (a) Install the engine under cover assembly rear with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 4. INSTALL GENERATOR ASSEMBLY (See page CH-16) 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–413 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. DRAIN ENGINE COOLANT (See page CO-3) 3. REMOVE V-BANK COVER (a) Remove the 2 nuts, then remove the V-bank cover. ES A075593E01 4. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the ventilation hose No. 2. A075594E01 (b) Disconnect the vacuum hose. (c) Disconnect the mass air flow meter connector. (d) Remove the 2 wire harness clamps. A075595E01 (e) Loosen the 2 hose clamps. (f) Remove the 2 bolts, then remove the air cleaner. A075596E01 ES–414 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY 5. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY (a) Disconnect the water by-pass hose No. 5. A075597E01 (b) Disconnect the water by-pass hose No. 4. ES A075598E01 (c) Disconnect the throttle motor connector. (d) Remove the 4 bolts, then remove the throttle w/ motor body and gasket. A075599E01 INSPECTION 1. M+ MA059778E15 INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard Tester Connection Specified Condition 1 (M-) - 2 (M+) 0.3 to 100 Ω at 20°C (68°F) If the result is not as specified, replace the throttle with motor body assembly. 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–415 INSTALLATION 1. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (a) Install a new gasket and the throttle with motor body with the 4 bolts. Torque: 11 N*m (112 kgf*cm, 9 ft.*lbf) (b) Connect the throttle motor connector. A075599E01 (c) Connect the water by-pass hose No. 4. ES A075598E01 (d) Connect the water by-pass hose No. 5. A075597E01 2. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Tighten the 2 hose clamps. A075596E01 (c) Install the 2 wire harness clamps. (d) Connect the mass air flow meter connector. (e) Connect the vacuum hose. A075595E01 ES–416 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY (f) Connect the ventilation hose No. 2. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 4. ADD ENGINE COOLANT (See page CO-3) 5. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-4) 6. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) A075594E01 ES A075593E01 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–427 REMOVAL 1. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See page EM-82) 2. DISCONNECT HEATER WATER INLET HOSE A (a) Disconnect the heater water inlet hose A. ES A076171 3. REMOVE WATER OUTLET PIPE NO.1 (a) Remove the 4 wire harness clamps [A]. (b) Remove the 3 bolts [B] and the water outlet pipe. 4. REMOVE KNOCK SENSOR (a) Disconnect the 2 knock sensor connectors. (b) Remove the 2 bolts and the 2 knock sensors. [A] [B] [A] [A] [B] [A] [B] G038530E01 A075662 INSPECTION 1. Ohmmeter A065174E19 INSPECT KNOCK SENSOR (a) Using an ohmmeter, measure the resistance between terminals. Resistance: 120 to 280 kΩ at 20°C (68°F) HINT: If the resistance is not as specified, replace the sensor. ES–428 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR LH Bank: INSTALLATION Upper Engine Rear 1. INSTALL KNOCK SENSOR (a) Install the 2 knock sensors with the 2 bolts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the 2 knock sensor connectors. 2. INSTALL WATER OUTLET PIPE NO.1 (a) Install the 3 bolts [A] and the water outlet pipe. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Install the 4 wire harness clamps [B]. 3. CONNECT HEATER WATER INLET HOSE A (a) Connect the heater water inlet hose A. 4. INSTALL CYLINDER HEAD SUB-ASSEMBLY (See page EM-85) 0 to 15° ES RH Bank: Upper Engine Front 0 to 15° A078438E08 [B] [A] [B] [B] [A] [B] [A] G038530E02 A076171 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–33 DIAGNOSIS SYSTEM 1. FI00534E01 G039021 2. 3. DESCRIPTION When troubleshooting On-Board Diagnostics (OBD II) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the Data Link Connector 3 (DLC3) of the vehicle. Various data in the vehicle's Engine Control Module (ECM) can then be read. OBD ll regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (a)The emission control systems components (b)The power train control components (which affect vehicle emissions) (c) The computer itself In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not recur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. To check the DTCs, connect the intelligent tester to the DLC3. The tester displays DTCs, freeze frame data, and a variety of engine data. The DTCs and freeze frame data can be erased with the tester. In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, the Control Area Network (CAN) communication is used in this system. It minimizes the gap between technician skills and vehicle technology. CAN is a network which uses a pair of data transmission lines that span multiple ECUs and sensors. It allows high speed communication between the systems and simplifies the wire harness connections. The CAN Vehicle Interface Module (CAN VIM) must be connected with the intelligent tester to display any information from the ECM. The intelligent tester and ECM uses CAN communication signals to communicate. Connect the CAN VIM between the intelligent tester and DLC3. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, 2 trip detection logic is used to ensure accurate detection of malfunctions. Check mode is also available as an option for technicians. In check mode, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (intelligent tester only) (See page ES-35). 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip). ES ES–34 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. FREEZE FRAME DATA Freeze frame data records the engine conditions (fuel system, calculated engine load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred. 5. DATA LINK CONNECTOR 3 (DLC3) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. DLC3 ES 1 2 3 4 5 6 7 8 9 10 1112131415 16 A082779E98 Symbols Terminal No. Names Reference terminal Results Condition SIL CG 7 Bus "+" line 5 - Signal ground Pulse generation During transmission 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 11 to 14 V Always CANH 6 CAN "High" line CANL 54 to 69 Ω Ignition switch OFF CANH 6 CAN "High" line Battery positive 6 kΩ or higher Ignition switch OFF CANH 6 CAN "High" line CG 200 Ω or higher Ignition switch OFF CANL 14 CAN "Low" line Battery positive 6 kΩ or higher Ignition switch OFF CANL 14 CAN "Low" line CG 200 Ω or higher Ignition switch OFF 6. HINT: The DLC3 is the interface prepared for reading various data from the vehicle's ECM. After connecting the cable of an intelligent tester, turn the ignition switch to ON and turn the tester ON. If a communication failure message is displayed on the tester screen (on the tester: UNABLE TO CONNECT TO VEHICLE), a problem exists in either the vehicle or tester. In order to identify the location of the problem, connect the tester to another vehicle. If communication is normal: Inspect the DLC3 on the original vehicle. If communication is impossible: The problem is probably with the tester itself. Consult the Service Department listed in the instruction manual. BATTERY VOLTAGE Battery Voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–35 7. MIL (Malfunction Indicator Lamp) (a) The MIL is illuminated when the ignition switch is first turned ON (the engine is not running). (b) The MIL should turn OFF when the engine is started. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the ignition switch is first turned ON, check the MIL circuit (See page ES-397). ES ES–36 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC CHECK / CLEAR NOTICE: When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of DTCs and freeze frame data. HINT: • DTCs stored in the ECM can be displayed on the intelligent tester. The intelligent tester can display current and pending DTCs. • The some DTCs are not set if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, malfunctions detected on only one occasion are stored as pending DTCs. ES 1. Intelligent Tester CAN VIM 2. DLC3 G039021E03 3. CHECK DTC (Using the intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Check the DTC(s) and freeze frame data, and then write them down. (f) Check the details of the DTC(s) (See page ES-50). CLEAR DTC (Using the intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (e) Press the YES button. CLEAR DTC (Without using the intelligent tester) (a) Perform one of the following operations. (1) Disconnect the negative (-) battery cable for more than 1 minute. (2) Remove the EFI NO. 1 and ETCS fuses from the engine room junction block located inside the engine compartment for more than 1 minute. (b) Perform the initialization procedure (See page AT19). ES–411 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY THROTTLE BODY 1GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (76, 66 in.*lbf) 7.5 (76, 66 in.*lbf) ES V-BANK COVER THROTTLE BODY ASSEMBLY 8.0 (82, 71 in.*lbf) NO. 4 WATER BY-PASS HOSE VACUUM HOSE 11 (112, 9) AIR CLEANER ASSEMBLY THROTTLE BODY GASKET THROTTLE MOTOR CONNECTOR 8.0 (82, 71 in.*lbf) MASS AIR FLOW METER CONNECTOR NO. 5 WATER BY-PASS HOSE NO. 2 VENTILATION HOSE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A113542E03 ES–412 1GR-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ON-VEHICLE INSPECTION 1. A075905 ES INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) Check for operating sound [A]. (1) Turn the ignition switch ON. (2) When turning the accelerator pedal position sensor lever, listen to a running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See page ES-414), wiring and ECM. (b) Inspect the throttle position sensor [B]. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) When turning the accelerator pedal position sensor lever to the full-open position, check that the percentage of throttle valve opening angle (THROTTLE POS) of the CURRENT DATA. Standard percentage of the valve opening angle: 60% or more If operation is not as specified, check that the accelerator pedal position sensor (See page ES-436), the wiring and the ECM. If you do not have the intelligent tester, measure voltage between the terminals (VTA1 - E2, VTA2 - E2) of the ECM connector (See page ES-23). (c) Inspect the air assist system [C]. (1) Start the engine and check that the MIL does not illuminate. (2) Let the engine warm up to the normal operating temperature. (3) Switch the A/C compressor from ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 +- 50 rpm NOTICE: Perform inspection under condition without electrical load. (d) After checking the above [B] and [C], perform the driving test. ES–37 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA 1. DTC set point 0.5 0.5 Seconds Seconds 0.5 Seconds Freeze frame data recorded point G038619E03 2. LABEL (Intelligent Tester Display) DESCRIPTION (a) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. HINT: If it is impossible to replicate the problem even though a DTC is detected, confirm the freeze frame data. (b) The ECM records engine conditions in the form of freeze frame data every 0.5 seconds. Using the intelligent tester, five separate sets of freeze frame data, including the data values at the time when the DTC was set, can be checked. • 3 data sets before the DTC was set • 1 data set when the DTC was set • 1 data set after the DTC was set These data sets can be used to simulate the condition of the vehicle around the time of the occurrence of the malfunction. The data may assist in identifying of the cause of the malfunction, and in judging whether it was temporary or not. LIST OF FREEZE FRAME DATA Measurement Item Diagnostic Note Freeze DTC Freeze DTC INJECTOR Injector - Ignition advance - IGN ADVANCE CALC LOAD VEHICLE LOAD MAF Calculate load Vehicle load Mass air flow volume - Calculated load by ECM If value approximately 0.0 g/s: • Mass air flow meter power source circuit open or short • VG circuit open or short If value 160.0 g/s or more: • E2G circuit open ENGINE SPD Engine speed VEHICLE SPD Vehicle speed Speed indicated on speedometer Engine coolant temperature If value -40°C (-40°F), sensor circuit open If value 140°C (284°F), sensor circuit shorted Intake air temperature If value -40°C (-40°F), sensor circuit open If value 140°C (284°F), sensor circuit shorted COOLANT TEMP INTAKE AIR - AIR-FUEL RATIO Air-fuel ratio - PURGE DENSITY Learning value of purge density - Purge flow - EVAP PURGE VSV PURGE FLOW EVAP purge VSV duty ratio - KNOCK CRRT VAL Correction learning value of knocking - Feedback value of knocking - KNOCK FB VAL ES ES–38 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) EVAP VAPOR PRES Diagnostic Note EVAP vapor pressure - ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1 - ACCEL POS #2 Absolute APP No. 2 - THROTTLE POS Throttle position Read value with ignition switch on (Do not start engine) THROTTLE POS Throttle sensor positioning Read value with ignition switch on (Do not start engine) THROTTLE POS#2 THROTTLE MOT ES Measurement Item Throttle sensor positioning#2 - Throttle motor - O2S B1 S2 Heated oxygen sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor O2S B2 S2 Heated oxygen sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor AFS B1 S1 A/F sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor AFS B2 S1 A/F sensor output Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor TOTAL FT #1 Total fuel trim (bank 1) - TOTAL FT #2 Total fuel trim (bank 2) - SHORT FT #1 Short-term fuel trim (bank 1) Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim (bank 1) Overall fuel compensation carried out in longterm to compensate a continual deviation of short-term fuel trim from central valve SHORT FT #2 Short-term fuel trim (bank 2) Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #2 Long-term fuel trim (bank 2) Overall fuel compensation carried out in longterm to compensate a continual deviation of short-term fuel trim from central valve • • • FUEL SYS #1 Fuel system status (bank 1) • • • • • FUEL SYS #2 Fuel system status (bank 2) • • OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning O2FT B1 S2 Fuel trim at heated oxygen sensor Same as SHORT FT #1 O2FT B2 S2 Fuel trim at heated oxygen sensor Same as SHORT FT #1 ES–39 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) AF FT B1 S1 AFS B1 S1 AF FT B2 S1 Measurement Item Fuel trim at A/F sensor A/F sensor output current Diagnostic Note Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check current output of sensor Fuel trim at A/F sensor - CAT TEMP B1 S1 Catalyst temperature - CAT TEMP B2 S1 Catalyst temperature - CAT TEMP B1 S2 Catalyst temperature - CAT TEMP B2 S2 Catalyst temperature - Sub heated oxygen sensor impedance - Sub heated oxygen sensor impedance - Initial engine coolant temperature - S O2S B1 S2 S O2S B2 S2 INI COOL TEMP INI INTAKE TEMP INJ VOL STARTER SIG PS SW PS SIGNAL Initial intake air temperature - Injection volume - Starter signal - Power steering signal - Power steering signal (history) This signal status usually ON until ignition switch turned off CTP SW Closed throttle position switch - A/C SIG A/C signal - ELECT LOAD SIG Electrical load signal - STOP LIGHT SW Stop light switch - BATTERY VOLTAGE ATM PRESSURE FUEL PMP SP CTL ACIS CTRL B2 ACT VSV Battery voltage - Atmospheric pressure - Fuel pump speed control status - ACIS VSV status - A/C cut status - VVT CTRL B2 VVT control status - EVAP (Purge) VSV EVAP purge VSV FUEL PUMP/SPD VVT CTRL B1 Fuel pump speed status VSV for EVAP controlled by ECM (ground side duty control) VVT control status - VACUUM PUMP Key-off EVAP system pump status - EVAP VENT VAL Key-off EVAP system vent valve status - TC and TE1 terminals of DLC3 - ENG SPEED #1 TC/TE1 Engine speed for cylinder 1 - ENG SPEED #2 Engine speed for cylinder 2 - ENG SPEED #3 Engine speed for cylinder 3 - ENG SPEED #4 Engine speed for cylinder 4 - ENG SPEED #5 Engine speed for cylinder 5 - Engine speed for cylinder 6 - Engine speed for all cylinders - ENG SPEED #6 ENG SPEED ALL VVTL AIM ANGL #1 VVT CHNG ANGL #1 VVT aim angle - VVT change angle - VVT OCV DUTY B1 VVT OCV operation duty - VVTL AIM ANGL #2 VVT aim angle - VVT change angle - VVT OCV operation duty - VVT CHNG ANGL #2 VVT OCV DUTY B2 FC IDL Idle fuel cut ON: when throttle valve fully closed and engine speed over 1,500 rpm ES ES–40 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) ES Measurement Item FC TAU FC TAU IGNITION Ignition Diagnostic Note The fuel cut is being performed under very light load to prevent the engine combustion from becoming incomplete - CYL #1 Cylinder #1 misfire rate Displayed only during idling CYL #2 Cylinder #2 misfire rate Displayed only during idling CYL #3 Cylinder #3 misfire rate Displayed only during idling CYL #4 Cylinder #4 misfire rate Displayed only during idling CYL #5 Cylinder #5 misfire rate Displayed only during idling CYL #6 Cylinder #6 misfire rate Displayed only during idling CYL ALL All cylinder misfire rate Displayed only during idling MISFIRE RPM Misfire RPM - MISFIRE LOAD Misfire load - Misfire monitoring - MISFIRE MARGIN ENG RUN TIME Accumulated engine running time - TIME DTC CLEAR Cumulative time after DTC cleared - DIST DTC CLEAR WU CYC DTC CLEAR MODEL CODE FAN MOTOR VAPOR PRESS ENG OIL PRES SW ENGINE TYPE CYLINDER NUMBER Accumulated distance after DTC cleared - Warm-up cycle after DTC cleared - Identifying the model code: GRN21# Electric fan motor - Vapor pressure Pressure inside of fuel tank as read by the vapor pressure sensor Engine oil pressure switch signal Always ON while engine is running Identifying the engine type 1GR Identifying the cylinder number 6 DESTINATION Identifying the destination A (America) MODEL YEAR Identifying the model year 200# Identifying the engine system GASLIN (gasoline engine) SYSTEM 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–417 KNOCK SENSOR 1GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (76, 66 in.*lbf) V-BANK COVER ES 12 (122, 9) COOL AIR INLET W/ AIR CLEANER HOSE 8.0 (82, 71 in.*lbf) VACUUM HOSE VENTILATION HOSE NO. 2 AIR CLEANER ASSEMBLY MASS AIR FLOW METER CONNECTOR BATTERY CLAMP BATTERY BATTERY TRAY FUEL PIPE SUB-ASSEMBLY NO. 1 FUEL PIPE SUB-ASSEMBLY NO. 2 N*m (kgf*cm, ft.*lbf) : Specified torque FUEL PIPE CLAMP A119805E01 ES–418 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR CLIP 5.0 (51, 44 in.*lbf) ES RADIATOR SUPPORT SEAL UPPER FAN PULLEY FAN SHROUD 21 (214, 15) FAN W/ FLUID COUPLING FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A137117E01 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–419 ATF LEVEL GAUGE OIL LEVEL GAUGE 12 (122, 9) OIL LEVEL GAUGE GUIDE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) O-RING ES O-RING VANE PUMP CONNECTOR VANE PUMP ASSEMBLY 43 (438, 32) TERMINAL CAP 9.8 (100, 7) GENERATOR ASSEMBLY GENERATOR WIRE GENERATOR CONNECTOR 43 (438, 32) COOLER COMPRESSOR ASSEMBLY 8.0 (82, 71 in.*lbf) 43 (438, 32) 8.0 (82, 71 in.*lbf) 25 (255, 18) WIRE HARNESS CLAMP BRACKET COOLER COMPRESSOR CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119806E01 ES–420 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE NO. 3 O-RING ES WATER INLET GASKET 9.0 (92, 80 in.*lbf) WATER BY-PASS HOSE NO. 1 39 (398, 29) V-RIBBED BELT TENSIONER IDLER PULLEY SUB-ASSEMBLY NO. 2 54 (551, 40) IDLER PULLEY SUB-ASSEMBLY NO. 1 OIL COOLER HOSE (W/ OIL COOLER) O-RING 10 (102, 7) 36 (367, 27) OIL PAN SUB-ASSEMBLY GASKET 21 (214, 15) OIL STRAINER SUB-ASSEMBLY 9.0 (92, 80 in.*lbf) 21 (214, 15) OIL PA SUB-ASSEMBLY NO. 2 10 (102, 7) 9.0 (92, 80 in.*lbf) GASKET 40 (408, 30) OIL PAN DRAIN PLUG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119800E01 ES–421 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 28 (286, 21) VSV CONNECTOR WATER BY-PASS HOSE ES INTAKE AIR SURGE TANK VSV CONNECTOR FUEL VAPOR FEED HOSE THROTTLE BODY W/ MOTOR CONNECTOR SURGE TANK STAY NO. 2 21 (214, 15) 21 (214, 15) SURGE TANK STAY NO. 1 THROTTLE BODY BRACKET VENTILATION HOSE NO. 1 21 (214, 15) 9.0 (92, 80 in.*lbf) GASKET OIL BAFFLE PLATE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119844E01 ES–422 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR IGNITION COIL ASSEMBLY CYLINDER HEAD COVER SUB-ASSEMBLY 10 (102, 7) 9.0 (92, 80 in.*lbf) SEAL WASHER CYLINDER HEAD COVER SUB-ASSEMBLY LH 10 (102, 7) ES 9.0 (92, 80 in.*lbf) CYLINDER HEAD COVER GASKET NO. 2 CYLINDER HEAD COVER GASKET VVT SENSOR 8.0 (82, 71 in.*lbf) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A119949E01 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–423 TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 23 (235, 17) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL ES 23 (235, 17) 250 (2,549, 184) 23 (235, 17) CHAIN VIBRATION DAMPER NO. 2 CRANKSHAFT PULLEY CHAIN TENSIONER ASSEMBLY NO. 1 NO. 1 CHAIN SUB-ASSEMBLY 10 (102, 7) CHAIN TENSIONER SLIPPER IDLE GEAR SHAFT NO. 1 IDLE GEAR NO. 1 O-RING 60 (612, 44) IDLE GEAR SHAFT NO. 2 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134409E01 ES–424 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 26 (265, 19) 9.0 (92, 80 in.*lbf) INTAKE MANIFOLD COMPRESSION SPRING ES 43 (440, 32) GASKET EXHAUST PIPE ASSEMBLY FRONT GASKET GASKET GASKET 48 (490, 35) GASKET 62 (630, 46) 30 (306, 22) 9.0 (92, 80 in.*lbf) 40 (408, 30) HEATER WATER OUTLET HOSE (FROM HEATER UNIT) WATER BY-PASS JOINT RR MANIFOLD STAY 40 (408, 30) EXHAUST MANIFOLD SUB-ASSEMBLY RH GASKET O-RING GASKET 9.0 (92, 80 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119808E01 ES–425 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 9.0 (92, 80 in.*lbf) 24 (245, 18) CAMSHAFT BEARING CAP NO. 3 CAMSHAFT BEARING CAP NO. 1 NO. 1 CAMSHAFT 24 (245, 18) CAMSHAFT BEARING CAP NO. 2 9.0 (92, 80 in.*lbf) CAMSHAFT TIMING GEAR ES CAMSHAFT BEARING CAP NO. 3 CAMSHAFT TIMING GEAR ASSEMBLY NO. 2 CAMSHAFT 100 (1,020, 74) NO. 2 CHAIN SUB-ASSEMBLY 100 (1,020, 74) * 1ST: 36 (367, 27) 2ND: TURN 180° PLATE WASHER 19 (194, 14) CHAIN TENSIONER ASSEMBLY NO. 2 CAMSHAFT BEARING NO. 2 CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part *: See title CYLINDER HEAD A119809E01 ES–426 1GR-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 24 (245, 18) 9.0 (92, 80 in.*lbf) CAMSHAFT BEARING CAP NO. 3 CAMSHAFT BEARING CAP NO. 4 CAMSHAFT BEARING CAP NO. 3 NO. 3 CAMSHAFT SUB-ASSEMBLY 24 (245, 18) CAMSHAFT BEARING CAP NO. 2 9.0 (92, 80 in.*lbf) NO. 2 CHAIN SUB-ASSEMBLY ES NO. 4 CAMSHAFT SUB-ASSEMBLY CAMSHAFT TIMING GEAR ASSEMBLY * 100 (1,020, 74) 100 (1,020, 74) 1ST: 36 (367, 27) 2ND: TURN 180° 19 (194, 14) CAMSHAFT TIMING GEAR CHAIN TENSIONER ASSEMBLY NO. 3 PLATE WASHER 30 (306, 22) CYLINDER HEAD LH CYLINDER HEAD GASKET NO. 2 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part *: See title CYLINDER HEAD A119813E01 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–41 CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to normal mode, check mode is more sensitive to malfunctions. Therefore, check mode can detect the malfunctions that cannot be detected by normal mode. NOTICE: All the stored DTCs and freeze frame data are erased if: 1) the ECM is changed from normal mode to check mode or vice versa; or 2) the ignition switch is turned from ON to ACC or OFF while in check mode. Before changing modes, always check and make a note of any DTCs and freeze frame data. 1. Intelligent Tester CAN VIM DLC3 CHECK MODE PROCEDURE (Using the intelligent tester) (a) Check and ensure the following conditions: (1) Positive (+) battery voltage of 11 V or more. (2) Throttle valve fully closed. (3) Transmission in the P or N position. (4) A/C switch OFF. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / CHECK MODE. (g) Switch the ECM from normal mode to check mode. G039021E03 0.13 seconds ON OFF 0.13 seconds A076900E08 (h) Make sure the MIL flashes as shown in the illustration. (i) Start the engine. (j) Make sure the MIL turns OFF. (k) Simulate the conditions of the malfunction described by the customer. (l) Check DTCs and freeze frame data using the tester. ES ES–42 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE CHART If any of the following DTCs are set, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. DTCs ES Components Fail-Safe Operations Fail-Safe Deactivation Conditions P0031, P0032, P0051 and P0052 Air-Fuel Ratio (A/F) Sensor Heater ECM turns off A/F sensor heater Ignition switch off P0037, P0038, P0057 and P0058 Heated Oxygen (HO2) Sensor Heater ECM turns off HO2 sensor heater Ignition switch off P0100, P0102 and P0103 Mass Air Flow (MAF) Meter ECM calculates ignition timing according to engine speed and throttle valve position Pass condition detected P0110, P0112 and P0113 Intake Air Temperature (IAT) Sensor ECM estimates IAT to be 20°C (68°F) Pass condition detected P0115, P0117 and P0118 Engine Coolant Temperature (ECT) Sensor ECM estimates ECT to be 80°C (176°F) Pass condition detected P0120, P0121, P0122, P0123, P0220, P0222, P0223, P0604, P0606, P0607, P0657, P2102, P2103, P2111, P2112, P2118, P2119 and P2135 Electronic Throttle Control System (ETCS) ECM cuts off throttle actuator current and throttle valve returned to 6.5° throttle position by return spring ECM then adjusts engine output by controlling fuel injection (intermittent fuel-cut) and ignition timing in accordance with accelerator pedal opening angle, to allow vehicle to continue at Pass condition detected and then ignition switch turned off minimal speed* P0327, P0328, P0332 and P0333 Knock Sensor ECM sets ignition timing to maximum retard Ignition switch off P0351 to P0356 Igniter ECM cuts fuel Pass condition detected Accelerator Pedal Position (APP) Sensor APP sensor has 2 sensor circuits: Main and Sub If either of circuits malfunctions, ECM controls engine using the other circuit If both of circuits malfunction, ECM regards accelerator pedal as being released. As a result, throttle valve is closed and engine idles Pass condition detected and then ignition switch turned off P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 NOTE: * : The vehicle can be driven slowly when the accelerator pedal is depressed firmly and slowly. If the accelerator pedal is depressed quickly, the vehicle may speed up and slow down erratically. ES–43 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: By reading the DATA LIST displayed on an intelligent tester, you can check values, including those of the switches, sensors, and actuators, without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method of shortening diagnostic time. NOTICE: In the table below, the values listed under Normal Condition are for reference only. Do not depend solely on these values when determining whether or not a part is faulty. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect an intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the tester ON. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) Check the values by referring to the table below. HINT: If no idling conditions are specified, the transmission gear selector lever should be in the N or P position, and the A/C switch and all accessory switches should be OFF. Tester Display Measurement Item/Range INJECTOR Injection period of No. 1 cylinder: Min.: 0 ms, Max.: 32.64 ms 1.6 to 2.4 ms: Idling - IGN ADVANCE Ignition timing advance for No. 1 cylinder/ Min.: -64 deg., Max.: 63.5 deg. BTDC 7 to 24°: Idling - • • - CALC LOAD VEHICLE LOAD Calculated load by ECM: Min.: 0 %, Max.: 100 % Vehicle load: Min.: 0 %, Max.: 25,700 % Normal Condition Diagnostic Note 11.4 to 16.4 %: Idling 13.1 to 18.9 %: Running without load (2,500 rpm) Actual vehicle load If value approximately 0.0 g/sec: • Mass air flow meter power source circuit open • VG circuit open or short If value 160.0 g/sec or more: • E2G circuit open MAF Air flow rate from MAF meter: Min.: 0 g/sec, Max.: 655.35 g/sec 3.2 to 4.7 g/sec: Idling 13.1 to 18.9 g/sec: 2,500 rpm ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383.75 rpm 650 to 750 rpm: Idling - VEHICLE SPD Vehicle speed: Min.: 0 km/h, Max.: 255 km/h Actual vehicle speed Speed indicated on speedometer COOLANT TEMP Engine coolant temperature: Min.: -40°C, Max.: 140°C 80 to 100°C (176 to 212°F):After warming up Intake air temperature: Min.: -40°C, Max.: 140°C Equivalent to ambient air temperature • • • INTAKE AIR • If value -40°C (-40°F): sensor circuit open If value 140°C (284°F) or more: sensor circuit shorted If value -40°C (-40°F): sensor circuit open If value 140°C (284°F) or more: sensor circuit shorted ES ES–44 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Normal Condition Diagnostic Note AIR-FUEL RATIO 0.8 to 1.2: During idling PURGE DENSITY Learning value of purge density/ Min.: -50 , Max.: 350 -40 to 0 %: Idling Purge flow: Min.: 0 %, Max.: 102.4 % 0 to 100 %: Idling EVAP (Purge) VSV control duty: Min.: 0 %, Max.: 100 % 0 to 100 %: During idling Order signal from ECM VAPOR PRES PUMP Vapor pressure: Min.: 33.853 kPa, Max.: 125.596 kPa Approximately 100 kPa: Ignition switch ON EVAP system pressure monitored by canister pressure sensor VAPOR PRES CALC Vapor pressure: (calculated) Min.: -5.632 kPa, Max.: 7,153,264 kPa Approximately 100 kPa: Ignition switch ON EVAP system pressure monitored by canister pressure sensor KNOCK CRRT VAL Correction learning value of knocking: Min.: -64° CA, Max.: 1,984° CA 0 to 22 °CA: Driving, 44 mph (70 km/h) Service data KNOCK FB VAL Feedback value of knocking: Min.: -64° CA, Max.: 1,984° CA -22 to 0 °CA Driving, 44 mph (70 km/h) Service data ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1: Min.: 0 %, Max.: 100 % 10 to 22 %: Accelerator pedal released 54 to 86 %: Accelerator pedal fully depressed - ACCEL POS #2 Absolute APP No. 2: Min.: 0 %, Max.: 100 % 12 to 42 %: Accelerator pedal released 66 to 98 %: Accelerator pedal fully depressed - ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 5 V 0.5 to 1.1 V: Accelerator pedal released. 2.6 to 4.5t V: Accelerator pedal fully depressed. - ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 5 V 1.2 to 2.0 V: Accelerator pedal released. 3.4 to 5.0 V: Accelerator pedal fully depressed. - ACCEL IDL POS Whether or not accelerator pedal position sensor detecting idle: ON or OFF ON: Idling - THRTL LEARN VAL Throttle valve fully closed (learned value): Min.: 0 V, Max.: 5 V 0.4 to 0.8 V - ACCEL SSR #1 AD Accelerator fully closed value No.1 (AD): Min.: 0, Max.: 4.9804 V - ETCS service data ACCEL LRN VAL#1 Accelerator fully closed learning value No.1: Min.: 0, Max.: 124.512 - ETCS service data ACCEL LRN VAL#2 Accelerator fully closed learning value No.2: Min.: 0, Max.: 124.512 - ETCS service data FAIL #1 Whether or not fail safe function executed: ON or OFF ON: ETCS has failed - FAIL #2 Whether or not fail safe function executed: ON or OFF ON: ETCS has failed - ST1 Starter signal: ON or OFF ON: Cranking - SYS GUARD JUDGE System guard: ON or OFF - EVAP PURGE FLOW EVAP PURGE VSV ES Measurement Item/Range Air-fuel ratio: Min.: 0, Max.: 1.999 Service data - ETCS service data ES–45 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display OPN MALFUNCTION THROTTLE POS Measurement Item/Range Open side malfunction: ON or OFF Absolute throttle position sensor: Min.: 0 %, Max.: 100 % Normal Condition • • Diagnostic Note ETCS service data 10 to 24 %: Throttle fully closed 64 to 96 %: Throttle fully open Read value with intrusive operation (active test) Whether or not throttle position sensor detecting idle: ON or OFF ON: Idling - THRTL REQ POS Throttle requirement position: Min.: 0 V, Max.: 5 V 0.5 to 1.0 V: Idling - THROTTLE POS Throttle sensor positioning: Min.: 0 %, Max.: 100 % 0 to 10 %: Idling Calculated value based on VTA1 Throttle sensor positioning #2: Min.: 0 %, Max.: 100 % - Calculated value based on VTA2 THROTTL IDL POS THROTTLE POS #2 • 0.5 to 1.2 V: Throttle fully closed 3.2 to 4.8 V: Throttle fully opened THROTTLE POS #1 Throttle position No. 1: Min.: 0 V, Max.: 5 V THROTTLE POS #2 Throttle position No. 2: Min.: 0 V, Max.: 5 V THRTL COMND VAL Throttle position command value: Min.: 0 V, Max.: 4.98 V 0.5 to 4.8 V ETCS service data THROTTLE SSR #1 Throttle sensor opener position No. 1: Min.: 0 V, Max.: 4.9804 V 0.6 to 1.0 V ETCS service data THROTTLE SSR #2 Throttle sensor opener position No. 2: Min.: 0 V, Max.: 4.9804 V 2.0 to 2.6 V ETCS service data THRTL SSR #1 AD Throttle sensor opener position No.1 (AD): Min.: 0 V, Max.: 4.9804 V 0.6 to 0.9 V ETCS service data THROTTLE MOT Whether or not throttle motor control permitted: ON or OFF ON: Idling Read value with ignition switch ON (Do not start engine) THROTTLE MOT Throttle motor current: Min.: 0 A, Max.: 80 A 0 to 3.0 A: Idling - THROTTLE MOT Throttle motor: Min.: 0 %, Max.: 100 % 0.5 to 40 %: Idling - THRTL MOT (OPN) Throttle motor duty ratio (open): Min.: 0 %, Max.: 100 % - ETCS service data THRTL MOT (CLS) Throttle motor duty ratio (close): Min.: 0 %, Max.: 100 % - ETCS service data O2S B1 S2 Heated oxygen sensor output voltage for bank 1 sensor 2: Min.: 0 V, Max.: 1.275 V 0.1 to 0.9 V: Driving 44 mph (70 km/h) Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor O2S B2 S2 Heated oxygen sensor output voltage for bank 2 sensor 2: Min.: 0 V, Max.: 1.275 V 0.1 to 0.9 V: Driving 44 mph (70 km/h) Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor AFS B1 S1 A/F sensor output voltage for bank 1 sensor 1: Min.: 0 V, Max.: 7.999 V 2.8 to 3.8 V: Idling Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor AFS B1 S1 A/F sensor output current for bank 1 sensor 1: Min.: -128 mA, Max.: 127.99 mA - Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor • • • 2.0 to 2.9 V: Throttle fully closed 4.6 to 5.0 V: Throttle fully open - Read value with intrusive operation (active test) ES ES–46 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display ES Measurement Item/Range Normal Condition Diagnostic Note 2.8 to 3.8 V: Idling Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of sensor A/F sensor output current for bank 2 sensor 1: Min.: -128 mA, Max.: 127.99 mA - Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check current output of sensor TOTAL FT #1 Total fuel trim of bank 1 Average value for fuel trim system of bank 1: Min.: -0.5, Max.: 0.496 -0.2 to 0.2: Idling - TOTAL FT #2 Total fuel trim of bank 2 Average value for fuel trim system of bank 2: Min.: -0.5, Max.: 0.496 -0.2 to 0.2: Idling - SHORT FT #1 Short-term fuel trim of bank 1: Min.: -100 %, Max.: 99.2% 0 +- 20 % Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #1 Long-term fuel trim of bank 1: Min.: -100 %, Max.: 99.2 % 0 +- 20 % Overall fuel compensation carried out in long-term to compensate continual deviation of short-term fuel trim from central value SHORT FT #2 Short-term fuel trim of bank 2: Min.: -100 %, Max.: 99.2% 0 +- 20 % Short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio LONG FT #2 Long-term fuel trim of bank 2: Min.: -100 %, Max.: 99.2 % 0 +- 20 % Overall fuel compensation carried out in long-term to compensate continual deviation of short-term fuel trim from central value AFS B2 S1 A/F sensor output voltage for bank 2 sensor 1: Min.: 0 V, Max.: 7.999 V AFS B2 S1 • • FUEL SYS #1 Fuel system status (Bank1): OL or CL or OL DRIVE or OL FAULT or CL FAULT • CL: Idling after warming up • • • • FUEL SYS #2 Fuel system status (Bank2): OL or CL or OL DRIVE or OL FAULT or CL FAULT • CL: Idling after warming up • • O2FT B1 S2 Short-term fuel trim associated with bank 1 sensor 2: Min.: -100 %, Max.: 99.2 % - OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control, malfunctioning OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control. OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control, malfunctioning - ES–47 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range O2FT B2 S2 Short-term fuel trim associated with bank 2 sensor 2: Min.: -100 %, Max.: 99.2 % AF FT B1 S1 Short-term fuel trim associated with bank 1 sensor 1: Min.: 0, Max.: 1.999 Normal Condition • AFS B1 S1 A/F sensor output current for bank 1 sensor 1: Min.: -128 mA, Max.: 127.99 mA Diagnostic Note • • Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air-fuel ratio=1 Value greater than 1 (1.001 to 1.999) = RICH Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check current output of sensor - • - Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air-fuel ratio=1 Value greater than 1 (1.001 to 1.999) = RICH AF FT B2 S1 Short-term fuel trim associated with bank 2 sensor 1: Min.: 0, Max.: 1.999 CAT TEMP B1S1 Catalyst temperature (Bank 1, Sensor 1): Min.: -40, Max.: 6,513.5 °C - - CAT TEMP B2S1 Catalyst temperature (Bank 2, Sensor 1): Min.: -40, Max.: 6,513.5 °C - - CAT TEMP B1S2 Catalyst temperature (Bank 1, Sensor 2): Min.: -40, Max.: 6,513.5 °C - - CAT TEMP B2S2 Catalyst temperature (Bank 2, Sensor 2): Min.: -40, Max.: 6,513.5 °C - - S O2S B1 S2 Sub heated oxygen sensor impedance (Bank 1, Sensor 2): Min.: 0 Ω, Max.: 21247.68 Ω - - S O2S B2 S2 Sub heated oxygen sensor impedance (Bank 2, Sensor 2): Min.: 0 Ω, Max.: 21247.68 Ω - - Initial engine coolant temperature: Min.: -40°C, Max.: 120°C Coolant temperature when engine started Service data INI INTAKE TEMP Initial intake air temperature: Min.: -40°C, Max.: 120°C Intake air temperature when engine started Service data INJ VOL Injection volume (cylinder 1): Min.: 0 ml, Max.: 2.048 ml 0 to 0.5 ml Quantity of fuel injection volume for 10 times Starter signal: ON or OFF ON: Cranking - Power steering signal: ON or OFF ON: Power steering operation - PS SIGNAL Power steering signal (history): ON or OFF ON: When steering wheel first turned after battery terminals connected This signal status usually ON until battery terminals disconnected CTP SW Closed throttle position switch: ON or OFF ON: Throttle fully closed OFF: Throttle open - A/C signal: ON or OFF ON: A/C ON - PNP switch status: ON or OFF ON: P or N position - ELECT LOAD SIG Electrical load signal: ON or OFF ON: Headlights or defogger turned ON - STOP LIGHT SW Stop light switch: ON or OFF ON: brake pedal depressed - INI COOL TEMP STARTER SIG PS SW A/C SIGNAL PNP SW [NSW] • • - ES ES–48 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Normal Condition Diagnostic Note ON: Ignition switch ON and system normal +BM voltage: Min.: 0, Max.: 19.92182 11 to 14 (V): Ignition switch ON and system normal BATTERY VOLTAGE Battery voltage: Min.: 0 V, Max.: 65.535 V 11 to 14 V: Idling ACTUATOR POWER Actuator power supply: ON or OFF ON: Idling Atmospheric pressure: Min.: 0 kPa, Max.: 255 kPa Equivalent to atmospheric pressure (absolute pressure) - Fuel pump speed control status: ON/H or OFF/L Idling: ON - ACIS VSV ACIS VSV: ON or OFF - ON: Open OFF: Closed ACT VSV A/C cut status for Active Test: ON or OFF - Active Test support data VVT CTRL B2 VVT control (bank 2) status: ON or OFF - Active Test support data EVAP (Purge) VSV VSV status for EVAP control: ON or OFF - Active Test support data FUEL PUMP / SPD Fuel pump/status: ON or OFF - Active Test support data VVT CTRL B1 VVT control (bank 1) status: ON or OFF - Active Test support data VACUUM PUMP Key-off EVAP system pump status: ON or OFF - Active Test support data EVAP VENT VAL Key-off EVAP system vent valve status: ON or OFF - Active Test support data TC/TE1 TC and CG (TE1) terminal of DLC3: ON or OFF - - ENG SPEED #1 Engine RPM for cylinder 1: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED #2 Engine RPM for cylinder 2: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED #3 Engine RPM for cylinder 3: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED #4 Engine RPM for cylinder 4: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED #5 Engine RPM for cylinder 5: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED #6 Engine RPM for cylinder 6: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST ENG SPEED ALL Engine RPM for all cylinders: Min.: 0 rpm, Max.: 25,600 rpm - Output only when FUEL CUT ALL or COMPRESS CHECK is performed using ACTIVE TEST VVT aim angle (bank 1): Min.: 0 %, Max.: 100 % 0 to 100 % VVT duty signal value during intrusive operation VVT change angle: Min.: 0°FR, Max.: 60°FR 0 to 56 °FR Displacement angle during intrusive operation +BM +BM VOLTAGE ATM PRESSURE FUEL PMP SP CTL ES Measurement Item/Range Whether or not electric throttle control system power inputted: ON or OFF VVTL AIM ANGL #1 *1 VVT CHNG ANGL #1 *1 - ETCS service data ETCS service data ES–49 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display VVT OCV DUTY B1 Measurement Item/Range Normal Condition Diagnostic Note VVT OCV operation duty: Min.: 0 %, Max.: 100 % 0 to 100 % Requested duty value for intrusive operation VVT aim angle (bank 2): Min.: 0 %, Max.: 100 % 0 to 100 % VVT duty signal value during intrusive operation VVT change angle (bank 2): Min.: 0°FR, Max.: 60°FR 0 to 56 °FR Displacement angle during intrusive operation VVT OCV (bank 2) operation duty: Min.: 0 %, Max.: 100 % 0 to 100 % Requested duty value for intrusive operation FC IDL Fuel cut idle: ON or OFF ON: Fuel cut operation FC IDL = "ON" when throttle valve fully closed and engine speed over 3,500 rpm FC TAU Fuel cut TAU: Fuel cut during very light load: ON or OFF ON: Fuel cut operating Fuel cut being performed under very light load to prevent engine combustion from becoming incomplete Ignition counter: Min.: 0, Max.: 600 0 to 600 CYL #1 Misfire ratio of cylinder 1: Min.: 0, Max.: 255 0 This item displayed in only idling CYL #2 Misfire ratio of cylinder 2: Min.: 0, Max.: 255 0 This item displayed in only idling CYL #3 Misfire ratio of cylinder 3: Min.: 0, Max.: 255 0 This item displayed in only idling CYL #4 Misfire ratio of cylinde 4: Min.: 0, Max.: 255 0 This item displayed in only idling CYL #5 Misfire ratio of cylinder 5: Min.: 0, Max.: 255 0 This item displayed in only idling CYL #6 Misfire ratio of cylinder 6: Min.: 0, Max.: 255 0 This item displayed in only idling CYL ALL All cylinders misfire rate: Min.: 0, Max.: 255 0 to 35 - MISFIRE RPM Engine RPM for first misfire range: Min.: 0 rpm, Max.: 6,375 rpm 0 rpm: Misfire 0 - MISFIRE LOAD Engine load for first misfire range: Min.: 0 g/rev, Max.: 3.98 g/rev 0 g/rev: Misfire 0 - Margin to detect engine misfire: Min.: -100 %, Max.: 99.22 % -100 to 99.2 % Number of detected DTCs: Min.: 0, Max.: 255 0: No DTC detected Check mode: ON or OFF ON: Check mode ON SPD TEST Check mode result for vehicle speed sensor: COMPL or INCMPL - - MISFIRE TEST Check mode result for misfire monitor: COMPL or INCMPL - - OXS2 TEST Check mode result for HO2 sensor (bank 2) : COMPL or INCMPL - - OXS1 TEST Check mode result for HO2 sensor (bank 1) : COMPL or INCMPL - - Check mode result for air-fuel ratio sensor (bank 2) : COMPL or INCMPL - - *1 VVTL AIM ANGL #2 *1 VVT CHNG ANGL #2 *1 VVT OCV DUTY B2 * 1 IGNITION MISFIRE MARGIN #CODES CHECK MODE A/F SSR TEST B2 - Misfire detecting margin See page ES-35 ES ES–50 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note Check mode result for air-fuel ratio sensor (bank 1) : COMPL or INCMPL - - MIL status: ON or OFF ON: MIL ON - MIL ON RUN DIST MIL ON RUN Distance: Min.: 0 km, Max.: 65,535 km Drive distance after DTC detected - MIL ON RUN TIME Running time from MIL ON: Min.: 0 min., Max.: 65,535 min. Equivalent to running time after MIL ON - Engine run time: Min.: 0 s., Max.: 65,535 s. Time after engine start TIME DTC CLEAR Time after DTC cleared: Min.: 0 min., Max.: 65,535 min. Equivalent to time after DTCs erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km, Max.: 65,535 km Equivalent to drive distance after DTCs erased - Number of warm-up cycles after DTC cleared: Min.: 0, Max.: 255 - - A/F SSR TEST B1 MIL ENG RUN TIME ES WU CYC DTC CLEAR OBD CERT Service data OBD requirement OBD2 - #CARB CODES Number of emission related DTCs 0: No emission related DTC detected - COMP MON Comprehensive component monitor: NOT AVL or AVAIL - - FUEL MON Fuel system monitor: NOT AVL or AVAIL - - MISFIRE MON Misfire monitor: NOT AVL or AVAIL - - EGR MON EGR monitor: NOT AVL or AVAIL - - EGR MON EGR monitor: COMPL or INCMPL - - O2S (A/FS) HTR O2S (A/FS) heater monitor: NOT AVL or AVAIL - - O2S (A/FS) HTR O2S (A/FS) heater monitor: COMPL or INCMPL - - O2S (A/FS) MON O2S (A/FS) monitor: NOT AVL or AVAIL - - O2S (A/FS) MON O2S (A/FS) monitor: COMPL or INCMPL - - A/C MON A/C monitor: NOT AVL or AVAIL - - A/C MON A/C monitor: COMPL or INCMPL - - 2nd AIR MON 2nd air monitor: NOT AVL or AVAIL - - 2nd AIR MON 2nd air monitor: COMPL or INCMPL - - EVAP MON EVAP monitor: NOT AVL or AVAIL - - EVAP MON EVAP monitor: COMPL or INCMPL - - Heated catalyst monitor: NOT AVL or AVAIL - - HTD CAT MON ES–51 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note Heated catalyst monitor: COMPL or INCMPL - - CAT MON Catalyst monitor: NOT AVL or AVAIL - - CAT MON Catalyst monitor: COMPL or INCMPL - - CCM ENA Comprehensive component monitor: UNABLE or ENABLE - - CCM CMPL Comprehensive component monitor: COMPL or INCMPL - - FUEL ENA Fuel system monitor: UNABLE or ENABLE - - FUEL CMPL Fuel system monitor: COMPL or INCMPL - - MISFIRE ENA Misfire monitor: UNABLE or ENABLE - - Misfire monitor: COMPL or INCMPL - - EGR monitor: UNABLE or ENABLE - - EGR monitor: COMPL or INCMPL - - HTR ENA O2S (A/FS) heater monitor: UNABLE or ENABLE - - HTR CMPL O2S (A/FS) heater monitor: COMPL or INCMPL - - O2S (A/FS) ENA O2S (A/FS) monitor: UNABLE or ENABLE - - O2S (A/FS) CMPL O2S (A/FS) monitor: COMPL or INCMPL - - ACRF ENA A/C monitor: UNABLE or ENABLE - - A/C monitor: COMPL or INCMPL - - 2nd air monitor: UNABLE or ENABLE - - AIR CMPL 2nd air monitor: COMPL or INCMPL - - EVAP ENA EVAP monitor: UNABLE or ENABLE - - EVAP monitor: COMPL or INCMPL - - HCAT ENA Heated catalyst monitor: UNABLE or ENABLE - - HCAT CMPL Heated catalyst monitor: COMPL or INCMPL - - Catalyst monitor: UNABLE or ENABLE - - Catalyst monitor: COMPL or INCMPL - - MODEL CODE Identifying model code GSJ1## - ENGINE TYPE Identifying engine type 1GRFE - Identifying cylinder number: Min.: 0, Max.: 255 6 - Identifying transmission type: MT or 5AT MT: Manual transmission 5AT: Automatic transmission - HTD CAT MON MISFIRE CMPL EGR ENA EGR CMPL ACRF CMPL AIR ENA EVAP CMPL CAT ENA CAT CMPL CYLINDER NUMBER TRANSMISSION ES ES–52 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note DESTINATION Identifying destination A (America) - MODEL YEAR Identifying model year: Min.: 1900, Max.: 2155 200# - Identifying engine system GASLIN (gasoline engine) - SYSTEM 2. ES Tester Display *1: DATA LIST values are only displayed when performing the following ACTIVE TESTs: VVT B1 or VVT B2. For other ACTIVE TESTs, the DATA LIST value will be 0. ACTIVE TEST HINT: Performing an ACTIVE TEST enables components including the relays, VSV (Vacuum Switching Valve), and actuators, to be operated without removing any parts. The ACTIVE TEST can be performed with an intelligent tester. Performing an ACTIVE TEST as the first step of troubleshooting is one method of shortening diagnostic time. DATA LIST can be displayed during ACTIVE TESTs. (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (e) Perform the ACTIVE TEST by referring to the table below. Test Part Control Range Diagnostic Notes • • INJ VOL Change injection volume Between -12.5 % and 24.8 % • • • All injectors tested at same time Perform test at less than 3,000 rpm Injection volume can be changed in 0.1 % graduations within control range Perform test at less than 3,000 rpm A/F CONTROL enables checking and graphing of A/F (Air Fuel Ratio) sensor and Heated Oxygen (HO2) sensor voltage outputs To conduct test, select following menu items: ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2, and press YES and ENTER followed by F4 A/F CONTROL Change injection volume Lower by 12.5 % or increase by 25 % FUEL PMP SP CTL Fuel pump speed control ON (low speed)/ OFF (high speed) - INTAKE CTL VSV1 ACIS VSV ON/OFF - EVAP VSV (ALONE) Activate EVAP VSV control ON/OFF - A/C CUT SIG Control A/C cut signal ON/OFF - FUEL PUMP/SPD Activate fuel pump (C/OPN Relay) ON/OFF - • ES–53 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Test Part Control Range Diagnostic Notes • TC/TE1 Turn on and off TC and CG (TE1) connection ON/OFF FC IDL PROHBT Prohibit idling fuel cut control ON/OFF ETCS OPEN SLOW Throttle actuator ON: throttle valve opens slowly ETCS CLOSE SLOW Throttle actuator ON: throttle valve closes slowly ETCS OPEN FAST Throttle actuator ON: throttle valve opens fast ETCS CLOSE FAST Throttle actuator ON: throttle valve closes fast Control the VVT (bank 1) -128 to 127 % This value added to present OCV control duty 100 %: Maximum advance -100 % : Maximum retard VVT B1 • Test possible when following conditions met: • Ignition switch ON • Engine does not start • Fully depressing accelerator pedal (APP: 58 degrees or more) • • • VVT CTRL B1 VVT B2 Turn on and off OCV (Oil Control Valve) ON/OFF Control the VVT (bank 2) -128 to 127 % This value added to present OCV control duty 100 %: Maximum advance -100 % : Maximum retard ON: TC and CG (TE1) connected OFF: TC and CG (TE1) disconnected • • • • Engine stall or rough idle when VVT actuator operated by 100 % Test possible during engine idling Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV off Engine stall or rough idle when VVT actuator operated by 100 % Test possible during engine idling Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV off VVT CTRL B2 Turn on and off OCV (Oil Control Valve) ON/OFF VACUUM PUMP Leak detection pump ON/OFF - VENT VALVE Vent valve ON/OFF - FUEL CUT #1 Cylinder #1 injector fuel cut ON/OFF FUEL CUT #2 Cylinder #2 injector fuel cut ON/OFF FUEL CUT #3 Cylinder #3 injector fuel cut ON/OFF FUEL CUT #4 Cylinder #4 injector fuel cut ON/OFF FUEL CUT #5 Cylinder #5 injector fuel cut ON/OFF FUEL CUT #6 Cylinder #6 injector fuel cut ON/OFF FUEL CUT ALL All cylinder injectors fuel cut ON/OFF COMPRESS CHECK All cylinder injectors fuel cut and ignition stop ON/OFF • Test possible during vehicle stopping and engine idling * HINT: *: When cranking the engine, each cylinder measures the engine rpm. In this ACTIVE TEST, the fuel and ignition of all cylinders are cut, and cranking occurs for approximately 10 seconds. Then, each cylinder measures the engine rpm. If a cylinder's engine rpm is higher than the others, that cylinder's compression pressure is compared to the others, and is determined whether it is low or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester to the DLC3. 4. Turn the ignition switch ON and turn the intelligent tester on. ES ES–54 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ᵏ ᵓᵏᵏᵗᵗ ᵐ ᵓᵏᵏᵗᵗ ᵑ ᵓᵏᵏᵗᵗ ᵒ ᵓᵏᵏᵗᵗ ᵓ ᵓᵏᵏᵗᵗ ᵔ ᵓᵏᵏᵗᵗ ᵓᵏᵏᵗᵗ ES A133492 ᵏ ᵐᵒᵑ ᵐ ᵐᵒᵒ ᵑ ᵐᵒᵓ ᵒ ᵐᵒᵒ ᵓ ᵐᵒᵒ ᵔ ᵐᵒᵒ ᵐᵒᵒ A133493 5. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / COMPRESS CHECK. HINT: If the results are not displayed normally, select the display items from the DATA LIST before performing the ACTIVE TEST. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / ENG SPEED #1, ENG SPEED #2, ENG SPEED #3, ENG SPEED #4, ENG SPEED #5, ENG SPEED #6 (Press the YES button to change the ENG SPEED #1 to #6) and then press the ENTER button. 6. While the engine is not running, press the RIGHT or LEFT button to change the COMPRESS CHECK to ON. HINT: After performing the above procedure, the ACTIVE TEST's COMPRESS CHECK will start. Fuel injection for all cylinders is prohibited, and each cylinder's engine rpm measurement will enter standby mode. 7. Fully open the throttle. 8. Crank the engine for about 10 seconds. 9. Monitor the engine speed (ENG SPEED #1 to #6) displayed on the tester. HINT: At first, the tester's display will show each cylinder's engine rpm measurement to be extremely high. After approximately 10 seconds of engine cranking, each cylinder's engine rpm measurement will change to the actual engine rpm. NOTICE: • After the ACTIVE TEST's COMPRESS CHECK is turned ON, it will automatically turn off after 255 seconds. • When the COMPRESS CHECK test is OFF and the engine is cranked, the engine will start. • If the COMPRESS CHECK test needs to be performed after it is turned ON and performed once, press EXIT to return to the ACTIVE TEST menu screen. Then perform the COMPRESS CHECK test again. • Use a fully-charged battery. ES–55 1GR-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. Tester Display SYSTEM CHECK HINT: Performing a SYSTEM CHECK enables the system, which consists of multiple actuators, to be operated without removing any parts. In addition, it can show whether or not any DTCs are set, and can detect potential malfunctions in the system. The SYSTEM CHECK can be performed with an intelligent tester. (a) Connect an intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK. (e) Perform the SYSTEM CHECK by referring to the table below. Test Part Control Range Diagnostic Notes • EVAP SYS CHECK (AUTO OPERATION) Perform 5 steps in order to operate EVAP key-off monitor automatically - • • • EVAP SYS CHECK (MANUAL OPERATION) Perform 5 steps in order to operate EVAP key-off monitor manually • • If no DTCs in PENDING CODE after performing this test, system functioning normally Refer to EVAP Inspection Procedure (See page ES343) Recommended fuel temperature is 35°C (95°F) or less Used to detect malfunctioning parts Refer to EVAP Inspection Procedure (See page ES343) Recommended fuel temperature is 35°C (95°F) or less ES ES–429 1GR-FE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY INSPECTION Battery 1. Ohmmeter A098613E02 INSPECT EFI RELAY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the EFI relay. ES ES–434 1GR-FE ENGINE CONTROL SYSTEM – ECM REMOVAL 1. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 2. REMOVE GLOVE COMPARTMENT DOOR SUBASSEMBLY 3. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 4. REMOVE ECM (a) Disconnect the 5 the ECM connectors from the ECM. (b) Remove the 3 nuts and the ECM. (c) Remove the 2 screws and the ECM bracket No. 1 from the ECM. (d) Remove the 2 screws and the ECM bracket No. 2 from the ECM. ES A072578 INSTALLATION 1. INSTALL ECM (a) Install the ECM bracket No. 2 with the 2 screws to the ECM. (b) Install the ECM bracket No. 1 with the 2 screws to the ECM. (c) Install the ECM with the 3 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (d) Connect the 5 ECM connectors to the ECM. 2. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.2 3. INSTALL GLOVE COMPARTMENT DOOR SUBASSEMBLY 4. INSTALL INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 A072578 1GR-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–437 INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD ASSEMBLY NOTICE: • Avoid physical shock to the accelerator pedal assembly. • Do not disassemble the accelerator pedal assembly. (a) Install the accelerator pedal assembly with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the accelerator pedal connector. ES A067127 ES–430 1GR-FE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY INSPECTION Battery 1. Ohmmeter ES A098613E02 INSPECT CIRCUIT OPENING RELAY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the circuit opening relay. ES–431 1GR-FE ENGINE CONTROL SYSTEM – FUEL PUMP RELAY FUEL PUMP RELAY INSPECTION 1. INSPECT FUEL PUMP RELAY ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Battery Ohmmeter Ohmmeter Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (Apply battery voltage to terminals 1 and 2) 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the fuel pump relay. A094494E01 ES ES–432 1GR-FE ENGINE CONTROL SYSTEM – ECM ECM 1GR-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES ECM A119838E01 1GR-FE ENGINE CONTROL SYSTEM – ECM ES–433 ES INSTRUMENT PANEL FINISH PANEL LOWER NO.2 GLOVE COMPARTMENT DOOR SUB-ASSEMBLY INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO. 2 B120192E01 1GR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL ROD: REMOVAL (2007 4Run... Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Control Model Year: 2007 Model: 4Runner Doc ID: RM0000028B2002X Title: 1GR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL ROD: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE ACCELERATOR PEDAL ROD ASSEMBLY (a) Disconnect the accelerator pedal connector. (b) Remove the 2 nuts and the accelerator pedal assembly. ES–3 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION FUEL INJECTOR PURGE VSV VSV FOR AIR INJECTION CONTROL (BANK 1) ECM VSV FOR AIR INJECTION CONTROL (BANK 2) ACIS VSV AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) COMBINATION METER PARK / NEUTRAL POSITION SWITCH THROTTLE BODY STOP LIGHT SWITCH MASS AIR FLOW METER CANISTER FUEL PUMP HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) ENGINE COOLANT TEMPERATURE SENSOR HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) DLC3 ACCELERATOR PEDAL KNOCK SENSOR (NO. 2) KNOCK SENSOR (NO. 1) AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) ENGINE ROOM RELAY BLOCK: - STARTER RELAY - EFI RELAY - CIRCUIT OPENING RELAY A152304E01 ES ES–4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NO. 2 AIR SWITCHING VALVE (NO. 2 ASV) (BANK 2) VVT SENSOR (BANK 2) ES NO. 2 AIR SWITCHING VALVE (NO. 2 ASV) (BANK 1) OCV (BANK 2) AIR PUMP VVT SENSOR (BANK 1) CAMSHAFT POSITION SENSOR AIR SWITCHING VALVE (ASV) IGNITION COIL ASSEMBLY CRANKSHAFT POSITION SENSOR OCV (BANK 1) A119841E03 ES–5 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM IG SW ECM IGSW Combination Meter W MIL To Battery STSW STA Relay PNP SW OC1+ STAR/NSW STA To Battery VVT OCV (Bank 1) ES OC1- OC2+ VVT OCV (Bank 2) OC2- To Starter EFI BATT To Battery EFI Relay KNK1 Knock Sensor (Bank 1) EKNK MREL KNK2 Knock Sensor (Bank 2) EKN2 G2+ ETCS To Battery +BM G2- To VC Terminal Camshaft Position Sensor +B Accelerate Pedal Position Sensor +B2 NE+ VCPA NE- VPA VV1+ EPA VV1- VCP2 VV2+ VPA2 VV2- Crankshaft Position Sensor VVT Sensor (Bank 1) VVT Sensor (Bank 2) EPA2 G039841E05 ES–6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM To Battery To A/F HEATER Relay A/F Sensor (Bank 1 Sensor 1) HA1A Fuel Injector #1 A1A+ A1AA/F Sensor (Bank 2 Sensor 1) HA2A A2A+ To EFI Relay #10 Fuel Injector #2 #20 Fuel Injector #3 #30 Fuel Injector #4 A2AHO2 Sensor (Bank 1 Sensor 2) ES HT1B OXIB #40 Fuel Injector #5 #50 Fuel Injector #6 To EFI No. 2 Fuse HO2 Sensor (Bank 2 Sensor 2) HT2B #60 Fuel Injector #7 OX2B #70 E2 VSV (Purge) Fuel Injector #8 #80 PRG IGT1 Ignition Coil and Igniter No. 1 IGT2 Ignition Coil and Igniter No. 2 IGT3 Ignition Coil and Igniter No. 3 IGT4 Ignition Coil and Igniter No. 4 IGT5 Ignition Coil and Igniter No. 5 IGT6 Ignition Coil and Igniter No. 6 PPMP IGT7 Ignition Coil and Igniter No. 7 VPMP IGT8 Ignition Coil and Igniter No. 8 VSV (ACIS) ACIS VSV (AI Control) AIV1 VSV (AI Control) AIV2 Mass Air Flow Meter To VC Terminal THA E2G VG E2 ETC Sensor THW Pump Module Pressure Sensor Control Valve IGF1 MPMP IGF2 G039842E03 ES–7 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM To Battery To EFI Relay ACC Cut Relay AI Driver ACCR To Battery AIDI To IG SW AIRP AIRV Air Pump ASV To E2 Terminal Stop Light SW To IGN1 Fuse ST1Pressure Sensor AIP ES To Battery STP E01 Throttle Body E02 GE01 E04 M+ M- VTA1 To E2 Terminal VC E05 E1 E03 ME01 VTA2 EC C/OPN Relay To Battery DLC3 FC EOM TC To EFI Relay Fuel Pump Relay Fuel Pump Resister TC CANL CANL CANH CANH FPR Fuel Pump G039843E01 ES–8 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. ES NEXT 3 CHECK DTC AND FREEZE FRAME DATA* HINT: Record or print DTCs and freeze frame data, if necessary (See page ES-35). NEXT 4 CLEAR DTC AND FREEZE FRAME DATA* HINT: (See page ES-35) NEXT 5 CONDUCT VISUAL INSPECTION NEXT 6 SET CHECK MODE DIAGNOSIS* HINT: (See page ES-36) NEXT ES–9 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CONFIRM PROBLEM SYMPTOMS HINT: If the engine does not start, first perform the "check DTC" procedures and "conduct basic inspection" procedures below. B Result Proceed to Malfunction does not occur A Malfunction occurs B GO TO STEP 9 A 8 ES SIMULATE SYMPTOMS NEXT 9 CHECK DTC* HINT: (See page ES-35) B Result Proceed to Malfunction code A No code B GO TO STEP 11 A 10 REFER TO DTC CHART HINT: (See page ES-48) NEXT GO TO STEP 13 11 CONDUCT BASIC INSPECTION HINT: (See page ES-10) Result Proceed to Malfunctioning parts not confirmed A Malfunctioning parts confirmed B ES–10 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B GO TO STEP 16 A 12 REFER TO PROBLEM SYMPTOMS TABLE HINT: (See page ES-26) ES Result Proceed to Malfunctioning circuit confirmed A Malfunctioning parts confirmed B B GO TO STEP 16 A 13 CHECK ECM POWER SOURCE CIRCUIT HINT: (See page ES-454) NEXT 14 CONDUCT CIRCUIT INSPECTION Result Proceed to Malfunction not confirmed A Malfunction confirmed B B GO TO STEP 17 A 15 CHECK FOR INTERMITTENT PROBLEMS HINT: (See page ES-10) NEXT GO TO STEP 17 16 NEXT CONDUCT PARTS INSPECTION 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 17 ES–11 IDENTIFY PROBLEM NEXT 18 ADJUST, REPAIR OR REPLACE NEXT 19 NEXT END CONDUCT CONFIRMATION TEST ES ES–43 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST 1. Tester Display DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) According to the display on the tester, use the DATA LIST. Measurement Item/Range Normal Condition Diagnostic Note INJECTOR Injection period of the No. 1 cylinder: Min.: 0 ms, Max.: 32.64 ms 2.3 to 3.8 ms: idling - IGN ADVANCE Ignition timing advance for No. 1 cylinder: Min.: -64 deg., Max.: 63.5 deg. BTDC 4 to 17°: Idling - CALC LOAD Calculated load by ECM: Min.: 0 %, Max.: 100 % • • - VEHICLE LOAD Vehicle load: Min.: 0%, Max.: 25700 % 11 to 21 %: Idling 12 to 22 %: Running without load (2,500 rpm) Actual vehicle load - MAF Air flow rate from Mass air flow (MAF) meter: Min.: 0 g/sec., Max.: 655 g/sec. 2.0 to 3.9 g/sec.: Idling If the value approximately 0.0 g/sec.: • Mass air flow meter power source circuit open • VG circuit open or short if the value 160.0 g/sec. or more: • E2G circuit open ENGINE SPD Engine speed: Min.: 0 rpm, Max.: 16,383 rpm 550 to 650 rpm: Idling - VEHICLE SPD Vehicle speed: Min.: 0 km/h, Max.: 255 km/h Actual vehicle speed Speed indicated on speedometer COOLANT TEMP Engine coolant temperature: Min.: -40°C, Max.: 140°C 80 to 100°C (176 to 212°F): After warming up If the value -40°C (-40°F): sensor circuit open If the value 140°C (284°F): sensor circuit shorted INTAKE AIR Intake air temperature: Min.: -40°C, Max.: 140°C Equivalent to ambient air temperature If the value -40°C (-40°F): sensor circuit open If the value 140°C (284°F): sensor circuit shorted SECONDARY AIR Second air system status: ON or OFF ON: Second air system operation - AIR-FUEL RATIO Air fuel ratio: Min.: 0, Max.: 1.999 0.8 to 1.2: During idling - PURGE DENSITY Learning value of purge density: Min.: -50, Max.: 350 Idling: -40 to 0 % Service data PURGE FLOW Purge flow: Min.: 0 %, Max.: 102.4 % 0 to 100 %: Idling - ES ES–44 Tester Display 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item/Range Normal Condition Diagnostic Note EVAP PURGE VSV Purge VSV control duty: Min.: 0 %, Max.: 100 % 0 to 100 %: During idling Order signal from ECM VAPOR PRESS Vapor pressure: Min.: -4.125 kPa, Max.: 2.125 kPa 0 KPa: Fuel tank cap removed Pressure inside fuel tank monitored by vapor pressure sensor KNOCK CRRT VAL Correction learning value of knocking: Min.: -64 CA, Max.: 1984 CA 0 to 22° CA: Driving, 70 km/h (44 mph) Service data KNOCK FB VAL Feedback value of knocking: Min.: -64 CA, Max.: 1984 CA -22 to 0° CA: Driving, 70 km/h (44 mph) Service data EVAP VAPOR PRES EVAP vapor pressure: Min.: -8192 Pa, Max.: 8191 Pa 0 Pa: Fuel tank cap removed - ACCEL POS #1 Absolute Accelerator Pedal Position (APP) No. 1: Min.: 0%, Max.: 100 % 10 to 22 %: accelerator pedal is released 54 to 86 %: accelerator pedal is fully depressed - ACCEL POS #2 Absolute APP No. 2: Min.: 0 %, Max.: 100 % 12 to 42 %: accelerator pedal is released 66 to 98 %: accelerator pedal is fully depressed - ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze data ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 4.98 V - ETCS freeze data ACCEL POS #1 APP sensor No. 1 voltage: Min.: 0 V, Max.: 5 V 0.5 to 1.1 V: accelerator pedal is released 2.6 to 4.5 V: or pedal is fully depressed - ACCEL POS #2 APP sensor No. 2 voltage: Min.: 0 V, Max.: 5 V 1.2 to 2.0 V: accelerator pedal is released 3.4 to 5.3 V: accelerator pedal is fully depressed - ACCEL IDL POS Whether or not accelerator pedal position sensor detecting idle: ON or OFF ON: Idling - THRTL LEARN VAL Throttle valve fully closed (learned value) 0.4 to 0.8 V - ACCEL SSR #1 AD Accelerator fully closed value No. 1 (AD): Min.: 0, Max.: 4.98 V - ETCS service data ACCEL LRN VAL#1 Accelerator fully closed learning value No. 1: Min.: 0, Max.: 124.512 - ETCS service data ACCEL LRN VAL#2 Accelerator fully closed learning value No. 2: Min.: 0, Max.: 124.512 - ETCS service data FAIL #1 Whether or not fail-safe function executed: ON or OFF ON: ETCS has failed - FAIL #2 Whether or not fail-safe function executed: ON or OFF ON: ETCS has failed - ST1 Stater signal: ON or OFF ON: Cranking - SYS GUARD JUDGE System guard: ON or OFF - ETCS service data OPN MALFUNCTION Open side malfunction: ON or OFF - ETCS service data THROTTLE POS Absolute throttle position sensor: Min.: 0 %, Max.: 100 % • • ES 10 to 24 %: Throttle fully closed 64 to 96 %: Throttle fully open Read the value with intrusive operation (Active Test) ES–45 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note THROTTLE IDL POS Whether or not throttle position sensor detecting idle: ON or OFF ON: Idling - THROTTLE REQ POS Throttle requirement position: Min.: 0 V, Max.: 5 V 0.5 to 1.0 V: Idling - THROTTLE POS Throttle sensor positioning: Min.: 0 %, Max.: 100 % 10 to 18 %: Idling Calculated value based on VTA1 THROTTLE POS #2 Throttle sensor positioning #2: Min.: 0 %, Max.: 100 % - Calculated value based on VTA2 THROTTLE POS #1 Throttle position sensor No. 1 output voltage: Min.: 0 V, Max.: 4.9 V - ETCS freeze data THROTTLE POS #2 Throttle position sensor No. 2 output voltage: Min.: 0 V, Max.: 4.9 V - ETCS freeze data THROTTLE POS #1 Throttle position No. 1: Min.: 0 V, Max.: 5 V • • 0.5 to 1.2 V: Throttle fully closed 3.2 to 4.8 V: Throttle fully open - THROTTLE POS #2 Throttle position No. 2: Min.: 0 V, Max.: 5 V • • 2.0 to 2.9 V: Throttle fully closed 4.6 to 5.5 V: Throttle fully open Read the value with intrusive operation (Active Test) THRTL COMND VAL Throttle position command value: Min.: 0 V, Max.: 4.98 V 0.5 to 4.8 V ETCS service data THROTTLE SSR #1 Throttle sensor opener position No. 1: Min.: 0 V, Max.: 4.98 V 0.6 to 0.9 V ETCS service data THROTTLE SSR #2 Throttle sensor opener position No. 2: Min.: 0 V, Max.: 4.98 V 2.2 to 2.6 V ETCS service data THRTL SSR #1 AD Throttle sensor opener position No. 1 (AD): Min.: 0 V, Max.: 4.98 V 0.6 to 0.9 V ETCS service data THROTTLE MOT Whether or not throttle actuator control permitted: ON or OFF ON: Idling Read the value with the ignition switch ON (Do not start engine) THROTTLE MOT Throttle actuator current: Min.: 0 A, Max.: 80 A 0 to 3.0 A: Idling - THROTTLE MOT Throttle actuator: Min.: 0 %, Max.: 100 % 0.5 to 40 %: Idling - THROTTLE MOT Throttle actuator current: Min.: 0 A, Max.: 19.92 A 0 to 3.0 A: Idling - THROTL OPN DUTY Throttle actuator opening duty ratio: Min.: 0 %, Max.: 100 % 0 to 40 %: During idling When accelerator pedal depressed, duty ratio increased THROTL CLS DUTY Throttle actuator closed duty ratio: Min.: 0 %, Max.: 100 % 0 to 40 %: During idling When accelerator pedal released quickly, duty ratio increased THRTL MOT (OPN) Throttle actuator duty ratio (open): Min.: 0 %, Max.: 100 % - ETCS service data THRTL MOT (CLS) Throttle actuator duty ratio (close): Min.: 0 %, Max.: 100 % - ETCS service data O2S B1 S2 Heated oxygen sensor output voltage for bank 1 sensor 2: Min.: 0 V, Max.: 1.275 V 0.1 to 0.9 V: Driving 44 mph (70 km/h) Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor O2S B2 S2 Heated oxygen sensor output voltage for bank 2 sensor 2: Min.: 0 V, Max.: 1.275 V 0.1 to 0.9 V: Driving 44 mph (70 km/h) Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor AFS B1 S1 Air fuel ratio sensor output voltage for bank 1 sensor 1: Min.: 0 V, Max.: 7.999 V 2.8 to 3.8 V: Idling Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor ES ES–46 Tester Display 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item/Range Normal Condition Diagnostic Note AFS B2 S1 Air fuel ratio sensor output voltage for bank 2 sensor 1: Min.: 0 V, Max.: 7.999 V 2.8 to 3.8 V: Idling Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor TOTAL FT #1 Total fuel trim of bank 1 Average value for fuel trim system of bank 1: Min.: -0.5 V, Max.: 1496 V -0.2 to 0.2: idling - TOTAL FT #2 Total fuel trim of bank 2 Average value for fuel trim system of bank 2: Min.: -0.5 V, Max.: 1496 V -0.2 to 0.2: idling - SHORT FT #1 Short-term fuel trim of bank 1: Min.: -100 %, Max.: 99.2 % -20 to +20 % This item refers to the short-term fuel compensation used to maintain the air fuel ratio at stoichiometric air-fuel ratio SHORT FT #2 Short-term fuel trim of bank 2: Min.: -100 %, Max.: 99.2 % -20 to +20 % This item refers to the short-term fuel compensation used to maintain the air fuel ratio at stoichiometric air-fuel ratio -20 to +20 % This item refers to the overall fuel compensation carried out in longterm to compensate a continual deviation of the short-term fuel trim from the central value -20 to +20 % This item refers to the overall fuel compensation carried out in longterm to compensate a continual deviation of the short-term fuel trim from the central value ES LONG FT #1 Long-term fuel trim of bank 1: Min.: -100 %, Max.: 99.2 % LONG FT #2 Long-term fuel trim of bank 2: Min.: -100 %, Max.: 99.2 % • • FUEL SYS #1 Fuel system status (bank 1): OL, CL, OL DRIVE, OL FAULT or CL FAULT • CL: Idling after warming up • • • • FUEL SYS #2 Fuel system status (bank 2): OL, CL, OL DRIVE, OL FAULT or CL FAULT • CL: Idling after warming up • • O2 FT B1 S2 Short-term fuel trim associated with the bank 1 sensor 2: Min.: -100 %, Max.: 99.2 % -20 to +20 % OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which used for fuel control malfunctioning Same as SHORT FT #1 ES–47 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note O2 FT B2 S2 Short-term fuel trim associated with the bank 2 sensor 2: Min.: -100 %, Max.: 99.2 % AF FT B1 S1 Short-term fuel trim associated with the bank 1 sensor 1: Min.: 0, Max.: 1.999 AF FT B2 S1 Short-term fuel trim associated with the bank 2 sensor 1: Min.: 0, Max.: 1.999 CAT TEMP B1S1 Catalyst temperature (bank 1, sensor 1): Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B2S1 Catalyst temperature (bank 2, sensor 1): Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B1S2 Catalyst temperature (bank 1, sensor 2): Min.: -40, Max.: 6,513.5°C - - CAT TEMP B2S2 Catalyst temperature (bank 2, sensor 2): Min.: -40, Max.: 6,513.5°C - - INI COOL TEMP Initial engine coolant temperature: Min.: -40°C , Max.: 140°C Close to ambient air temperature Service data INI INTAKE TEMP Initial intake air temperature: Min.: -40°C , Max.: 140°C Close to ambient air temperature Service data INJ VOL Injection volume (cylinder 1): Min.: 0 ml, Max.: 2.048 ml 0 to 0.5 ml Quantity of fuel injection volume for 10 times STARTER SIG Starter signal: ON or OFF ON: Cranking - AIR PMP PRS (A) Air pump pressure (absolute): Min.: 0 kPa, Max.: 320 kPa - Air pump pressure (absolute) ACC RELAY Acc Relay status: ON or OFF ON: Cranking - STARTER RELAY Starter relay status: ON or OFF ON: Cranking - STARTER CONTROL Starter switch status: ON or OFF ON: Cranking - CTP SW Closed throttle position switch: ON or OFF • • - A/C SIGNAL A/C signal: ON or OFF ON: A/C ON - ELECT LOAD SIG Electrical load signal: ON or OFF ON: Headlights or defogger is turned ON - STOP LIGHT SW Stop light switch: ON or OFF ON: Brake pedal is depressed. - +BM Whether or not electric throttle control system power inputted: ON or OFF ON: Idling - +BM VOLTAGE +BM voltage: Min.: 0, Max.: 19.92 10 to 15 V: Idling ETCS service data BATTERY VOLTAGE Battery voltage: Min.: 0 V, Max.: 65,535 V 9 to 14 V: Idling - ACTUATOR POWER Actuator power supply: ON or OFF ON: Idling ETCS service data ATM PRESSURE Atmospheric pressure: Min.: 0 kPa, Max.: 150 kPa Equivalent to atmospheric pressure (absolute pressure) - -20 to +20 % • • • • • • Same as SHORT FT #1 Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air fuel ratio = 1 Value greater than 1 (1.001 to 1.999) = Rich - Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air fuel ratio = 1 Value greater than 1 (1.001 to 1.999) = Rich - ON: Throttle fully closed OFF: Throttle open ES ES–48 Tester Display ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Measurement Item/Range Normal Condition Diagnostic Note SECOND AIR VSV Secondary air injection system status ON: Secondary air injection system operation FUEL PMP SP CTL F/PMP relay status: ON or OFF - Active test support data ACIS VSV VSV status for ACIS control: ON or OFF - Active test support data ACT VSV A/C cut status for Active Test: ON or OFF - Active Test support data EVAP (Purge) VSV VSV status for EVAP control: ON or OFF - Active Test support data FUEL PUMP / SPD Fuel pump/speed status: ON or OFF - Active Test support data VVT CTRL B1 Variable valve timing (VVT) control status (bank 1): ON or OFF - Active Test support data VVT CTRL B2 VVT control status (bank 2): ON or OFF - Active Test support data VACUUM PUMP Key-off EVAP system pump status: ON or OFF - Active Test support data EVAP VENT VAL Key-off EVAP system vent valve status: ON or OFF - Active Test support data TC/TE1 TC and TE1 terminal of DLC3: ON or OFF - - AI STATUS AI operation prohibit: OK or NG OK - VVTL AIM ANGL #1 VVT aim angle (bank 1): Min.: 0 %, Max.: 100 % 0 %: Idling VVT duty signal value during intrusive operation VVTL AIM ANGL #2 VVT aim angle (bank 2): Min.: 0 %, Max.: 100 % 0 %: Idling VVT duty signal value during intrusive operation VVTL CHAG ANGL #1 VVT change angle (bank 1): Min.: 0° FR , Max.: 60° FR 0 to 5° FR: Idling Displacement angle during intrusive operation VVT CHNG ANGL #2 VVT change angle (bank 2): Min.: 0° FR , Max.: 60° FR 0 to 5° FR: Idling Displacement angle during intrusive operation VVT OCV DUTY B1 VVT OCV operation duty (bank 1): Min.: 0 %, Max.: 100 % 0 %: Idling Requested duty value for intrusive operation VVT OCV DUTY B2 VVT OCV operation duty (bank 2): Min.: 0 %, Max.: 100 % 0 %: Idling Requested duty value for intrusive operation FC IDL Fuel cut idle: ON or OFF ON: Fuel cut operation FC IDL = "ON" when throttle valve fully closed and engine speed over 2800 rpm FC TAU Fuel cut TAU: Fuel cut during very light load: ON or OFF ON: Fuel cut operation The fuel cut being performed under very light load to prevent the engine combustion from becoming incomplete IGNITION Ignition counter: Min.: 0, Max.: 800 0 to 800 - CYL #1, #2, #3, #4, #5, #6, #7, #8 Misfire ratio of the cylinder 1 to 8: Min.: 0, Max.: 255 0% This item displayed only when idling engine CYL ALL All cylinders misfire rate: Min.: 0, Max.: 255 0 to 35 - CYLS Multiple Cylinder Misfire rate: Min.: 0 Max.:65,535 0 to 65,535 - MISFIRE RPM Engine RPM for first misfire range: Min.: 0 rpm, Max.: 6,375 rpm 0 rpm: Misfire 0 - MISFIRE LOAD Engine load for first misfire range: Min.: 0 g/rev, Max.: 3.98 g/rev 0 g/rev: Misfire 0 - MISFIRE MARGIN Misfire monitoring: Min.: -100 %, Max.: 99.22 % -100 to 99.2 % Misfire detecting margin - ES–49 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Measurement Item/Range Normal Condition Diagnostic Note #CODES #Codes: Min.: 0, Max.: 255 - Number of detected DTCs CHECK MODE Check mode: 0: ON, 1: OFF ON: Check mode ON See page ES-36 SPD TEST Check mode result for vehicle speed sensor: 0: COMPL, 1: INCOMPL - - AS TEST Check mode result for secondary air injection system: 0: COMPL, 1: INCOMPL - - MISFIRE TEST Check mode result for misfire monitor: 0: COMPL, 1: INCOMPL - - OXS1 TEST Check mode result for heated oxygen sensor (bank 1): 0: COMPL, 1: INCOMPL - - OXS2 TEST Check mode result for heated oxygen sensor (bank 2): 0: COMPL, 1: INCOMPL - - A/F SSR TEST B1 Check mode result for air fuel ratio sensor (bank 1): 0: COMPL, 1: INCOMPL - - A/F SSR TEST B2 Check mode result for air fuel ratio sensor (bank 2): 0: COMPL, 1: INCOMPL - - MIL MIL status: ON or OFF ON: MIL ON - MIL ON RUN DIST MIL ON run distance: Min.: 0 km, Max.: 65,535 km Distance after DTC detected - MIL ON RUN TIME Running time from MIL ON: Min.: 0 minutes, Max.: 65,535 minutes Equivalent to running time after MIL was ON - ENG RUN TIME Engine run time: Min.: 0 seconds, Max.: 65,535 seconds Time after engine start Service data TIME DTC CLEAR Time after DTC cleared: Min.: 0 minutes, Max.: 65,535 minutes Equivalent to time after DTCs were erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km, Max.: 65,535 km Equivalent to drive distance after DTCs were erased - WU CYC DTC CLEAR Warm-up cycle after DTC cleared: Min.: 0, Max.: 255 - Number of warm-up cycles after DTC cleared MODEL CODE Model code - Identifying the model code: UCK30 (2WD), UCK40 (4WD) ENGINE TYPE Engine type - Identifying the engine type: 2UZFE CYLINDER NUMBER Cylinder number: Min.: 0, Max.: 255 - Identifying the cylinder number: 8 TRANSMISSION Transmission type - Identifying the transmission type: ECT (5AT) DESTINATION Destination - Identifying the destination: A (America) MODEL YEAR Model year: Min.: 0, Max.: 255 - Identifying the model year: 200# SYSTEM System identification - Identifying the engine system: GASLIN (gasoline engine) ES ES–50 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Normal Condition: If no conditions are specifically stated for "idling", the shift lever is in the N or P position, and the A/C switch is OFF and all accessory switches are OFF. 2. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, Vacuum Switching Valve (VSV), actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (g) According to the display on the tester, perform the ACTIVE TEST. ES Tester Display Test Part Control Range Diagnostic Note • • INJ VOL Change injection volume Between -12 % and 25 % • • • All injectors tested at the same time Perform test at less than 3,000 rpm Injection volume can be changed in 1 % graduations within control range Perform test at less than 3,000 rpm A/F CONTROL enables checking and graphing of A/F (Air Fuel Ratio) sensor voltage outputs To conduct test, select following menu items: ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2, and press YES and ENTER followed by F4 Change injection volume Lower by 12.5 % or increase 25 % • FUEL PMP SP CTL Fuel pump speed control ON (low speed) / OFF (high speed) Test possible when following conditions met: • Engine switch On (IG) • Engine is stopped INTAKE CTL VSV1 Activate VSV for ACIS ON/OFF - EVAP VSV (ALONE) Activate purge VSV control ON/OFF A/F CONTROL • VVT CTRL B1 Turn on and off Oil Control Valve (OCV) VVT CTRL B2 Turn on and off Oil Control Valve (OCV) ON/OFF AC CUT SIG Control A/C cut signal ON/OFF - FUEL PUMP / SPD Activate fuel pump (C/OPN Relay) ON/OFF - ON/OFF • • • Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV off Engine stalls or idles roughly when OCV turned ON Normal engine running or idling when OCV off ES–51 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Display Test Part Control Range Diagnostic Note TC/TE1 Turn on and off TC and TE1 connection ON/OFF • • ON: TC and TE1 connected OFF: TC and TE1 disconnected FC IDL PROHBT Prohibit idling fuel cut control ON/OFF - STARTER Active Starter relay ON/OFF - ACC CUT Active ACC cut relay ON/OFF Test possible when following conditions met: • Engine switch On (IG) • Engine is stopped ETCS OPEN SLOW Throttle actuator ON: throttle valve opens slowly This test is possible when the following conditions are met: • Ignition switch ON • Engine does not start • Fully depressing accelerator pedal (APP: 58 degrees or more) ETCS CLOSE SLOW Throttle actuator ON: throttle valve closes slowly Same as above ETCS OPEN FAST Throttle actuator ON: throttle valve opens fast Same as above ETCS CLOSE FAST Throttle actuator ON: throttle valve closes fast Same as above • VVT B1 Control VVT (bank 1) Between -128 and 127 % • • VVT B2 Control VVT (bank 2) Between -128 and 127 % • Engine stall or rough idle when VVT actuator operated by 100% Test possible during engine idling Engine stall or rough idle when VVT actuator operated by 100% Test possible during engine idling FUEL CUT #1 Cylinder #1 injector fuel cut ON/OFF This test is possible when the vehicle is stopped and the engine is idling. FUEL CUT #2 Cylinder #2 injector fuel cut ON/OFF Same as above FUEL CUT #3 Cylinder #3 injector fuel cut ON/OFF Same as above FUEL CUT #4 Cylinder #4 injector fuel cut ON/OFF Same as above FUEL CUT #5 Cylinder #5 injector fuel cut ON/OFF Same as above FUEL CUT #6 Cylinder #6 injector fuel cut ON/OFF Same as above FUEL CUT #7 Cylinder #7 injector fuel cut ON/OFF Same as above FUEL CUT #8 Cylinder #8 injector fuel cut ON/OFF Same as above VENT VALVE (ALONE) Activate vent valve (built into canister pump module) ON/OFF - VACUUM PUMP Activate vacuum pump (built into canister pump module) ON/OFF - 3. SYSTEM CHECK HINT: Performing a SYSTEM CHECK enables the system, which consists of multiple actuators, to be operated without removing any parts. In addition, it can show whether or not any DTCs are set, and can detect potential malfunctions in the system. The SYSTEM CHECK can be performed with the intelligent tester. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK. ES ES–52 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) Perform the SYSTEM CHECK by referring to the table below. Tester Display Test Part Control Range Diagnostic Note • EVAP SYS CHECK (AUTOMATIC) Perform 5 steps in order to operate EVAP key-off monitor automatically EVAP SYS CHECK (MANUAL) Perform 5 steps in order to operate EVAP key-off monitor manually 35°C (95°F) or less • AIR INJ CHECK (AUTOMATIC) Perform 6 steps in order to operate air injection system automatically - If no DTCs in PENDING CODES menu after performing this test, system functioning normally AIR INJ CHECK (MANUAL) Perform 8 operations in order to operate air injection system monitor manually - Used to detect malfunctioning parts 35°C (95°F) or less • • ES If no DTCs in PENDING CODES menu after performing this test, system functioning normally Refer to EVAP Inspection Procedure (See page ES423) Used to detect malfunctioning parts Refer to EVAP Inspection Procedure (See page ES423) 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–53 DIAGNOSTIC TROUBLE CODE CHART HINT: The parameters listed in the chart are for reference only. Factors such as instrument type may cause readings to differ slightly from stated values. If any DTCs are displayed during a check mode DTC check, check the circuit for the DTCs listed in the table below. For details of each DTC, refer to the page indicated. 2UZ-FE SFI SYSTEM DTC Code Detection Item Trouble Area MIL Memory See page P0010 Camshaft Position "A" Actuator Circuit (Bank 1) 1. Open or short in Oil Control Valve (OCV) (bank 1) circuit 2. Oil Control Valve (OCV) (bank 1) 3. ECM Comes on DTC stored ES-66 P0011 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 1) 1. Oil Control Valve (OCV) 2. Valve timing 3. VVT controller assembly 4. ECM Comes on DTC stored ES-71 P0012 Camshaft Position "A" - Timing OverRetarded (Bank 1) Same as P0011 Comes on DTC stored ES-71 P0016 Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor A) 1. Open or short in VVT sensor circuit 2. VVT sensor 3. ECM Comes on DTC stored ES-76 P0018 Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A) Same as P0016 Comes on DTC stored ES-76 P0020 Camshaft Position "A" Actuator Circuit (Bank 2) 1. Open or short in OCV (bank 2) circuit 2. OCV (bank 2) 3. ECM Comes on DTC stored ES-66 P0021 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 2) Same as P0011 Comes on DTC stored ES-71 P0022 Camshaft Position "A" - Timing OverRetarded (Bank 2) Same as P0011 Comes on DTC stored ES-71 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) 1. Open in Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) heater circuit 2. Air Fuel Ratio (A/ F)sensor heater (bank 1 sensor 1) 3. A/F relay 4. ECM Comes on DTC stored ES-79 P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) 1. Short in A/F sensor (bank 1 sensor 1) heater circuit 2. A/F sensor heater (bank 1 sensor 1) 3. A/F relay 4. ECM Comes on DTC stored ES-79 ES ES–54 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) 1. Open in Heated Oxygen (HO2) sensor heater circuit 2. Heated Oxygen (HO2) sensor heater (bank 1 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) 1. Open in A/F sensor (bank 2 sensor 1) heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F relay 4. ECM Comes on DTC stored ES-79 P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) 1. Short in A/F sensor (bank 2 sensor 1) heater circuit 2. A/F sensor heater (bank 2 sensor 1) 3. A/F relay 4. ECM Comes on DTC stored ES-79 P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) 1. Open in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) 1. Short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 P0100 Mass Air Flow Circuit Malfunction 1. Open or short in Mass Air Flow (MAF) meter circuit 2. Mass Air Flow (MAF) meter 3. ECM Comes on DTC stored ES-92 P0101 Mass Air Flow Circuit Range / Performance Problem Mass Air Flow (MAF) meter Comes on DTC stored ES-99 P0102 Mass Air Flow Circuit Low 1. Open or short in Mass Air Flow (MAF) meter circuit 2. Mass Air Flow (MAF) meter 3. ECM Comes on DTC stored ES-92 P0103 Mass Air Flow Circuit High 1. Open or short in Mass Air Flow (MAF) meter circuit 2. Mass Air Flow (MAF) meter 3. ECM Comes on DTC stored ES-92 ES MIL Memory See page 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area MIL Memory ES–55 See page P0110 Intake Air Temperature Circuit 1. Open or short in Intake Air Temperature (IAT) sensor circuit 2. Intake Air Temperature (IAT) sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-102 P0111 Intake Air Temperature Sensor Gradient Too High Mass air flow meter Comes on DTC stored ES-107 P0112 Intake Air Temperature Circuit Low Input 1. Short in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-102 P0113 Intake Air Temperature Circuit High Input 1. Open in IAT sensor circuit 2. IAT sensor (built into MAF meter) 3. ECM Comes on DTC stored ES-102 P0115 Engine Coolant Temperature Circuit 1. Open or short in Engine Coolant Temperature (ECT) sensor circuit 2. Engine Coolant Temperature (ECT) sensor 3. ECM Comes on DTC stored ES-110 P0116 Engine Coolant Temperature Circuit Range / Performance Problem Engine Coolant Temperature (ECT) sensor Comes on DTC stored ES-115 P0117 Engine Coolant Temperature Circuit Low Input 1. Short in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-110 P0118 Engine Coolant Temperature Circuit High Input 1. Open in ECT sensor circuit 2. ECT sensor 3. ECM Comes on DTC stored ES-110 P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit 1. Throttle Position (TP) sensor (built into throttle body) 2. ECM Comes on DTC stored ES-118 P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem Throttle Position (TP) sensor (built into throttle body) Comes on DTC stored ES-126 P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input 1. Throttle Position (TP) sensor (built into throttle body) 2. Short in VTA1 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-118 ES ES–56 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input 1. Throttle Position (TP) sensor (built into throttle body) 2. Open in VTA1 circuit 3. Open in E2 circuit 4. Short between VC and VTA1 circuits 5. ECM Comes on DTC stored ES-118 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control 1. Cooling system 2. Engine Coolant Temperature (ECT) sensor 3. Thermostat Comes on DTC stored ES-128 P0128 Thermostat Malfunction 1. Thermostat 2. Cooling system 3. Engine Coolant Temperature (ECT) sensor 4. ECM Comes on DTC stored ES-131 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in Heated Oxygen (HO2) sensor circuit 2. Heated Oxygen (HO2) sensor (bank 1 sensor 2) 3. Heated Oxygen (HO2) sensor heater (bank 1 sensor 2) 4. Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) 5. EFI relay 6. Gas leakage from exhaust system Comes on DTC stored ES-135 P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) 1. Open in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. HO2 sensor heater (bank 1 sensor 2) 4. EFI relay 5. Gas leakage from exhaust system Comes on DTC stored ES-135 P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) 1. Short in HO2 sensor (bank 1 sensor 2) circuit 2. HO2 sensor (bank 1 sensor 2) 3. ECM internal circuit malfunction Comes on DTC stored ES-135 P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) 1. Open or short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 1 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area MIL Memory ES–57 See page P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) 1. Open or short in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor2) 4. A/F sensor (bank 2 sensor 1) 5. EFI relay 6. Gas leakage from exhaust system Comes on DTC stored ES-135 P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) 1. Open in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. HO2 sensor heater (bank 2 sensor 2) 4. EFI relay 5. Gas leakage from exhaust system Comes on DTC stored ES-135 ES P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) 1. Short in HO2 sensor (bank 2 sensor 2) circuit 2. HO2 sensor (bank 2 sensor 2) 3. ECM internal circuit malfunction Comes on DTC stored ES-135 P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) 1. Open or short in HO2 sensor heater circuit 2. HO2 sensor heater (bank 2 sensor 2) 3. EFI relay 4. ECM Comes on DTC stored ES-84 P0171 System Too Lean (Bank 1) 1. Air induction system 2. Injector blockage 3. Mass Air Flow (MAF) meter 4. Engine Coolant Temperature (ECT) sensor 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in HO2 sensor (bank 1 sensor 1) circuit 8. HO2 sensor (bank 1 sensor 1) 9. HO2 sensor heater (bank 1 sensor 1) 10. EFI relay 11. PCV piping 13. ECM Comes on DTC stored ES-155 ES–58 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0172 System Too Rich (Bank 1) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in HO2 sensor (bank 1 sensor 1) circuit 8. HO2 sensor (bank 1 sensor 1) 9. ECM Comes on DTC stored ES-155 P0174 System Too Lean (Bank 2) 1. Air Induction system 2. Injector blockage 3. MAF meter 4. ECT sensor 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in HO2 sensor (bank 2 sensor 1)circuit 8. HO2 sensor (bank 2 sensor 1) 9. HO2 sensor heater (bank 2 sensor 1) 10. EFI relay 11. PCV piping 12. ECM Comes on DTC stored ES-155 P0175 System Too Rich (Bank 2) 1. Injector leakage or blockage 2. MAF meter 3. ECT sensor 4. Ignition system 5. Fuel pressure 6. Gas leakage in exhaust system 7. Open or short in exhaust system (bank 2 sensor 1) circuit 8. HO2 sensor (bank 2 sensor 1) 9. ECM Comes on DTC stored ES-155 P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit 1. Throttle Position (TP) sensor (built into throttle body) 2. ECM Comes on DTC stored ES-118 P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input 1. Throttle Position (TP) sensor (built into throttle body) 2. Short in VTA2 circuit 3. Open in VC circuit 4. ECM Comes on DTC stored ES-118 P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input 1. Throttle Position (TP) sensor (built into throttle body) 2. Open in VTA2 circuit 3. Open in E2 circuit 4. Short between VC and VTA2 circuits 5. ECM Comes on DTC stored ES-118 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area MIL Memory ES–59 See page P0230 Fuel Pump Primary Circuit 1. Open or short in fuel pump relay circuit 2. Fuel pump relay 3. Circuit opening relay 4. Fuel pump 5. ECM - DTC stored ES-168 P0300 Random / Multiple Cylinder Misfire Detected 1. Open or short in engine wire harness 2. Connector connection 3. Vacuum hose connection 4. Ignition system 5. Fuel injector 6. Fuel pressure 7. Mass Air Flow (MAF) meter 8. Engine Coolant Temperature (ECT) sensor 9. Compression pressure 10. Valve clearance 11. Valve timing 12. PCV hose connection 13. PCV hose 14. ECM Comes on or blinks DTC stored ES-173 ES P0301 Cylinder 1 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0302 Cylinder 2 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0303 Cylinder 3 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0304 Cylinder 4 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0305 Cylinder 5 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0306 Cylinder 6 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0307 Cylinder 7 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0308 Cylinder 8 Misfire Detected Same as P0300 Comes on or blinks DTC stored ES-173 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) 1. Short in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Comes on DTC stored ES-187 P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) 1. Open in knock sensor 1 circuit 2. Knock sensor 1 3. ECM Comes on DTC stored ES-187 P0332 Knock Sensor 2 Circuit Low Input (Bank 2) 1. Short in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Comes on DTC stored ES-187 P0333 Knock Sensor 2 Circuit High Input (Bank 2) 1. Open in knock sensor 2 circuit 2. Knock sensor 2 3. ECM Comes on DTC stored ES-187 ES–60 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0335 Crankshaft Position Sensor "A" Circuit 1. Open or short in Crankshaft Position (CKP) sensor circuit 2. Crankshaft Position (CKP) sensor 3. Signal plate (crankshaft position sensor plate) 4. ECM Comes on DTC stored ES-193 P0339 Crankshaft Position Sensor "A" Circuit Intermittent 1. Open or short in Crankshaft Position (CKP) sensor circuit 2. Crankshaft Position (CKP) sensor 3. Signal plate (crankshaft position sensor plate) 4. ECM - DTC stored ES-193 P0340 Camshaft Position Sensor Circuit Malfunction 1. Open or short in camshaft position sensor circuit 2. Camshaft position sensor 3. Bank 1 camshaft timing pulley 4. Timing belt has a jumped tooth 5. ECM Comes on DTC stored ES-198 P0341 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 1 or Single Sensor) Same as P0340 Comes on DTC stored ES-198 P0345 Camshaft Position Sensor "A" Circuit (Bank 2) Same as P0340 Comes on DTC stored ES-198 P0346 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 2) Same as P0340. Comes on DTC stored ES-198 P0351 Ignition Coil "A" Primary / Secondary Circuit 1. Open or short in IGF1 or IGT1 circuit between No. 1 ignition coil and ECM 2. No. 1 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0352 Ignition Coil "B" Primary / Secondary Circuit 1. Open or short in IGF2 or IGT2 circuit between No. 2 ignition coil and ECM 2. No. 2 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0353 Ignition Coil "C" Primary / Secondary Circuit 1. Open or short in IGF2 or IGT3 circuit between No. 3 ignition coil and ECM 2. No. 3 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–61 DTC Code Detection Item Trouble Area P0354 Ignition Coil "D" Primary / Secondary Circuit 1. Open or short in IGF1 or IGT4 circuit between No. 4 ignition coil and ECM 2. No. 4 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored See page ES-203 P0355 Ignition Coil "E" Primary / Secondary Circuit 1. Open or short in IGF2 or IGT5 circuit between No. 5 ignition coil and ECM 2. No. 5 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0356 Ignition Coil "F" Primary / Secondary Circuit 1. Open or short in IGF1 or IGT6 circuit between No. 6 ignition coil and ECM 2. No. 6 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0357 Ignition Coil "G" Primary / Secondary Circuit 1. Open or short in IGF1 or IGT7 circuit between No. 7 ignition coil and ECM 2. No. 7 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0358 Ignition Coil "H" Primary / Secondary Circuit 1. Open or short in IGF2 or IGT8 circuit between No. 8 ignition coil and ECM 2. No. 8 ignition coil (primary ignition) 3. Ignition system 4. ECM Comes on DTC stored ES-203 P0412 Secondary Air Injection System Switching Valve "A" Circuit 1. Open in air switching valve drive circuit 2. Short between air switching valve circuit and +B circuit 3. Short between air switching valve circuit and body ground 4. Air injection control driver 5. Air switching valve 6. ECM Comes on DTC stored ES-214 P0418 Secondary Air Injection System Control "A" Circuit 1. Open in air pump drive circuit 2. Short between air pump circuit and +B circuit 3. Short between air pump circuit and body ground 4. Air injection control driver 5. ECM Comes on DTC stored ES-223 ES ES–62 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0420 Catalyst System Efficiency Below Threshold (Bank 1) 1. Gas leakage from exhaust system 2. Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) 3. Heated Oxygen (HO2) sensor (bank 1 sensor 2) 4. Three-way catalytic converter Comes on DTC stored ES-230 P0430 Catalyst System Efficiency Below Threshold (Bank 2) 1. Gas leakage on exhaust system 2. A/F sensor (bank 2 sensor 1) 3. HO2 sensor (bank 2 sensor 2) 4. Three-way catalytic converter Comes on DTC stored ES-230 P043E Evaporative Emission System Leak Detection Reference Orifice Low Flow 1. Pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM 4. Leakage from EVAP system Comes on DTC stored ES-237 P043F Evaporative Emission System Reference Orifice High Flow 1. Pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM 4. Leakage from EVAP system Comes on DTC stored ES-237 P0441 Evaporative Emission Control System Incorrect Purge Flow 1. Purge VSV 2. Connector/Wire harness (Purge VSV - ECM) 3. ECM 4. Pump module 5. Leakage from EVAP system Comes on DTC stored ES-243 P0450 Evaporative Emission Control System Pressure Sensor Malfunction 1. Canister pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-251 P0451 Evaporative Emission Control System Pressure Sensor Range / Performance 1. Pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-251 P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input 1. Pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-251 P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input 1. Pump module 2. Connector/Wire harness (Pump module - ECM) 3. ECM Comes on DTC stored ES-251 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–63 DTC Code Detection Item Trouble Area P0455 Evaporative Emission Control System Leak Detected (Gross Leak) 1. Fuel cap (loose) 2. Leakage from EVAP line (Canister Fuel tank) 3. Leakage from EVAP line (Purge VSV - canister) 4. Pump module 5. Leakage from fuel tank 6. Leakage from canister Comes on DTC stored See page ES-258 P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) Same as P0445 Comes on DTC stored ES-258 P0500 Vehicle Speed Sensor "A" 1. Combination meter 2. Open or short in vehicle speed sensor circuit 3. Vehicle speed sensor 4. Skid control ECU 5. ECM Comes on DTC stored ES-263 P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High 1. Combination meter 2. Open or short in vehicle speed sensor circuit 3. Vehicle speed sensor 4. Skid control ECU 5. ECM - DTC stored ES-263 P0504 Brake Switch "A" / "B" Correlation 1. Short in stop light switch signal circuit 2. Stop light fuse 3. Stop light switch assembly 4. ECM - DTC stored ES-266 P0505 Idle Control System Malfunction 1. ECTS 2. Air induction system 3. Ventilation hose connection 4. ECM Comes on DTC stored ES-270 P050A Cold Start Idle Air Control System Performance 1. ETCS 2. MAF meter 3. Air induction system 4. Ventilation hose connections 5. ECM Comes on DTC stored ES-273 P050B Cold Start Ignition Timing Performance 1. Throttle body 2. MAF meter 3. Air induction system 4. Ventilation hose connections 5. VVT system 6. ECM Comes on DTC stored ES-273 P0560 System Voltage 1. Open in back-up power source circuit 2. EFI fuse 3. ECM Comes on DTC stored ES-279 P0604 Random Access Memory (RAM) ECM Comes on DTC stored ES-284 ES ES–64 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0606 ECM / PCM Processor 1. Exhaust gas leak 2. Heated oxygen sensor 3. ECM Comes on/- DTC stored ES-285 P0607 Control Module Performance ECM Comes on DTC stored ES-288 P0617 Starter Relay Circuit High 1. Starter relay circuit 2. Park/Neutral position switch 3. Ignition switch 4. ECM Comes on DTC stored ES-290 P0630 VIN not Programmed or Mismatch - ECM / PCM ECM Comes on DTC stored ES-294 P0657 Actuator Supply Voltage Circuit / Open ECM Comes on DTC stored ES-296 P1340 Camshaft Position Sensor "A" (Bank 1 Sensor 2) 1. Open or short in camshaft position sensor circuit 2. Camshaft position sensor 3. Camshaft timing pulley LH 4. ECM Comes on DTC stored ES-297 P1341 Camshaft Position Sensor "A" (Bank 1 Sensor 2 ) 1. Open or short in camshaft position sensor circuit 2. Camshaft position sensor 3. Camshaft timing pulley LH 4. ECM Comes on DTC stored ES-297 P1440 Secondary Air Injection Vacuum Switching Valve Circuit Malfunction Bank 1 1. Open or short in VSV for air injection system (bank 1) 2. VSV power source 3. VSV for air injection system (bank 1) 4. ECM Comes on DTC stored ES-301 P1441 Stuck Open in Secondary Air Injection Vacuum Switching Valve Bank 1 1. VSV for air injection system (bank 1) 2. No. 2 air switching valve (bank 1) 3. VSV for air injection system (bank 1) 4. ECM Comes on DTC stored ES-304 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–65 DTC Code Detection Item Trouble Area P1442 Stuck Close in Secondary Air Injection Vacuum Switching Valve Bank 1 1. VSV for air injection system circuit (bank 1) 2. Vacuum hose (VSV for air injection system - No. 2 air switching valve) 3. Air injector pipe (No. 2 air switching valve - exhaust manifold) 4. No. 2 air switching valve (bank 1) 5. VSV for air injection system (bank 1) 6. ECM Comes on DTC stored See page ES-318 P1443 Secondary Air Injection Vacuum Switching Valve Circuit Malfunction Bank 2 1. Open or short in VSV for air injection system circuit (bank 2) 2. VSV power source 3. VSV for air injection system (bank 2) 4. ECM Comes on DTC stored ES-301 P1444 Stuck Open in Secondary Air Injection Vacuum Switching Valve Bank 2 1. VSV for air injection system circuit (bank 2) 2. No. 2 air switching valve (bank 2) 3. VSV for air injection system (bank 2) 4. ECM Comes on DTC stored ES-304 P1445 Stuck Close in Secondary Air Injection Vacuum Switching Valve Bank 2 1. VSV for air injection system circuit (bank 2) 2. Vacuum hose (VSV for air injection system - No. 2 air switching valve) 3. Air injection pipe (No. 2 air switching valve - exhaust manifold) 4. No. 2 air switching valve (bank 2) 5. VSV for air injection system (bank 2) 6. ECM Comes on DTC stored ES-318 ES ES–66 DTC Code ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P1613 Secondary Air Injection Driver Malfunction 1. Air injection control driver (AID) 2. Open in air injection control driver ground circuit 3. Short in diagnostic information signal circuit (AID - ECM) 4. Open or short in air pump and air switching valve command signal circuit (AID - ECM) 5. Open or short in AID power source circuit 6. ECM Comes on DTC stored ES-328 P2102 Throttle Actuator Control Motor Circuit Low 1. Open in throttle actuator circuit 2. Throttle actuator 3. ECM Comes on DTC stored ES-340 P2103 Throttle Actuator Control Motor Circuit High 1. Short in throttle actuator circuit 2. Throttle actuator 3. Throttle valve 4. Throttle body 5. ECM Comes on DTC stored ES-340 P2111 Throttle Actuator Control System Stuck Open 1. Throttle actuator 2. Throttle valve 3. Throttle body Comes on DTC stored ES-343 P2112 Throttle Actuator Control System Stuck Closed Same as P2111 Comes on DTC stored ES-343 P2118 Throttle Actuator Control Motor Current Range / Performance 1. Open in ETCS power source circuit 2. ETCS fuse 3. ECM Comes on DTC stored ES-346 P2119 Throttle Actuator Control Throttle Body Range / Performance 1. ETCS 2. ECM Comes on DTC stored ES-350 P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 1. Accelerator pedal position (APP) sensor 2. ECM Comes on DTC stored ES-353 P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 1. APP sensor 2. ECM Comes on DTC stored ES-361 P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 1. APP sensor 2. Open in VCPA circuit 3. Open or ground short VPA circuit 4. ECM Comes on DTC stored ES-353 P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 1. APP sensor 2. Open in EPA circuit 3. ECM Comes on DTC stored ES-353 P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 1. APP sensor 2. ECM Comes on DTC stored ES-353 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area MIL Memory ES–67 See page P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 1. APP sensor 2. Open in VCP2 circuit 3. Open or ground short VPA2 circuit 4. ECM Comes on DTC stored ES-353 P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 1. APP sensor 2. Open in EPA2 circuit 3. ECM Comes on DTC stored ES-353 P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation 1. Short between VTA1 and VTA2 circuit 2. Throttle Position (TP) sensor (built into throttle body) 3. ECM Comes on DTC stored ES-118 P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 1. Short between VPA and VPA2 circuit 2. APP sensor 3. ECM Comes on DTC stored ES-353 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) 1. Open or short in Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) circuit 2. Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) 3. Air Fuel Ratio (A/F) sensor heater (bank 1 sensor 1) 4. A/F heater relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Fuel injector 9. ECM Comes on DTC stored ES-364 P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) Same as P2195 Comes on DTC stored ES-364 P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F relay 5. A/F sensor heater and relay circuits 6. Air induction system 7. Fuel pressure 8. Fuel injector 9. ECM Comes on DTC stored ES-364 P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) Same as P2197 Comes on DTC stored ES-364 P2237 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) 1. Open or short in A/ F sensor (bank 1 sensor 1) circuit 2. A/F sensor (bank 1 sensor 1) 3. ECM Comes on DTC stored ES-380 ES ES–68 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Code Detection Item Trouble Area P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) 1. Open or short in Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) circuit 2. Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) 3. Air Fuel Ratio (A/F) sensor heater (bank 1 sensor 1) 4. A/F heater relay 5. A/F sensor heater and relay circuits 6. ECM Comes on DTC stored ES-380 P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) Same as P2238 Comes on DTC stored ES-380 P2240 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. ECM Comes on DTC stored ES-380 P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1)circuit 2. A/F sensor (bank 2 sensor 1) 3. A/F sensor heater (bank 2 sensor 1) 4. A/F relay 5. A/F sensor heater and relay circuit 6. ECM Comes on DTC stored ES-380 P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) Same as P2241 Comes on DTC stored ES-380 P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) Same as P2238 Comes on DTC stored ES-380 P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) Same as P2238 Comes on DTC stored ES-380 P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) Same as P2241 Comes on DTC stored ES-380 P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) Same as P2241 Comes on DTC stored ES-380 P2401 Evaporative Emission Leak Detection Pump Stuck OFF 1. Canister pump module 2. Connector/Wire harness (Canister pump module - ECM) 3. ECM Comes on DTC stored ES-387 ES MIL Memory See page 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–69 DTC Code Detection Item Trouble Area P2402 Evaporative Emission Leak Detection Pump Stuck ON 1. Canister pump module 2. Connector/Wire harness (Canister pump module - ECM) 3. ECM Comes on DTC stored See page ES-387 P2419 Evaporative Emission Pressure Switching Valve Stuck ON 1. Canister pump module 2. Connector/Wire harness (Canister pump module - ECM) 3. ECM Comes on DTC stored ES-393 P2420 Evaporative Emission Pressure Switching Valve Stuck OFF 1. Canister pump module 2. Connector/Wire harness (Canister pump module - ECM) 3. ECM Comes on DTC stored ES-393 P2430 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Bank1 1. Pressure sensor 2. Open or short in pressure sensor circuit 3. ECM Comes on DTC stored ES-399 P2431 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Range / Performance Bank1 1. Pressure sensor 2. Open or short in pressure sensor circuit 3. ECM Comes on DTC stored ES-399 P2432 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Low Bank1 1. Pressure sensor 2. Open or short in pressure sensor circuit 3. ECM Comes on DTC stored ES-399 P2433 Secondary Air Injection System Air Flow / Pressure Sensor Circuit High Bank1 1. Pressure sensor 2. Open or short in pressure sensor circuit 3. ECM Comes on DTC stored ES-399 P2440 Secondary Air Injection System Switching Valve Stuck Open Bank1 1. Air switching valve 2. No. 2 air switching valve (bank 1 and/or 2) 3. VSV for air injection system (bank 1 and/or 2) 4. Air injection control driver 5. Air injection control driver circuit 6. ECM Comes on DTC stored ES-304 ES ES–70 DTC Code 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P2441 Secondary Air Injection System Switching Valve Stuck Close Bank1 1. Vacuum hoses (Throttle body - VSVs for air injection system) 2. Air switching valve 3. Air injection pipe (No. 2 air switching valve - exhaust manifold) 4. Air injection hose 5. No. 2 air switching valve (bank 1 and/or 2) 6. VSV for air injection system (bank 1 and/or 2) 7. Air injection control driver 8. Air injection control driver circuit 9. ECM Comes on DTC stored ES-318 P2444 Secondary Air Injection System Pump Stuck On Bank1 1. Short in air pump circuit 2. Pressure sensor 3. Air injection control driver 4. Open or short in pressure sensor circuit 5. ECM Comes on DTC stored ES-403 P2445 Secondary Air Injection System Pump Stuck Off Bank1 1. Air pump fuse 2. Vacuum hose 3. Air pump assembly 4. Air injection control driver 5. Open in air pump circuit 6. Air injection system piping 7. Pressure sensor 8. Open or short in pressure sensor circuit 9. ECM Comes on DTC stored ES-403 P2610 ECM / PCM Internal Engine Off Timer Performance ECM Comes on DTC stored ES-413 P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) 1. Open or short in Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) circuit 2. Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) 3. ECM Comes on DTC stored ES-415 P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) 1. Open or short in A/ F sensor (bank 2 sensor 1) circuit 2. A/F sensor (bank 2 sensor 1) 3. ECM Comes on DTC stored ES-415 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. HINT: Initialization cannot be completed by only removing the battery. ES ES–2 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DEFINITION OF TERMS Terms Definitions Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Preconditions that allow ECM to detect malfunctions. With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s). Sequence of operation Order of monitor priority, applied if multiple sensors and components are involved in single malfunction detection process. Each sensor and component monitored in turn and not monitored until previous detection operation completed. Required sensor/components Sensors and components used by ECM to detect each malfunction. Frequency of operation Number of times ECM checks for each malfunction during each driving cycle. "Once per driving cycle" means ECM only performs checks for that malfunction once during single driving cycle. "Continuous" means ECM performs checks for that malfunction whenever enabling conditions are met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC. Timing begins when Typical Enabling Conditions are met. Malfunction thresholds Value beyond which ECM determines malfunctions exist and sets DTCs. MIL operation Timing of MIL illumination after malfunction detected. "Immediate" means ECM illuminates MIL as soon as malfunction detected. "2 driving cycle" means ECM illuminates MIL if same malfunction detected second time during next sequential driving cycle. ES ES–71 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1) DTC P0020 Camshaft Position "A" Actuator Circuit (Bank 2) DESCRIPTION HINT: These DTCs relate to the Oil Control Valve (OCV). The Variable Valve Timing (VVT) system includes the ECM, Oil Control Valve (OCV) and VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed according to engine operating conditions such as intake air volume, throttle valve position and engine coolant temperature. The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve, and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual intake valve timing using signals from the camshaft and crankshaft position sensors, and performs feedback control. This is how the target intake valve timing is verified by the ECM. ECM Crankshaft Position Sensor Duty Control Target Valve Timing Mass Air Flow Meter Throttle Position Sensor Engine Coolant Temperature Sensor Feedback Correction Camshaft Timing Oil Control Valve (OCV) Vehicle Speed Signal Camshaft Position Sensor Actual Valve Timing A117755E01 DTC No. P0010 DTC Detection Condition Open or short in Oil Control Valve (OCV) (bank 1) circuit (1 trip detection logic) Trouble Area • • • Open or short in Oil Control Valve (OCV) (bank 1) circuit Oil Control Valve (OCV) (bank 1) ECM ES ES–72 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. P0020 DTC Detection Condition Open or short in OCV (bank 2) circuit (1 trip detection logic) Trouble Area • • • Open or short in OCV (bank 2) circuit OCV (bank 2) ECM MONITOR DESCRIPTION After the ECM sends the "target" duty-cycle signal to the OCV (Oil Control Valve), the ECM monitors the OCV current to establish an "actual" duty-cycle. When the actual duty-cycle ratio varies from the target duty-cycle, the ECM sets a DTC. MONITOR STRATEGY ES Related DTCs P0010: OCV (bank 1) range check P0020: OCV (bank 2) range check Required Sensors/Components (Main) VVT OCV Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None Starter OFF Ignition switch ON Time after ignition switch OFF to ON 0.5 seconds or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met Condition A, B or C A. All of the following conditions are met Condition (a), (b) and (c) a. Battery voltage 11 V or more, and less than 13 V b. Target duty ratio Less than 70 % c. Output signal duty ratio 100 % or more B. All of the following conditions are met Condition (a), (b) and (c) a. Battery voltage 13 V or more b. Target duty ratio Less than 80 % c. Output signal duty ratio 100 % or more C. Both of the following conditions are met Condition (a) and (b) a. Current cut status Not cut b. Output signal duty ratio 3 % or less COMPONENT OPERATING RANGE Output signal duty for OCV More than 3 %, and less than 100 % ES–73 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM C2 OCV (Bank 1) ECM 1 17 P E6 OC1+ 2 LG 16 E6 OC1- 1 R-W 15 E6 OC2+ 2 Y-R 14 E6 OC2- C3 OCV (Bank 2) ES A115908E02 INSPECTION PROCEDURE HINT: • If DTC P0010 is displayed, check the bank 1 VVT system circuit. • Bank 1 refers to the bank that includes cylinder No. 1. • If DTC P0020 is displayed, check the bank 2 VVT system circuit. • Bank 2 refers to the bank that does not include cylinder No. 1. • Read freeze frame data using a intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OCV OPERATION) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Start the engine and warm it up. (c) Turn the ignition switch ON and turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (e) Operate the Oil Control Valve (OCV) and check the engine condition at idling. OK Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) OK CHECK FOR INTERMITTENT PROBLEMS ES–74 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OPERATION) Battery (-) Battery (+) Valve (a) Disconnect the C13 or C14 OCV connectors. (b) Apply battery voltage to the terminals of the OCV. (c) Check the engine speed. OK: Rough idle or engine stalled. (d) Reconnect the OCV connectors. NG ES REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY A088857E03 OK 3 CHECK ECM (OCV SIGNAL) ECM Connector E6 (a) Inspect the ECM using an oscilloscope. (b) While idling the engine, check the waveform of the E6 ECM connector using an oscilloscope. Standard voltage Tester Connection OC1+ (E6-17) - OC1- (E6-16) OC2+ (E6-15) - OC2- (E6-14) OC1+ OC1- OC2+ OC2- NG OCV Signal Waveform 5 V/DIV. GND 200 msec./DIV. G035623E17 OK REPLACE ECM Specified Condition Correct waveform is as shown ES–75 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (OCV - ECM) (a) Disconnect the C2 or C3 OCV connectors. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side OCV Connector C2 Tester Connection Specified condition OCV (C2-1) - OC1+ (E6-17) C3 OCV (C2-2) - OC1- (E6-16) Front View OCV (C3-1) - OC2+ (E6-15) Below 1 Ω OCV (C3-2) - OC2- (E6-14) E6 ECM Connector Standard resistance (Check for short) Tester Connection Specified condition OCV (C2-1) or OC1+ (E6-17) - Body ground E1 OC1+ OC1- OCV (C2-2) or OC1- (E6-16) - Body ground OC2- OCV (C3-1) or OC2+ (E6-15) - Body ground OC2+ 10 kΩ or higher OCV (C3-2) or OC2- (E6-14) - Body ground A115689E02 (d) Reconnect the OCV connectors. (e) Reconnect the ECM connector. NG OK CHECK FOR INTERMITTENT PROBLEMS REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–76 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) DTC P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) DTC P0021 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 2) DTC P0022 Camshaft Position "A" - Timing Over-Retarded (Bank 2) ES DESCRIPTION HINT: Refer to DTC P0010 (See page ES-66). DTC No. DTC Detection Condition P0011 P0021 Advanced cam timing: After engine is warmed up and engine speed is at 400 to 4,000 rpm, condition (a) continues (1 trip detection logic): (a) Valve timing does not change from current valve timing P0012 P0022 Retarded cam timing: After engine is warmed up and engine speed is at 400 to 4,000 rpm, condition (a) continues (2 trip detection logic): (a) Valve timing does not change from current valve timing Trouble Area • • • • • Oil Control Valve (OCV) Valve timing OCV filter VVT controller assembly ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the OCV and the VVT actuator. The ECM sends a target "duty-cycle" control signal to the OCV. This control signal, applied to the OCV, regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. Example: A DTC will set if: 1) the difference between the target and actual valve timing is more than 5° of the Crankshaft Angle (CA) and the condition continues for more than 4.5 sec.; or 2) the OCV is forcibly activated 63 times or more. Advanced cam DTCs are subject to 1 trip detection logic. Retarded cam DTCs are subject to 2 trip detection logic. The monitor runs if all the conditions below are met: MONITOR STRATEGY Related DTCs P0011: Advance camshaft timing (bank 1) P0012: Retard camshaft timing (bank 2) P0021: Advance camshaft timing (bank 1) P0022: Retard camshaft timing (bank 2) Required Sensors/Components (Main) VVT OCV and VVT actuator Required Sensors/Components (Related) Engine Coolant Temperature sensor, Camshaft position sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration 10 seconds ES–77 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation P0011 and P0021: Immediate P0012 and P0022: 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0351 - P0358 (igniter) Battery voltage 11 V or more Engine RPM 400 to 4,000 rpm ECT 75 to 100°C (167 to 212°F) ES TYPICAL MALFUNCTION THRESHOLDS Advance: Both of the following conditions are met - (a) Deviation of valve timing More than 5° CA (crankshaft angle) (b) Valve timing No change at advanced valve timing Retarded: Both of the following conditions are met - (a) Deviation of valve timing More than 5° CA (crankshaft angle) (b) Valve timing No change at retarded valve timing WIRING DIAGRAM Refer to DTC P0010 (See page ES-68). INSPECTION PROCEDURE HINT: Abnormal bank Advanced timing over (Valve timing is out of specified range) Retarded timing over (Valve timing is out of specified range) Bank 1 P0011 P0012 Bank 2 P0021 P0022 • If DTC P0011 or P0012 is displayed, check the bank 1 Variable Valve Timing (VVT) system circuit. • If DTC P0021 or P0022 is displayed, check the bank 2 VVT system circuit. • Bank 1 includes No. 1 cylinder, but bank 2 does not. No. 1 cylinder is located in the front part of the engine, opposite the transmission. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OCV OPERATION) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Start the engine and warm it up. ES–78 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (d) Using the intelligent tester, operate the Oil Control Valve (OCV) and check the engine speed. Standard Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall HINT: DTC P0011, P0012, P0021 or P0022 is also output when a foreign object is detected in some parts of the system in the engine oil, and then the system returns to normal in a short time. As the ECM is controlled to eject a foreign object, there is no problem with the VVT. There is also no problem with the VVT as the oil filter should catch the foreign object in the engine oil. ES OK VVT SYSTEM OK NG 2 CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TOOTH OF TIMING BELT) (a) Check the valve timing (See page EM-16). NG ADJUST VALVE TIMING OK 3 CHECK HARNESS AND CONNECTOR (OCV-ECM) OCV Signal Waveform 5V / Division A A A GND NG 200 msec. / Division E6 OC1+ OC1- (a) Inspect using an oscilloscope. (b) During idling, check the waveform between the specified terminals of the E6 ECM connector. HINT: The waveform frequency (A) is lengthened as the engine speed becomes higher. Standard: The correct waveform is as shown. ECM Connector E1 OC2OC2+ A115690E01 REPLACE ECM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–79 OK 4 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Ohmmeter A115691E01 (a) Remove the V-bank cover. (b) Remove the air cleaner inlet and intake air connector. (c) Disconnect the C13 and C14 Oil Control Valve (OCV) connectors. (d) Measure the resistance of the OCV. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) (e) Reconnect the OCV connector. (f) Reinstall the air cleaner inlet and intake air connector. (g) Reinstall the V-bank cover. NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY OK 5 INSPECT VVT CONTROLLER ASSEMBLY (a) (b) (c) (d) (e) A115692 Remove the timing belt (See page EM-16). Remove the cylinder head cover. Remove the OCV. Drain the oil in the VVT controller assembly. Check whether the oil in VVT controller assembly is drained or not. Standard: The oil in VVT controller assembly is drained. (f) Reinstall the OCV. (g) Reinstall the cylinder head cover. (h) Reinstall the timing belt. OK NG 6 NEXT REPLACE VVT CONTROLLER ASSEMBLY Go to step 7 ES ES–80 7 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT OIL CONTROL VALVE FILTER (a) Remove the cylinder head cover (See page EM-107). (b) Remove the camshaft bearing cap and OCV filter. (c) Check that the filter is not clogged. OK: The filter is not clogged. (d) Reinstall the camshaft bearing cap and OCV filter. (e) Reinstall the cylinder head cover. NG CLEAN OIL CONTROL VALVE FILTER A086178E01 ES OK 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P0011, P0012, P0021 OR P0022) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Clear DTCs. (d) Start the engine and warm it up. (e) Switch the ECM from normal mode to check mode using the tester. (f) Drive the vehicle for more than 10 minutes. (g) Read output DTCs using the tester. Standard: No DTC output. HINT: DTC P0011 or P0012 is output when foreign objects in engine oil are caught in some parts of the system. These codes will stay registered even if the system returns to normal after a short time. These foreign objects are then captured by the oil filter, thus eliminating the source of the problem. OK NG REPLACE ECM SYSTEM OK ES–81 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) DTC P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) DESCRIPTION VVT sensor (VVL or VVR signal) consist of a signal plate and pickup coil. The VVL or VVR signal plate has 1 tooth on its outer circumference and is mounted on the intake camshafts. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The actual camshaft angle is detected by the VVT sensor and it provides feedback to the ECM to control the intake valve timing in response to during condition. DTC No. P0016 P0018 DTC Detection Condition Deviation in crankshaft and camshaft position sensor signals (2 trip detection logic) Trouble Area • • • Open or short in VVT sensor circuit VVT sensor ECM MONITOR DESCRIPTION The ECM optimizes the valve timing by using the VVT (Variable Valve Timing) system to control the intake camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal applied to the OCV, regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. The ECM calibrates the intake valve timing by setting the intake camshaft to the most retarded angle while the engine is idling. The ECM closes the OCV to retard the cam. The ECM stores this value as the VVT learning value. When the difference between the target and actual intake valve timings is 5°CA (Crankshaft Angle) or less, the ECM stores it. If the VVT learning value matches the following conditions, the ECM determines the existence of a malfunction in the VVT system, and sets the DTC. • VVT learning value: Less than 22.5°CA (Crankshaft Angle), or more than 44°CA (47.5°CA). • Above condition continues for 18 seconds or more. MONITOR STRATEGY Related DTCs P0016: Camshaft timing (bank 1) misalignment P0018: Camshaft timing (bank 2) misalignment Required Sensors/Components (Main) VVT actuator Required Sensors/Components (Related) Camshaft position sensor, Crankshaft position sensor Frequency of Operation Once per driving cycle Duration Within 60 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0011 (VVT system 1 - advance) P0012 (VVT system 1 - retard) P0021 (VVT system 2 - advance) P0115 - P0118 (ECT sensor) Engine speed 400 to 1,400 rpm ES ES–82 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met Condition (a) or (b) (a) VVT learning value at maximum retarded valve timing Less than 22.5°CA (crankshaft angle) (b) VVT learning value at maximum retarded valve timing bank 1: More than 44°CA (crankshaft angle) bank 2: More than 47.5°CA (crankshaft angle) WIRING DIAGRAM ES V4 VVT Sensor (Bank 1) ECM Shielded 1 R 18 VV2+ E6 2 G 28 VV2E6 V3 VVT Sensor (Bank 2) Shielded 1 Y 25 VV1+ E6 2 L 24 VV1E6 W-B W-B E J28 J/C E ED A130711E03 INSPECTION PROCEDURE HINT: • If DTC P0016 is displayed, check left bank VVT sensor. • If DTC P0018 is displayed, check right bank VVT sensor. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–83 • Read freeze frame data using the intelligent tester or OBD II scan tool. Because the ECU records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of malfunction. 1 CHECK VALVE TIMING (CHECK FOR LOOSE AND JUMPED TOOTH OF TIMING BELT) (a) Check valve timing (See page EM-16). NG ADJUST VALVE TIMING OK REPLACE ECM ES ES–84 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) DTC P0051 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1) DTC P0052 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1) ES DESCRIPTION Refer to DTC P2195 (See page ES-364). HINT: • Although the DTC titles refer to the "oxygen sensor", these DTCs relate to the Air Fuel Ratio (A/F) sensor. • The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The A/F sensor heater circuit uses a relay on the +B side of the circuit. Reference (Bank 1 Sensor 1 System Diagram) A/F HEATER A/F Sensor ECM A/F Heater Fuse From Battery Heater +B HT HA1A AF+ A1A+ Sensor AF- A1A- Duty Control From EFI Relay A118002E16 DTC No. DTC Detection Condition Trouble Area P0031 P0051 Air Fuel Ratio (A/F) sensor heater current less than 0.8 A (1 trip detection logic) • • • • Open in Air Fuel Ratio (A/F) sensor heater circuit Air Fuel Ratio (A/F) sensor heater A/F relay ECM P0032 P0052 Air Fuel Ratio (A/F) sensor heater current more than 10 A (1 trip detection logic) • • • • Short in A/F sensor heater circuit A/F sensor heater A/F relay ECM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–85 HINT: • Bank 1 refers to the bank that includes No. 1 cylinder. • Bank 2 refers to the bank that does not include No. 1 cylinder. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The ECM uses information from the Air Fuel Ratio (A/F) sensor to regulate the air fuel ratio and keep it close to the stoichiometric level. This maximizes the ability of the Three-Way Catalytic Converter (TWC) to purify the exhaust gases. The A/F sensor detects oxygen levels in the exhaust gas and transmits the information to the ECM. The inner surface of the sensor element is exposed to the outside air. The outer surface of the sensor element is exposed to the exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates a small voltage when there is a large difference in the oxygen concentrations between the exhaust gas and outside air. The platinum coating amplifies this voltage generation. The A/F sensor is more efficient when heated. When the exhaust gas temperature is low, the sensor cannot generate useful voltage signals without supplementary heating. The ECM regulates the supplementary heating using a duty-cycle approach to adjust the average current in the sensor heater element. If the heater current is outside the normal range, the signal transmitted by the A/F sensor will be inaccurate. As a result, the ECM will be unable to regulate air fuel ratio properly. When the current in the A/F sensor heater is outside the normal operating range, the ECM interprets this as a malfunction in the sensor heater and sets a DTC. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater (bank 1) range check (low current) P0032: A/F sensor heater (bank 1) range check (high current) P0051: A/F sensor heater (bank 2) range check (low current) P0052: A/F sensor heater (bank 2) range check (high current) Required sensors / components (Main) A/F sensor heater Required sensors / components (Related) - Frequency of operation Continuous Duration 10 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs not present None P0031 and P0051 (Low current): Battery voltage 10.5 V or more A/F sensor heater duty ratio 50 % or more Time after engine start 10 seconds or more P0032 and P0052 (High current): Time after engine start 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0031 and P0051 (Low current): A/F sensor heater current Less than 0.8 A ES ES–86 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0032 and P0052 (High Current): A/F sensor heater current More than 10 A COMPONENT OPERATING RANGE P0031 and P0051: A/F sensor heater current 1.8 to 3.4 A at 20°C (68°F) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Refer to DTC P2195 (See page ES-368). ES INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 and A13 Air Fuel Ratio (A/F) sensor connectors. (b) Measure the resistance of the A/F sensor connectors. Standard resistance Component Side A/F Sensor A12 A13 HT +B AF- AF+ Tester Connection Specified Condition HT (1) - +B (2) 1.8 Ω to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connectors. Front View A085152E60 NG REPLACE AIR FUEL RATIO SENSOR OK 2 INSPECT A/F RELAY (a) Remove the A/F relay from the engine room R/B. (b) Measure the resistance of the A/F relay. Standard resistance B016200E03 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F relay. NG REPLACE A/F RELAY ES–87 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 3 INSPECT ECM (HA1A OR HA2A VOLTAGE) ECM Connector E5 (a) Turn the ignition switch ON. (b) Measure the voltage of the E5 ECM connector. Standard voltage Tester Connection HA1A (E5-2) - Body ground HA2A (E5-1) - Body ground HA2A HA1A E118245E20 9 to 14 V HINT: • The HA1A means the A/F sensor bank 1 sensor 1. • The HA2A means the A/F sensor bank 2 sensor 1. OK NG Specified Condition REPLACE ECM ES ES–88 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM, A/F SENSOR - A/F RELAY) (a) (b) (c) (d) Wire Harness Side: A/F Sensor Connector Turn the ignition switch OFF. Disconnect the A12 or A13 A/F sensor connector. Disconnect the E5 ECM connector. Measure the resistance. Standard resistance (Check for open) Tester Connection HT +B HT (A12-1) - HA1A (E5-2) HT (A13-1) - HA2A (E5-1) A12 Specified Condition Below 1 Ω Standard resistance (Check for short) A13 ES Tester Connection Front View HT (A12-1) or HA1A (E5-2) - Body ground HT (A13-1) or HA2A (E5-1) - Body ground Specified Condition 10 kΩ or higher (e) Remove A/F relay from engine room R/B. (f) Measure the resistance. Standard resistance (Check for open) E5 Tester Connection HA2A HA1A ECM Connector +B (A12-2) - A/F relay (3) +B (A13-2) - A/F relay (3) Engine Room R/B: Specified Condition Below 1 Ω Standard resistance (Check for short) Tester Connection +B (A12-2) or A/F relay (3) - Body ground +B (A13-2) or A/F relay (3) - Body ground A/F Sensor Heater Relay A137813E01 Specified Condition 10 kΩ or higher (g) Reinstall the A/F relay from engine room R/B. (h) Reconnect the ECM connector. (i) Reconnect the A/F sensor connectors. NG OK CHECK FOR INTERMITTENT PROBLEMS REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) DTC P0057 Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2) DTC P0058 Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2) DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) DTC P0161 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) ES–89 DESCRIPTION HINT: Sensor 2 refers to the sensor mounted behind the Three-Way Catalyst Converter (TWC) and located far from the engine assembly. In order to obtain a high purification rate of the carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxide (NOx) components in the exhaust gas, a TWC is used. For the most efficient use of the TWC, the air fuel ratio must be precisely controlled so that it is always close to the stoichiometric air fuel level. For the purpose of helping the ECM to deliver accurate air fuel ratio control, a Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air fuel ratio becomes lean, the oxygen concentration in the exhaust gas is rich. The HO2 sensor informs the ECM that the post-TWC air fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air fuel ratio is richer than the stoichiometric air fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor has the property of changing its output voltage drastically when the air fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air fuel ratio control. ES ES–90 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Ideal Air Fuel Mixture Atmosphere Air Housing Output Voltage Platinum Electrode Solid Electrolyte (Zirconia Element) Heater ES Coating (Ceramic) Cover Richer - Air Fuel Ratio - Leaner Exhaust Gas A115539E02 HINT: The ECM provides a pulse width modulated control circuit to adjust the current through the heater. The heated oxygen sensor heater circuit uses a relay on the +B side of the circuit. Reference (System Diagram of Bank 1 Sensor 2) ECM Heated Oxygen Sensor EFI EFI Fuse EFI No. 2 Fuse Heater HT1B From Battery Sensor OX1B Duty Control E2 MREL Ground A137814E04 DTC No. DTC Detection Condition Trouble Area • P0037 P0057 Heater current is 0.25 A or less when the heater operates with more than 10.5 V positive battery voltage • • • Open in Heated Oxygen (HO2) sensor heater circuit Heated Oxygen (HO2) sensor heater EFI Relay ECM ES–91 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0038 P0058 When heater operates, heater current exceeds 2.0 A (1 trip detection logic) • • • • P0141 P0161 Cumulative heater resistance correction value exceeds threshold (2 trip detection logic) • • • • Short in HO2 sensor heater circuit HO2 sensor heater EFI Relay ECM Open or short in HO2 sensor heater circuit HO2 sensor heater EFI relay ECM HINT: • Bank 1 refers to the bank that includes No. 1 cylinder. • Bank 2 refers to the bank that does not include No. 1 cylinder. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The sensing portion of the Heated Oxygen (HO2) sensor has a zirconia element which is used to detect the oxygen concentration in the exhaust gas. If the zirconia element is at the appropriate temperature, and the difference between the oxygen concentration surrounding the inside and outside surfaces of the sensor is large, the zirconia element generates voltage signals. In order to increase the oxygen concentration detecting capacity of the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. Heated oxygen sensor heater range check (P0037, P0038, P0057 and P0058): The ECM monitors the current applied to the O2 sensor heater to check the heater for malfunctions. If the current is below the threshold value, the ECM determines that there is an open circuit in the heater. If the current is above the threshold value, the ECM determines that there is a short circuit in the heater. The ECM constantly monitors the current applied to the heater. IF the ECM detects an open or short circuit, the ECM turns the MIL on and sets a DTC. If a malfunction is detected, the ECM cuts off the current applied to the heater. Example: The ECM sets DTC P0038 or P0058 when the current in the HO2 sensor heater is more than 2 A. Conversely, when the heater current is less than 0.3 A, DTC P0037 or P0057 is set. Heated oxygen sensor heater performance (P0141 and P0161): After the accumulated heater ON time exceeds 100 seconds, the ECM calculates the heater resistance using the battery voltage and the current applied to the heater. If the resistance is above the threshold value, the ECM determines that there is a malfunction in the HO2 sensor heater and sets DTC P0141 or P0161. MONITOR STRATEGY Related DTCs P0037: Heated oxygen sensor heater (bank 1) range check (low current) P0038: Heated oxygen sensor heater (bank 1) range check (high current) P0057: Heated oxygen sensor heater (bank 2) range check (low current) P0058: Heated oxygen sensor heater (bank 2) range check (high current) P0141: Heated oxygen sensor heater performance (bank 1) P0161: Heated oxygen sensor heater performance (bank 2) Required sensors / components Heated oxygen sensor heater Required sensors / components Vehicle speed sensor (VSS) Frequency of operation Continuous: P0037, P0038, P0057 and P0058 Once per driving cycle: P0141 and P0161 Duration 1 second: P0037, P0038, P0057 and P0058 10 seconds: P0141 and P0161 MIL operation Immediate: P0037, P0038, P0057 and P0058 2 driving cycle: P0141 and P0161 ES ES–92 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None P0037 and P0057 (Low current): ES duration of the following conditions are met: 0.5 seconds or more (a) Time after heaters are OFF 1 second or more (b) Following conditions are met - Battery voltage 10.5 V or more to less than 20 V Learned heater current during heater OFF Completed Intrusive heating Not operating Heater is OFF Less than 0.1 seconds Heater current Less than 0.3 A P0038 and P0058 (High current): When one of following conditions is met: Condition (a), (b) or (c) (a) When all conditions are met: - Battery voltage 10.5 V or more Engine Running Starter OFF Catalyst monitoring active A/F control Not operating Active heater OFF control Not operating Active heater ON control Not operating (b) When all conditions below are met: - Battery voltage 10.5 V or more to less than 20 V Learned heater current during heater OFF Completed Active heater OFF control Not operating Active heater On control Not operating Heater OFF time Less than 0.1 seconds Heater current 2 A or more (c) Heater OFF time 1 second or more P0141 and P0161 Battery voltage 10.5 V or more Fuel cut OFF Time after fuel cut ON to OFF 30 seconds or more Accumulated heater ON time 100 seconds or more Learned heater current during heater OFF Completed TYPICAL MALFUNCTION THRESHOLDS P0037 and P0057 (Low current): Heater current - Learned heater OFF current Less than 0.3 A P0038 and P0058 (High current): When either condition below is met: Condition A or B A. Learned heater OFF current More than 2 A B. Heater current - Learned heater OFF current 5 A or more P0141 and P0161 Heater resistance Varies with sensor element temperature (example: More than 23 Ω) ES–93 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE HO2S heater current 0.4 to 1 A (at idle, warmed-up engine and +B: 11 to 14 V) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Engine Room R/B ECM EFI Relay W-B 2 L 2 1 5 3 2 35 IC4 W-G 2 2 Engine Room R/B H8 Heated Oxygen Sensor (Bank 2 Sensor 2) B L-W 2 EFI No. 2 2 J28 J/C J4 J/C L-W A 17 L-W IC3 2 1 W 33 E5 OX2B D H6 Heated Oxygen Sensor (Bank 1 Sensor 2) C D L-W L-W EFI 5 E5 HT2B P BR E1 OX 4 3 12 L-W IM1 C C Engine Room R/B 1 (Shielded) 1 L-W 2 +B HT 2 2 A 8 E8 MREL W-G 2 +B HT 1 G-Y (Shielded) BR E1 OX 4 3 B 1 E4 HT1B 18 E4 OX1B 2 28 E4 E2 BR J2 B J/C E J28 J/C B J3 B W-B E W-B EB E 1 E6 E1 W-B Battery ED EE A131128E01 ES ES–94 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the H6 or H8 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance of the HO2 sensor connector. Standard resistance Component Side HO2 Sensor ES +B HT H6 Tester Connection Specified Condition HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E1 (4) 10 kΩ or higher (c) Reconnect the HO2 sensor connectors. H8 NG E1 REPLACE HEATED OXYGEN SENSOR OX A137828E02 OK 2 INSPECT EFI RELAY (a) Remove the EFI relay from the engine room relay block. (b) Measure the resistance of the EFI relay. Standard resistance B016200E03 Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the EFI relay. NG OK Terminal Connection REPLACE EFI RELAY ES–95 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 INSPECT ECM (HT1B OR HT2B VOLTAGE) ECM Connector E4 E5 (a) Turn the ignition switch ON. (b) Measure the voltage of the E4 and E5 ECM connectors. Standard voltage Terminal Connection HT1B (E4-1) - Body ground HT2B (E5-5) - Body ground HT1B HT2B E118245E21 9 to 14 V HINT: • The HT1B means the heated oxygen sensor bank 1 sensor 2. • The HT2B means the heated oxygen sensor bank 2 sensor 2. OK NG Specified Condition REPLACE ECM ES ES–96 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - EFI RELAY, HEATED OXYGEN SENSOR - ECM) Wire Harness Side: Heated Oxygen Sensor Connector (a) (b) (c) (d) Turn the ignition switch OFF. Disconnect the H6 or H8 oxygen sensor connectors. Disconnect the E4 and E5 ECM connectors. Measure the resistance. Standard resistance (Check for open) H6 Bank 1 +B H8 Bank 2 HT E4 Specified Condition Below 1 Ω HT (H8-1) - HT2B (E5-5) Below 1 Ω Standard resistance (Check for short) Front View ES Terminal Connection HT (H6-1) - HT1B (E4-1) E5 Terminal Connection Specified Condition HT (H6-1) or HT1B (E4-1) - Body ground 10 kΩ or higher HT (H8-1) or HT2B (E5-5) - Body ground 10 kΩ or higher (e) Remove EFI relay from engine room R/B. (f) Measure the resistance. Standard resistance (Check for open) Tester Connection HT2B +B (H6-2) - EFI relay (3) ECM Connector HT1B +B (H8-2) - EFI relay (3) Engine Room R/B: Tester Connection +B (H8-2) or EFI relay (3) - Body ground EFI Relay A137829E01 Specified Condition 10 kΩ or higher (g) Reconnect the ECM connectors. (h) Reconnect the oxygen sensor connectors. (i) Reinstall the EFI relay. NG REPLACE ECM Below 1 Ω Standard resistance (Check for short) +B (H6-2) or EFI relay (3) - Body ground OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR ES–97 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0100 Mass Air Flow Circuit Malfunction DTC P0102 Mass Air Flow Circuit Low DTC P0103 Mass Air Flow Circuit High DESCRIPTION The Mass Air Flow (MAF) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air passing through the sensor. The ECM interprets this voltage as the intake air amount. The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. B+ Temperature Sensor Platinum Hot Wire (Heater) Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor G032710E01 DTC No. DTC Detection Condition Trouble Area P0100 Open or short in mass air flow meter circuit with more than 3 seconds engine speed 4,000 rpm or less • • • Open or short in mass air flow meter circuit Mass air flow meter ECM P0102 Open or short in mass air flow meter circuit with more than 3 seconds engine speed 4,000 rpm or less • • • • Open in mass air flow meter circuit Short in ground circuit Mass air flow meter ECM P0103 Open in mass air flow meter circuit with more than 3 seconds (E2G circuit) engine speed 4,000 rpm or less Short in mass air flow meter circuit with more than 3 seconds (+B circuit) engine speed 4,000 rpm or less • • • • Open in mass air flow meter circuit (E2G circuit) Short in mass air flow meter circuit (+B circuit) Mass air flow meter ECM HINT: After confirming DTC P0100, P0102 or P0103, use the intelligent tester to confirm the MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Mass Air Flow Rate (g/sec.) Approximately 0.0 271.0 or more Malfunction • • MAF meter power source circuit open VG circuit open or short E2G circuit open ES ES–98 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION If there is a defect in the Mass Air Flow (MAF) meter or an open or short circuit, the voltage level will deviate outside the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC. Example: When the sensor output voltage is less than 0.2 V or more than 4.9 V and if either condition continues for more than 3 seconds, the ECM will set a DTC. MONITOR STRATEGY ES Related DTCs P0100: MAF meter range check (fluttering) P0102: MAF meter range check (low voltage) P0103: MAF meter range check (high voltage) Required Sensors/Components (Main) MAF meter Required Sensors/Components (Related) Crankshaft position sensor Frequency of operation Continuous Duration 3 seconds MIL operation Immediate: Engine RPM is less than 4,000 rpm 2 driving cycles: Engine RPM is 4,000 rpm or more Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present None The typical enabling condition is not available - TYPICAL MALFUNCTION THRESHOLDS P0100: MAF meter voltage Less than 0.2 V or more than 4.9 V P0102: MAF meter voltage Less than 0.2 V P0103: MAF meter voltage More than 4.9 V COMPONENT OPERATING RANGE MAF meter voltage Between 0.4 and 2.2 V ES–99 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Engine Room R/B ECM EFI Relay L J/C 2 2 EFI 2 2 3 8 MREL E8 B B J2 W-G W-B 2 2 B J3 2 1 IC4 35 EFI No. 2 J4 J/C 1 5 A L-W 2 2 W-G 2 1 A 2 Engine Room R/B ES L-W M1 Mass Air Flow Meter 17 IC3 B L-W W-B 12 L-W IM1 C L-W 1 +B C J28 J/C Battery VG 3 W-R 30 VG E4 E2G 2 B-W 29 E2G E4 EB A131129E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (MASS AIR FLOW RATE) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Allow the engine to idle. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF. (d) Read the values displayed on the tester. Result Mass Air Flow Rate (g/sec.) Proceed to 0.0 A 271.0 or more B Between 1.0 and 270.0 (*1) C ES–100 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: *1: The value must change when the throttle valve is open or closed. B C Go to step 6 CHECK FOR INTERMITTENT PROBLEMS A 2 INSPECT MASS AIR FOW METER (POWER SOURCE VOLTAGE) Wire Harness Side MAF Meter Connector ES M1 +B (+) (a) Disconnect the M1 Mass Air Flow (MAF) meter connector. (b) Turn the ignition switch ON. (c) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition +B (M1-1) - Body ground 9 to 14 V (d) Reconnect the MAF meter connector. A054396E48 NG Go to step 5 OK 3 INSPECT ECM (VG VOLTAGE) ECM Connector E4 VG (+) E2G (-) (a) Start the engine. (b) Measure the voltage of the E4 ECM connector. HINT: Move the shift lever to P or N and turn the A/C switch OFF. Standard voltage Tester Connection Condition Specified Condition VG (E4-30) - E2G (E429) Engine is idling 0.5 to 3.0 V E118245E22 OK NG REPLACE ECM ES–101 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) Wire Harness Side Mass Air Flow Meter Connector (a) Disconnect the M1 mass air flow meter connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection VG (M1-3) - VG (E4-30) Below 1 Ω E2G (M1-2) - E2G (E4-29) Below 1 Ω VG (M1-3) or VG (E4-30) - Body ground 10 kΩ or higher M1 E2G E4 Front View VG Specified Condition (d) Reconnect the ECM connector. (e) Reconnect the MAF connector. ECM Connector NG E2G VG A115696E02 OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–102 5 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - EFI RELAY) (a) Remove the EFI No. 2 fuse from the engine room R/B. (b) Measure the resistance in the EFI No. 2 fuse. Standard: Below 1 Ω (c) Reinstall the EFI No. 2 fuse. (d) Disconnect the M1 mass air flow meter connector. (e) Remove the EFI relay from the engine room R/B. (f) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: +B (+) M1 Mass Air Flow Meter Connector Front View ES Engine Room R/B: Tester Connection Specified Condition +B (M1-1) - Engine room R/B (EFI relay terminal 3) Below 1 Ω +B (M1-1) or Engine room R/B (EFI relay terminal 3) - Body ground 10 kΩ or higher (g) Reconnect the MAF meter connector. (h) Reinstall the EFI relay. NG EFI Relay REPAIR OR REPLACE HARNESS OR CONNECTOR A137830E01 OK CHECK ECM POWER SOURCE CIRCUIT 6 INSPECT ECM (SENSOR GROUND) ECM Connector (a) Measure the resistance of the ECM connector. Standard resistance Tester Connection Specified Condition E2G (E4-29) - Body ground Below 1 Ω E4 NG E2G E118245E23 OK REPLACE ECM ES–103 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the M1 mass air flow meter connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: Mass Air Flow Meter Connector Tester Connection M1 E2G VG Front View VG (M1-3) - VG (E4-30) Below 1 Ω E2G (M1-2) - E2G (E4-29) Below 1 Ω VG (M1-3) or VG (E4-30) - Body ground 10 kΩ or higher E2G (M1-2) or E2G (E4-29) - Body ground 10 kΩ or higher (d) Reconnect the MAF meter connector. (e) Reconnect the ECM connector. E4 NG VG Specified Condition E2G ECM Connector A137865E01 OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–104 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0101 Mass Air Flow Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0100 (See page ES-92). DTC No. DTC Detection Condition P0101 Conditions (a), (b), (c), (d) and (e) are met (2 trip detection logic): (a) Engine running (b) Engine coolant temperature 70°C (158°F) or higher (c) Throttle Position (TP) sensor voltage 0.24 V or more (d) Average engine load value ratio less than 0.85, or more than 1.92 (varies with estimated engine load) Average engine load value ratio = Average engine load based on MAF meter output / Average engine load estimated from driving conditions (e) Average air-fuel ratio less than -20%, or more than 20% ES Trouble Area • • • Mass Air Flow (MAF) meter Air induction system PCV hose connections MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the airflow through the sensor, and the ECM uses it to calculate the intake air volume. The ECM monitors the average engine load value ratio to check the MAF meter for malfunctions. The average engine load value ratio is obtained by comparing the average engine load calculated from the MAF meter output to the average engine load estimated from the driving conditions, such as the engine speed and the throttle opening angle. If the average engine load value ratio is below the threshold value, the ECM determines that the intake air volume is low, and if the average engine load value ratio is above the threshold value, the ECM determines that the intake air volume is high. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0101: MAF Meter Rationality (low voltage) P0101: MAF Meter Rationality (high voltage) Required Sensors/Components (Main) MAF meter Required Sensors/Components (Related) Engine speed sensor, Engine coolant temperature sensor, Throttle position sensor Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ALL: Monitor will run whenever these DTCs are not present P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (insufficient ECT for closed loop) P0335 (CKP sensor) Throttle position 0.24 V or more Engine Running ES–105 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or more Engine coolant temperature 70°C (158°F) or more IAT sensor circuit Not detected ECT sensor circuit Not detected CKP sensor circuit Not detected TP sensor circuit Not detected Canister pressure sensor circuit Not detected Leak detection pump fail Not detected Vent valve fail Not detected TYPICAL MALFUNCTION THRESHOLDS Average lode value ratio Less than 0.85% or more than 1.92% Average air-fuel ratio Less than -20% or more than 20 ES WIRING DIAGRAM Refer to DTC P0100 (see page ES-94). CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the mass air flow performance monitor. Vehicle Speed Approximately 62 mph (100 km/h) Idling Time Warming Up 20 seconds or more A112632E01 1. 2. 3. 4. 5. 6. 7. Connect the intelligent tester to the DLC3. Turn the ignition switch ON. Turn the tester ON. Clear DTCs (See page ES-35). Start the engine, and warm it up until the engine coolant temperature reaches 70°C (158°F) or higher. Drive the vehicle at approximately 62 mph (100 km/h) for 20 seconds or more. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any DTCs (any pending DTCs) are set. ES–106 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0101) (a) Connect the intelligent tester to the DLC3 with the CAN VIM. (b) Turn the ignition switch ON and tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. ES Result Display (DTC Output) Proceed to P0101 and other codes are output A Only P0101 is output B HINT: If any other codes besides P0101 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 3 CHECK VENTILATION HOSE OK: Ventilation hose is connected correctly and is not damaged. NG OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE VENTILATION HOSE 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0110 Intake Air Temperature Circuit DTC P0112 Intake Air Temperature Circuit Low Input DTC P0113 Intake Air Temperature Circuit High Input ES–107 DESCRIPTION Fig. 1 Resistance kΩ ES Acceptable Temperature °C (°F) A067628E03 The Intake Air Temperature (IAT) sensor, built into the Mass Air Flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the intake air temperature. When the intake air temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM terminal (see Fig. 1). The IAT sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the IAT sensor from terminal THA via resistor R. The resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes in accordance with changes in the intake air temperature, the voltage at terminal THA (THAR) also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. DTC No. P0110 DTC Detection Condition Open or short in IAT sensor circuit for 0.5 seconds Trouble Area • • • Open or short in Intake Air Temperature (IAT) sensor circuit Intake Air Temperature (IAT) sensor (built into Mass Air Flow [MAF] meter) ECM P0112 Short in IAT sensor circuit for 0.5 seconds • • • Short in IAT sensor circuit IAT sensor (built into MAF meter) ECM P0113 Open in IAT sensor circuit for 0.5 seconds • • • Open in IAT sensor circuit IAT sensor (built into MAF meter) ECM ES–108 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: After confirming DTC "P0110, P0112 or P0113", use the intelligent tester to confirm the intake air temperature in the "DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL". Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) Short circuit MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT sensor and sets a DTC. Example: When the sensor voltage output is -40°C (-40°F) or more than 140°C (284°F). ES MONITOR STRATEGY Related DTCs P0110: IAT sensor range check (fluttering) P0112: IAT sensor range check (low resistance) P0113: IAT sensor range check (high resistance) Required Sensors/Components (Main) IAT sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None The typical enabling condition is not available - TYPICAL MALFUNCTION THRESHOLDS P0110: IAT sensor voltage [Intake air temperature] Less than 0.18 V, or more than 4.91 V (More than 140°C (284°F), or less than -40°C (40°F)) P0112: IAT sensor voltage [Intake air temperature] Less than 0.18 V (More than 140°C (284°F)) P0113: IAT sensor voltage [Intake air temperature] More than 4.91 V (Less than -40°C (-40°F)) COMPONENT OPERATING RANGE IAT sensor resistance [IAT] 0.18 V (140°C (284°F)) to 4.91 V (-40°C (-40°F)) ES–109 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM M1 Intake Air Temperature Sensor (Built in Mass Air Flow Meter) ECM 5V THA 4 Y-B E2 5 BR 22 THA E4 28 R E2 E4 ES A072925E26 INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (INTAKE AIR TEMPERATURE) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. (d) Read the values. Standard: Same value as actual Intake Air Temperature (IAT). Result Intake Air Temperature Proceed to -40°C (-40°F) A 140°C (284°F) or more B OK (same as present temperature) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or more. B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS ES–110 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) (a) Disconnect the M1 Mass Air Flow (MAF) meter connector. (b) Connect terminals THA and E2 of the MAF meter wire harness side connector. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. (f) Read the value. Standard: 140°C (284°F) (g) Reconnect the MAF meter connector. ECM MAF Meter Connector THA E2 ES Wire Harness Side: MAF Meter Connector OK M1 CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE MASS AIR FLOW METER THA E2 Front View A137831E01 NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) MAF Meter Connector (a) Disconnect the M1 MAF meter connector. (b) Connect terminals THA and E2 of the E4 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. (f) Read the value. Standard: 140°C (284°F) (g) Reconnect the MAF meter connector. ECM THA E2 E4 NG THA E2 ECM Connector A137832E01 CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–111 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) MAF Meter Connector ECM THA E2 A084869E61 (a) Disconnect the M1 MAF meter connector. (b) Connect the intelligent tester to the DLC3 with CAN VIM. (c) Turn the ignition switch ON and turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. (e) Read the value. Standard: -40°C (-40°F) (f) Reconnect the MAF meter connector. OK REPLACE MASS AIR FLOW METER NG 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) MAF Meter Connector ECM THA E2 (a) (b) (c) (d) Disconnect the M1 MAF meter connector. Disconnect the E4 ECM connector. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. (f) Read the value. Standard: -40°C (-40°F) (g) Reconnect the ECM connector. (h) Reconnect the MAF meter connector. NG E4 ECM Connector A137834E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE ECM ES ES–12 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK FOR INTERMITTENT PROBLEMS ES HINT: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with the intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic. 1. Clear the DTCs (See page ES-35). 2. Switch the ECM from normal mode to check mode using the intelligent tester (See page ES-36). 3. Perform a simulation test (See page IN-30). 4. Check and wiggle the harness(es), connector(s) and terminal(s) (See page IN-38). ES–13 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When the malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Perform this check with the engine stopped and ignition switch OFF. NG Result Proceed to 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK WHETHER ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 3 CHECK WHETHER ENGINE STARTS NG GO TO STEP 6 OK 4 CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil. NG REPLACE AIR FILTER OK 5 CHECK IDLING SPEED (a) Check the idling speed (See page EM-2). NG PROCEED TO PROBLEM SYMPTOMS TABLE ES ES–14 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 6 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-6). NG PROCEED TO TROUBLESHOOTING OK 7 CHECK FOR SPARK (a) Check for spark (See page IG-1). ES NG OK PROCEED TO PROBLEM SYMPTOMS TABLE PROCEED TO TROUBLESHOOTING ES–112 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0111 Intake Air Temperature Sensor Gradient Too High DESCRIPTION Fig. 1 Resistance (kΩ) Acceptable ES Temperature (°C) (°F) A067628E24 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the IAT. The IAT sensor has a built-in thermistor with a resistance that varies according to the temperature of the intake air. When the IAT is low, the resistance of the thermistor increases. When the temperature is high, the resistance drops. These variations in resistance are transmitted to the ECM as voltage changes (see Fig. 1). The IAT sensor is powered by a 5 V supply from the THA terminal of the ECM, via resistor R. Resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes, the voltage at terminal THA also varies accordingly. Based on this signal, the ECM increases the fuel injection volume when the engine is cold to improve driveability. DTC No. DTC Detection Condition P0111 When either condition below is met: 1. The intake air temperature rise is large, from the previous trip warm-up to the following trip (2 trip detection logic). 2. When the change in the intake air temperature after engine start is less than the threshold value. Trouble Area Mass air flow meter assembly MONITOR DESCRIPTION The ECM performs OBD II monitoring based on the values from the intake air temperature sensor. If there is no change in the sensor value within the normal range, the ECM will not be able to perform OBD II monitoring or will misdiagnose that there is a malfunction in the sensor. The ECM detects the stuck intake air temperature sensor value by performing monitoring after the ignition switch is turned OFF or after the engine is started (short soak or long soak). 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–113 MONITOR STRATEGY Related DTCs P0111: Intake air temperature sensor rationality (After engine stop) P0111: Intake air temperature sensor rationality (After cold engine start) Required Sensors/Components (Main) Intake Air Temperature (IAT) sensor Required Sensors/Components (Sub) - Frequency of Operation Once per driving cycle Duration 0.5 hours or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs are not present None After engine stop: Time after engine start 10 seconds or more Battery voltage 10.5 V or more ECT sensor circuit OK ECT change since engine Less than 180°C (356°F) ECT before engine stop 70°C (158°F) or more Time that MAF is low before engine stop 70 minutes Accumulated MAF amount before engine stop 2,567 g or more Key-off duration 30 minutes After cold engine start: Key-off duration 5 hours Time after engine start 10 seconds or more ECT sensor circuit OK ECT 70°C (158°F) or more Accumulated MAF amount 2,567 g or more Either of the following conditions 1 or 2 is met: - 1. Duration while engine load is low 10 seconds or more 2. Duration while engine load is high 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS After engine stop: IAT change Less than 1°C (2°F) After cold engine start: IAT change Less than 1°C (2°F) WIRING DIAGRAM Refer to DTC P0110 (see page ES-104). INSPECTION PROCEDURE 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0111) (a) Connect the intelligent tester to the DLC3. ES ES–114 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0111 and other DTCs A P0111 B HINT: If any DTCs other than P0111 are output, troubleshoot those DTCs first. ES B A GO TO DTC CHART REPLACE MASS AIR FLOW METER 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–115 DTC P0115 Engine Coolant Temperature Circuit DTC P0117 Engine Coolant Temperature Circuit Low Input DTC P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as the Intake Air Temperature (IAT) sensor. HINT: If the ECM detects the DTC P0115, P0117 or P0118, it operates the fail-safe function in which the ECT is assumed to be 80°C (176°F). DTC No. DTC Detection Condition Trouble Area P0115 Open or short in Engine Coolant Temperature (ECT) sensor circuit for 0.5 seconds • • • Open or short in Engine Coolant Temperature (ECT) sensor circuit Engine Coolant Temperature (ECT) sensor ECM P0117 Short in ECT sensor circuit for 0.5 seconds • • • Short in ECT sensor circuit ECT sensor ECM P0118 Open in ECT sensor circuit for 0.5 seconds • • • Open in ECT sensor circuit ECT sensor ECM HINT: After confirming DTC "P0115, P0117 or P0118", use the intelligent tester to confirm the engine coolant temperature in the "DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL". Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) or more Short circuit MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the ECT. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: When the ECM calculates that the ECT is -40°C (-40°F) (P0118) or more than 140°C (284°F) (P0117) and if either condition continues for 0.5 seconds or more, the ECM will set a DTC. MONITOR STRATEGY Related DTCs P0115: ECT sensor range check (fluttering) P0117: ECT sensor range check (low resistance) P0118: ECT sensor range check (high resistance) Required Sensors/Components (Main) ECT sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds ES ES–116 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None The typical enabling condition is not available - TYPICAL MALFUNCTION THRESHOLDS P0115: ECT sensor voltage [Engine coolant temperature] ES Less than 0.14 V, or more than 4.91 V (More than 140°C (284°F), or less than -40°C (40°F)) P0117: ECT sensor voltage [Engine coolant temperature] Less than 0.14 V (More than 140°C (284°F)) P0118: ECT sensor voltage [Engine coolant temperature] More than 4.91 V (Less than -40°C (-40°F)) COMPONENT OPERATING RANGE ECT sensor voltage [ECT] 0.14 V (140°C (284°F)) to 4.91 V (-40°C (-40°F)) WIRING DIAGRAM ECM E2 Engine Coolant Temperature Sensor 5V 2 R-L 21 THW E4 1 BR 28 E4 R E2 A115913E02 INSPECTION PROCEDURE HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–117 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ VALUE OF INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. (d) Read the values. Standard: Same value as the actual ECT. Result Engine Coolant Temperature Proceed to -40°C (-40°F) A 140°C (284°F) or more B OK (same as present temperature) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F) or more. B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) ECM ECT Sensor E2 THW E2 Wire Harness Side ECT Sensor Connector (a) Disconnect the E2 Engine Coolant Temperature (ECT) sensor connector. (b) Connect terminals 1 and 2 of the ECT sensor wire harness side connector. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. (f) Read the value. Standard: 140°C (284°F) or more (g) Reconnect the ECT sensor connector. OK E2 Front View A103711E11 CONFIRM GOOD CONNECTION TO SENSOR. IF OK, REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES ES–118 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) E2 ECT Sensor ECM THW E2 ES E4 (a) Disconnect the E2 ECT sensor connector. (b) Connect terminals THW and E2 of the E4 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. (f) Read the value. Standard: 140°C (284°F) or more (g) Reconnect the ECT sensor connector. NG THW E2 CONFIRM GOOD CONNECTION TO ECM. IF OK, REPLACE ECM ECM Connector A112667E12 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) E2 ECT Sensor ECM THW E2 A075766E19 (a) Disconnect the E2 ECT sensor connector. (b) Connect the intelligent tester to the DLC3 with CAN VIM. (c) Turn the ignition switch ON and turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. (e) Read the value. Standard: -40°C (-40°F) (f) Reconnect the ECT sensor connector. OK NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 ES–119 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) ECT Sensor E2 ECM THW E2 (a) (b) (c) (d) Disconnect the E2 ECT sensor connector. Disconnect the E4 ECM connector. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. (f) Read the value. Standard: -40°C (-40°F) (g) Reconnect the ECT sensor connector. (h) Reconnect the ECM connector. NG E4 ECM Connector A112668E11 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE ECM ES 2UZ-FE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–483 MASS AIR FLOW METER VG +B E2G Air 30 20 E2 THA INSPECTION 1. INSPECT OUTPUT VOLTAGE (a) Apply battery voltage across terminals 3 (+B) and 4 (E2G). (b) Connect the positive (+) tester probe to terminal 5 (VG), and the negative (-) tester probe to terminal 4 (E2G). (c) Blow air into the MAF meter, and check if the voltage fluctuates. 2. INSPECT RESISTANCE (a) Using an ohmmeter, measure the resistance between terminals 2 (THA) and 1 (E2). Resistance: 12.5 to 16.9 kΩ at -20°C (-4°F) 2.19 to 2.67 kΩ at 20°C (68°F) 0.50 to 0.68 kΩ at 60°C (140°F) 5 4 3 2 1 RESISTANCE kΩ 10 5 3 2 1 0.5 0.3 0.2 Acceptable 0.1 20 40 60 80 100 -20 0 (-4) (32) (68) (104) (140) (176) (212) TEMPERATURE °C (°F) A076691E01 3. Air INSPECT MASS AIR FLOW METER (a) If using a intelligent tester: (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Blow air into the MAF meter, and check that the air flow value of the CURRENT DATA changes. If operation is not as specified, check the MAF meter as well as the wiring and the ECM. A072564E01 ECM VG E2G Voltmeter A072565E02 (b) If not using a intelligent tester: (1) Turn the ignition switch to the ON position. (2) Connect the positive tester probe of the voltmeter to terminal VG of the ECM and the negative tester probe of the voltmeter to terminal E2G of the ECM. (3) Blow air into the air flow meter, and check if the voltage fluctuates. If operation is not as specified, check the MAF meter, the wiring and the ECM. ES ES–120 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0116 Engine Coolant Temperature Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0115 (See page ES-110). ES DTC No. DTC Detection Condition P0116 When either of following conditions met (2 trip detection logic): • When cold engine started and engine warmed up, Engine Coolant Temperature (ECT) sensor value does not change. • After warmed up engine stopped and then next cold engine start performed, ECT sensor value does not change. Trouble Area • • Thermostat Engine Coolant Temperature (ECT) sensor MONITOR DESCRIPTION ECT sensor cold start monitor When a cold engine start is performed and then the engine is warmed up, if the ECT sensor value does not change, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. ECT sensor soak monitor If the ECT sensor value does not change after the warmed up engine is stopped and then the next cold engine start is performed, it is determined that a malfunction has occurred. If this is detected in 2 consecutive driving cycles, the MIL is illuminated and a DTC is set. MONITOR STRATEGY Related DTCs P0116: Engine Coolant Temperature (ECT) sensor stuck (low ECT) P0116: ECT sensor stuck (high ECT) Required Sensors/Components (Main) Engine Coolant Temperature sensor Required Sensors/Components (Related) Intake air temperature sensor, Crankshaft position sensor, Mass air flow meter Frequency of Operation Once per driving cycle Duration 1 seconds or more MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF sensor) Cold start monitor: Battery voltage 10.5 V or more Time after engine start 1 second or more ECT at engine start Less than 60°C (140°F) IAT sensor circuit OK Soak time 0 seconds or more Accumulated MAF 2,157 g or more Fuel cut OFF Difference between ECT at engine start and IAT Less than 40°C (72°F) Soak monitor: Battery voltage 10.5 V or more Engine Running ES–121 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IAT sensor circuit OK Soak time 5 hours or more ECT at engine start 60°C (140°F) or more Accumulated MAF 4,202 g or more TYPICAL MALFUNCTION THRESHOLDS Cold start monitor: ECT sensor value change Less than 5°C (9°F) Engine Coolant Temperature sensor stuck (high Engine Coolant Temperature): Difference between current ECT sensor value and previous ECT sensor value when engine stopped Less than 5°C (9°F) COMPONENT OPERATING RANGE Engine coolant temperature ES Varies with actual engine coolant temperature WIRING DIAGRAM Refer to DTC P0115 (See page ES-111). INSPECTION PROCEDURE HINT: • If DTC P0115, P0116, P0117, P0118 and P0125 are output simultaneously, the ECT sensor circuit may be open or shorted. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0116) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0116 A P0116 and other DTCs B B GO TO RELEVANT DTC CHART A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-9). (b) Check the valve opening temperature of the thermostat (See page CO-9). ES–122 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard opening temperature: 80 to 84°C (176 to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-10). NG REPLACE THERMOSTAT OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–123 DTC P0120 Throttle / Pedal Position Sensor / Switch "A" Circuit DTC P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input DTC P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input DTC P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit DTC P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input DTC P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input DTC P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation HINT: This is the purpose for the "throttle position sensor". DESCRIPTION HINT: • This Electronic Throttle Control System (ETCS) does not use a throttle cable. • This throttle position sensor is a non-contact type. The Throttle Position (TP) sensor is mounted on the throttle body and it detects the opening angle of the throttle valve. This sensor is electronically controlled and uses Hall-effect elements so that accurate control and reliability can be obtained. The throttle position sensor has 2 sensor elements, VTA1 and VTA2, each with their own signal outputs. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. Voltage applied to VTA1 and VTA2 changes between 0 V to 5 V in proportion to the opening angle of the throttle valve. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor. The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA1 and VTA2, and the ECM controls the throttle actuator to set the throttle valve angle properly in response to driver inputs. ES ES–124 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail-safe Angle* Throttle Position Sensor Output Voltage VTA2 VTA1 2.55 V Throttle Position Sensor Magnet ES 5.0 V IC No. 1 2.25 V 0.93 V 0.69 V ECM 7° 5V VC Usable Range 0° 84° Throttle Valve Opening Angle VTA1 Throttle Valve Fully Closed (Throttle position expressed as percentage (VTA1) 10 to 20%) VTA2 E2 IC No. 2 Throttle Valve Fully Opened (Throttle position expressed as percentage (VTA1) 64 to 96%) Magnet *: Fail-safe Angle 7° (Throttle position expressed as percentage (VTA1) about 10 to 16%) A019802E48 DTC No. - P0120 P0122 P0123 DTC Detection Condition Trouble Area Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues for 2 seconds (Open or short in the throttle position sensor circuit) - Detection conditions for DTCs P0122 and P0123 are not satisfied but condition (a) is satisfied: (a) VTA1 is "0.2 V or less" or VTA1 is "4.435 V or more" • • Throttle position sensor (built in throttle body) ECM (a) VTA1 is 0.2 V or less • • • • Throttle position sensor (built in throttle body) Short in VTA1 circuit Open in VC circuit ECM (a) VTA1 is 4.535 V or more • • • • • Throttle position sensor (built in throttle body) Open in VTA1 circuit Open in E2 circuit VC and VTA1 circuit are short-circuited ECM ES–125 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0220 Detection conditions for DTCs P0222 and P0223 are not satisfied but condition (a) is satisfied (a) VTA2 is "1.75 V or less" or VTA2 is "4.8 V or more" • • Throttle position sensor (built in throttle body) ECM P0222 (a) VTA2 is 1.75 V or less • • • • Throttle position sensor (built in throttle body) Short in VTA2 circuit Open in VC circuit ECM P0223 (a) VTA2 is 4.8 V or more, and VTA1 is between 0.2 V and 2.02 V • • • • • Throttle position sensor (built in throttle body) Open in VTA2 circuit Open in E2 circuit VC and VTA2 circuits are short-circuited ECM P2135 Condition (a) continues for 0.5 second or more, or condition (b) continues for 0.4 second or more: (a) Difference between VTA1 and VTA2 is 0.02 V or less (b) VTA1 is 0.2 V or less and VTA2 is 1.75 V or less • • • VTA1 and VTA2 circuits are short-circuited Throttle position sensor (built in throttle body) ECM NOTICE: When a malfunction is detected, the throttle valve is locked at a certain opening angle. Also, the whole electronically controlled throttle operation is cancelled until the system returns to normal and the ignition switch is turned OFF. HINT: • After confirming DTCs, use the intelligent tester to confirm the throttle valve opening percentage and closed throttle position switch condition. • THROTTLE POS is the VTA1 signal. THROTTLE POS #2 is the VTA2 signal. Reference (Normal condition): Tester Display Accelerator Pedal Fully Released Accelerator Pedal Fully Depressed THROTTLE POS 10 to 24% 64 to 96% THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.5 V MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. (a)There is a specific voltage difference expected between VTA1 and VTA2 for each throttle opening angle. If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a fault and will set a DTC. (b)VTA1 and VTA2 each have a specific voltage operating range. If VTA1 or VTA2 is out of the normal operating range, the ECM interprets this as a fault and will set a DTC. (c) VTA1 and VTA2 should never be close to the same voltage levels. If VTA1 is within 0.02 V of VTA2, the ECM interprets this as a short circuit in the throttle position sensor system and will set a DTC. FAIL-SAFE If the ETCS (Electronic Throttle Control System) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel infection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimum speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. ES ES–126 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY ES Related DTCs P0120: Throttle position sensor 1 range check (fluttering) P0122: Throttle position sensor 1 range check (low voltage) P0123: Throttle position sensor 1 range check (high voltage) P0220: Throttle position sensor 2 range check (fluctuating) P0222: Throttle position sensor 2 range check (low voltage) P0223: Throttle position sensor 2 range check (high voltage) P2135: Throttle position sensor range check (correlation) Required sensors/components (Main) Throttle position sensor Required sensors/components (Related) - Frequency of operation Continuous Duration Accelerator pedal ON: 2 seconds Accelerator pedal OFF: 10 seconds P2135: 0.5 seconds or 0.4 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None Throttle control motor power ON Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less, or 4.435 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.535 V or more P0220: VTA1 voltage 1.75 V or less or 4.8 V or more P0222: VTA2 voltage 1.75 V or less P0223: VTA2 voltage when the VTA1 is 0.2 to 2.02 V 4.8 V or more P2135: Either of the following condition A or B is met - Condition A - Difference between VTA and VTA2 voltage 0.02 V or less Condition B - VTA1 voltage 0.2 V or less VTA2 voltage 1.75 V or less COMPONENT OPERATING RANGE VTA1 voltage 0.6 to 3.96 V VTA2 voltage 2.25 to 5.0 V ES–127 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM T2 Throttle Position Sensor (Built in Throttle w/ Motor Body) VC VTA1 VTA2 E2 5 R ECM 23 VC E4 L-R 6 20 E4 Y 19 VTA2 E4 R-B 4 3 W VTA1 BR ES 28 E4 E2 G038679E01 INSPECTION PROCEDURE HINT: • If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (THROTTLE POS, THROTTLE POS #2) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS and THROTTLE POS #2 . (d) Read the value. Depressed Released FI07052E06 Result Throttle position expressed as percentage and voltage Accelerator pedal depressed THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) Accelerator pedal released THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) Trouble Area Proceed to ES–128 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 0% 0 to 0.2 V 0% 0 to 0.2 V VC circuit open 100 % 4.5 to 5.5 V 100 % 4.5 to 5.5 V E2 circuit open 0 % or 100 % 2.1 to 3.1 V (fail-safe) 0 % or 100 % 2.1 to 3.1 V (fail-safe) VTA1 circuit open or ground short 10 to 24 % (fail-safe) 0 to 0.2 or 4.5 to 5.5 V 10 to 24 % (Fail safe) 0 to 0.2 or 4.5 to 5.5 V VTA2 circuit open or ground short 10 to 24 % 2.1 to 3.1 V 64 to 96 % (Does not fail safe) 4.5 to 5.5 V (Does not fail safe) TP sensor circuit is normal B A B Go to step 5 A ES 2 CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - ECM) Wire Harness Side Throttle Body Assembly Connector (a) Disconnect the T2 throttle body connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance VTA2 Tester Connection VTA1 T2 VTA1 (T2-6) - VTA1 (E4-20) E2 Front View VC Specified Condition VC (T2-5) - VC (E4-23) VTA2 (T2-4) - VTA2 (E4-19) Below 1 Ω E2 (T2-3) - E2 (E4-28) VC (T2-5) or VC (E4-23) - Body ground ECM Connector E4 VTA1 (T2-6) or VTA1 (E4-20) - Body ground 10 kΩ or higher VTA2 (T2-4) or VTA2 (E4-19) - Body ground VTA2 VC E2 VTA1 OK (d) Reconnect the throttle body connector. (e) Reconnect the ECM connector. NG A115698E02 REPAIR OR REPLACE HARNESS OR CONNECTOR ES–129 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK ECM (VC VOLTAGE) Wire Harness Side Throttle Body Assembly Connector T2 (a) Disconnect the T2 throttle body connector. (b) Turn the ignition switch ON. (c) Measure the voltage of the ECM. Standard voltage Tester Connection Specified Condition VC (E4-23) - E2 (E4-28) 4.5 to 5.5 V (d) Reconnect the throttle body connector. VC Front View E2 NG REPLACE ECM ES ECM Connector E4 VC E2 A115699E03 OK 4 REPLACE THROTTLE BODY (a) Replace the throttle body (See page ES-495). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (THROTTLE POSITION SENSOR DTCS ARE OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Clear the DTC (See page ES-35). (d) Start the engine and allow the engine to idle for 15 seconds or more. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (f) Read the DTC. Result Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 or P2135 A No output B B SYSTEM OK ES–130 A REPLACE ECM ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0121 ES–131 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem HINT: This is the purpose of the throttle position sensor. DESCRIPTION Refer to DTC P0120 (See page ES-118). DTC No. P0121 DTC Detection Condition Difference between voltage output of VTA1 and VTA2 deviates from the threshold for 2.0 seconds. Trouble Area Throttle Position (TP) sensor (built into throttle body) MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. This sensor includes 2 signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor and VTA1. There is a specific voltage difference expected between VTA1 and VTA2 for each throttle opening angle. If the voltage output difference of the VTA1 and VTA2 deviates from the normal operating range, the ECM interprets this as a malfunction of the throttle position sensor. The ECM will illuminate the MIL and set a DTC. This monitor runs for 2 seconds (the first 2 seconds of engine idle) after the engine is started (1 trip detection logic). MONITOR STRATEGY Related DTCs P0121: Throttle Position (TP) sensor rationality Required Sensors/Components (Main) TP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration Within 2 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present None Either of following conditions is set Condition A or B A. Ignition switch ON B. Electric throttle motor power ON TP sensor malfunction (P0120, P0122, P0123, P0220, P0222, P0223, P2135) Not detected TYPICAL MALFUNCTION THRESHOLDS Either of following conditions is met - Difference of TP sensor voltage between VTA1 and (VTA2 x 0.8) Higher than 1.6 V Difference of TP sensor voltage between VTA1 and (VTA2 x 0.8) Lower than 0.8 V ES ES–132 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE If the ETCS (Electronic Throttle Control System) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel infection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimum speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. WIRING DIAGRAM Refer to DTC P0120 (See page ES-122). INSPECTION PROCEDURE ES HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • This is the repair procedure of the throttle position sensor. 1 READ OTHER DTC OUTPUT (IN ADDITION TO DTC P0121) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0121 A P0121 and other DTCs B HINT: If any other codes besides P0121 are output, perform the troubleshooting for those codes first. B A REPLACE THROTTLE BODY GO TO RELEVANT DTC CHART ES–133 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Insufficient Coolant Temperature for Closed Loop Fuel Control P0125 DESCRIPTION Refer to DTC P0115 (See page ES-110). DTC No. DTC Detection Condition Trouble Area Engine coolant temperature hardly changes for 77 seconds after engine start (2 trip detection logic) P0125 Engine coolant temperature hardly changes for 129 seconds after engine start (2 trip detection logic) • • • Cooling system Engine coolant temperature sensor Thermostat Engine coolant temperature hardly changes for 1200 seconds after engine start (2 trip detection logic) MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the temperature of the engine coolant. The resistance of the sensor varies with the actual coolant temperature. The ECM applies a voltage to the sensor and the varying resistance of the sensor causes the signal voltage to vary. The ECM monitors the ECT signal voltage after engine start-up. If the sensor still reports that the engine is not warmed up enough for closed-loop fuel control after sufficient time has passed, the ECM interprets this as a fault in the sensor or cooling system and sets a DTC. Example: The ECT is 0°C (32°F) at engine start. After 77 seconds running time, the ECT sensor still indicates that the engine is not warm enough to begin air-fuel ratio feedback control of the air-fuel ratio. The ECM interprets this as a fault in the sensor or cooling system and will set a DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient engine coolant temperature for closed-loop fuel control Required Sensors/Components (Main) Thermostat, Cooling system Required Sensors/Components (Related) Engine coolant temperature sensor, Mass air flow meter Frequency of Operation Continuous Duration 77 seconds: -8.34°C (16.98°F) or more 129 seconds: -19.45 to -8.34°C (-3.01 to 16.98°F) 1200 seconds: Less than -19.45°C (-3.01°F) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present P0100 - P0103 (MAF sensor) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) Case 1 Engine coolant or intake air temperature at engine start -8.34°C (16.98°F) or higher Case 2 Engine coolant or intake air temperature at engine start Between -19.45°C (-3.01°F) and -8.34°C (16.98°F) Case 3 Engine coolant or intake air temperature at engine start Lower than -19.45°C (-3.01°F) ES ES–134 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Engine coolant temperature sensor output Less than 0°C (32°F) WIRING DIAGRAM Refer to DTC P0115 (See page ES-111). INSPECTION PROCEDURE ES HINT: • If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, an ECT sensor circuit may be open or shorted. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0125) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P0125 A P0125 and other DTCs B HINT: If any other codes besides P0125 is output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART A 2 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-9). (b) Check the valve opening temperature of the thermostat (See page CO-9). OK: Valve opening temperature is 80 to 84°C (176 to 183°F) HINT: Also check that the valve is completely closed below the opening temperature shown above. (c) Reinstall the thermostat (See page CO-10). NG REPLACE THERMOSTAT 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–135 OK 3 CHECK COOLING SYSTEM (a) Check that there is a defect in the cooling system which causes overcool, such as abnormal radiator fan operation, modified cooling system and so on. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES ES–136 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0128 Thermostat Malfunction HINT: This is the purpose of the thermostat malfunction detection. DESCRIPTION This DTC is output when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. DTC No. P0128 ES DTC Detection Condition Trouble Area Conditions (a), (b) and (c) are met: (a) Cold start (b) After sufficient warm-up time has elapsed (c) ECT is less than 75°C (167°F) • • • • Thermostat Cooling system Engine Coolant Temperature (ECT) sensor ECM MONITOR DESCRIPTION 5 seconds Estimated ECT Threshold (75°C (167°F)) Indicated ECT Reading ECT Time DTC Set (after 2 Driving Cycles) A121605E02 The ECM estimates the coolant temperature based on starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated coolant temperature reaches 75°C (167°F), the ECM checks the actual ECT. If the actual ECT is less than 75°C (167°F), the ECM will interpret this as a fault in the engine cooling system or thermostat and set a DTC. MONITOR STRATEGY Related DTCs P0128: Coolant thermostat Required Sensors/Components (Main) Thermostat, Engine cooling system 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–137 Required Sensors/Components (Related) Engine coolant temperature sensor, Intake air temperature sensor, Vehicle speed sensor Frequency of Operation Once per drive cycle Duration 15 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0010, P0020 (OCV Bank 1, 2) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0021 (VVT System 2 - Advance) P0022 (VVT System 2 - Retard) P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0340 - P0346 (VVT sensor 1, 2) P0351 - P0358 (igniter) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2237, P2240 (A/F sensor - open) P2A00, P2A03 (A/F sensor - slow response) Battery voltage 11 V or higher Either of the following conditions is met Condition 1 or 2 1. All of the following conditions are met Conditions (a), (b) and (c) (a) ECT at engine start - IAT at engine start -15 to 7°C (-27 to 12.6°F) (b) ECT at engine start -10 to 56°C (14 to 133°F) (c) IAT at engine start -10 to 56°C (14 to 133°F) 2. All of the following conditions are met Conditions (a), (b) and (c) (a) ECT at engine start - IAT at engine start More than 7°C (12.6°F) (b) ECT at engine start 56°C (133°F) or less (c) IAT at engine start -10°C (14°F) or more Accumulated time that vehicle speed is 80 mph (128 km/h) or more Less than 20 sec. TYPICAL MALFUNCTION THRESHOLDS Duration that all of following conditions are met 5 seconds or more (a) Estimated ECT 75°C (167°F) or higher (b) ECT sensor output Lower than 75°C (167°F) MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). ES ES–138 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0128) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED II / DTC INFO / CURRENT CODES. (d) Read the DTC. ES Result Display (DTC Output) Proceed to P0128 A P0128 and other DTCs B HINT: If any other codes besides P0128 are output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK COOLING SYSTEM (a) Check for defects in the cooling system that might cause the system to be too cold, such as an abnormal radiator fan operation or a modified cooling system. (b) Check the valve opening temperature of the thermostat. OK: Valve opening temperature is 80 to 84°C (176 to 183°F) HINT: Also check that the valve is completely closed below the opening temperature shown above. NG REPAIR OR REPLACE COOLING SYSTEM OK 3 INSPECT THERMOSTAT (a) Remove the thermostat (See page CO-9). (b) Check the valve opening temperature of the thermostat (See page CO-9). Standard: 80 to 84°C (176 to 183°F) 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–139 HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (See page CO-10). NG REPLACE THERMOSTAT OK REPLACE ECM ES ES–140 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) DTC P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) DTC P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) DTC P0156 Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) DTC P0157 Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2) DTC P0158 Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2) ES DESCRIPTION HINT: Sensor 2 refers to the sensor mounted behind the Three-Way Catalyst Converter (TWC) and located far from the engine assembly. In order to obtain a high purification rate of the carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxide (NOx) components in the exhaust gas, a TWC is used. For the most efficient use of the TWC, the air fuel ratio must be precisely controlled so that it is always close to the stoichiometric air fuel level. For the purpose of helping the ECM to deliver accurate air fuel ratio control, a Heated Oxygen (HO2) sensor is used. The HO2 sensor is located behind the TWC, and detects the oxygen concentration in the exhaust gas. Since the sensor is integrated with the heater that heats the sensing portion, it is possible to detect the oxygen concentration even when the intake air volume is low (the exhaust gas temperature is low). When the air fuel ratio becomes lean, the oxygen concentration in the exhaust gas is rich. The HO2 sensor informs the ECM that the post-TWC air fuel ratio is lean (low voltage, i.e. less than 0.45 V). Conversely, when the air fuel ratio is richer than the stoichiometric air fuel level, the oxygen concentration in the exhaust gas becomes lean. The HO2 sensor has the property of changing its output voltage drastically when the air fuel ratio is close to the stoichiometric level. The ECM uses the supplementary information from the HO2 sensor to determine whether the air fuel ratio after the TWC is rich or lean, and adjusts the fuel injection time accordingly. Thus, if the HO2 sensor is working improperly due to internal malfunctions, the ECM is unable to compensate for deviations in the primary air fuel ratio control. ES–141 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Atmosphere Air Ideal Air Fuel Mixture Housing Output Voltage Platinum Electrode Solid Electrolyte (Zirconia Element) Heater ES Coating (Ceramic) Cover Richer - Air Fuel Ratio - Leaner Exhaust Gas A115539E02 DTC No. DTC Detection Condition P0136 P0156 During active air fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) Heated Oxygen (HO2) sensor voltage does not decrease to less than 0.2 V (b) HO2 sensor voltage does not increase to more than 0.6 V P0136 P0156 Sensor impedance less than 5 Ω for more than 30 seconds when ECM presumes sensor to being warmed up and operating normally (1 trip detection logic) P0137 P0157 During active air fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) HO2 sensor voltage output less than 0.21 V (b) Target air fuel ratio rich P0137 P0157 High impedance: Sensor impedance 348.1 MΩ or more for more than 90 seconds when ECM presumes sensor to being warmed up and operating normally (1 trip detection logic) P0138 P0158 During active air fuel ratio control, following conditions (a) and (b) are met for certain period of time (2 trip detection logic): (a) HO2 sensor voltage output 0.59 V or more (b) Target air fuel ratio lean P0138 P0158 HO2 sensor voltage output exceeds 1.2 V for more than 30 seconds (1 trip detection logic) Trouble Area • • • • Open or short in Heated Oxygen (HO2) sensor (bank 1, 2 sensor 2) circuit Heated Oxygen (HO2) sensor (bank 1 sensor 2) Heated Oxygen (HO2) sensor heater (bank 1, 2 sensor 2) Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) EFI relay Gas leakage from exhaust system • • • • • Open in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) HO2 sensor heater (bank 1, 2 sensor 2) EFI relay Gas leakage from exhaust system • • • • Short in HO2 sensor (bank 1, 2 sensor 2) circuit HO2 sensor (bank 1, 2 sensor 2) ECM internal circuit malfunction Air-Fuel ratio (A/F) sensor (bank 1, 2) • • ES–142 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION ES 1. Active Air Fuel ratio Control The ECM usually performs air fuel ratio feedback control so that the Air Fuel Ratio (A/F) sensor output indicates a near stoichiometric air fuel level. This vehicle includes active air fuel ratio control in addition to regular air fuel ratio control. The ECM performs active air fuel ratio control to detect any deterioration in the Three-Way Catalytic Converter (TWC) and Heated Oxygen (HO2) sensor malfunctions (refer to the diagram below). Active air fuel ratio control is performed for approximately 15 to 20 seconds while driving with a warm engine. During active air fuel ratio control, the air fuel ratio is forcibly regulated to become lean or rich by the ECM. If the ECM detects a malfunction, one of the following DTCs is set: DTC P0136, P0156 (abnormal voltage output), P0137, P0157 (open circuit) and P0138, P0158 (short circuit). 2. Abnormal Voltage Output of HO2 Sensor (DTC P0136 and P0156) While the ECM is performing active air fuel ratio control, the air fuel ratio is forcibly regulated to become rich or lean. If the sensor is not functioning properly, the voltage output variation is small. For example, when the HO2 sensor voltage does nor decrease to less than 0.21 V and does not increase to more than 0.59 V during active air fuel ratio control, the ECM determines that the sensor voltage output is abnormal and sets DTC P0136. HO2 SENSOR CIRCUIT MALFUNCTION (P0136 and P0156: ABNORMAL VOLTAGE) 15 to 20 seconds Operation Active air fuel ratio control Off Normal 0.59 V HO2 sensor voltage Abnormal 0.21 V A115540E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–143 3. Open or short in the Heated Oxygen (HO2) Sensor Circuit (DTC P0137, P0157, P0138 or P0158) During active air fuel ratio control, the ECM calculates the Oxygen Storage Capacity (OSC)* of the Three-Way Catalytic Converter (TWC) by forcibly regulating the air fuel ratio to become rich or lean. If the HO2 sensor has an open or short, or the voltage output of the sensor noticeably decreases, the OSC indicates an extraordinarily high value. Even if the ECM attempts to continue regulating the air fuel ratio to become rich or lean, the HO2 sensor output does not change. While performing active air fuel ratio control, when the target air fuel ratio is rich and the HO2 sensor voltage output is 0.21 V or less (lean), the ECM interprets this as an abnormally low sensor output voltage and sets DTC P0137 or P0157. When the target air fuel ratio is lean and the voltage output is 0.59 V or more (rich) during active air fuel ratio control, the ECM determines that the sensor voltage output is abnormally high, and sets DTC P0138 or P0158. HINT: DTC P0138 or P0158 is also set if the HO2 sensor voltage output is more than 1.2 V for 30 seconds or more. *: The TWC has the capability to store oxygen. The OSC and the emission purification capacity of the TWC are mutually related. The ECM determines whether the catalyst has deteriorated, based on the calculated OSC value (See page ES-230). ES ES–144 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HO2 SENSOR CIRCUIT LOW VOLTAGE (P0137 and P0157: OPEN) 15 to 20 seconds Operation Active air fuel ratio control Target air fuel ratio Off Abnormal Normal Stoichiometric Air Fuel Level Normal Rich ES HO2 sensor voltage 0.21 V Abnormal HO2 SENSOR CIRCUIT HIGH VOLTAGE (P0138 and P0158: SHORT) Operation Active air fuel ratio control Target air fuel ratio HO2 sensor voltage Off Lean Stoichiometric Air Fuel Level Abnormal 0.59 V A115541E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–145 4. High or Low Impedance of Heated Oxygen (HO2) Sensor (DTC P0136, P0156, P0137 or P0157) Interrelation between temperature of the element and impedance: DTC Detection Area Impedance Ω 15,000 1,000 100 10 5 300 (572) 400 (752) 500 600 700 800 (932) (1,112) (1,292) (1,472) Temperature °C (°F) A131134E01 During normal air fuel ratio feedback control, there are small variations in the exhaust gas oxygen concentration. In order to continuously monitor the slight variation of the HO2 sensor signal while the engine is running, the impedance* of the sensor is measured by the ECM. The ECM determines that there is a malfunction in the sensor when the measured impedance deviates from the standard range. HINT: • *: The effective resistance in an alternating current electrical circuit. • The impedance cannot be measured using an ohmmeter. • DTC P0136 or P0156 indicates the deterioration of the HO2 sensor. The ECM sets the DTC by calculating the impedance of the sensor when the typical enabling conditions are satisfied (1 driving cycle). • DTC P0137 or P0157 indicates an open circuit in the HO2 sensor (1 driving cycle). The ECM sets this DTC when the impedance of the sensor exceeds the threshold 348.1 MΩ. MONITOR STRATEGY Related DTCs P0136: Heated oxygen sensor (Bank 1) output voltage (Output voltage) P0136: Heated oxygen sensor (Bank 1) impedance (Low) P0137: Heated oxygen sensor (Bank 1) output voltage (Low voltage) P0137: Heated oxygen sensor (Bank 1) impedance (High) P0138: Heated oxygen sensor (Bank 1) output voltage (High voltage) P0138: Heated oxygen sensor (Bank 1) output voltage (Extremely high) P0156: Heated oxygen sensor (Bank 2) output voltage (Output voltage) P0156: Heated oxygen sensor (Bank 2) impedance (Low) P0157: Heated oxygen sensor (Bank 2) output voltage (Low voltage) P0157: Heated oxygen sensor (Bank 2) impedance (High) P0158: Heated oxygen sensor (Bank 2) output voltage (High voltage) P0158: Heated oxygen sensor (Bank 2) output voltage (Extremely high) Required Sensors/Components (Main) Heated oxygen sensor Required Sensors/Components (Related) Mass air flow meter Frequency of Operation Once per driving cycle: Active air-fuel ratio control detection Continuous: Others ES ES–146 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 20 seconds: Heated oxygen sensor output (Output voltage, High voltage, Low voltage) 30 seconds: Heated oxygen sensor impedance (Low) 90 seconds: Heated oxygen sensor impedance (High) 10 seconds: Heated oxygen sensor output voltage (Extremely high) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS All: ES The monitor will run whenever these DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0455, P0456 (EVAP system) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2237, P2240 (A/F sensor - open) P2440 (AIR control valve stuck open) P2441 (AIR control valve stuck close) P2444 (AIP stuck ON) P2445 (AIP stuck OFF) P2A00, P2A03 (A/F sensor - slow response) Heated oxygen sensor output voltage (Output voltage, High voltage, Low voltage): Active air-fuel ratio control Executing Active air-fuel ratio control being when all of following conditions are met: - Battery voltage 11 V or more Engine coolant temperature 75°C (167°F) or more Idle OFF Engine RPM Less than 3,200 rpm A/F sensor status Activated Fuel system status Closed loop Fuel-cut OFF Engine load 10 to 70 % Shift position 4th or more Heated oxygen sensor impedance (Low): Battery voltage 11 V or higher Estimated sensor temperature Lower than 700°C (1,292°F) ECM monitor Completed P0606 Not set Heated oxygen sensor impedance (High): Battery voltage 11 V or more Estimated sensor temperature 450 to 750°C (842 to 1,382°F) P0606 Not set Heated oxygen sensor output voltage (Extremely high): Battery voltage 11 V or more Time after engine start 2 seconds or more 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–147 TYPICAL MALFUNCTION THRESHOLDS Heated oxygen sensor output voltage (Output voltage): Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions are met: Conditions (a), (b) and (c) (a) Commanded air-fuel ratio 14.3 or less (b) Rear HO2S voltage 0.21 to 0.59 V (c) OSC (Oxygen Storage Capacity of catalyst) 3 g or more 2. All of the following conditions are met: Conditions (a), (b) and (c) (a) Commanded air-fuel ratio 14.9 or more (b) Rear HO2S voltage 0.21 to 0.59 V (c) OSC (Oxygen Storage Capacity of catalyst) 3 g or more Heated oxygen sensor output voltage (Low voltage): All of the following conditions are met: Conditions 1, 2 and 3 1. Commanded air-fuel ratio 14.3 or less 2. Rear HO2S voltage Less than 0.21 V 3. OSC (Oxygen Storage Capacity of catalyst) 3 g or more Heated oxygen sensor output voltage (High voltage): All of the following conditions are met: Conditions 1, 2 and 3 1. Commanded air-fuel ratio 14.9 or more 2. Rear HO2S voltage More than 0.59 V 3. OSC (Oxygen Storage Capacity of catalyst) 3 g or more Heated oxygen sensor impedance (Low): Duration of the following condition 30 seconds or more Heated oxygen sensor impedance Less than 5 Ω Heated oxygen sensor impedance (High): Duration of the following condition 90 seconds or more Heated oxygen sensor impedance 348.1 MΩ or more Heated oxygen sensor output voltage (Extremely high): Duration of the following condition 10 seconds or more Heated oxygen sensor voltage More than 1.2 V COMPONENT OPERATING RANGE Heated Oxygen sensor voltage Varies between 0.1 and 0.9 V MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Refer to DTC P0037 (See page ES-88). ES ES–148 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN Vehicle Speed Between [H] 40 and 70 mph (64 and 113 km/h ) Idling ES [G] Ignition Switch ON Warm up 10 minutes Time (Note: Even when vehicle stops during pattern, test can be resumed.) A115372E39 A116412 NOTICE: This test will not be completed if the vehicle is driven under absolutely constant speed, such as with cruise control activated. 1. Connect the intelligent tester to the DLC3 with CAN VIM [A]. 2. Turn the ignition switch ON [B]. 3. Turn the tester ON [C]. 4. Clear DTCs (if set) (See page ES-35) [D]. 5. Enter the following menus: DIAGNOSIS / CARB OBD II / READINESS TESTS [E]. 6. Check that O2S EVAL is INCMPL (incomplete) [F]. 7. Start the engine and warm it up [G]. 8. Drive the vehicle at between 40 mph and 70 mph (64 km/h and 113 km/h) for at least 10 minutes [H]. 9. Note the state of the Readiness Tests items. Those items will change to COMPL (complete) as O2S EVAL monitor operates [I]. ES–149 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10.Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES and check if any pending DTCs are set [J]. HINT: If O2S EVAL does not change to COMPL, and any pending DTCs fail to set, extend the driving time. INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.5 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - ES ES–150 Case 2 3 ES 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.5 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. HINT: • If other DTCs relating to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • If the OX1B wire from the ECM connector is short-circuited to the +B wire, DTC P0136 will be set. • If the OX2B wire from the ECM connector is short-circuited to the +B wire, DTC P0156 will be set. 1 CHECK OTHER DTC OUTPUT (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0138 or P0158 A P0137 or P0157 B P0136 or P0156 C B Go to step 13 ES–151 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM C Go to step 6 A 2 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) After warming up the engine, run the engine at 2,500 rpm for 3 minutes. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2 or O2S B2S2. (d) Allow the engine to idle. (e) Read the Heated Oxygen (HO2) sensor output voltage while idling. Result HO2 Sensor Output Voltage Proceed to More than 1.2 V A Less than 1.0 V B B Go to step 5 A 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT) (a) Turn the ignition switch OFF and wait for 5 minutes. (b) Disconnect the E4 and E5 ECM connectors. (c) Check the resistance. Standard resistance E4 E5 Tester Connection Specified Condition HT1B (E4-1) - OX1B (E4-18) 10 kΩ or higher HT2B (E5-5) - OX2B (E5-33) 10 kΩ or higher (d) Reconnect the ECM connector. HT2B OK HT1B OX2B OX1B ECM Connector A116424E04 NG REPLACE ECM ES ES–152 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) Disconnect the H6 or H8 Heated Oxygen (HO2) sensor connector. (b) Measure the resistance of the HO2 sensor connector. Standard resistance (Bank 1, 2 sensor 2) Component Side HO2 Sensor +B HT H6 Tester Connection Specified Condition HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E1 (4) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. H8 NG ES E1 REPLACE HEATED OXYGEN SENSOR OX A137828E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK AIR FUEL RATIO SENSOR HINT: This A/F sensor test is to check the A/F sensor current during the fuel-cut. When the sensor is normal, the sensor current will indicate below 3 mA in this test. (a) Clear DTC. (b) Drive the vehicle by the drive pattern as listed below: (1) Warm up the engine. (2) Drive the vehicle at 60 km/h (40 mph) or more for 10 minutes or more. (3) Stop the vehicle. (4) Accelerator the vehicle until 60 km/h (40 mph) or more and decelerate for 3 seconds or more. Perform this three times. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–153 Drive Pattern: 40 mph (60 km/h) 0 mph (0 km/h) 10 minutes or more ES 3 seconds or more 3 seconds or more 3 seconds or more A152792E01 (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR RESULT. (d) Confirm that RANGE B1S1 is either PASS or FAIL. (e) Select RANGE B1S1 an press ENTER. (f) Read the test value. Standard: Less than 3.0 mA NOTICE: Do not turn the engine switch Off during this step because the test results will be lost. OK Go to step 9 NG REPLACE AIR FUEL RATIO SENSOR 6 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Start the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2. (e) After warming up the engine, run the engine at an engine speed of 2,500 rpm for 3 minutes. (f) Read the output voltage of the HO2 sensor when the engine rpm is suddenly increased. ES–154 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Quickly accelerate the engine to 4,000 rpm 3 times using the accelerator pedal. Standard voltage: Fluctuates between 0.4 V or less and 0.5 V or more. NG Go to step 13 OK 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT ES 8 READ DTC OUTPUT (DTC P0136, P0156) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (b) Read DTCs. Result Display (DTC Output) Proceed to P0136 or P0156 A No output B B CHECK FOR INTERMITTENT PROBLEMS A 9 REPLACE HEATED OXYGEN SENSOR (a) Replace the HO2 sensor (See page EX-2). NEXT 10 PERFORM CONFIRMATION DRIVING PATTERN NEXT 11 READ DTC OUTPUT (DTC P0136 or P0156) (a) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (b) Read DTCs. Result Display (DTC Output) Proceed to P0136 or P0156 A No output B ES–155 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B REPAIR COMPLETE A 12 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INJECTION VOLUME) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Start the engine and turn the tester ON. Warn up the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. (e) Change the injection volume using the tester, monitoring the voltage output of Air Fuel Ratio (A/F) and HO2 sensors displayed on the tester. HINT: • Change the fuel injection volume within the range of 12 % and +12 %. The injection volume can be changed in 1 % graduations within the range. • The A/F sensor is displayed as AFS B1S1 (AFS B2S1), and the HO2 sensor is displayed as O2S B1S2 (O2S B2S2) on the intelligent tester. Result Tester Display (Sensor) Voltage Variations Proceed to AFS B1S1 (AFS B2S1) (A/F) Alternates between more than 3.3 V and less than 3.3 V OK AFS B1S1 (AFS B2S1) (A/F) Remains at more than 3.3 V NG AFS B1S1 (AFS B2S1) (A/F) Remains at less than 3.3 V NG HINT: A normal HO2 sensor voltage (O2S B1S2 or O2S B2 S2) reacts in accordance with increases and decreases in fuel injection volumes. When the A/F sensor voltage remains at either less than 3.3 V or more than 3.3 V despite the HO2 sensor indicating a normal reaction, the A/F sensor is malfunctioning. ES ES–156 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Injection Volume +12 % Malfunction -12 % A/F Sensor Output Normal 3.3 V HO2 Sensor Output ES Malfunction 1V 0V A121606E01 NG REPLACE AIR FUEL RATIO SENSOR OK CHECK AND REPAIR EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO AND REPAIR CAUSE (FUEL INJECTOR, FUEL PRESSURE, EXHAUST GAS LEAKAGE, ETC.) 13 CHECK FOR EXHAUST GAS LEAK (a) Check for exhaust gas leakage from the exhaust manifold and pipe. OK: No exhaust gas leakage. NG OK REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT ES–157 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 14 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the H6 or H8 HO2 sensor connector. (b) Measure the resistance of the HO2 sensor connector. Standard resistance (Bank 1, 2 sensor 2) Component Side HO2 Sensor +B HT Tester Connection Specified Condition HT (1) - +B (2) 11 to 16 Ω at 20°C (68°F) HT (1) - E1 (4) 10 kΩ or higher (c) Reconnect the HO2 sensor connector. H6 NG H8 E1 REPLACE HEATED OXYGEN SENSOR ES OX A137828E02 OK 15 INSPECT EFI RELAY (a) Remove the EFI relay from the engine room relay block. (b) Measure the resistance of the EFI relay. Standard resistance B016200E02 Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) (c) Reinstall the EFI relay. NG OK Tester Connection REPLACE EFI RELAY ES–158 16 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - HEATED OXYGEN SENSOR) Wire Harness Side Heated Oxygen Sensor Connector Bank 1 Sensor 2, Bank 2 Sensor 2 H6 HT (a) Disconnect the heated oxygen sensor connector. (b) Disconnect the E4 and E5 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance +B H8 OX E1 ES ECM Connector E4 E5 Tester Connection Specified Condition OX (H6-3) - OX1B (E4-18) Below 1 Ω HT (H6-1) - HT1B (E4-1) Below 1 Ω OX (H8-3) - OX2B (E5-33) Below 1 Ω HT (H8-1) - HT2B (E5-5) Below 1 Ω OX (H6-3) or OX1B (E4-18) - Body ground 10 kΩ or higher HT (H6-1) or HT1B (E4-1) - Body ground 10 kΩ or higher OX (H8-3) or OX2B (E5-33) Body ground 10 kΩ or higher HT (H8-1) or HT2B (E5-5) - Body ground 10 kΩ or higher HT2B HT1B OX1B OX2B A121612E05 Reference (System Diagram of Bank 1 Sensor 2) ECM Heated Oxygen Sensor EFI EFI Fuse EFI No. 2 Fuse Heater HT1B From Battery Sensor OX1B Duty Control E2 MREL Ground A137814E04 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–159 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HEATED OXYGEN SENSOR ES ES–160 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0171 System Too Lean (Bank 1) DTC P0172 System Too Rich (Bank 1) DTC P0174 System Too Lean (Bank 2) DTC P0175 System Too Rich (Bank 2) DESCRIPTION ES The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim consists of both the short-term and the long-term fuel trims. The short-term fuel trim is fuel compensation that is used to constantly maintain the air fuel ratio at stoichiometric levels. The signal from the Air Fuel Ratio (A/F) sensor indicates whether the air fuel ratio is rich or lean compared to the stoichiometric ratio. This triggers a reduction in the fuel injection volume if the air fuel ratio is rich and an increase in the fuel injection volume if it is lean. Factors such as individual engine differences, wear over time and changes in operating environment cause short-term fuel trim to vary from the central value. The long-term fuel trim, which controls overall fuel compensation, compensates for long-term deviations in the fuel trim from the central value caused by the short-term fuel trim compensation. If both the short-term and long-term fuel trims are lean or rich beyond predetermined values, it is interpreted as a malfunction, and the ECM illuminates the MIL and sets a DTC. DTC No. P0171 P0174 DTC Detection Condition When air fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on LEAN side (2 trip detection logic) Trouble Area • • • • • • • • • • • • P0172 P0175 When air fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on RICH side (2 trip detection logic) • • • • • • • • • Air induction system Injector blockage Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Fuel pressure Gas leakage in exhaust system Open or short in heated oxygen sensor (bank 1, 2 sensor 2) Heated oxygen sensor (bank 1, 2 sensor 1) Heated oxygen sensor heater (bank 1, 2 sensor 1) EFI relay PCV piping ECM Injector leak or blockage MAF meter ECT sensor Ignition system Fuel pressure Gas leakage in exhaust system Open or short in heated oxygen sensor (bank 1, 2 sensor 1) circuit Heated oxygen sensor (bank 1, 2 sensor 1) ECM HINT: • When DTC P0171 or P0174 is recorded, the actual air fuel ratio is on the LEAN side. When DTC P0172 or P0175 is recorded, the actual air fuel ratio is on the RICH side. • If the vehicle runs out of fuel, the air fuel ratio is LEAN and DTC P0171 or P0174 may be recorded. The MIL is then illuminated. • If the total of the short-term fuel trim value and long-term fuel trim value is within the malfunction threshold (and ECT is more than 75°C (167°F)), the system is functioning normally. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–161 MONITOR DESCRIPTION Under closed-loop fuel control, fuel injection amounts that deviate from the ECM's estimated fuel amount will cause a change in the long-term fuel trim compensation value. Long-term fuel trim value is adjusted when persistent deviations in the short-term fuel trim's value are present. Also, the smoothed fuel trim learning value is adjusted when deviations from the ECM's simulated fuel injection value are present. The smoothed fuel trim learning value is the combination of smoothed short-term fuel trim (fuel feedback compensation value) and smoothed long-term fuel trim (learning value of the air fuel ratio). When the smoothed fuel trim learning value exceeds the malfunction threshold, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The average fuel trim learning value is more than +35 % or less than -35 %, the ECM interprets this as a fuel system malfunction. ES Fuel Compensation Amount P0171, P0174 +35%: Malfunction Threshold of LEAN Condition 1.35 1.0 P0172, P0175 -35%: Malfunction Threshold of RICH Condition 0.65 A121607E01 MONITOR STRATEGY Related DTCs P0171: Fuel trim Lean (bank 1) P0172: Fuel trim Rich (bank 1) P0174: Fuel trim Lean (bank 2) P0175: Fuel trim Rich (bank 2) Required Sensors/Components (Main) Oxygen sensor, A/F sensor Required Sensors/Components (Related) Engine coolant temperature sensor, Mass Air Flow meter, Crankshaft position sensor Frequency of Operation Continuous Duration Within 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES–162 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present ES P0010, P0020 (OCV Bank 1, 2) P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0021 (VVT System 2 - Advance) P0022 (VVT System 2 - Retard) P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0351 - P0358 (Igniter) P0500 (VSS) P2440 (AIR control valve stuck open) P2441 (AIR control valve stuck close) P2444 (AIP stuck ON) P2445 (AIP stuck OFF) Battery voltage 11 V or more Fuel system status Closed loop Either of following conditions is met Condition (a) or (b) (a) Engine RPM Less than 1,000 rpm (b) Intake air amount per revolution 0.26 g/rev. or more Catalyst monitor Not executed TYPICAL MALFUNCTION THRESHOLDS Fuel trim: EVAP purge-cut Executing Either of following conditions is met Condition (a) or (b) (a) Average between short-term fuel trim and long-term fuel trim +35 % or more (varies with ECT) (b) Average between short-term fuel trim and long-term fuel trim -35 % or less (varies with ECT) WIRING DIAGRAM Refer to DTC P2195 (See page ES-368). INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. ES–163 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Each sensor reacts in accordance with increases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES ES–164 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • A low A/F sensor voltage could be caused by a rich air fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0171, P0172, P0174, P0175) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. ES Result Display (DTC Output) Proceed to P0171, P0172, P0174 or P0175 A P0171, P0172, P0174 or P0175 and other DTCs B HINT: If any DTCs other than P0171, P0172, P0174 and P0175 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK CONNECTION OF VENTILATION HOSE OK: Ventilation hose is connected correctly and is not damaged. NG REPAIR OR REPLACE VENTILATION HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leaks. OK : No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Start the engine and turn the tester ON. ES–165 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. (d) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (e) Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume.) (f) Monitor the outputs of A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 Result Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F Sensor Condition Misfires Lean/Rich Lean/Rich Normal - Suspected Trouble Area Proceed to - C • • • • Lean Lean Actual air fuel ratio lean May occur • • • • • • Rich Rich Actual air fuel ratio lean • • • • Ventilation valve and hose Ventilation hose connections Injector blockage Gas leakage from exhaust system Air induction system Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor A Injector leakage or blockage Gas leakage from exhaust system Injection system Fuel pressure MAF meter ECT sensor A ES ES–166 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F Sensor Condition Misfires Lean Lean/Rich A/F sensor malfunction - • A/F sensor B Rich Lean/Rich A/F sensor malfunction - • A/F sensor B Suspected Trouble Area Proceed to Lean: During A/F CONTROL, the A/F sensor output voltage (AFS) is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL of the ACTIVE TEST, the output voltage of the heated oxygen sensor alternates correctly. ES B Go to step 11 C Go to step 15 A 5 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the COOLANT TEMP value when the engine is cold and warmed-up. Standard: ECT when the engine is cold: Same as ambient temperature ECT when the engine is warmed-up: 75 to 95°C (167 to 203°F) NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 6 READ VALUE OF INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (d) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (e) Read the MAF with the engine in an idling condition and at an engine speed of 2, 500 rpm. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–167 Standard: MAF at idle rpm: 1.4 g/sec. and 2.3 g/sec. (shift lever is in N position and A/C is OFF) MAF at 2,500 rpm: 5.4 g/sec. and 7.9 g/sec. (shift lever is in N position and A/C is OFF) NG REPLACE MASS AIR FLOW METER OK 7 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-6). NG REPAIR OR REPLACE FUEL SYSTEM OK 8 CHECK FOR EXHAUST GAS LEAK OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST SYSTEM OK 9 CHECK FOR SPARK AND IGNITION (a) Check for spark and ignition (See page IG-1). HINT: If the spark plugs or ignition system malfunction, engine misfire may occur. The misfire counter can be read with the intelligent tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #8). NG REPAIR OR REPLACE IGNITION SYSTEM OK 10 INSPECT FUEL INJECTOR (INJECTION AND VOLUME) (a) Inspect the fuel injector (See page FU-11). HINT: If the injectors are malfunctioning, engine misfire may occur. The misfire counter can be read with the intelligent tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / CYL #1 (to CYL #8). NG OK REPLACE FUEL INJECTOR ES ES–168 11 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 Air Fuel Ratio (A/F) sensor connectors. (b) Measure the resistance of the A/F sensor. Standard resistance Component Side A/F Sensor A12 A13 HT +B AF- Specified Condition HT (1) - +B (2) 1.8 to 3.4 kΩ at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher AF+ Front View A085152E60 ES Tester Connection NG REPLACE AIR FUEL RATIO SENSOR OK 12 INSPECT A/F RELAY (a) Remove the A/F relay from the engine room relay block. (b) Measure the resistance of the A/F relay. Standard resistance B016200E02 OK NG Terminal Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) REPLACE A/F RELAY ES–169 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch to ON. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side A/F Sensor Connector A12 HT +B AF- ECM Connector E5 HA1A HA2A A2A+ A1A+ A2A- A1A- Specified Condition +B (2) - Body ground 9 to 14 V (d) Turn the ignition switch to OFF. (e) Disconnect the E5 ECM connector. (f) Check the resistance. Standard resistance (Check for open) A13 AF+ Tester Connection Tester connection Specified Condition HT (A12-1) - HA1A (E5-2) HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A12-4) - A1A- (E5-30) AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A121613E02 Tester connection Specified Condition HT (A12-1) or HA1A (E5-2) - Body ground HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the ECM connector. (h) Reconnect the A/F sensor connector. ES ES–170 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (Bank 1 Sensor 1 System Diagram) A/F HEATER A/F Sensor ECM A/F Heater Fuse From Battery Heater +B HT HA1A AF+ A1A+ Sensor AF- A1A- ES Duty Control From EFI Relay A118002E16 NG OK 14 NEXT REPLACE AIR FUEL RATIO SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 15 ES–171 PERFORM CONFIRMATION DRIVING PATTERN Vehicle Speed Between [F] 38 and 75 mph (60 and 120 km/h) Idling ES [E] Ignition Switch OFF [A], [B], [C], [D] Warming up 3 to 5 minutes Time A115372E40 (a) Connect the intelligent tester to the DLC3 with CAN VIM [A]. (b) Turn the ignition switch ON and turn the tester ON [B]. (c) Clear DTCs (See page ES-35) [C]. (d) Switch the ECM from normal mode to check mode using the tester (See page ES-36) [D]. (e) Start the engine and warm it up with all the accessories switched OFF [E]. (f) Drive the vehicle at between 38 and 75 mph (60 and 120 km/h) and at an engine speed of between 1,400 rpm and 3,200 rpm for 3 to 5 minutes [F]. HINT: If the system is still malfunctioning, the MIL will be illuminated during step [F]. NOTICE: If the conditions in this test are not strictly followed, no malfunction will be detected. NEXT 16 CHECK WHETHER DTC OUTPUT RECURS (DTC P0171, P0172, P0174 OR P0175) (a) On the intelligent tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (b) Read DTCs. ES–172 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to No output A P0171, P0172, P0174 or P0175 B B A END ES Go to step 5 ES–173 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0230 Fuel Pump Primary Circuit DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal STAR NSW of the ECM to the starter relay coil and also current flows to terminal STA of the ECM (STA signal). When the STA signal and NE signal are input to the ECM, the Tr1 (power transistor 1) is turned ON, current flows to the coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump, and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps the Tr1 ON (circuit opening relay ON) and the fuel pump also keeps operating. The fuel pump speed is controlled at two levels (high speed or low speed) by the engine condition (starting, light load, heavy load). When the engine starts (STA ON), the Tr2 (power transistor 2) in the ECM is OFF, so the fuel pump relay closes and battery positive voltage is applied directly to the fuel pump. The fuel pump operates at high speed. After the engine starts during idling or light loads, since the Tr2 goes ON, power is supplied to the fuel pump via the fuel pump resistor. The fuel pump operates at low speed. EFI ECM EFI Relay Fuel Pump Resistor MREL C/OPN Relay Fuel Pump Relay Ignition Switch FPR Tr2 STA FC Tr1 IGN Fuel Pump AM2 STA Relay Park/Neutral Position Switch N P Battery Starter Crankshaft Position Sensor (NE Signal) STAR NE+ A078887E02 ES ES–174 DTC No. P0230 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Detection Condition Open or short in fuel pump relay circuit Trouble Area • • • • • Open or short in fuel pump relay circuit Fuel pump relay ECM Circuit opening relay Fuel pump ES–175 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C/OPN Relay B-O 2 C J4 J/C 2 C B-O 1 2 5 3 GR-B 2 GR-B 10 E8 FC 35 IC4 W-G 8 E8 MREL 2 B-W Engine Room R/B B Driver Side J/B 23 1E 33 IC4 W-G IGN B-W Engine Room R/B 6 1D 2 2 3 2 EFI Relay B-R 5 FUEL PUMP Relay 5 2 1 2 B-R 2 B-Y 1 J/C L 2 G-R 5 G-R IC4 F8 Fuel Pump Resistor W-B B J2 7 2 4 2 IG2 2 I18 Ignition SW 6 3 1 2 19 30 G-R IM2 E6 FPR AM2 B J3 R 2 2 2 1 B-R B-R 2 AM2 2 2 IB1 EFI 1 W-B 4 B-R F14 Fuel Pump 5 W-B 2 Engine Room R/B A J41 B Battery EB A J41 A J40 W-B BO W-B BL A131137E02 HINT: This troubleshooting procedure is based on the premise that the engine is started. If the engine is not started, proceed to the problem symptoms table (See page ES-26). ES ES–176 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ECM (FPR VOLTAGE) ECM Connector E6 ES FPR (a) Measure the voltage of the ECM connector. Standard voltage Tester Connection Condition Specified Condition FPR (E6-30) - E1 (E6-1) STA signal ON 9 to 14 V FPR (E6-30) - E1 (E6-1) STA signal OFF 0 to 3 V NG E1 REPLACE ECM E118245E07 OK 2 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay from the engine room relay block. (b) Measure the resistance of the fuel pump relay. Standard resistance Tester Connection Specified Condition 1 - 2, 3 - 4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A030519E02 (c) Reinstall the fuel pump relay. NG OK REPLACE FUEL PUMP RELAY ES–177 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (FUEL PUMP RELAY - ECM) ECM Connector E6 FPR (a) Remove the fuel pump relay from the engine room relay block. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between wire harness side connectors. Standard resistance Tester Connection Specified Condition Engine Room R/B (Fuel pump relay terminal 1) - FPR (E6-30) Below 1 Ω Engine Room R/B (Fuel pump relay terminal 1) or FPR (E6-30) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reinstall the fuel pump relay. Engine Room R/B: NG Fuel Pump Relay A137919E01 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–15 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. The intelligent tester is required to register the VIN. 1. 2. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN. (a) Input Instructions: Explains the general VIN input instructions using an intelligent tester. (b) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle's ECM, are the same. (c) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the VIN and VIN do not match, the VIN can be registered, or overwritten in the ECM by following this procedure. INPUT INSTRUCTIONS HINT: Below are the general VIN input instructions using the intelligent tester. (a) General The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used to input the VIN. (b) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (c) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (d) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) After input, the cursor should move. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (e) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT button. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. (f) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. ES ES–16 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (2) Press the ENTER button on the tester. 3. READ VIN (Vehicle Identification Number) HINT: Below are the VIN reading instructions. Use the procedures and flowchart below. Reading the VIN stored in the ECM is necessary when comparing it to the VIN provided with the vehicle. (a) Read VIN using the intelligent tester. (b) Check the vehicle's VIN. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. ES Menu Screen: Select VIN READ DTC P0630 Set VIN Previously Stored VIN Not Stored 17-digit VIN displayed [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 ES–17 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. WRITE VIN HINT: Below are the VIN writing instructions. Use the procedures and flowchart below. This process allows the VIN to be input into the ECM. If the ECM is changed, or the ECM VIN and Vehicle VIN do not match, the VIN can be registered or overwritten in the ECM by following this procedure. (a) Write VIN using the intelligent tester. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON. (d) Turn the tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. ES Menu Screen: Select VIN WRITE VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 ES–18 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM New Registration Input Instructions [ENTER] ES [ENTER] [ENTER] [ENTER] Input Error [EXIT] Continue to next illustration A103814E07 ES–19 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Writing Successful Writing Error Communication Error ES [ENTER] To Menu Screen [EXIT] To Menu Screen [EXIT] To Menu Screen A103815E03 ES–178 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0300 Random / Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected DTC P0307 Cylinder 7 Misfire Detected DTC P0308 Cylinder 8 Misfire Detected DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) enter the exhaust in high concentrations. If the HC concentration is too high, exhaust emissions levels may increase. High concentrations of HC can also cause the temperature of the catalyst to increase, possibly damaging the catalyst. To prevent the increase in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the catalyst reaches a point of thermal degradation, the ECM will begin flashing the MIL. For monitoring misfires, the ECM uses both the Camshaft Position (CMP) sensor and the Crankshaft Position (CKP) sensor. The CMP sensor is used to identify misfiring cylinders and the CKP sensor is used to measure variations in the crankshaft rotation speed. The misfire counter records how many times the crankshaft rotation speed variations exceed threshold values. If the misfiring rate exceeds the threshold value and could cause emissions to deteriorate, the ECM illuminates the MIL. DTC No. DTC Detection Condition Trouble Area P0300 Misfiring of random cylinder is detected • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connections Ignition system Fuel injector Fuel pressure Mass Air Flow (MAF) meter Engine Coolant Temperature (ECT) sensor Compression pressure Valve timing Valve clearance Ventilation valve and hose Ventilation hose connections ECM P0301 P0302 P0303 P0304 P0305 P0306 P0307 P0308 Misfiring of each cylinder is detected Same as DTC No. P0300 ES–179 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: In some cases, several DTCs for misfired cylinders (DTCs P0301 to P0308) are recorded but the random/ multiple cylinder misfire DTC (P0300) is not recorded. This is an indication that the misfires were detected and recorded at different times. Random misfire codes are recorded only when several misfires occur at the same time. Reference: Inspect using an oscilloscope. With the engine idling, check the waveform between terminals #10 to #80 and E1 of the ECM connectors. The correct waveform is as shown. Injector Signal Waveform Magnification 10 V/DIV. 10 V/DIV. ES GND GND 100 msec./DIV. (Idling) Injection Duration 1 msec./DIV. (Idling) A121608E02 MONITOR DESCRIPTION Camshaft position sensor Crankshaft position sensor ECM (36-2 teeth or 12 teeth) A121609E03 The ECM illuminates the MIL (2 trip detection logic) if: When the percentage of misfire exceeds the specified limit per 1,000 engine revolutions. One occurrence of excessive misfire during engine start will set the MIL. Four occurrences are required to set the MIL 1,000 revolutions after engine start. The ECM begins blinking the MIL as follows (2 trip detection logic is used and DTC is stored after 2 trip detection): • Within 200 crankshaft revolutions at a high rpm, the threshold for "percent of misfires causing catalyst damage" is reached once. • Within 200 crankshaft revolutions at a normal rpm, the threshold for "percent of misfires causing catalyst damage" is reached 3 times. ES–180 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0300: Multiple cylinder misfire P0301: Cylinder 1 misfire P0302: Cylinder 2 misfire P0303: Cylinder 3 misfire P0304: Cylinder 4 misfire P0305: Cylinder 5 misfire P0306: Cylinder 6 misfire P0307: Cylinder 7 misfire P0308: Cylinder 8 misfire Required Sensors/Components (Main) Camshaft position sensor, Crankshaft position sensor Required Sensors/Components (Related) Engine coolant temperature sensor, Intake air temperature sensor, Throttle position sensor Frequency of Operation Continuous Duration Every 1,000 revolutions (soon after engine is started: 1 time, other: 4 times) (emission related misfire) Every 200 revolutions (1 or 3 times) (catalyst deteriorating misfire) MIL Operation 2 driving cycles: MIL ON Blinking immediately: Catalyst-damaged-misfire Sequence of Operation None ES TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0327 - P0333 (knock sensor) P0335 (CKP sensor) P0500 (VSS) Battery voltage 8 V or more Throttle position learning Completed VVT system Not operate by scan tool Engine RPM 400 to 5,700 rpm Fuel cut OFF When both conditions below are met Conditions 1 and 2 1. ECT -10°C (14°F) or more 2. Either of following conditions is met Conditions (a) or (b) (a) Engine start ECT Higher than -7°C (19°F) (b) ECT Higher than 20°C (68°F) Monitor period of emission-related misfire: First 1,000 revolutions after engine start, or Check Mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions x 4 Monitor period of emission-related misfire: All of following conditions 1, 2 and 3 are met Crankshaft 200 revolutions Except above Crankshaft 200 revolutions x 3 1. Driving cycles 1st 2. Check Mode OFF 3. RPM Less than 2,800 revolutions TYPICAL MALFUNCTION THRESHOLDS Emission-related-misfire: Misfire rate 1.2 % or more 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–181 Catalyst-damage-misfire (MIL blinks): Number of misfire per 200 revolutions 93 or more (varies with intake air amount and RPM) Multiple cylinders misfire Detected MONITOR RESULT Refer to detailed information on CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Refer to DTC P0351 (See page ES-208). ES ES–182 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM I9 Injector No. 1 B-R B-R R-L 1 B-R 4 EB1 ES R-L 2 A I11 Injector No. 3 B-R B-R B-R B-R B-R IG2 I18 Ignition SW 4 #30 E6 G 6 #50 E6 W 3 #70 E4 L 3 #20 E6 Y 5 #40 E6 R 7 #60 E6 BR 2 #80 E4 W-B 7 E01 E4 1 2 I10 Injector No. 2 B-R B-R 1 2 I12 Injector No. 4 B-R AM2 7 B-R 1 2 I14 Injector No. 6 R B-R B-R 2 Engine Room R/B 2 1 2 I16 Injector No. 8 AM2 B-R 1 1 2 2 #10 E6 W 1 2 I15 Injector No. 7 8 EA1 6 A 1 2 I13 Injector No. 5 B-R B-R ECM J26 J/C 2 B W-B 6 E02 E4 Battery EE A131141E01 CONFIRMATION DRIVING PATTERN 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Record the DTC and freeze frame data. 3. Set check mode on the intelligent tester (See page ES-36). 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–183 4. Read the value on the misfire counter for each cylinder when idling. If the value is displayed on the misfire counter, skip the following procedure of confirmation driving. 5. Drive the vehicle several times while using the DATA LIST's MISFIRE RPM and MISFIRE LOAD menu items to keep track of the vehicle's engine speed, load and its surrounding range. If you have no intelligent tester, turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process. HINT: In order to force output of the DTC, it is necessary to drive with MISFIRE RPM and MISFIRE LOAD selected in the DATA LIST for the period of time in the chart below. Do not turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode and all DTCs, freeze frame data and other data are erased. Engine RPM Time Idling 3.5 minutes or more 1,000 rpm 3 minutes or more 2,000 rpm 1.5 minutes or more 3,000 rpm 1 minute or more 6. Check if a misfire occurs by monitoring DTC output and the freeze frame data. Then, record the DTCs, freeze frame data and misfire counter data. 7. Turn the ignition switch OFF and wait for at least 5 seconds. INSPECTION PROCEDURE HINT: • If DTCs other than misfire DTCs are output simultaneously, troubleshoot the non-misfire DTCs first. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred. • If the misfire does not occur when the vehicle is brought to the workshop, the misfire can be confirmed by reproducing the conditions recorded in the freeze frame data. Also, after finishing repairs, confirm that no misfire occurs (see confirmation driving pattern). • On 6 and 8 cylinder engines, cylinder-specific misfire fault codes are disabled at high engine speeds. If the misfire starts in a high engine speed range or the misfire occurs only in a high engine speed area, only general fault code P0300 will be stored. When only P0300 is stored: (a)Erase the general misfire fault code from the intelligent tester. (b)Start the engine and drive the confirmation pattern (see confirmation driving pattern). (c) Read the value of the misfire ratio for each cylinder. Or, check if a DTC was output. (d)Perform repairs on the cylinder that has a high misfire ratio. Or repair the cylinder indicated by any output DTCs. (e)After finishing repairs, drive the confirmation pattern again and confirm that no misfire occurs. • If either SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is +-20 %, there is a possibility that the air fuel ratio is becoming RICH (-20 % or less) or LEAN (+20 % or more). • When COOLANT TEMP in the freeze frame data is less than 75°C (167°F), a misfire is only possible during engine warm-up. • If the misfire cannot be reproduced, the cause may be: 1) low fuel in the vehicle, 2) improper fuel in the vehicle, 3) a contaminated ignition plug, or 4) another problem. • Be sure to check the value on the misfire counter after repairs. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO MISFIRE DTCS) (a) Connect the intelligent tester to the DLC3 with CAN VIM. ES ES–184 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the CURRENT CODES. Result Display (DTC Output) Proceed to P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 or P0308 A P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 or P0308 and other DTCs B HINT: If any DTCs other than P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 and P0308 are output, troubleshoot those DTCs first. ES B GO TO RELEVANT DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (MISFIRE RPM AND MISFIRE LOAD) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / MISFIRE / MISFIRE RPM and MISFIRE LOAD. (d) Read and note the MISFIRE RPM and the MISFIRE LOAD (engine load) with the DATA LIST. HINT: The MISFIRE RPM and MISFIRE LOAD displays have vehicle data that can help lead to successful repairs of any misfiring cylinders. NEXT 3 CHECK CONNECTION OF VENTILATION HOSE OK: Ventilation hose is connected correctly and is not damaged. NG REPAIR OR REPLACE VENTILATION HOSE OK 4 CHECK MISFIRE COUNT (CYL #1, #2, #3, #4, #5, #6, #7, #8) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Clear the DTCs. ES–185 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / CYL#1 to CYL#8. (e) Allow the engine to idle. (f) Read the misfire count of the cylinders #1 to #8. If no misfire is counted for all of the cylinders, move the shift lever into the D position and repeat the 2 previous steps. If misfires are still not counted, perform the next 2 steps. (g) Drive the vehicle with MISFIRE RPM and MISFIRE LOAD selected in the DATA LIST. (h) Read the misfire count of cylinders #1 to #8, or check for any output DTCs. Result Misfire count in each cylinder Proceed to 1 or 2 cylinders have some misfire counts A 3 cylinders or more have some misfire counts B B Go to step 14 A 5 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL CUT #1 TO #8) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL CUT #1 (to #8). (e) If a cylinder has a high misfire count, cut fuel to the cylinder. Compare the misfire count of the cylinder before fuel cut and after fuel cut. Result Misfire count in each cylinder Proceed to Misfire count of the cylinder before fuel cut and after fuel cut are roughly the same A Misfire count of the cylinder before fuel cut is lower than after fuel cut B HINT: If the misfire count of the cylinder before fuel cut and after fuel cut are roughly the same, the cylinder is misfiring. If the misfire count of the cylinder before fuel cut is lower than after fuel cut, the cylinder misfires sometimes. NOTICE: This ACTIVE TEST cannot be performed while the vehicle is being driven. B A Go to step 12 ES ES–186 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT SPARK PLUG (a) Remove the engine cover. (b) Remove the ignition coil and the spark plug of misfire cylinder. (c) Measure the spark plug electrode gap. Standard: The electrode gap is 1.0 to 1.3 mm (0.039 to 0.051 in.) (d) Check the electrode for carbon deposits. Recommended spark plug Electrode Gap A088861E04 ES Manufacturer Spark Plug Type DENSO SK20R11 NGK IFR6A11 NOTICE: If the electrode gap is larger than the standard, replace the spark plug. Do not adjust the electrode gap. NG REPLACE SPARK PLUG OK 7 CHECK SPARK AND IGNITION (a) Disconnect the fuel injector connectors to prevent the engine from starting. (b) Install the spark plug to the ignition coil. (c) Attach the spark plug to the cylinder head cover. (d) Crank the engine for 2 seconds or less and check if a spark occurs. OK: Spark occurs A088862E01 NG Go to step 9 OK 8 CHECK CYLINDER COMPRESSION PRESSURE ON MISFIRING CYLINDER (a) Measure the cylinder compression pressure of the misfiring cylinder. OK Go to step 10 NG CHECK ENGINE TO DETERMINE CAUSE OF LOW COMPRESSION ES–187 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER (a) For inspection purposes, remove the current spark plug and install a normally functioning spark plug. (b) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if a spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK REPLACE SPARK PLUG NG REPLACE IGNITION COIL (THEN CONFIRM THAT THERE IS NO MISFIRE) 10 CHECK ECM (#10, #20, #30, #40, #50, #60, #70, #80 VOLTAGE) #30 (+) #20 (+) #40 (+) E4 E01 (-) #10 (+) E6 #80 (+) #70 (+) #50 (+) #60 (+) A116425E07 NG (a) Turn the ignition switch ON. (b) Measure the voltage of the ECM connectors. Standard voltage OK Tester Connection Specified Condition #10 (E6-2) - E01 (E4-7) 9 to 14 V #20 (E6-3) - E01 (E4-7) 9 to 14 V #30 (E6-4) - E01 (E4-7) 9 to 14 V #40 (E6-5) - E01 (E4-7) 9 to 14 V #50 (E6-6) - E01 (E4-7) 9 to 14 V #60 (E6-7) - E01 (E4-7) 9 to 14 V #70 (E4-3) - E01 (E4-7) 9 to 14 V #80 (E4-2) - E01 (E4-7) 9 to 14 V CHECK FUEL INJECTOR OF MISFIRING CYLINDER ES ES–188 11 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - ECM) (a) Check the harness and connector between the ignition coil and ECM (IGF terminal). (1) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil connector. (2) Disconnect the E4 ECM connector. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: Ignition Coil Connector I1 I2 I3 I4 I5 I6 I7 I8 ES E4 ECM Connector Tester Connection Specified Condition IGF (I1-2) - IGF1 (E4-24) Below 1 Ω IGF (I2-2) - IGF2 (E4-25) Below 1 Ω IGF (I3-2) - IGF2 (E4-25) Below 1 Ω IGF (I4-2) - IGF1 (E4-24) Below 1 Ω IGF (I5-2) - IGF2 (E4-25) Below 1 Ω IGF (I6-2) - IGF1 (E4-24) Below 1 Ω IGF (I7-2) - IGF1 (E4-24) Below 1 Ω IGF (I8-2) - IGF2 (E4-25) Below 1 Ω Standard resistance (Check for short) IGF2 IGF1 A137920E01 Tester Connection Specified Condition IGF (I1-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I2-2) or IGF2 (E4-25) - Body ground 10 kΩ or higher IGF (I3-2) or IGF2 (E4-25) - Body ground 10 kΩ or higher IGF (I4-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I5-2) or IGF2 (E4-25) - Body ground 10 kΩ or higher IGF (I6-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I7-2) or IGF1 (E4-24) - Body ground 10 kΩ or higher IGF (I8-2) or IGF2 (E4-25) - Body ground 10 kΩ or higher (4) Reconnect the ignition coil connector. (5) Reconnect the ECM connector. ES–189 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Check the harness and connector between the ignition coil and ECM (IGT terminals). (1) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil connector. (2) Disconnect the E4 ECM connector. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: Ignition Coil Connector I1 I2 I3 I4 I5 I6 I7 I8 E4 ECM Connector IGT2 IGT1 IGT7 IGT5 IGT8 IGT4 IGT3 IGT6 Tester Connection Specified Condition IGT (I1-3) - IGT1 (E4-8) Below 1 Ω IGT (I2-3) - IGT2 (E4-15) Below 1 Ω IGT (I3-3) - IGT3 (E4-11) Below 1 Ω IGT (I4-3) - IGT4 (E4-10) Below 1 Ω IGT (I5-3) - IGT5 (E4-13) Below 1 Ω IGT (I6-3) - IGT6 (E4-12) Below 1 Ω IGT (I7-3) - IGT7 (E4-14) Below 1 Ω IGT (I8-3) - IGT8 (E4-9) Below 1 Ω Standard resistance (Check for short) A137920E02 Tester Connection Specified Condition IGT (I1-3) or IGT1 (E4-8) - Body ground 10 kΩ or higher IGT (I2-3) or IGT2 (E4-15) - Body ground 10 kΩ or higher IGT (I3-3) or IGT3 (E4-11) - Body ground 10 kΩ or higher IGT (I4-3) or IGT4 (E4-10) - Body ground 10 kΩ or higher IGT (I5-3) or IGT5 (E4-13) - Body ground 10 kΩ or higher IGT (I6-3) or IGT6 (E4-12) - Body ground 10 kΩ or higher IGT (I7-3) or IGT7 (E4-14) - Body ground 10 kΩ or higher IGT (I8-3) or IGT8 (E4-9) - Body ground 10 kΩ or higher (4) Reconnect the ignition coil connector. (5) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 12 CHECK FUEL INJECTOR OF MISFIRING CYLINDER Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor). NG REPLACE FUEL INJECTOR OK 13 CHECK VALVE CLEARANCE OF MISFIRING CYLINDER NG OK ADJUST VALVE CLEARANCE ES ES–190 14 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 15 CHECK VALVE TIMING ES (a) (b) (c) (d) Remove the engine cover. Remove the drive belt. Remove the timing belt cover LH and RH. Turn the crankshaft to align the matchmarks of the crankshaft. (e) Align the notch of the crankshaft pulley with the "0" position. (f) Confirm whether the matchmarks of the camshaft pulley and cylinder head cover are facing each other. (g) If the matchmarks are not facing each other, turn the crankshaft clockwise by 360°. Confirm again if the matchmarks are facing each other. OK: The matchmarks of the camshaft pulley and the cylinder head cover face each other when the notch of the crankshaft pulley is in the "0" position. NG ADJUST VALVE TIMING OK 16 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-6). NG CHECK AND REPLACE FUEL PUMP, FUEL PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER OK 17 READ VALUE OF INTELLIGENT TESTER (COOLANT TEMP) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–191 (d) Read the COOLANT TEMP value when the engine is cold and warmed-up. Standard: ECT when the engine is cold: Same as ambient temperature ECT when the engine is warmed-up: 75 to 95°C (167 to 203°F) NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 18 READ VALUE OF INTELLIGENT TESTER (MAF) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF and COOLANT TEMP. (d) Allow the engine to idle until the COOLANT TEMP reaches 75°C (167°F) or more. (e) Read the MAF with the engine in an idling condition and at an engine speed of 2,500 rpm. Standard: MAF at idle rpm: 4.0 to 8.0 g/sec. (shift lever is in N position and A/C is OFF) MAF at 2,500 rpm: 10.0 to 20.0 g/sec. (shift lever is in N position and A/C is OFF) NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE MASS AIR FLOW METER ES ES–192 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) DTC P0332 Knock Sensor 2 Circuit Low Input (Bank 2) DTC P0333 Knock Sensor 2 Circuit High Input (Bank 2) DESCRIPTION ES A flat type knock sensor (non-resonant type) has a structure that can detect vibrations between approximately 6 kHz and 15 kHz. Knock sensors are fitted onto the engine block to detect engine knocking. The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The voltage is generated when the engine block vibrates due to knocking. Any occurrence of engine knocking can be suppressed by delaying the ignition timing. DTC No. DTC Detection Condition Trouble Area P0327 P0332 Output voltage of knock sensor 1 or 2 is less than 0.5 V (1 trip detection logic) • • • Short in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM P0328 P0333 Output voltage of knock sensor 1 or 2 is more than 4.5 V (1 trip detection logic) • • • Open in knock sensor 1 or 2 circuit Knock sensor 1 or 2 ECM Reference: Inspect using an oscilloscope The correct waveform is as shown. KNK1 Signal Waveform 1V/ DIV. GND 1 msec./ DIV. A116426E01 Item Content Terminals KNK1 - EKNK or KNK2 -EKN2 Equipment Settings 0.01 to 10 V/DIV. 0.01 to 10 msec./DIV. Conditions Keep engine speed at 4,000 rpm with warm engine 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–193 MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When spark knock occurs, the piezoelectric element of the sensor vibrates. When the ECM detects a voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, or if the knock sensor output voltage is outside the normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. MONITOR STRATEGY Related DTCs P0327: Knock sensor (Bank 1) open/short (Low voltage) P0328: Knock sensor (Bank 1) open/short (High voltage) P0332: Knock sensor (Bank 2) open/short (Low voltage) P0333: Knock sensor (Bank 2) open/short (High voltage) Required Sensors/Components (Main) Knock sensor Required Sensors/Components (Related) Crankshaft position sensor, Camshaft position sensor, Engine coolant temperature sensor, Mass air flow meter Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present None Battery voltage 10.5 V or more Time after engine start 5 seconds or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Low voltage) P0327 and P0332: Knock sensor voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328 and P0333: Knock sensor voltage More than 4.5 V ES ES–194 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM K2 Knock Sensor (Bank 2) ES 2 (*1) B 1 W K1 Knock Sensor (Bank 1) (*1) B 8 EB1 2 EB1 (*1) 2 R 7 EB1 1 G 6 EB1 (*1) 3 EB1 BR W (*1) BR 20 E5 EKN2 21 E5 KNK2 R 28 E5 EKNK G 29 E5 KNK1 (*1) W-B E J28 J/C E W-B ED *1: Shielded A130712E01 INSPECTION PROCEDURE HINT: • DTCs P0327 and P0328 are for the bank 1 knock sensor circuit. • DTCs P0332 and P0333 are for the bank 2 knock sensor circuit. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–195 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 READ OUTPUT DTC (CHECK KNOCK SENSOR CIRCUIT) ECM EB1 Knock Sensor (a) Disconnect the EB1 connector. (b) Using lead wires, connect the EB1 connectors as follows. Male Connector - Female Connector 2 2 1 1 6 6 7 7 2 2 8 8 29 E5 28 E5 21 E5 20 E5 Terminal 6 - Terminal 2 Terminal 2 - Terminal 6 Terminal 7 - Terminal 8 Terminal 8 - Terminal 7 (c) (d) (e) (f) Warm up the engine. Race the engine at 3,000 rpm for 10 seconds or more. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the intelligent tester ON. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II/ DTC INFO / CURRENT CODES. (h) Read DTCs. EB1 Female Connector Male Connector A115701E02 Result Display Proceed to DTC is same as when vehicle brought in (for example, P0327 and P0328 are output again, or P0332 and P0333 are output again) A DTC is different from when vehicle brought in (for example, P0327 and P0328 are output at first, but then P0332 and P0333 are output, or vice versa) B (i) B A Reconnect the EB1 connector. Go to step 5 ES ES–196 2 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (CONNECTOR - ECM) (a) Disconnect the EB1 connector. (b) Disconnect the E5 ECM connector. (c) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: Male Connector EB1 4 3 2 1 8 7 6 5 Front View ES E5 ECM Connector KNK2 EKN2 EKNK KNK1 A152654E01 Tester Connection Specified Condition EB1 male connector 6 - KNK1 (E5-29) Below 1 Ω EB1 male connector 7 - EKNK (E5-28) Below 1 Ω EB1 male connector 2 - KNK2 (E5-21) Below 1 Ω EB1 male connector 8 - EKN2 (E5-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition EB1 male connector 6 or KNK1 (E5-29) - Body ground 10 kΩ or higher EB1 male connector 7 or EKNK (E5-28) - Body ground 10 kΩ or higher EB1 male connector 2 or KNK2 (E5-21) - Body ground 10 kΩ or higher EB1 male connector 8 or EKN2 (E5-20) - Body ground 10 kΩ or higher (d) Reconnect the EB1 connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM KNK2 (a) Disconnect the E5 ECM connector. (b) Turn the ignition switch to ON. (c) Measure the voltage between the specified ECM terminals. Standard voltage EKN2 Tester Connection KNK1 E5 4.5 to 5.5 V KNK2 (E5-21) - EKN2 (E5-20) 4.5 to 5.5 V (d) Reconnect the ECM connector. NG OK KNK1 (E5-29) - EKNK (E5-28) EKNK A131127E01 Specified Condition REPLACE ECM ES–197 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK FOR INTERMITTENT PROBLEMS NOTICE: The fault may be intermittent. Check the harness and connectors carefully, and reset. NEXT END 5 INSPECT KNOCK SENSOR Wire Harness Side Female Connector (a) Disconnect the EB1 connector. (b) Measure the resistance of the EB1 female connector. Standard resistance Tester Connection EB1 EB1 female connector 6 - 7 1 2 3 4 5 6 7 8 EB1 female connector 2 - 8 Specified Condition 120 to 280 kΩ (c) Reconnect the EB1 connector. Front View A152655E01 OK CHECK FOR INTERMITTENT PROBLEMS NG 6 CHECK HARNESS AND CONNECTOR (CONNECTOR - KNOCK SENSOR) (a) Check the harness and connector between the EB1 connector and the knock sensors. NG OK REPLACE KNOCK SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–484 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Intelligent Tester CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ON-VEHICLE INSPECTION 1. CAN VIM DLC3 ES A094482E03 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Start and warm up the engine. (d) Connect the intelligent tester and select VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the intelligent tester. Idle speed: 650 to 750 rpm OK Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–485 INSPECTION 1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 1 (+B) - 2 (GND) 6.9 to 7.9 kΩ at 20°C (68°F) If the result is not as specified, replace the camshaft timing oil control valve. Spool Valve A097066E16 (b) Check the operation. (1) Apply battery voltage across the terminals, and check that the spool valve operates. NOTICE: Check that the spool valve is not stuck. HINT: The spool valve may not return if foreign objects are caught in it. This may cause subtle pressure leaks to the advance side, and a DTC may be set. ES ES–198 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0335 Crankshaft Position Sensor "A" Circuit DTC P0339 Crankshaft Position Sensor "A" Circuit Intermittent DESCRIPTION The Crankshaft Position (CKP) sensor system consists of a CKP sensor plate and a pickup coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of windings, an iron core and magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is created. The pickup coil generates 32 signals for each engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. ES DTC No. DTC Detection Condition • P0335 P0339 • No CKP position sensor signal to ECM during cranking (1 trip detection logic) No CKP sensor signal to ECM with engine at 450 rpm or more (1 trip detection logic) No CKP sensor signal to ECM is input for 0.05 seconds or more, and conditions (a), (b) and (c) are met: (a) 1,000 rpm or more (b) Starter is OFF (c) 3 seconds or more have elapsed after STA signal is switched from ON or OFF Trouble Area • • • • Open or short in Crankshaft Position (CKP) sensor circuit Crankshaft Position (CKP) sensor Signal plate (CKP sensor plate) ECM • • • • Open or short in CKP sensor circuit CKP sensor Signal plate (CKP sensor plate) ECM VV1, VV2 and NE Signal Waveforms 2 V/DIV VV1 Ground VV2 Ground NE Ground 20 msec./DIV (idling) A131145E01 Reference: Inspect using an oscilloscope. The correct waveform is as shown. Tester Connection Specified Condition VV1+ (E6-25) - VV1- (E6-24) VV2+ (E6-18) - VV2- (E6-28) G2+ (E6-19) - G2- (E6-29) Correct waveform is as shown NE+ (E6-21) - NE- (E6-20) MONITOR DESCRIPTION If there is no signal from the Crankshaft Position (CKP) sensor even though the engine is revolving, the ECM interprets this as a malfunction of the sensor. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–199 MONITOR STRATEGY Related DTCs Crankshaft position sensor range check or rationality Required Sensors/Components Crankshaft position (CKP) sensor Required Sensors/Components - Frequency of Operation Continuous Duration Case 1: 3 times Case 2: 0.016 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None ES Case 1: Time after starter OFF to ON 0.3 seconds or more Number of camshaft position sensor signal pulse 6 times Battery voltage 7 V or more Ignition switch ON CMP sensor circuit fail Not detected Case 2: Starter OFF Engine RPM 450 rpm or more Time after starter from ON to OFF 3 seconds or more TYPICAL MALFUNCTION THRESHOLDS Case 1: Number of CKP sensor signal pulse 132 or less, or 174 or more Case 2: Engine speed signal No signal for 0.016 second ES–200 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM C1 Camshaft Position Sensor B 19 G2+ E6 W 29 G2E6 2 Camshaft Timing Pulley LH 1 3 ES C4 Crankshaft Position Sensor L-R E4 VC W-B E E J28 J/C W-B L 21 NE+ E6 Y 20 NEE6 1 Crankshaft Position Sensor Plate No. 1 2 (Shielded) ED A152658E01 INSPECTION PROCEDURE HINT: • If no problem is found by this diagnostic troubleshooting procedure, troubleshoot the engine mechanical system. • Check the engine speed. The engine speed can be checked by using the intelligent tester. To check, follow the operation below: (a)Connect the intelligent tester to the DLC3 with CAN VIM. (b)Start the engine. (c) Turn the tester ON. (d)Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ENGINE SPD. • The engine speed may be indicated as zero despite the engine revolving normally. This is caused by a lack of NE signals from the crankshaft position (CKP) sensor. Alternatively, the engine speed may be indicated as lower than the actual engine speed if the CKP sensor output voltage is insufficient. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–201 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT CRANKSHAFT POSITION SENSOR (a) Disconnect the C4 Crankshaft Position (CKP) sensor connector. (b) Measure the resistance of the sensor. Standard resistance Component Side Crankshaft Position Sensor Tester Connection Condition Specified Condition 1-2 Cold 1,630 to 2,740 Ω 1-2 Hot 2,065 to 3,225 Ω C4 A115704E02 HINT: In the above section, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). (c) Reconnect the crankshaft position sensor connector. NG REPLACE CRANKSHAFT POSITION SENSOR OK 2 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) (a) Disconnect the C4 crankshaft position sensor connector. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: Crankshaft Position Sensor C4 Tester Connection Crankshaft position sensor (C4-1) NE+ (E6-21) Crankshaft position sensor (C4-2) NE- (E6-20) ECM Connector E6 Crankshaft position sensor (C4-1) or NE+ (E6-21) - Body ground Crankshaft position sensor (C4-2) or NE- (E6-20) - Body ground Specified Condition Below 1 Ω 10 kΩ or higher (d) Reconnect the CKP sensor connector. (e) Reconnect the ECM connector. NG NE+ NEA137922E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–202 3 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) (a) Check the sensor installation. OK: Sensor is installed correctly. NG OK SECURELY REINSTALL SENSOR NG BR03795E15 ES OK 4 CHECK CRANKSHAFT POSITION SENSOR PLATE (TOOTH OF PLATE) (a) Remove the crankshaft position sensor plate (See page EM-18). (b) Check the tooth of the signal plate. OK: Sensor plate does not have any cracks or deformation. NG OK REPLACE ECM REPLACE CRANKSHAFT POSITION SENSOR PLATE ES–203 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0340 Camshaft Position Sensor Circuit Malfunction DTC P0341 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 1 or Single Sensor) DTC P0345 Camshaft Position Sensor "A" Circuit (Bank 2) DTC P0346 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 2) DESCRIPTION The VVT sensor consists of a magnet, an iron core and a pick-up coil. This sensor monitors a timing rotor located on the camshaft and is used by the ECM to detect the camshaft angle. The camshaft rotation synchronizes with the crankshaft rotation, and this sensor communicates the rotation of the camshaft timing rotor as a pulse signal to the ECM. If there is no signal from the VVT sensor even though the engine is turning or the rotation of the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction in the sensor and sets a DTC. DTC No. DTC Detection Condition • Trouble Area No VVT sensor signal to ECM during cranking (2 trip detection logic) No VVT sensor signal to ECM with engine speed 600 rpm or more (1 trip detection logic) P0340 P0345 • P0341 P0346 While crankshaft rotates twice, VVT sensor signal is input to ECM 12 times or more (1 trip detection logic) • • • • • Open or short in VVT sensor circuit VVT sensor Intake camshaft Timing belt has a jumped tooth ECM Same as DTC No. P0340/P0345 HINT: • DTC P0340 and P0345 indicate a malfunction related to the VVT sensor (+) circuit (wire harness (from ECM to VVT sensor) and VVT sensor). • DTC P0341 and P0346 indicate a malfunction related to the VVT sensor (-) circuit (wire harness (from ECM to VVT sensor) and VVT sensor). VV1, VV2 and NE Signal Waveforms 2 V/DIV. VV1+ Ground VV2+ Ground NE+ Ground 20 msec./DIV. (idling) A106052E02 Reference: Inspect using an oscilloscope. During cranking or idling, check the waveform of the ECM connector. ES ES–204 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition VV1+ (E6-25) - VV1- (E6-24) Correct waveform is as shown VV2+ (E6-18) - VV2- (E6-28) Correct waveform is as shown NE+ (E6-21) - NE- (E6-20) Correct waveform is as shown G2+ (E6-19) - G2- (E6-29) Correct waveform is as shown MONITOR DESCRIPTION If there is no signal from the VVT sensor even though the engine is revolving, or if the rotation of the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY ES Related DTCs P0340: VVT sensor (bank 1) range check / rationality P0341: VVT sensor (bank 1) range check / rationality P0345: VVT sensor (bank 2) range check / rationality P0346: VVT sensor (bank 2) range check / rationality Required Sensors/Components (Main) VVT sensor Required Sensors/Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 5 seconds MIL Operation P0340, P0345 case 1: 2 driving cycles P0340, P0345 case 2, P0341, P0346: Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor will run whenever these DTCs are not present None P0340, P0345 Case 1: Starter ON Minimal battery voltage while starter ON Less than 11 V P0340, P0345 Case 2: Engine RPM 600 rpm or more Starter OFF Battery voltage 8 V or more Ignition switch ON P0341, P0346: Starter After OFF to ON timing Engine revolution 720°CA TYPICAL MALFUNCTION THRESHOLDS P0340, P0345 Case 1: VVT sensor signal No signal P0340, P0345 Case 2: VVT sensor signal No signal P0341, P0346: VVT sensor count 12 or more / 720°CA (=Engine 2 revolutions) ES–205 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE VVT sensor signal input during every 720°CA 3 WIRING DIAGRAM V4 VVT Sensor (Bank 1) ECM Shielded 1 R 18 VV2+ E6 2 G 28 VV2E6 V3 VVT Sensor (Bank 2) ES Shielded 1 Y 25 VV1+ E6 2 L 24 VV1E6 W-B W-B E E J28 J/C ED A130711E03 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–206 1 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT VVT SENSOR (RESISTANCE) (a) Disconnect the V3 and V4 VVT sensor connectors. (b) Measure the resistance of the VVT sensor. Standard resistance Component Side: VVT Sensor V3 Tester Connection Condition Specified Condition 1-2 Cold 835 to 1,400 Ω 1-2 Hot 1,060 to 1,645 Ω V4 Front View A066132E08 ES HINT: In the above chart, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). NG REPLACE VVT SENSOR OK 2 CHECK HARNESS AND CONNECTOR (VVT SENSOR - ECM) (a) Disconnect the V3 or V4 VVT sensor connectors. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side VVT Sensor Connector Tester Connection V3 Specified Condition VVT sensor (V3-1) - VV1+ (E6-25) V4 VVT sensor (V3-2) - VV1- (E6-24) VVT sensor (V4-1) - VV2+ (E6-18) Front View Below 1 Ω VVT sensor (V4-2) - VV2- (E6-28) E6 ECM Connector VVT sensor (V3-1) or VV1+ (E6-25) Body ground VVT sensor (V3-2) or VV1- (E6-24) Body ground VVT sensor (V4-1) or VV2+ (E6-18) Body ground VV2+ VV1+ VV2VV1- 10 kΩ or higher VVT sensor (V4-2) or VV2- (E6-28) Body ground (d) Reconnect the VVT sensor connectors. (e) Reconnect the ECM connector. A115706E02 NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 ES–207 CHECK SENSOR INSTALLATION (VVT SENSOR) (a) Check the sensor installation. OK: Sensor is installed correctly. NG OK SECURELY REINSTALL SENSOR NG BR03795E15 ES OK 4 CHECK CAMSHAFT (TOOTH) (a) Remove the cylinder head cover (See page EM-107 ). (b) Check the tooth of the camshaft. OK: The camshaft does not have any cracks or deformation. NG OK REPLACE ECM REPLACE CAMSHAFT ES–208 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0351 Ignition Coil "A" Primary / Secondary Circuit DTC P0352 Ignition Coil "B" Primary / Secondary Circuit DTC P0353 Ignition Coil "C" Primary / Secondary Circuit DTC P0354 Ignition Coil "D" Primary / Secondary Circuit DTC P0355 Ignition Coil "E" Primary / Secondary Circuit DTC P0356 Ignition Coil "F" Primary / Secondary Circuit DTC P0357 Ignition Coil "G" Primary / Secondary Circuit DTC P0358 Ignition Coil "H" Primary / Secondary Circuit DESCRIPTION HINT: • These DTCs indicate a malfunction related to a primary circuit. • If DTC P0351 is displayed, check No. 1 ignition coil circuit. • If DTC P0352 is displayed, check No. 2 ignition coil circuit. • If DTC P0353 is displayed, check No. 3 ignition coil circuit. • If DTC P0354 is displayed, check No. 4 ignition coil circuit. • If DTC P0355 is displayed, check No. 5 ignition coil circuit. • If DTC P0356 is displayed, check No. 6 ignition coil circuit. • If DTC P0357 is displayed, check No. 7 ignition coil circuit. • If DTC P0358 is displayed, check No. 8 ignition coil circuit. A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug. The spark of the spark plug passes from the center electrode to the ground electrode. The ECM determines the ignition timing and outputs the ignition signals (IGTs) for each cylinder. Using the IGTs, the ECM turns the power transistor inside the igniter on/off, which switches on/off current to the primary coil. When current to the primary coil is cut off, high voltage is generated in the secondary coil and this voltage is applied to the spark plugs to create sparks inside the cylinders. As the ECM cuts current to the primary coil, the igniter sends back ignition confirmation signals (IGFs) for each cylinder ignition to the ECM. ES–209 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM No. 1 Ignition Coil with Igniter From Battery ECM Igniter IGT1 No. 1 Cylinder IGF1 Ignition Coil Crankshaft Position Sensor IGT2 No. 2 Ignition Coil with Igniter No. 2 Cylinder IGF2 ES IGT3 No. 3 Ignition Coil with Igniter No. 3 Cylinder IGT4 No. 4 Ignition Coil with Igniter No. 4 Cylinder IGT5 No. 5 Ignition Coil with Igniter No. 5 Cylinder IGT6 No. 6 Ignition Coil with Igniter No. 6 Cylinder IGT7 No. 7 Ignition Coil with Igniter No. 7 Cylinder IGT8 No. 8 Ignition Coil with Igniter No. 8 Cylinder Camshaft Position Sensor Other Sensor (Engine Coolant Temperature Sensor, Mass Air Flow Meter, Throttle Position Sensor, etc.) TAC to Tachometer A117778E04 ES–210 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition P0351 P0352 P0353 P0354 P0355 P0356 P0357 P0358 Trouble Area • • No IGF signal to ECM while engine is running • • Ignition system Open or short in IGF or IGT circuit (1 to 8) between ignition coil with igniter and ECM No. 1 to No. 8 ignition coil (primary ignition) ECM 2 V/DIV. CH 1 Ground CH 2 Ground ES 20 msec./DIV. A093278E13 Reference: Inspect using an oscilloscope. While cranking or idling the engine, check the waveform between terminals IGT1 to IGT8 and E1, and IGF1 to IGF2 and E1 of the E6, E8 and E6 ECM connectors. Items Terminals Contents CH1: IGT1, IGT2, IGT3, IGT4, IGT5, IGT6, IGT7, IGT8 - E1 CH2: IGF1, IGF2 - E1 Equipment Settings 2 V/DIV. 20 msec./DIV. Condition While the engine is cranking or idling ES–211 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION Ignition Coil with Igniter IGT Ignition Coil ECM Igniter IGF ES Ignition Signal (IGT) Ignition Confirmation Signal (IGF) Normal Open Open Time A082388E19 If the ECM does not receive an IGF after sending an IGT, it interprets this as a fault in the igniter and sets a DTC. MONITOR STRATEGY Related DTCs P0351: Igniter (cylinder 1) malfunction P0352: Igniter (cylinder 2) malfunction P0353: Igniter (cylinder 3) malfunction P0354: Igniter (cylinder 4) malfunction P0355: Igniter (cylinder 5) malfunction P0356: Igniter (cylinder 6) malfunction P0357: Igniter (cylinder 7) malfunction P0358: Igniter (cylinder 8) malfunction Required Sensors/Components (Main) Igniter Required Sensors/Components (Related) Crankshaft position sensor Frequency of Operation Continuous Duration 0.256 seconds + 4 sparks MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Either of the following condition is met: Condition 1 or 2 1. Starter OFF 2. Engine RPM 1,500 rpm or less Either of the following condition is met: Condition (a) or (b) ES–212 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a) All of the following conditions are met: - Engine RPM 500 rpm or less Battery voltage 6 V or more (b) All of the following conditions are met: - Engine RPM More than 500 rpm Battery voltage 10 V or more Number of sparks after CPU is reset 5 sparks or more TYPICAL MALFUNCTION THRESHOLDS ES Ignition signal fail count More than 2 times Ignition signal fail count When IGF does not return despite sending IGT COMPONENT OPERATING RANGE IGF signal Igniter outputs IGF signal when it receives IGT signal from ECM ES–213 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM I1 Ignition Coil and Igniter No. 1 B-R B-R B-R ECM B-R LG 1 3 W-B 4 2 R-Y 1 EB1 I3 Ignition Coil and Igniter No. 3 W-B R-Y L-W B-R B-R 1 W-B 4 B-Y R-Y 8 E4 IGT1 24 E4 IGF1 3 R-W 2 11 E4 IGT3 I5 Ignition Coil and Igniter No. 5 W-B 7 EA1 2 B-R N1 Noise Filter (Ignition No. 1) B-R 1 B-R W-B 4 B-R 1 IG2 1 I18 Ignition SW W-B 4 2 R-W W-B 7 N2 Noise Filter (Ignition No. 2) Engine Room R/B 2 2 LG-B B-R R 2 1 3 W-B 4 2 B-R 1 W-B 4 R-W R-W L-Y L-Y 10 E4 IGT4 G 12 E4 IGT6 G-B 9 E4 IGT8 3 R-Y 2 I6 Ignition Coil and Igniter No. 6 1 1 W-B 2 B-R 1 W-B W-B 4 W-B 3 R-Y 2 I8 Ignition Coil and Igniter No. 8 B W-B B-R 1 B Battery EC ER ED 15 E4 IGT2 25 E4 IGF2 I4 Ignition Coil and Igniter No. 4 W-B AM2 14 E4 IGT7 3 R-Y I2 Ignition Coil and Igniter No. 2 AM2 G-W 3 R-W 2 I7 Ignition Coil and Igniter No. 7 W-B 6 B-L 13 E4 IGT5 W-B ED W-B 4 3 R-W 2 A133712E01 ES ES–214 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • If DTCs P0351, P0354, P0356 and P0357 are output simultaneously, IGF1 circuit may be open or short. • If DTCs P0352, P0353, P0355 and P0358 are output simultaneously, IGF2 circuit may be open or short. 1 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER ES (a) Check the spark plug and spark of misfiring cylinder (See page IG-1). NG Go to step 4 OK 2 CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM [IGF SIGNAL TERMINAL]) (a) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil with igniter connectors. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side I1 I2 I3 I4 I5 I6 Tester Connection I7 I8 Ignition coil (I1-2) - IGF1 (E4-24) Ignition Coil with Igniter Connector Ignition coil (I2-2) - IGF2 (E4-25) Ignition coil (I3-2) - IGF2 (E4-25) Ignition coil (I4-2) - IGF1 (E4-24) E4 Specified Condition Ignition coil (I5-2) - IGF2 (E4-25) Below 1 Ω Ignition coil (I6-2) - IGF1 (E4-24) Ignition coil (I7-2) - IGF1 (E4-24) Ignition coil (I8-2) - IGF2 (E4-25) Ignition coil (I1-2) or IGF1 (E4-24) Body ground IGF1 IGF2 ECM Connector Ignition coil (I2-2) or IGF2 (E4-25) Body ground A115891E02 Ignition coil (I3-2) or IGF2 (E4-25) Body ground Ignition coil (I4-2) or IGF1 (E4-24) Body ground Ignition coil (I5-2) or IGF2 (E4-25) Body ground Ignition coil (I6-2) or IGF1 (E4-24) Body ground Ignition coil (I7-2) or IGF1 (E4-24) Body ground Ignition coil (I8-2) or IGF2 (E4-25) Body ground 10 kΩ or higher ES–215 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Reconnect the ignition coil with igniter connectors. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT ECM (IGF1 AND IGF2 VOLTAGE) ECM Connector E4 IGF2 (+) E6 IGF1 (+) E1 (-) (a) Disconnect the ignition coil with igniter connectors. (b) Turn the ignition switch ON. (c) Measure the voltage of the E4 and E6 ECM connectors. Standard voltage Tester Connection Specified Condition IGF1 (E4-24) - E1 (E6-1) 4.5 to 5.5 V IGF2 (E4-25) - E1 (E6-1) 4.5 to 5.5 V (d) Reconnect the ignition coil with igniter connectors. E118245E24 NG REPLACE ECM OK REPLACE IGNITION COIL WITH IGNITER 4 CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM [IGT SIGNAL TERMINAL]) (a) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil with igniter connectors. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side I1 I2 I3 I4 I5 I6 I7 I8 Tester Connection IGT (I1-3) - IGT1 (E4-8) Ignition Coil with Igniter Connector IGT (I2-3) - IGT2 (E4-15) IGT (I3-3) - IGT3 (E4-11) IGT (I4-3) - IGT4 (E4-10) E4 IGT (I5-3) - IGT5 (E4-13) IGT (I6-3) - IGT6 (E4-12) IGT (I7-3) - IGT7 (E4-14) IGT2 IGT7 IGT5 Specified Condition IGT (I8-3) - IGT8 (E4-9) IGT1 IGT8 IGT4 IGT3 ECM IGT6 Connector A115891E03 Below 1 Ω ES ES–216 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition IGT (I1-3) or IGT1 (E4-8) - Body ground IGT (I2-3) or IGT2 (E4-15) - Body ground IGT (I3-3) or IGT3 (E4-11) - Body ground IGT (I4-3) or IGT4 (E4-10) - Body ground IGT (I5-3) or IGT5 (E4-13) - Body ground 10 kΩ or higher IGT (I6-3) or IGT6 (E4-12) - Body ground IGT (I7-3) or IGT7 (E4-14) - Body ground IGT (I8-3) or IGT8 (E4-9) - Body ground ES (d) Reconnect the ignition coil with igniter connectors. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT ECM (IGT1, IGT2, IGT3, IGT4, IGT5, IGT6, IGT7 OR IGT8 VOLTAGE) IGT3 (+) IGT4 (+) IGT8 (+) (a) Measure the voltage of the E4 and E6 ECM connectors when the engine is cranked. Standard voltage Tester Connection IGT1 (+) Specified Condition IGT1 (E4-8) - E1 (E6-1) E4 IGT2 (E4-15) - E1 (E6-1) E6 IGT3 (E4-11) - E1 (E6-1) IGT4 (E4-10) - E1 (E6-1) IGT5 (E4-13) - E1 (E6-1) IGT6 (E4-12) - E1 (E6-1) IGT2 (+) IGT7 (E4-14) - E1 (E6-1) IGT5 (+) IGT6 (+) E1 (-) IGT8 (E4-9) - E1 (E6-1) IGT7 (+) A116425E08 OK NG REPLACE ECM 0.1 to 4.5 V ES–217 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 INSPECT ECM (IGT1, IGT2, IGT3, IGT4, IGT5, IGT6, IGT7 OR IGT8 VOLTAGE) IGT3 (+) IGT4 (+) IGT8 (+) IGT1 (+) E4 (a) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil with igniter connectors. (b) Measure the voltage of the E4 and E6 ECM connectors when the engine is cranked. Standard voltage Tester Connection E6 Specified Condition IGT1 (E4-8) - E1 (E6-1) IGT2 (E4-15) - E1 (E6-1) IGT3 (E4-11) - E1 (E6-1) IGT4 (E4-10) - E1 (E6-1) 4.5 V or more IGT5 (E4-13) - E1 (E6-1) IGT5 (+) IGT6 (+) E1 (-) IGT2 (+) IGT6 (E4-12) - E1 (E6-1) IGT7 (E4-14) - E1 (E6-1) IGT7 (+) IGT8 (E4-9) - E1 (E6-1) A116425E08 (c) Reconnect the ignition coil with igniter connectors. NG REPLACE ECM OK 7 INSPECT IGNITION COIL WITH IGNITER (POWER SOURCE) (a) Disconnect the I1, I2, I3, I4, I5, I6, I7 and I8 ignition coil with igniter connectors. (b) Turn the ignition switch ON or START. (c) Measure the voltage of the wire harness side connector and body ground. Standard voltage Wire Harness Side I1 I2 I3 I4 I5 I6 I7 I8 Tester Connection +B Ignition Coil with Igniter Connector Specified Condition +B (I1-1) - Body ground +B (I2-1) - Body ground A054393E46 +B (I3-1) - Body ground +B (I4-1) - Body ground +B (I5-1) - Body ground 9 to 14 V +B (I6-1) - Body ground +B (I7-1) - Body ground +B (I8-1) - Body ground (d) Reconnect the ignition coil connectors. OK NG REPLACE IGNITION COIL ES ES–218 8 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (IGNITION COIL - IGNITION SWITCH) (a) Disconnect the I1, I2, I3, I4, I5, I6, I7 or I8 ignition coil with igniter connectors. (b) Disconnect the I18 ignition switch connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side I1 I2 I3 I4 I5 I6 I7 I8 Tester Connection Specified Condition Ignition coil (I1-1) - IG2 (I18-6) Ignition coil (I2-1) - IG2 (I18-6) Ignition Coil with Igniter Ignition coil (I3-1) - IG2 (I18-6) Ignition coil (I4-1) - IG2 (I18-6) ES Ignition coil (I5-1) - IG2 (I18-6) Below 1 Ω Ignition coil (I6-1) - IG2 (I18-6) I18 Ignition coil (I7-1) - IG2 (I18-6) Ignition coil (I8-1) - IG2 (I18-6) Ignition coil (I1-1) or IG2 (I18-6) Body ground Ignition Switch IG2 A115892E01 Ignition coil (I2-1) or IG2 (I18-6) Body ground Ignition coil (I3-1) or IG2 (I18-6) Body ground Ignition coil (I4-1) or IG2 (I18-6) Body ground Ignition coil (I5-1) or IG2 (I18-6) Body ground 10 kΩ or higher Ignition coil (I6-1) or IG2 (I18-6) Body ground Ignition coil (I7-1) or IG2 (I18-6) Body ground Ignition coil (I8-1) or IG2 (I18-6) Body ground (d) Reconnect the ignition switch connector. (e) Reconnect the ignition coil with igniter connectors. NG OK REPLACE IGNITION COIL REPAIR OR REPLACE HARNESS OR CONNECTOR ES–219 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0412 Secondary Air Injection System Switching Valve "A" Circuit DESCRIPTION The Secondary Air Injection (AIR) system pumps air to the exhaust port to accelerate the activation of the catalyst. The secondary air injection system consists of the ECM, air pump, Air Switching Valve (ASV) (EASV), No. 2 Air Switching Valve (No. 2 ASV) (ASV1, 2), pressure sensor and Air Injection Control Driver (AID). The Air Switching Valve (ASV) (EASV) is an electromagnetic type and No. 2 Air Switching Valve (No. 2 ASV)(ASV1, 2) is a vacuum type. The secondary air injection system pumps pressurized air to the exhaust port by the air pump through the ASV and No. 2 ASV. The ASV assists the No. 2 ASV. The No. 2 ASV also controls air supply. The ECM sends signals to the AID, and then the AID operates the air pump and ASV. The pressure sensor detects pressure and exhaust pulsation in the system when the system operates and when it does not operate, and sends the data to the ECM. Air Switching Valve (ASV) (EASV) To Bank 1 No. 2 Air Switching Valve (No. 2 ASV) (ASV1) Pressure Sensor Engine Coolant Temperature Sensor Air Pump Air ECM To Bank 2 VSV (for Air Injection system) Air Injection Control Driver (AID) Mass Air Flow Meter Intake Air Temperature Sensor No. 2 Air Switching Valve (No. 2 ASV) (ASV2) A115362E02 ES ES–220 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition P0412 Both of the following conditions are met when engine is idling just after cold start (1 trip detection logic): 1. Air injection (AIR) system does not operate (Air pump OFF and all ASVs OFF) 2. Air injection control driver (AID) diagnostic signal duty is 40 % P0412 Both of the following conditions are met when engine is idling just after cold start (1 trip detection logic): 1. Air injection (AIR) system operates (Air pump ON and all ASVs ON) 2. Air injection control driver (AID) diagnostic signal duty is 40 % Trouble Area • • • • • • • • • Open in air switching valve drive circuit Short between air switching valve circuit and +B circuit Air injection control driver (AID) Air switching valve (ASV) ECM Short between air switching valve circuit and body ground AID ASV ECM MONITOR DESCRIPTION The Air Injection Control Driver (AID) detects an open or short in the circuit according to the voltage of the air pump terminal (VP) and electromagnetic air switching valve terminal (VV), and sends a signal as diagnostic information to the ECM. The AID outputs the air switching valve terminal malfunction signal to the ECM if: 1) VV terminal voltage is low despite the AID receiving the command signal from the ECM to drive the air switching valve terminal or 2) VV terminal voltage is high despite the AID not receiving the command signal from the ECM. The ECM stores the DTC based on the diagnostic signal from the AID and illuminates the MIL. MONITOR STRATEGY Related DTCs P0412: Air switching valve circuit malfunction (Secondary air injection system) Required sensors/components Air injection control driver, Air switching valve Frequency of operation Continuous Duration 3 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present None Case 1: Air pump Operating Air switching valve Operating Battery voltage 8 V or more Ignition switch ON Starter OFF Case 2: Air pump Not operating Air switching valve Not operating Battery voltage 8 V or more Ignition switch ON Starter OFF 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–221 TYPICAL MALFUNCTION THRESHOLDS Case 1, 2: Diagnostic signal duty ratio from air injection driver 31 to 48 % COMPONENT OPERATING RANGE Diagnostic signal duty ratio from air injection control driver 70 to 90 % when secondary air injection system operating and 0 % when secondary air injection system not operating ES ES–222 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 35 IC4 W-G 8 E8 MREL W-G V13 VSV J4 J/C L-W A 17 L-W IC3 L-W A 2 2 ES J28 J/C EFI Engine Room No. 2 R/B B B 2 2 2 EFI Relay 2 A/PUMP 1 5 2 2 Engine Room R/B 2 V12 VSV 2 2 L 26 E4 AIV2 2 VP A43 G G 25 E8 AIRP Y Y 4 E8 AIRV V V 13 E8 AIDI 2 4 IC3 14 IC3 10 IC3 L 4 EA1 G 3 EA1 4 IN1 L BR 1 2 B 2 L 1 A44 E BR ALT 2 W-B 1 1 3 5 SIV A44 A44 +B 2 1 DI A44 R A43 BATT Engine Room 6 R/B VV A44 B 3 27 E4 AIV1 P L-W 4 SIP A44 2 1 L-W (Air Switching Valve Bank 1) Air Injection Control Driver 1 2 (Air Switching Valve Bank 2) 12 L-W L-W IM1 C D C D L-W G A J35 Engine Room R/B J/C E J36 BR EFI 1 1 2 A46 Air Pump 1 A47 Air Switching Valve 2 W-B W-B 9 IM2 2 B J2 J/C B J3 W-B EB BR B W-B Battery ED EQ A133715E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–223 INSPECTION PROCEDURE HINT: The diagnostic information output from Air Injection Control Driver (AID) can be confirmed by connecting an oscilloscope to the diagnostic information terminal of the AID. It narrows a trouble area search to read the waveform on the oscilloscope when performing the AIR system intrusive operation function provided in the SYSTEM CHECK. 1. Start the engine and warm it up. 2. Turn the ignition switch OFF. 3. Connect the intelligent tester to the DLC3 with CAN VIM. 4. Connect an oscilloscope probe to the AIDI terminal of the ECM. ECM Connector ES E1 AIDI G035614E71 5. Start the engine and turn the tester ON. 6. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL OPERATION / OPERATION 1 and 2. AIR INJ CHECK AIR PUMP ON EASV OPEN ASV1 OPEN ASV2 OPEN A/F BANK1 19.05 A/F BANK2 19.05 PRESSURE 17 kPa-g PULSATION 25.39 kPa-g AI STATUS OK Remaining Time 05 sec. Press[EXIT]to quit G032717E01 HINT: OPERATION 1: AP: OFF; EASV: CLOSE; ASV1: CLOSE; ASV2: CLOSE OPERATION 2: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: OPEN 7. Monitor the voltage output of the AID (duty ratio signal). Example: 80% Duty Signal 5 V/DIV. GND 20 msec./DIV. A116420E03 ES–224 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Oscilloscope range Items ES Contents Terminals CH1: AIDI - E1 Equipment Settings 5 V/DIV., 20 to 40 ms/DIV. Conditions Idling NOTICE: • This AIR INJECTION CHECK only allows technicians to operate the AIR system for 5 seconds. Furthermore, the check can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between checks. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • Performing the AIR INJ CHECK over and over again may cause damage in the secondary air injection system. If necessary, wait several minutes between tests to prevent overheating the system. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. AID Diagnostic Signal Waveform ECM Command DTC (ECM Output) Suspected Trouble Area • • 100 % Duty Ratio See waveform 1 Any Air Injection (AIR) System operation P1613 • • • 0 % Duty Ratio See waveform 2 AIR System: ON (Air pump ON, ASV ON) P1613 • • • • AIR System: OFF (Air pump OFF, ASV OFF) - • P0418 • • • 20 % Duty Ratio See waveform 3 • Air Pump: OFF P0418 Open or short in air pump or Air Switching Valve (ASV) command signal circuit (ECM - AID) Open in AID ground circuit Short between diagnostic signal circuit and body ground AID ECM Normal • Air Pump: ON Open in diagnostic signal circuit Air Injection Control Driver (AID) Open in AID +B circuit (AID power source) Short between +B circuit and diagnostic signal circuit • • • • Short between air pump drive circuit and body ground Harness & connector (AID Pump) Air Pump AID ECM Open in air pump drive circuit (AID - Pump), or short between air pump drive circuit and +B Harness & connector (AID Pump) Air Pump AID ECM ES–225 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM AID Diagnostic Signal Waveform DTC (ECM Output) ECM Command Suspected Trouble Area • • ASV: ON P0412 • • • 40 % Duty Ratio See waveform 4 • ASV: OFF 80 % Duty Ratio See waveform 5 Excluding Above (excluding 0, 20, 40, 80, 100 % duty) P0412 Short between ASV drive circuit and body ground Harness & connector (AID ASV) ASV AID ECM • • • Open in ASV drive circuit (AID - ASV), or short between ASV drive circuit and +B Harness & connector (AID ASV) AID ASV ECM AID ECM • AIR System: OFF (Air pump OFF, ASV OFF) P1613 • • AIR System: ON (Air pump ON, ASV ON) - Normal - P1613 • • 1. Waveform 1 100 % Duty Ratio 2. Waveform 2 0 % Duty Ratio 3. Waveform 3 20 % Duty Ratio Almost Same as Battery Voltage +B GND A112066E01 +B Fixed at Low Voltage GND A112067E01 20% +B GND A112068E01 AID Open in AID ground circuit ES ES–226 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. Waveform 4 40 % Duty Ratio 5. Waveform 5 80 % Duty Ratio 40% +B GND A112069E01 80% ES +B GND A112070E01 HINT: • Using the AIR INJ CHECK operation of the SYSTEM CHECK provided in the intelligent tester function, conditions for air fuel ratio and pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. It helps technicians to troubleshoot the system when it is malfunctioning. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT AIR SWITCHING VALVE (a) Remove the intake manifold (See page ES-501). (b) Disconnect the A47 Air Switching Valve (ASV) connector. (c) Measure the resistance of the ASV. Standard resistance Component Side A47 ASV Connector Specified Condition 1-2 4.5 to 5.5 Ω (d) Reconnect the ASV connector. G037724E07 OK Tester Connection NG REPLACE AIR SWITCHING VALVE ES–227 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (AIR SWITCHING VALVE - BODY GROUND) (a) Remove the intake manifold (See page ES-501). (b) Disconnect the A47 ASV connector. (c) Check the resistance between the wire harness side connector and body ground. Standard resistance Wire Harness Side A47 Tester Connection Specified Condition A47-2 - Body ground Below 1 Ω (d) Reconnect the ASV connector. ASV Connector A056870E27 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (AIR SWITCHING VALVE - AIR INJECTION CONTROL DRIVER) Wire Harness Side Air Injection Control Driver Connector A44 (a) (b) (c) (d) Remove the intake manifold (See page ES-501). Disconnect the A44 air injection driver connector. Disconnect the A47 air switching valve connector. Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection Specified Condition VV (A44-6) - A47-1 Below 1 Ω VV (A44-6) or A47-1 - Body ground 10 kΩ or higher VV (e) Reconnect the air injection driver connector. (f) Reconnect the ASV connector. Air Switching Valve Connector NG A47 A121615E03 OK REPLACE AIR INJECTION CONTROL DRIVER REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–228 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0418 Secondary Air Injection System Control "A" Circuit DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. DTC Detection Condition P0418 Both of the following conditions are met, when idling just after cold start (1 trip detection logic): 1. Air injection (AIR) system does not operate 2. Air injection control driver (AID) outputs air pump malfunction signal (20% duty signal) • • • • Open in air pump drive circuit Short between air pump circuit and +B circuit Air injection control driver (AID) ECM P0418 Both of the following conditions are met, when idling just after cold start (1 trip detection logic): 1. Air injection (AIR) system operates 2. Air injection control driver (AID) outputs air pump malfunction signal (20% duty signal) • • • Short between air pump circuit and body ground AID ECM ES Trouble Area MONITOR DESCRIPTION Air Injection Control Driver (AID) detects an open or short in the air pump and Air Switching Valve (ASV) circuit according to the terminal voltage and sends a signal as diagnostic information to the ECM. When the air injection system operation is required while the engine is warming up, the ECM transmits command signals to the AID to drive the air pump and ASV. The AID outputs the air pump malfunction signal to the ECM if: 1) VP terminal voltage is low despite the AID receiving the command signal from the ECM to drive the air pump or 2) VP terminal voltage is high despite the AID not receiving the command signal from the ECM. The ECM sets the DTC based on the diagnostic information from the AID. MONITOR STRATEGY Related DTCs P0418: Air pump range check Required sensors/components Air injection control driver, Air pump Frequency of operation Continuous Duration 3 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present None Case 1: Air pump Operating Air switching valve Operating Battery voltage 8 V or more Ignition switch ON Starter OFF Case 2: Air pump Not operating Air switching valve Not operating Battery voltage 8 V or more Ignition switch ON Starter OFF 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–229 TYPICAL MALFUNCTION THRESHOLDS Case 1, 2: Diagnostic signal duty ratio from air injection control driver 11 to 29 % COMPONENT OPERATING RANGE Diagnostic signal duty ratio from air injection control driver 70 to 90 % when secondary air injection system operating and 0 % when secondary air injection system not operating WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). ES INSPECTION PROCEDURE HINT: The diagnostic information output from the AID can be confirmed by connecting an oscilloscope to the diagnostic information terminal of the AID. It narrows the trouble area search to read the waveform on the oscilloscope when performing the AIR system intrusive operation function provided in the SYSTEM CHECK. 1. Start the engine and warm it up. 2. Turn the ignition switch OFF. 3. Connect the intelligent tester to the DLC3 with CAN VIM 4. Connect an oscilloscope probe to the AIDI terminal of the ECM. ECM Connector E1 AIDI G035614E71 5. Start the engine and turn the tester ON. 6. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ SYSTEM. 7. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL OPERATION / OPERATION 1 and 2. AIR INJ CHECK AIR PUMP ON EASV OPEN ASV1 OPEN ASV2 OPEN A/F BANK1 19.05 A/F BANK2 19.05 PRESSURE 17 kPa-g PULSATION 25.39 kPa-g AI STATUS OK Remaining Time 05 sec. Press[EXIT]to quit G032717E01 HINT: OPERATION 1: AP: OFF; EASV: CLOSE; ASV1: CLOSE; ASV2: CLOSE OPERATION 2: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: OPEN ES–230 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8. Monitor the voltage output of the AID (duty ratio signal). Example: 80% Duty Signal 5 V/DIV. GND 20 msec./DIV. ES A116420E03 Oscilloscope range Items Contents Terminals CH1: AIDI - E1 Equipment Settings 5 V/DIV., 20 to 40 ms/DIV. Conditions Idling NOTICE: • This AIR INJECTION CHECK only allows technicians to operate the AIR system for 5 seconds. Furthermore, the check can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between checks. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (AI STATUS NG) or ERROR. If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • Performing the AIR INJ CHECK over and over again may cause damage in the secondary air injection system. If necessary, wait several minutes between tests to prevent overheating the system. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. AID Diagnostic Signal Waveform ECM Command DTC (ECM Output) Suspected Trouble Area • • 100 % Duty Ratio See waveform 1 Any Air Injection (AIR) System operation P1613 • • Open in diagnostic signal circuit Air Injection Control Driver (AID) Open in AID +B circuit (AID power source) Short between +B circuit and diagnostic signal circuit ES–231 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM AID Diagnostic Signal Waveform DTC (ECM Output) ECM Command Suspected Trouble Area • 0 % Duty Ratio See waveform 2 AIR System: ON (Air pump ON, ASV ON) P1613 • • • • AIR System: OFF (Air pump OFF, ASV OFF) - Normal • • Air Pump: ON P0418 • • • 20 % Duty Ratio See waveform 3 • Air Pump: OFF P0418 • • • • • • ASV: ON P0412 • • • 40 % Duty Ratio See waveform 4 • ASV: OFF 80 % Duty Ratio See waveform 5 Excluding Above (excluding 0, 20, 40, 80, 100 % duty) P0412 Open or short in air pump or Air Switching Valve (ASV) command signal circuit (ECM - AID) Open in AID ground circuit Short between diagnostic signal circuit and body ground AID ECM Short between air pump drive circuit and body ground Harness & connector (AID Pump) Air Pump AID ECM Open in air pump drive circuit (AID - Pump), or short between air pump drive circuit and +B Harness & connector (AID Pump) Air Pump AID ECM Short between ASV drive circuit and body ground Harness & connector (AID ASV) ASV AID ECM • • • Open in ASV drive circuit (AID - ASV), or short between ASV drive circuit and +B Harness & connector (AID ASV) AID ASV ECM AID ECM • AIR System: OFF (Air pump OFF, ASV OFF) P1613 • • AIR System: ON (Air pump ON, ASV ON) - Normal - P1613 • • 1. Almost Same as Battery Voltage +B GND A112066E01 Waveform 1 100 % Duty Ratio AID Open in AID ground circuit ES ES–232 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. Waveform 2 0 % Duty Ratio 3. Waveform 3 20 % Duty Ratio 4. Waveform 4 40 % Duty Ratio 5. Waveform 5 80 % Duty Ratio +B Fixed at Low Voltage GND A112067E01 20% ES +B GND A112068E01 40% +B GND A112069E01 80% +B GND A112070E01 HINT: • Using the AIR INJ CHECK operation of the SYSTEM CHECK provided in the intelligent tester function, conditions for air fuel ratio and pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. It helps technicians to troubleshoot the system when it is malfunctioning. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–233 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT AIR PUMP (a) Remove the intake manifold (See page ES-501). (b) Disconnect the A46 air pump connector. (c) Measure the resistance of the air pump. Standard resistance Component Side A46 Tester Connection Specified Condition 1-2 0.4 to 1.0 Ω (d) Reconnect the air pump connector. G032723E03 NG REPLACE AIR PUMP ES OK 2 CHECK HARNESS AND CONNECTOR (AIR PUMP - BODY GROUND) (a) Remove the intake manifold (See page ES-501). (b) Disconnect the A46 air pump connector. (c) Measure the resistance of the wire harness side connectors and body ground. Standard resistance Wire Harness Side A46 Air Pump Connector Specified Condition A46-1 - Body ground Below 1 Ω (d) Reconnect the air pump connector. G032722E05 OK Tester Connection NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES–234 3 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (AIR INJECTION CONTROL DRIVER - AIR PUMP) Wire Harness Side Air Injection Control Driver Connector A43 (a) (b) (c) (d) Remove the intake manifold (See page ES-501). Disconnect the A43 air injection driver connector. Disconnect the A46 air pump connector. Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection VP Specified Condition VP (A43-2) - A46-2 Below 1 Ω VP (A43-2) or A46-2 - Body ground 10 kΩ or higher (e) Reconnect the air injection driver connector. (f) Reconnect the air pump connector. ES Air Pump Connector NG A46 A121616E02 OK REPLACE AIR INJECTION CONTROL DRIVER REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–235 DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) MONITOR DESCRIPTION The ECM uses sensors mounted in front of and behind the Three-way Catalytic Converter (TWC) to monitor its efficiency. The first sensor, the Air Fuel Ratio (A/F) sensor, sends pre-catalyst information to the ECM. The second sensor, the Heated Oxygen (HO2) sensor, sends post-catalyst information to the ECM. In order to detect any deterioration in the TWC, the ECM calculates the Oxygen Storage Capacity (OSC) of the TWC. This calculation is based on the voltage output of the HO2 sensor while performing active airfuel ratio control, rather than the conventional detecting method, which uses the locus ratio. The OSC value is an indication of the oxygen storage capacity of the TWC. When the vehicle is being driven with a warm engine, active air fuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the ECM deliberately sets the air fuel ratio to lean or rich levels. If a rich-lean cycle of the HO2 sensor is long, the OSC becomes greater. There is a direct correlation between the OSCs of the HO2 sensor and the TWC. The ECM uses the OSC value to determine the state of the TWC. If any deterioration has occurred, it illuminates the MIL and sets a DTC. DTC No. DTC Detection Condition Trouble Area P0420 OSC value smaller than standard value under active air fuel ratio control (2 trip detection logic) • • • • P0430 OSC value smaller than standard value under active air fuel ratio control (2 trip detection logic) • • • • Gas leakage from exhaust system Air Fuel Ratio (A/F) sensor (bank 1 sensor 1) Heated Oxygen (HO2) sensor (bank 1 sensor 2) Three-Way Catalytic Converter (TWC) (Exhaust manifold) Gas leakage from exhaust system A/F sensor (bank 2 sensor 1) HO2 sensor (bank 2 sensor 2) Three-Way Catalytic Converter (TWC) (Exhaust manifold) HINT: • Bank 1 refers to the bank that includes No. 1 cylinder. • Bank 2 refers to the bank that does not include No. 1 cylinder. • Sensor 1 refers to the sensor closest to the engine assembly. • Sensor 2 refers to the sensor farthest away from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Catalyst (Bank 1) detection P0430: Catalyst (Bank 2) detection Required Sensors/Components (Main) Catalyst Required Sensors/Components (Related) Heated oxygen sensor, Intake air temperature sensor, Mass air flow meter, Crankshaft position sensor, Engine coolant temperature sensor Frequency of Operation Once per driving cycle Duration About 30 seconds MIL Operation 2 driving cycles Sequence of Operation None ES ES–236 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present ES P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0021 (VVT System 2 - Advance) P0022 (VVT System 2 - Retard) P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (HO2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0136, P0156 (HO2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0351 - P0358 (Igniter) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2237, P2240 (A/F sensor - open) P2440 (AIR control valve stuck open) P2441 (AIR control valve stuck close) P2444 (AIP stuck ON) P2445 (AIP stuck OFF) P2A00, P2A03 (A/F sensor - slow response) Battery voltage 11 V or more Intake air temperature -10°C (14°F) or more Engine coolant temperature 75°C (167°F) or more Atmospheric pressure 76 kPa (570 mmHg) or more Idle OFF Engine RPM Less than 3,200 rpm A/F sensor Activated Fuel system status Closed-loop Engine load 10 to 70 % All of the following conditions are met Conditions 1, 2 and 3 1. MAF 6 to 75 g/sec. (Varies with engine RPM) 2. Front catalyst temperature (estimated) 715 to 830°C (1,319 to 1,526°F) 3. Rear catalyst temperature (estimated) 410 to 830°C (770 to 1,526°F) EVAP system monitor The monitor has not run yet or the vacuum introduction has been completed A/F sensor monitor Completed Rear HO2S heater monitor Completed Shift position 4th or more TYPICAL MALFUNCTION THRESHOLDS Oxygen storage capacity (OSC) of catalyst Less than 0.08 g MONITOR RESULT Detailed information on CHECKING MONITOR STATUS (See page ES-17). CONDITIONING FOR SENSOR TESTING HINT: Perform the operation with the engine speeds and time durations described below prior to checking the waveforms of the A/F and HO2 sensors. This is in order to activate the sensors sufficiently to obtain the appropriate inspection results. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–237 Engine Speed [C] 3,000 rpm [D] 2,000 rpm [B] Idling Ignition Switch OFF [D] [A] Time Warming up At least 3 minutes Check 2 seconds A118003E05 1. Connect the intelligent tester to the DLC3 with CAN VIM [A]. 2. Start the engine and warm it up with all the accessories switched OFF, until the engine coolant temperature stabilizes [B]. 3. Run the engine at an engine speed of between 2,500 rpm and 3,000 rpm for at least 3 minutes [C]. 4. While running the engine at 3,000 rpm for 2 seconds and 2,000 rpm for 2 seconds, check the waveforms of the A/F and HO2 sensors using the tester [D]. HINT: • If either of voltage outputs of the Air Fuel Ratio (A/F) or Heated Oxygen (HO2) sensors does not fluctuate, or either of the sensors makes a noise, the sensor may be malfunctioning. • If the voltage outputs of both the sensors remain lean or rich, the air fuel ratio may be extremely lean or rich. In such cases, perform the following A/F CONTROL using the intelligent tester. • If the Three-Way Catalytic Converter (TWC) has deteriorated, the HO2 sensor (located behind the TWC) voltage output fluctuates up and down frequently, even under normal driving conditions (active air fuel ratio control is not performed). ES ES–238 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Voltage output when active air-fuel ratio control not performed Normal Catalyst Waveform of A/F Sensor in front of TWC Deteriorated Catalyst 3.5 V 3.0 V Waveform of HO2 Sensor behind TWC ES 1.0 V 0V 10 seconds 10 seconds A121610E01 1. A/F CONTROL HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the voltage outputs of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%. • Each sensor reacts in accordance with increases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 ES–239 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. • To display the graph, enter the following menus on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P0420 AND/OR P0430) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. ES ES–240 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P0420 and/or P0430 A P0420 and/or P0430 and other DTCs B HINT: If any DTCs other than P0420 or P0430 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) ES 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25% Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5% Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25% Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5% Lean Less than 0.4 Result: Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F and HO2 Sensor Conditions Main Suspected Trouble Areas Misfire • Lean/Rich Lean/Rich Normal • Lean Lean/Rich A/F sensor malfunction - • Proceed to Three-Way Catalytic Converter (TWC) Gas leakage from exhaust system A A/F sensor B ES–241 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Status AFS B1S1 or AFS B2S1 Status O2S B1S2 or O2S B2S2 A/F Condition and A/F and HO2 Sensor Conditions Misfire Rich Lean/Rich A/F sensor malfunction May occur • A/F sensor B Lean/Rich Lean HO2 sensor malfunction - • • HO2 sensor Gas leakage from exhaust system C Lean/Rich Rich HO2 sensor malfunction - • • HO2 sensor Gas leakage from exhaust system C • Lean Actual air fuel ratio lean Extremely rich or lean actual air fuel ratio Gas leakage from exhaust system A Extremely rich or lean actual air fuel ratio Gas leakage from exhaust system A Lean Main Suspected Trouble Areas May occur • • Rich Rich Actual air fuel ratio lean • Proceed to ES Lean: During A/F CONTROL, the A/F sensor (AFS) output voltage is consistently more than 3.35 V, and the HO2 sensor output voltage (O2S) is consistently less than 0.4 V. Rich: During A/F CONTROL, the AFS is consistently less than 3.0 V, and the O2S is consistently more than 0.55 V. Lean/Rich: During A/F CONTROL, the output voltage of the HO2 sensor alternates correctly. B CHECK AND REPLACE AIR FUEL RATIO SENSOR C CHECK AND REPLACE HEATED OXYGEN SENSOR, AND CHECK AND REPAIR EXHAUST GAS LEAKAGE A 3 CHECK FOR EXHAUST GAS LEAK OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK REPLACE FRONT AND REAR THREE-WAY CATALYTIC CONVERTER IN BANK A WHERE MALFUNCTION IS DETECTED ES–242 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P043E Evaporative Emission System Leak Detection Reference Orifice Low Flow DTC P043F Evaporative Emission System Reference Orifice High Flow DTC SUMMARY DTCs Monitoring Items ES P043E P043F Reference orifice clogged Reference orifice high-flow Malfunction Detection Conditions Leak detection pump creates negative pressure through reference orifice, and EVAP system pressure measured to determine leak criterion. 0.02 inch leak criterion measured at start and at end of leak check. If system pressure lower than -4.85 kPa (-36.38 mmHg)*, ECM determines that reference orifice has clogging malfunction. Leak detection pump creates negative pressure through reference orifice, and EVAP system pressure measured to determine leak criterion. 0.02 inch leak criterion measured at start and at end of leak check. If system pressure higher than -1.06 kPa (-7.95 mmHg)*, ECM determines that reference orifice has high-flow malfunction. Trouble Areas • • • • • • • • Detection Timing Detection Logic Canister pump module Connector/wire harness (Canister pump module - ECM) ECM Leakage from EVAP system While ignition switch OFF 2 trip Canister pump module Connector / Wire harness (Canister pump module - ECM) ECM Leakage from EVAP system While ignition switch OFF 2 trip The threshold values vary according to the atmospheric pressure measured at EVAP monitor beginning. The values described in the table above are based on an atmospheric pressure of 100 kPa (750.1 mmHg) (absolute pressure). HINT: The reference orifice is located inside the canister pump module. DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-423). ES–243 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion (reference pressure) measurement In order to determine leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion (reference pressure) measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES ES–244 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation B, E: Operation A: Atmospheric Pressure Measurement 0.02 Inch Leak Criterion Measurement Purge VSV: OFF Canister Fuel Tank OFF OFF (vent) Vent Valve: OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter ON Leak Detection Pump: OFF ES Reference Orifice (0.02 Inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E02 ES–245 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P043E: Reference orifice clogged In operation B, the leak detection pump creates negative pressure (vacuum) through the reference orifice. The EVAP system pressure is then measured by the ECM using the canister pressure sensor to determine the 0.02 inch leak criterion. If the pressure is lower than -4.85 kPa (-36.38 mmHg)*, the ECM interprets this as a clog malfunction in the reference orifice, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Reference Orifice Clogged: ON: Open Purge VSV ON OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Negative OK First 0.02 Inch Leak Criterion Malfunction Sequence A B C D E Time (Second) 10 60 Within 900 10 60 A106056E06 ES ES–246 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P043F: Reference orifice high-flow In operation B, the leak detection pump creates negative pressure (vacuum) through the reference orifice. The EVAP system pressure is then measured by the ECM using the canister pressure sensor to determine the 0.02 inch leak criterion. If the pressure is higher than -1.06 kPa (-7.95 mmHg)*, the ECM interprets this as a high-flow malfunction in the reference orifice, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Reference Orifice High-flow Malfunction: ON: Open Purge VSV ON OFF: Closed ES Vent Valve ON: Closed ON OFF: Vent Leak Detection Pump ON EVAP Pressure Malfunction Positive Negative OK First 0.02 Inch Leak Criterion Sequence A B Time (Second) 10 60 C Within 900 D E 10 60 A106057E07 MONITOR STRATEGY Required Sensors/Components Canister pump module Frequency of Operation Once per driving cycle Duration Within 2 min. (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or higher Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–247 TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. One of following conditions met - EVAP pressure just after reference pressure measurement started Higher than -1 kPa (-7.5 mmHg) Reference pressure Lower than -4.85 kPa (726 mmHg) Reference pressure -1.05 kPa (754 mmHg) or higher Reference pressure Not saturated within 60 seconds Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) or higher MONITOR RESULT Refer to detailed information on Checking Monitor Status (See page ES-17). INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (See page ES-430). ES ES–248 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC SUMMARY DTC No. ES P0441 P0441 P0441 Monitoring Items Purge Vacuum Switching Valve (VSV) stuck open Purge VSV stuck closed Purge flow Malfunction Detection Conditions Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak criterion x 0.2], ECM determines that purge VSV stuck open. After EVAP leak check performed, purge VSV turned ON (open), and atmospheric air introduced into EVAP system. 0.02 inch leak criterion measured at start and at end of leak check. If pressure does not return to near atmospheric pressure, ECM determines that purge VSV stuck closed. While engine running, following conditions are met: • Negative pressure not created in EVAP system when purge VSV turned ON (open) • EVAP system pressure change less than 0.5 kPa (3.75 mmHg) when vent valve turned ON (closed) • Atmospheric pressure change before and after purge flow monitor less than 0.1 kPa (0.75 mmHg) Trouble Areas • • • • • • • • • • • • • • Detection Timing Detection Logic Purge VSV Connector/wire harness (purge VSV ECM) ECM Canister pump module Leakage from EVAP system While ignition switch OFF 2 trip Purge VSV Connector/wire harness (purge VSV ECM) ECM Canister pump module Leakage from EVAP system While ignition switch OFF 2 trip Purge VSV Connector/wire harness (purge VSV ECM) Leakage from EVAP line (purge VSV Intake manifold) ECM While engine running 2 trip ES–249 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-425). MONITOR DESCRIPTION The 2 monitors, key-off and purge flow, are used to detect malfunctions relating to DTC P0441. The keyoff monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the ignition switch is turned OFF. The purge flow monitor runs while the engine is running. 1. Key-off monitor 5 hours* after the ignition switch is turned OFF, the leak detection pump creates negative pressure(vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. Sequence - A B C D E Operations Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion (reference pressure) measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds Second 0.02 inch leak criterion (reference pressure) measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds ES ES–250 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence F Operations Final check Descriptions Duration Atmospheric pressure measured and then monitoring result recorded by ECM. - *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation B, E: Operation A: Atmospheric Pressure Measurement 0.02 Inch Leak Criterion Measurement Purge VSV: OFF Canister Fuel Tank OFF OFF (vent) Vent Valve: OFF (vent) ES Canister Pump Module Canister Pressure Sensor Canister Filter ON Leak Detection Pump: OFF Reference Orifice (0.02 Inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E02 ES–251 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (a)Purge VSV stuck open In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The EVAP system pressure is then measured by the ECM using the canister pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak criterion x 0.2], the ECM interprets this as the purge Vacuum Switching Valve (VSV) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Open: ON: Open OFF: Closed ON Purge VSV ON: Closed OFF: Vent ON Vent Valve ON Vacuum Pump Malfunction EVAP Pressure Positive Negative First 0.02 inch Leak Pressure Standard Sequence Time Second 0.02 inch Leak Pressure Standard x 0.2 OK A 10 sec. B 60 sec. C Within 15 minutes D 10 sec. E 60 sec. A133722E01 ES ES–252 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b)Purge VSV stuck closed In operation D, the canister pressure sensor measures the EVAP system pressure. The pressure measurement for the purge VSV monitor begins when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Closed: ES ON: Open OFF: Closed ON Purge VSV ON: Closed OFF: Vent ON Vent Valve ON Vacuum Pump EVAP Pressure OK Positive Negative First 0.02 inch Leak Pressure Standard Sequence Time Malfunction A 10 sec. B 60 sec. C Within 15 minutes D 10 sec. E 60 sec. A133723E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–253 2. Purge flow monitor EVAP Pressure During Purge Flow Monitor: Open Purge VSV ON (Closed) Vent Valve Malfunction 0.1 kPa EVAP Pressure OK 1st Monitor 0.5 kPa OK 2nd Monitor A071563E05 The purge flow monitor consists of the 2 step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary. • The 1st monitor While the engine is running and the purge VSV is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. • The 2nd monitor The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa (3.75 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressure, before and after conduction of the purge flow monitor, is measured by the ECM. MONITOR STRATEGY Related DTCs P0441: Purge VSV stuck open P0441: Purge VSV stuck closed P0441: Purge flow Required sensors/Components Purge VSV, Pump module Frequency of operation Once per driving cycle Duration Purge VSV stuck open and closed: Within 15 min. (varies with amount of fuel in tank) Purge flow: Within 10 min. MIL operation 2 driving cycles Sequence operation None ES ES–254 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present ES P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0021 (VVT System 2 - Advance) P0022 (VVT System 2 - Retard) P0100 - P0103 (MAF sensor) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0351 - P0358 (Ignitor) P0450 - P0453 (EVAP pressure sensor) P0500 (VSS) Purge VSV stuck open and closed: Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) Purge flow Engine Running ECT 4.4°C (40°F) or higher IAT 4.4°C (40°F) or higher EVAP pressure sensor Not detected EVAP canister purge VSV Not operated by scan tool EVAP system check Not operated by scan tool Battery voltage 10 V or more Purge duty cycle 8 % or more TYPICAL MALFUNCTION THRESHOLDS Purge VSV stuck open EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 Purge VSV stuck closed EVAP pressure change after EVAP canister purge valve is open Less than 0.3 kPa (2.25 mmHg) Purge flow Both of the following conditions are met Condition 1 or 2 1. EVAP pressure change when purge flow is started Less than 0.1 kPa (0.75 mmHg) 2. EVAP pressure change during purge flow when EVAP pressure switching valve is ON (closed) Less than 0.5 kPa (3.75 mmHg) 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–255 MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). INSPECTION PROCEDURE Refer to the Evaporative Emission (EVAP) System Inspection Procedure (See page ES-430). ES ES–256 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range / Performance DTC P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input DTC P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input ES DTC SUMMARY DTC No. P0450 P0451 P0451 Monitoring Items Pressure sensor voltage abnormal fluctuation Pressure sensor noising Pressure sensor stuck Malfunction Detection Conditions Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 second. Sensor output voltage fluctuates frequently in certain time period. Sensor output voltage does vary in certain time period. Trouble Area • • • • • • • • • P0452 P0453 Pressure sensor voltage low Pressure sensor voltage high Sensor output voltage is less than 0.45 V for 0.5 second. Sensor output voltage is more than 4.9 V for 0.5 second. • • • • • • Pump module Connector / Wire harness (Pump module - ECM) ECM Pump module Connector / Wire harness (Pump module - ECM) ECM Pump module Connector / Wire harness (Pump module - ECM) ECM Pump module Connector / Wire harness (Pump module - ECM) ECM Pump module Connector / Wire harness (Pump module - ECM) ECM Detection Timing • • • • Detection Logic EVAP monitoring (ignition OFF) Ignition ON 1 trip EVAP monitoring (ignition OFF) Engine running 2 trip EVAP monitoring (ignition OFF) 2 trip • • Ignition ON EVAP monitoring (ignition OFF) 1 trip • • Ignition ON EVAP monitoring (ignition OFF) 1 trip HINT: The Canister pressure sensor is built into the canister pump module. DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-425). 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–257 MONITOR DESCRIPTION 1. DTC P0450: Canister pressure sensor output abnormal fluctuation Pressure Sensor Specification: Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V 60 110 kPa kPa Pressure HINT: Standard atmospheric pressure is 101.3 kPa A133725E01 If the canister pressure sensor output rapidly fluctuates between less than 42.1 kPa and more than 123.8 kPa, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 2. DTC P0451: Canister pressure sensor noise or stuck If the canister pressure sensor voltage output fluctuates rapidly for 15 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the canister pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor voltage output does not change, the ECM interprets this as the sensor being stuck, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both of the malfunctions are detected by 2 trip detection logic). 3. DTC P0452: Canister pressure sensor voltage low If the canister pressure sensor output is below 42.1 kPa, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 4. DTC P0453: Canister pressure sensor voltage high If the canister pressure sensor output is 123.8 kPa or more, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). MONITOR STRATEGY Related DTCs P0450: Evaporative emission control system pressure sensor/switch chattering P0451: Evaporative emission control system pressure sensor noise P0451: Evaporative emission control system pressure sensor stuck P0452: Evaporative emission control system pressure sensor/switch low input P0453: Evaporative emission control system pressure sensor/switch high input Required Sensors/Components Canister pump module ES ES–258 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Frequency of Operation Once per driving cycle: P0451 sensor stuck Continuous: P0451 sensor noise, P0450, P0452 and P0453 Duration 0.5 seconds: P0450, P0452, P0453 15 seconds: P0451 sensor noise 120 seconds: P0451 sensor stuck MIL Operation Immediate: P0450, P0452, P0453 2 driving cycles: P0451 Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None Pressure sensor noise: ES Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more IAT 4.4 to 40°C (40 to 104°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Either of the following conditions is met Condition 1 or 2 1. Time after key off 5 or 7 or 9.5 hours 2. Engine condition Running Pressure sensor stuck: Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more IAT 4.4 to 40°C (40 to 104°F) EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected Time after key off 5 or 7 or 9.5 hours Pressure sensor chattering, low/high voltage: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Pressure sensor noise: Frequency that EVAP pressure change is 0.3 kPa or more 10 times or more for 10 sec. Pressure sensor stuck: EVAP pressure change during reference pressure measurement Less than 0.65 kPa (4.9 mmHg) Pressure sensor chattering: EVAP pressure Less than 42.11 kPa (316 mmHg), or more than 123.761 kPa (928 mmHg) Pressure sensor low pressure: EVAP pressure Less than 42.11 kPa (316 mmHg) Pressure sensor high pressure: EVAP pressure WIRING DIAGRAM Refer to EVAP System (See page ES-430). More than 123.761 kPa (928 mmHg) ES–259 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel cap. • Do not disassemble the canister pump module. • The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1 CONFIRM DTC AND EVAP PRESSURE (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the values. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / EVAP / VAPOR PRESS. (f) Read the EVAP pressure displayed on the intelligent tester. Result Display (DTC Output) Test Result P0451 - P0452 Suspected Trouble Areas • Canister pressure sensor A • Wire harness/connector (ECM - canister pressure sensor) Canister pressure sensor Short in ECM circuit B Wire harness/connector (ECM - canister pressure sensor) Canister pressure sensor Open in ECM circuit C Less than 45 kPa (338 mmHg) • • • P0453 More than 120 kPa (900 mmHg) • • A C Proceed to GO TO EVAP SYSTEM Go to step 4 B 2 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) E8 PPMP ECM Connector G035619E13 (a) Disconnect the E8 ECM connector. (b) Turn the ignition switch OFF. (c) Measure the resistance of the wire harness side connectors. ES ES–260 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas • 10 Ω or less • • 10 kΩ or more • Proceed to Wire harness/connector (ECM canister pressure sensor) Short in canister pressure sensor circuit A Wire harness/connector (ECM canister pressure sensor) Short in ECM circuit B (d) Reconnect the ECM connector. B Go to step 7 A ES 3 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Disconnect the L4 canister connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance of the wire harness side connectors. L4 E8 PPMP A137923E01 Result Test Results 10 kΩ or more 10 Ω or less Suspected Trouble Areas Proceed to • Short in canister pressure sensor circuit A • Short in wire harness / connector (ECM - canister pressure sensor) B (d) Reconnect the canister connector. (e) Reconnect the ECM connector. A Go to step 5 B Go to step 6 ES–261 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Disconnect the L4 canister connector. (b) Turn the ignition switch ON. (c) Measure the voltage of the canister pump module connector. Standard voltage L4 Tester Connection Specified Condition L4-4 - Body ground 4.5 to 5.0 V L4-3 - Body ground 4.5 to 5.0 V (d) Measure the resistance of the canister pump module connector. Standard resistance Wire Harness Side Canister Connector Tester Connections Specified Conditions L4-2 - Body ground 100 Ω or less L4 Front View A121713E02 Result Test Results Suspected Trouble Areas Proceed to Voltage and resistance within standard ranges • Open in canister pressure sensor circuit A Voltage and resistance outside standard ranges • Open in wire harness/connector (ECM - canister pressure sensor) B (e) Connect the canister connector. B Go to step 6 A 5 REPLACE CANISTER ASSEMBLY (a) Replace the canister assembly (See page EC-23). NEXT 6 Go to step 8 REPAIR OR REPLACE HARNESS OR CONNECTOR HINT: If the exhaust tailpipe has been removed, go to the next step before reinstalling it. NEXT Go to step 8 ES ES–262 7 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM (a) Replace the ECM (See page ES-510). NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Wait for at least 60 seconds. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the intelligent tester, the repair has been successfully completed. ES NEXT COMPLETED ES–20 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECKING MONITOR STATUS ES The purpose of the monitor result (mode 06) is to allow access to the results of on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalysts, evaporative emissions (EVAP) and thermostats. The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum and maximum test limits, the ECM (PCM) interprets this as a malfunction. If the test value is on the borderline of the test limits, the component is likely to malfunction in the near future. Perform the following procedures to view the monitor status. Although these procedures refer to the Lexus/Toyota diagnostic tester, the monitor status can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedural information. 1. PERFORM MONITOR DRIVE PATTERN (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch and the tester ON. (c) Clear the DTCs (see page ES-35). (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (see page ES-20). Do not turn the ignition switch OFF. NOTE: The test results will be lost if the ignition switch is turned OFF. 2. ACCESS MONITOR RESULT (a) Select the following items from the intelligent tester menus: DIAGNOSIS, ENHANCED OBD II, MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMP: The component has not been monitored yet. • PASS: The component is functioning normally. • FAIL: The component is malfunctioning. (b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The accuracy test value appears if the monitor status is either PASS or FAIL. 3. CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT). 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–21 (b) If the test value is between the minimum and maximum test limits, the component is functioning normally. If not, the component is malfunctioning. The test value is usually not near the test limits. If the test value is on the borderline of the test limits, the component is likely to malfunction in the near future. HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. 4. MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the test value by the scaling value listed below. A/F Sensor (Bank 1 Sensor 1) HO2S Bank 1 Sensor 1 Monitor ID Test ID Scaling Unit Description $01 $8E Multiply by 0.001 V A/F sensor deterioration level $01 $91 Multiply by 0.004 mA A/F sensor current HO2 Sensor (Bank 1 Sensor 2) Monitor ID Test ID Scaling Unit Description $02 $07 Multiply by 0.001 V Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.0003 g Maximum oxygen storage capacity A/F Sensor Bank 2 HO2S Bank 2 Sensor 1 Monitor ID Test ID Scaling Unit Description $05 $8E Multiply by 0.001 V A/F sensor deterioration level $05 $91 Multiply by 0.004 mA A/F sensor current HO2 Sensor (Bank 2 Sensor 2) Monitor ID Test ID Scaling Unit Description $06 $07 Multiply by 0.001 V Minimum sensor voltage $06 $08 Multiply by 0.001 V Maximum sensor voltage $06 $8F Multiply by 0.0003 g Maximum oxygen storage capacity Catalyst - Bank 1 Monitor ID $21 Test ID $A9 Scaling Multiply by 0.0003 Unit No dimension Description Oxygen storage capacity of catalyst bank 1 Catalyst - Bank 2 Monitor ID $22 Test ID $A9 Scaling Multiply by 0.0003 Unit No dimension Description Oxygen storage capacity of catalyst bank 2 EVAP Monitor ID Test ID Scaling Unit Description $3D $C9 Multiply by 0.001 kPa Test value for small leak (P0456) $3D $CA Multiply by 0.001 kPa Test value for gross leak (P0455) $3D $CB Multiply by 0.001 kPa Test value for leak detection pump stuck OFF (P2401) $3D $CD Multiply by 0.001 kPa Test value for leak detection pump stuck ON (P2402) $3D $CE Multiply by 0.001 kPa Test value for vent valve stuck OFF (P2420) $3D $CF Multiply by 0.001 kPa Test value for vent valve stuck ON (P2419) $3D $D0 Multiply by 0.001 kPa Test value for reference orifice low flow (P043E) ES ES–22 Monitor ID 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test ID Scaling Unit Description $3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F) $3D $D4 Multiply by 0.001 kPa Test value for purge VSV stuck closed (P0441) $3D $D5 Multiply by 0.001 kPa Test value for purge VSV stuck open (P0441) $3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441) Rear Oxygen Sensor Heater Monitor ID Test ID Scaling Unit Description $42 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 1 sensor 2 $46 $91 Multiply by 0.001 Ohm Oxygen sensor heater resistance bank 2 sensor 2 Secondary Air Injection (AIR) Monitor ID ES Test ID Scaling Unit Description $71 $E1 Multiply by 0.01 g/sec. Test value for AIR insufficient $71 $E2 Multiply by 0.01 kPa Test value for AIR pump ON stuck $71 $E3 Multiply by 0.01 kPa Test value for AIR pump OFF stuck $71 $E4 Multiply by 0.01 kPa Test value for AIR valve(s) ON stuck $71 $E5 Multiply by 0.01 kPa Test value for AIR valve(s) OFF stuck $71 $E6 Multiply by 0.01 kPa Test value for AIR electrical valve $71 $E7 Multiply by 0.01 kPa Test value for AIR VSV bank 1 $71 $E8 Multiply by 0.01 kPa Test value for AIR VSV bank 2 $71 $E9 Multiply by 0.01 kPa Test value for AIR VSVs bank 1 and bank 2 Misfire Monitor ID $A1 Test ID $0B Scaling Multiply by 1 Unit Time Description Total EWMA misfire count of all cylinders in last ten driving cycles EWMA: Exponential Weighted Moving Average • $A1 $0C Multiply by 1 Time $A2 $0B Multiply by 1 Time • Total EWMA misfire count of cylinder 1 in last ten driving cycles • $A2 $0C Multiply by 1 Time $A3 $0B Multiply by 1 Time • $0C Multiply by 1 Time $A4 $0B Multiply by 1 Time • $0C Multiply by 1 Time $A5 $0B Multiply by 1 Time • $0C Multiply by 1 Time $A6 $0B Multiply by 1 Time • $0C Multiply by 1 Time $A7 $0B Multiply by 1 Time When ignition switch is ON, total misfire count of cylinder 4 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 4 in current driving cycle is displayed. Total EWMA misfire count of cylinder 5 in last ten driving cycles • $A6 When ignition switch is ON, total misfire count of cylinder 3 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 3 in current driving cycle is displayed. Total EWMA misfire count of cylinder 4 in last ten driving cycles • $A5 When ignition switch is ON, total misfire count of cylinder 2 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 2 in current driving cycle is displayed. Total EWMA misfire count of cylinder 3 in last ten driving cycles • $A4 When ignition switch is ON, total misfire count of cylinder 1 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 1 in current driving cycle is displayed. Total EWMA misfire count of cylinder 2 in last ten driving cycles • $A3 When ignition switch is ON, total misfire count of all cylinders in last driving cycle is displayed. While engine is running, total misfire count of all cylinders in current driving cycle is displayed. • When ignition switch is ON, total misfire count of cylinder 5 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 5 in current driving cycle is displayed. Total EWMA misfire count of cylinder 6 in last ten driving cycles 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor ID Test ID Scaling Unit Description • $A7 $0C Multiply by 1 Time $A8 $0B Multiply by 1 Time $A8 $0C Multiply by 1 Time $A9 $0B Multiply by 1 Time • • Multiply by 1 Time When ignition switch is ON, total misfire count of cylinder 7 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 7 in current driving cycle is displayed. Total EWMA misfire count of cylinder 8 in last ten driving cycles • $0C When ignition switch is ON, total misfire count of cylinder 6 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 6 in current driving cycle is displayed. Total EWMA misfire count of cylinder 7 in last ten driving cycles • $A9 ES–23 • When ignition switch is ON, total misfire count of cylinder 8 in last driving cycle is displayed. While engine is running, total misfire count of cylinder 8 in current driving cycle is displayed. ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–263 DTC P0455 Evaporative Emission Control System Leak Detected (Gross Leak) DTC P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY DTC No. P0455 P0456 Monitoring Items EVAP gross leak EVAP small leak Malfunction Detection Conditions Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak criterion x 0.2], ECM determines that EVAP system has large leakage. Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system has small leakage. Trouble Area • • • • • • Fuel cap (loose) Leakage from EVAP line (canister - fuel tank) Leakage from EVAP line (purge VSV - canister) Canister pump module Leakage from fuel tank Leakage from canister Same as above Detection Timing Detection Logic ES While ignition switch OFF 2 trip While ignition switch OFF 2 trip DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-425). INSPECTION PROCEDURE Refer to the EVAP system (See page ES-430). MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. ES–264 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion (reference pressure) measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion (reference pressure) measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A Operations ES B *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–265 Operation B, E: Operation A: Atmospheric Pressure Measurement 0.02 Inch Leak Criterion Measurement Purge VSV: OFF Canister Fuel Tank OFF OFF (vent) Vent Valve: OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter ON Leak Detection Pump: OFF Reference Orifice (0.02 Inch) Operation C: EVAP System Pressure Measurement ES Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E02 1. P0455: EVAP gross leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak criterion x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic). ES–266 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P0456: EVAP very small leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than the second 0.02 inch leak criterion, the ECM determines that the EVAP system has a small leakage, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP System Leaks: ON Purge VSV ON: Open OFF: Closed ON: Closed ON Vent Valve OFF: Vent ES Leak Detection Pump ON EVAP Pressure P0455 Positive Negative P0456 0.02 Inch Leak Criterion OK A B C D E 10 60 Within 900 10 60 Sequence Time (Second) A106061E03 MONITOR STRATEGY Related DTCs P0455: Gross leak detected P0456: Very small leak (0.020 inch hole) detected Required sensors/Components Purge VSV, Pump module Frequency of operation Once per driving cycle Duration Within 15 min. (varies with amount of fuel in tank) MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–267 TYPICAL MALFUNCTION THRESHOLDS Small leak (0.020 inch) malfunction detection: EVAP pressure when vacuum introduction is complete Between reference pressure and reference pressure x 0.2 Gross leak detection: EVAP pressure when vacuum introduction is complete Higher than reference pressure x 0.2 MONITOR RESULT Refer to detailed information on CHECKING MONITOR STATUS (See page ES-17). ES ES–268 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0500 Vehicle Speed Sensor "A" DTC P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High DESCRIPTION Vehicles, which are equipped with ABS (Anti-Lock Brake System), detect the vehicle speed using the skid control ECU and wheel speed sensor. The wheel speed sensor monitors the wheel rotation speed and sends a signal to the skid control ECU. The skid control ECU converts the wheel speed signal into a 4pulse signal and transmits it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of the pulse signal. ES 4-Pulse From Wheel Speed Sensor 4-Pulse ECM Skid Control ECU Combination Meter A079413E03 DTC No. P0500 P0503 DTC Detection Condition The ECM detects following conditions simultaneously for 1 second (1 trip detection logic): • No SPD (speed sensor) signal while ECM detects NC (transmission counter gear) signal • Park / Neutral position switch is OFF (When shift lever is in other than P and N positions) • Transfer lever is in other than N position (4WD) Trouble Area • • • • • Open or short in vehicle speed sensor circuit Vehicle speed sensor Combination meter ECM Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is driven when the park/neutral position switch is OFF and it has been over 4 seconds since the actual vehicle speed was 6 mph (9 km/h) or more. If there is no signal from the vehicle speed sensor when these conditions are satisfied, the ECM concludes that there is a fault in the vehicle speed sensor. The ECM will turn on the MIL and a DTC is set. MONITOR STRATEGY Related DTCs P0500: Vehicle speed sensor "A" pulse input error Required Sensors/Components (Main) Vehicle speed sensor Required Sensors/Components (Related) Park / Neutral position switch, Engine coolant temperature sensor, Combination meter Frequency of Operation Continuous Duration 5 seconds MIL Operation Immediate Sequence of Operation None ES–269 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present P0120 - P0223, P2135 (TP sensor) Vehicle speed 9 km/h (6 mph) or more TYPICAL MALFUNCTION THRESHOLDS Sensor signal No pulse input WIRING DIAGRAM 11 1K 1 1G V-R Center J/B Driver Side J/B Combination Meter 5 C9 B 3D B 3D G J30 V-R V-R J/C ES V-R ECM G J29 V-R 8 SPD E7 A133728E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK OPERATION OF SPEEDOMETER (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch to ON and turn the tester ON. Start the engine. Enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / VEHICLE SPD. (e) Read the vehicle speed on the intelligent tester. Result Vehicle speed Proceed to Vehicle speed is same as actual speed A ES–270 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Vehicle speed Proceed to Vehicle speed remains 0 mph (0 km/h) B Vehicle speed is lower than actual speed B CHECK SPEEDOMETER CIRCUIT (COMBINATION METER) A 2 INSPECT ECM (SPD VOLTAGE) (a) (b) (c) (d) ES Wire Harness Side E6 E7 E1 SPD NG 4.5 to 5.5V Turn Wheel A115707E02 OK REPLACE ECM Tester Connection Specified Condition SPD (E7-8) - E1 (E6-1) Generated intermittently HINT: The output voltage should fluctuate up and down similarly to the diagram when the wheel is turned slowly. ECM Connector 0V Move the shift lever to the neutral position. Jack up the vehicle. Turn the ignition switch ON. Measure the voltage between the specified terminals of the E6 and E7 ECM connectors as the wheel is turned slowly. Standard CHECK AND REPAIR HARNESS AND CONNECTOR BETWEEN COMBINATION METER AND ECM 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES–485 CAMSHAFT POSITION SENSOR 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY ES FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A119828E01 ES–486 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES TIMING BELT COVER SUB-ASSEMBLY NO. 3 LH 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) OIL COOLER PIPE 7.5 (80, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A119829E01 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES–487 ES CAMSHAFT POSITION SENSOR 7.5 (80, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A119819E01 ES–271 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0504 Brake Switch "A" / "B" Correlation DESCRIPTION In addition to turning on the stop lights, the stop light switch signals are used for a variety of engine, transmission and suspension functions. The stop light switch is designed with 2 complementary signal outputs, STP and ST1-. The ECM analyzes these signal outputs to detect malfunctions in the stop light switch. HINT: Normal condition is as shown in the table below. Signal Brake Pedal Released In Transition Brake Pedal Depressed STP OFF ON ON ST1- ON ON OFF DTC No. P0504 DTC Detection Condition Conditions (a), (b) and (c) continue for 0.5 seconds or more: (a) Ignition switch ON (b) Brake pedal released (c) STP signal is OFF when the ST1- signal is OFF Trouble Area • • • • Short in stop light switch signal circuit STOP fuse Stop light switch assembly ECM ES ES–272 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 11 IC3 R-L 16 E8 ST1- R-L G-W From IGN Fuse From IG1 Fuse T14 Towing Converter Relay C B-O J4 J/C C B-O 3 2 ES G-W Y-R Y-R S12 Stop Light SW 4 D G-Y 2 2 1 2 E B G-Y 16 1F G-Y 2 5 STOP LPCTRL Relay STIN 8 G-Y D 2 2 Driver Side J/B J1 J/C Y-R B J4 J/C B Engine Room STOP R/B 24 1E E 1 R-L G-B C J41 C J41 1 J/C 4 G-Y 3 B J40 G-Y STOP 2 ALT 1 2 2 B J40 G-Y STOP 1 1 Engine Room R/B 2 LG 15 IC3 B Center J/B E 3C 2 Engine Room R/B G-B 16 S28 STPO Skid Control ECU with Actuator E E 6 R14 Rear Combination Light LH J4 J/C W-B A J40 G-Y H J31 B R15 Rear Combination Light RH W-B A J40 J/C E 3C 2 6 G-B A J41 J/C E J32 G-Y Battery W-B BL 15 E8 STP A133729E02 ES–273 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK OPERATION OF STOP LIGHT (a) Check if the stop lights turn on and off normally when the brake pedal is depressed and released. OK : Stop light turns ON when brake pedal is depressed. NG REPAIR OR REPLACE STOP LIGHT SWITCH CIRCUIT OK 2 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Check the stop light switch (See page LI-71). NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3 READ VALUE OF INTELLIGENT TESTER (STP SIGNAL AND ST1- VOLTAGE) Brake Pedal Depressed (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / STOP LIGHT SW. (d) Confirm the stop light switch status when the brake pedal is depressed and released. OK Brake Pedal Released Brake Pedal Condition ECM Connector E6 E1 (-) Specified Condition Depressed STP Signal ON Released STP Signal OFF (e) Measure the voltage of the ECM when the brake pedal is depressed and released. Standard voltage E8 ST1- (+) A112419E05 Tester Connection Brake Pedal Condition Specified Condition ST1- (E8-16) - E1 (E6-1) Depressed Below 1.5 V ST1- (E8-16) - E1 (E6-1) Released 7.5 to 14 V OK CHECK FOR INTERMITTENT PROBLEMS ES ES–274 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 4 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH - ECM) (a) Disconnect the S12 stop light switch connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: Stop Light Switch connector Tester Connection S12 Stop light switch (S12-1) - STP (E815) Stop light switch (S12-4) - ST1- (E816) Front View ES Stop light switch (S12-1) or STP (E815) - Body ground Stop light switch (S12-4) or ST1- (E816) - Body ground E8 OK REPLACE ECM ST1STP A138065E01 Below 1 Ω 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the stop light switch connector. NG ECM Connector Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR ES–275 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0505 Idle Control System Malfunction DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is comprised of: 1) one valve type throttle body; 2) the throttle actuator, which operates the throttle valve; 3) the throttle position sensor, which detects the opening angle of the throttle valve; 4) the accelerator pedal position sensor, which detects the accelerator pedal position; and 5) the ECM, which controls the ETCS. Based on the target idle speed, the ECM controls the throttle actuator to provide the proper throttle valve opening angle. DTC No. P0505 DTC Detection Condition Trouble Area Idle speed continues to vary greatly from target speed (1 trip detection logic) • • • • ETCS Air induction system Ventilation hose connection ECM ES MONITOR DESCRIPTION The ECM detects idle speed and idle air flow amount for Idle Speed Control (ISC). The ECM concludes that the ISC is malfunctioning if: 1) the learned value of the ISC remains at the maximum or minimum 5 times or more during a drive cycle, and 2) while driving at 6 mph (10 km/h) or more, the actual idle rpm varies from the target rpm by between 100 to 150 rpm 5 times or more during a drive cycle. Example: If the actual idle rpm varies from the target idle rpm by more than 100 rpm* 5 times during a drive cycle, the ECM will turn on the MIL and a DTC is set. HINT: *: rpm threshold varies with engine load. Example Idle Speed Idle Speed Learned Valve Maximum Large Target RPM 0 Minimum Actual Idle RPM Small Time Time A121611E01 ES–276 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0505: Idle air control malfunction Required Sensors/Components (Main) Crankshaft position sensor Required Sensors/Components (Related) ECT sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 minutes MIL Operation 2 drive cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ES Monitor will run whenever these DTCs are not present None Engine Running TYPICAL MALFUNCTION THRESHOLDS Either of the following condition is met: Condition 1 or 2 1. Frequency that both of following conditions (a) and (b) are met 5 times or more (a) Engine RPM - Target engine RPM (A/C OFF and NSW OFF) Less than -100 rpm, or more than 150 rpm (b) Vehicle condition Stop after vehicle was driven at 6 mph (10 km/h) or more 2. Frequency that both of following conditions (a) and (b) are met Once (a) Engine RPM - Target engine RPM Less than -100 rpm, or more than 150 rpm (b) IAC flow rate learning value 2.48 L/sec or less, or 11 L/sec or more INSPECTION PROCEDURE HINT: • The detection of DTC P0505 may also be caused by: 1) the floor carpet overlapping onto the accelerator pedal, causing the accelerator pedal to be slightly depressed (throttle position to be slightly open); or 2) the accelerator pedal not being fully released. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0505) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. HINT: If any other codes besides P0505 are output, perform troubleshooting for those DTCs first. Result Display (DTC Output) Proceed to P0505 A P0505 and other DTCs B 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–277 HINT: If any DTCs other than P0505 are output, troubleshoot those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK CONNECTION OF VENTILATION HOSE OK: Ventilation hose is connected correctly and is not damaged. NG REPAIR OR REPLACE VENTILATION HOSE OK 3 CHECK AIR INDUCTION SYSTEM (a) Check for vacuum leaks in the air induction system. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 CHECK THROTTLE VALVE (a) Check the throttle valve condition. NG OK REPLACE ECM REPLACE THROTTLE BODY ES ES–278 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P050A Cold Start Idle Air Control System Performance DTC P050B Cold Start Ignition Timing Performance DESCRIPTION The Electronic Throttle Control System (ETCS) controls the engine idling speed. The ETCS operates the throttle actuator to open and close the throttle valve, and adjusts the intake air amount to achieve the target idling speed. In addition, the ECM retards the ignition timing and the ETCS increases the intake air amount to quickly increase the catalyst temperature at cold start. DTC No. ES DTC Detection Conditions Trouble Areas P050A Accumulated intake air amount during 10 seconds of idling after cold start is less than threshold (2 trip detection logic) • • • • • P050B Ignition timing retard value insufficient for 5 seconds or more during 10 seconds of P050A monitoring duration at cold start (2 trip detection logic) • • • • • • Throttle body assembly Mass air flow meter Air induction system Ventilation hose connections ECM Throttle body assembly Mass air flow meter Air induction system Ventilation hose connections VVT system ECM MONITOR DESCRIPTION Ignition Timing Accumulated Intake Air Value P050B Detected Pass Detected (g) Advanced 5 or more P050A Detected Threshold Threshold Pass Detected 0 Retarded 10 3 (Second) (Second) Time Time Engine Start 10 3 Engine Start A112588E01 The ECM monitors the intake air amount during idling and the ignition timing. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–279 When the engine coolant temperature is between -10°C and 50°C (14°F and 122°F), the ECM calculates the idling intake air amount for 10 seconds, beginning 3 seconds after the engine starts. When the accumulated value is below the threshold, the ECM interprets this as a malfunction in the Idle Speed Control (ISC) system at cold start. The ECM also monitors the ignition timing at cold start, and judges it to be incorrect when it is advanced to the same value for a warm engine for 5 seconds or more of the 10 second monitoring period. Example: P050A is detected when all conditions below are met. 1. The engine coolant temperature is between -10°C and 50°C (14°F and 122°F) when the engine starts. 2. The engine idles for 13 seconds after engine start. 3. The accumulated intake air amount is below the threshold. The ECM sets the DTC and illuminates the MIL 3 seconds after the engine is next started (2 trip detection logic). NOTICE: When the negative battery terminal is disconnected during inspection or repairs, the ISC learning values are cleared. The ISC learning must be performed by warming up the engine and idling for 5 minutes with the engine coolant temperature at 75°C (167°F) or more because DTCs cannot be detected with the ISC learning values cleared. MONITOR STRATEGY Related DTCs P050A: Idle speed control problem at cold P050B: Idle ignition timing problem at cold Required Sensors/Components (Main) Mass air flow meter Required Sensors/Components (Related) Engine Coolant Temperature (ECT) sensor, Throttle position sensor, Vehicle speed sensor Frequency of Operation Once per driving cycle Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None P050A: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10°C to 50°C (14°F to 122°F) Engine idling time 3 seconds or more Fuel-cut OFF Vehicle speed Less than 1.86 mph (3 km/h) Time after shift position changed 1 second or more Atmospheric pressure 76 kPa (570 mmHg) or more P050B: Battery voltage 8 V or more Time after engine start 3 seconds or more Starter OFF ECT at engine start -10°C (14°F) or more ECT -10 to 50°C (14 to 122°F) Engine idling time 3 seconds or more ES ES–280 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel-cut OFF Vehicle speed Less than 1.86 mph (3 km/h) TYPICAL MALFUNCTION THRESHOLDS P050A: Accumulated air flow amount Varies with ECT (Example: Less than 102 g) P050B: Accumulated timing when ignition timing retard is cut off 5 seconds or more INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P050A) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON. Turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read the DTCs. Result Display (DTC Output) Proceed to P050A and/or P050B A P050A and/or P050B and other DTCs B HINT: If any DTCs other than P050A and P050B are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (FUEL TRIM) HINT: Calculate the total fuel trim values to check the characteristic deviation of the mass air flow meter. (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / SHORT FT #1 and LONG FT #1. (e) Read the values displayed on the tester. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (f) ES–281 Add together the SHORT FT #1 and LONG FT #1 values to obtain the total FUEL TRIM. OK: Total of the SHORT FT #1 and LONG FT #1 values is between -20% and 20%. OK Go to step 12 NG 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Start the engine and turn the tester ON. Warm up the engine. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. (e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester. OK Tester Operation Specified Condition OCV OFF Normal engine speed OCV ON Engine idles roughly or stalls (soon after OCV switched from OFF to ON) NG Go to step 8 OK 4 CHECK VENTILATION HOSE CONNECTIONS OK: Ventilation hose is connected correctly and is not damaged. NG Go to step 9 OK 5 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG OK Go to step 10 ES ES–282 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR CLEANER FILTER ELEMENT (a) Visually check that the air cleaner filter element is not excessively contaminated with dirt or oil. OK: Air cleaner filter element is not excessively contaminated with dirt or oil. NG Go to step 11 OK ES 7 REPLACE MASS AIR FLOW METER NEXT 8 CHECK AND REPAIR VVT SYSTEM NEXT 9 Go to step 15 REPLACE AIR CLEANER FILTER ELEMENT NEXT 12 Go to step 15 REPAIR OR REPLACE AIR INDUCTION SYSTEM NEXT 11 Go to step 15 REPAIR OR REPLACE VENTILATION HOSE NEXT 10 Go to step 15 Go to step 15 CHECK THROTTLE VALVE (a) Check for deposits around the throttle valve and throttle valve condition. OK: No deposits around the throttle valve and throttle valve moves smoothly NG OK Go to step 14 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 13 REPLACE ECM NEXT 14 Go to step 15 CLEAN OR REPLACE THROTTLE BODY ASSEMBLY NEXT 15 ES–283 Go to step 15 CHECK WHETHER DTC OUTPUT RECURS (DTC P050A AND/OR P050B) NOTICE: In this operation, the engine must be cold (the same level as the engine coolant temperature recorded in the freeze frame data). (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Clear DTCs (see page ES-35). (e) Switch the ECM from normal mode to check mode using the tester (see page ES-36). (f) Start the engine and idle it for a minute. OK: Stable fast idling. (g) Read DTCs. OK: No DTC output. NEXT END ES ES–284 DTC 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P0560 System Voltage MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the ECM to store data such as DTC history, freeze frame data, fuel trim values, and other data. If the battery voltage falls below a minimum level, the memory is cleared and the ECM will conclude that there is a fault in the power supply circuit. At the next engine start, the ECM will illuminate the MIL and set a DTC. DTC No. P0560 DTC Detection Condition Trouble Area • • • Open in ECM back-up power source circuit Open in back-up power source circuit EFI fuse ECM HINT: If DTC P0560 appears, the ECM does not store another DTC. ES MONITOR STRATEGY Related DTCs P0560: ECM system voltage Required Sensors/Components (Main) ECM Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 3 seconds MIL Operation Immediate (MIL will be illuminated after next engine start) Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS ECM power source Less than 3.5 V ES–285 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Engine Room R/B EFI B 2 1 2 2 L 12 IC4 3 BATT E8 L ES Battery A074726E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (BATTERY VOLTAGE) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / BATTERY VOLTAGE. Result Battery voltage Proceed to Battery voltage is 0 V A Battery voltage is except 0 V B B A Go to step 5 ES–286 2 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (EFI NO. 1) (a) Remove the EFI fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω Engine Room R/B: EFI Fuse NG REPLACE FUSE A072881E01 ES OK 3 CHECK ECM (BATT VOLTAGE) Wire Harness Side E6 E8 OK ECM Connector E1 NG (a) Measure the voltage between terminals of the E6 and E8 ECM connector. Standard voltage BATT A115711E02 Tester Connection Specified Condition BATT (E8-3) - E1 (E6-1) 9 to 14 V CHECK FOR INTERMITTENT PROBLEMS ES–287 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (ECM - EFI NO. 1 FUSE) Engine Room R/B: EFI Fuse (a) Check the harness and the connector between the EFI fuse and ECM. (1) Remove the EFI fuse from the engine room R/B. (2) Disconnect the E8 ECM connector. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition Engine room R/B (EFI fuse terminal 2) - BATT (E83) Below 1 Ω Standard resistance (Check for short) E8 ECM Connector BATT A138068E01 Tester Connection Specified Condition Engine room R/B (EFI fuse terminal 2) or BATT (E8-3) - Body ground 10 kΩ or higher (4) Reinstall the EFI fuse. (5) Reconnect the ECM connector. (b) Check the harness and the connector between the EFI fuse and battery. (1) Remove the EFI fuse from the engine room R/B. (2) Disconnect the negative battery cable. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition Positive battery cable - Engine room R/B (EFI fuse terminal 1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition Positive battery cable or Engine room R/B (EFI fuse terminal 1) - Body ground 10 kΩ or higher (4) Reinstall the EFI fuse. (5) Reconnect the negative battery cable. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT BATTERY (a) Check that the battery is not depleted. OK: Battery voltage is 11 V or more. NG REPLACE BATTERY ES ES–288 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK CHECK AND REPLACE ENGINE ROOM RELAY BLOCK ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0604 ES–289 Random Access Memory (RAM) DESCRIPTION The ECM continuously monitors its internal memory status. This self-check ensures that the ECM is functioning properly. This is diagnosed by internal "mirroring" of the main CPU and sub CPU to detect the Random Access Memory (RAM) errors. If outputs from these CPUs are different and deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. DTC No. DTC Detection Condition Trouble Area P0604 ECM RAM errors ECM MONITOR STRATEGY Related DTCs None Required sensors / components (main) ECM Required sensors / components (sub) None Frequency of operation Continuous Duration 16 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS None - TYPICAL MALFUNCTION THRESHOLDS Main CPU and sub CPU mirroring Fail INSPECTION PROCEDURE 1 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the cable from the negative battery terminal and wait for 1 minute. (d) Connect the cable to the negative battery terminal. (e) Turn the ignition switch ON. (f) Check DTC. OK: P0604 is not present. NG OK INTERMITTENT PROBLEMS REPLACE ECM ES ES–290 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0606 ECM / PCM Processor DESCRIPTION The ECM continuously monitors its internal processors (CPUs), A/F sensor transistors and heated oxygen sensor (HO2S) transistors. This self-check ensures that the ECM is functioning properly. This is diagnosed by internal "mirroring" of the main and sub CPUs to detect processor errors. If outputs from the processors deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. ES DTC No. DTC Detection Condition Trouble Area P0606 • • • • • • ECM CPUs malfunction A/F sensor transistors malfunction HO2S transistors malfunction Exhaust gas leak HO2S ECM NOTICE: First check for an exhaust gas leak around the HO2S if P0606 is present. An exhaust gas leak generates noise in the HO2S output. The ECM may interpret this as an HO2S transistor malfunction and set P0606. MONITOR STRATEGY Related DTCs None Required sensors / components (main) ECM Required sensors / components (sub) APP sensor, TP sensor, Brake switch, Cruise control, A/F sensor, HO2S Frequency of operation Continuous Duration 60 seconds MIL operation immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Engine Running Estimated A/F sensor temperature 450 - 800°C (842 - 1,472°F) Estimated HO2S temperature 450 - 800°C (842 - 1,472°F) TYPICAL MALFUNCTION THRESHOLDS Difference of main APP and sub APP 0.3 V or more Difference of main TP and sub TP 0.3 V or more Difference of main brake switch signal and sub brake switch signal Different A/F sensor transistors Fail HO2S transistors Fail INSPECTION PROCEDURE 1 CHECK FOR EXHAUST GAS LEAK (a) Allow the engine to idle. (b) Check for an exhaust gas leak around the HO2S. OK: No leak from the HO2S. NG REPAIR LEAK 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–291 OK 2 CHECK HEATED OXYGEN SENSOR Fuel-Trim and Rear HO2S Voltage Cross-reference Fuel-Trim 25% -12.5% ES HO2S Voltage 0.8 V 0.2 V A144391E01 (a) Warm up the engine. (b) Allow the engine to idle. (c) Select the tester menus: ENHANCED OBDII, ACTIVE TEST AND A/F CONTROL. (d) Check the O2S B1S2 (O2S B2S2) values when the A/F CONTROL is -12.5% (Lean fuel-trim). (e) Check the O2S B1S2 (O2S B2S2) values when the A/F CONTROL is 25% (Rich fuel-trim). Standard A/F CONTROL O2S B1S2 (O2S B2S2) -12.5% Less than 0.2 V 25% More than 0.8 V NG REPLACE HEATED OXYGEN SENSOR OK 3 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the cable from the negative battery terminal and wait for 1 minute. (d) Connect the cable to the negative battery terminal. (e) Start the engine. ES–292 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor Drive Pattern for P0606 Engine Coolant Temperature: 75°C (167°F) or more km/h (mph) 5 Minutes 80 (50) 60 (35) Time 0 ES A144392E01 (f) Perform the drive pattern. (1) Warm up the engine. (2) Accelerate the vehicle until 80 km/h (50 mph) and stop the vehicle. (3) Drive the vehicle by 60 to 80 km/h (35 to 50 mph) for 5 minutes or more. (g) Check DTC. OK: P0606 is not present. NG OK INTERMITTENT PROBLEMS REPLACE ECM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0607 ES–293 Control Module Performance DESCRIPTION The ECM continuously monitors its main and sub CPUs. This self-check ensures that the ECM is functioning properly. If outputs from the CPUs are different and deviate from the standards, the ECM will illuminate the MIL and set a DTC immediately. The ECM also monitors the cruise control cancel circuit. If this circuit malfunctions, the ECM will set a DTC immediately (MIL is not illuminated). DTC No. DTC Detection Condition Trouble Area P0607 • • • ECM ECM main CPU error ECM sub CPU error Cruise control cancel circuit malfunction ES MONITOR STRATEGY Related DTCs None Required sensors / components (main) ECM Required sensors / components (sub) - Frequency of operation Once per driving cycle Duration 16 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS CPU reset Occurred TYPICAL MALFUNCTION THRESHOLDS When either condition below is met: Condition 1 or 2 1. When all conditions below are met: - - CPU reset 1 time or more - Learned TP - Learned APP 0.4 V or more - Electronic throttle actuator OFF 2. CPU reset 2 times or more INSPECTION PROCEDURE 1 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the cable from the negative battery terminal and wait for 1 minute. (d) Connect the cable to the negative battery terminal. (e) Turn the ignition switch ON. (f) Check DTC. OK: P0607 is not present. NG REPLACE ECM ES–294 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK INTERMITTENT PROBLEMS ES ES–295 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0617 Starter Relay Circuit High DESCRIPTION HINT: While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. If the vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter control circuit is malfunctioning. The ECM will turn on the MIL and a DTC is set. DTC No. P0617 DTC Detection Condition Trouble Area The following conditions are met for 20 seconds: • Vehicle speed is greater than 12 mph (20 km/h) • Engine RPM is greater than 1,000 rpm • ECM detects STA • • • • Starter relay circuit Park/Neutral Position (PNP) switch Ignition switch ECM MONITOR STRATEGY ES Related DTCs P0617: Starter signal error Required Sensors/Components (Main) STARTER relay, PNP switch, Ignition switch Required Sensors/Components (Related) Vehicle speed sensor, Crankshaft position sensor Frequency of Operation Continuous Duration 20 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever these DTCs are not present None Battery voltage 10.5 V or more Vehicle speed 12.4 mph (20 km/h) or more Engine rpm 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON ES–296 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM R B-Y 8 E5 STAR / NSW P 2 2 5 2 2 1 AM2 ES N P B-Y 1 3 2 Engine Room R/B 5 2 2 B-Y 2 A Y-G J28 J/C W-B B B-R 1 S2 Battery 11 IM1 G EB 11 E6 STA B-Y 1 S3 Starter B-Y B-Y B J3 Y-G J/C A A 2 IC4 6 EA1 B P1 Park / Neutral Position Switch 4 STA Relay G B-Y J35 J/C A133731E01 INSPECTION PROCEDURE HINT: • This DTC chart is on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table (See page ES-26). • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. ES–297 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Confirm the starter signal status when the ignition switch is operated. OK Ignition Switch Position STARTER SIG ON OFF Start ON OK Go to step 5 NG 2 INSPECT PARK / NEUTRAL POSITION SWITCH (a) Move the shift lever to the P or N position. (b) Disconnect the P1 Park / Neutral Position (PNP) switch connector. (c) Measure the resistance of the PNP switch. Standard resistance Component Side P1 Shift Position Tester Connection Park/Neutral Position Switch Specified Condition P 2 - 6, 4 - 5 Below 1 Ω R 1-2 Below 1 Ω N 2 - 9, 4 - 5 Below 1 Ω D, 4 2-7 Below 1 Ω 3 2-4 Below 1 Ω 2, L 2-8 Below 1 Ω A093221E12 (d) Reconnect the park / neutral position switch connector. NG REPLACE PARK / NEUTRAL POSITION SWITCH (GO TO STEP 5 AFTER THE REPLACEMENT) OK 3 INSPECT IGNITION SWITCH ASSEMBLY Component Side: Ignition Switch I18 IG1 ST2 ACC 4 8 AM1 3 7 AM2 Front View 2 6 ST1 1 5 (a) Disconnect the I18 ignition switch connector. (b) Measure the resistance between the connector terminals shown in the chart below. Standard resistance Switch Position Tester Connection Specified Condition LOCK All Terminals 10 kΩ or higher ACC 2-3 Below 1 Ω ON 2-3, 2-4, 6-7 Below 1 Ω START 1-2, 2-4, 6-7, 6-8 Below 1 Ω IG2 A087913E10 (c) Reconnect the ignition switch connector. NG OK REPLACE IGNITION SWITCH ASSEMBLY (GO TO STEP 5 AFTER REPLACEMENT) ES ES–298 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (STARTER SIGNAL) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. (d) Read the values. OK ES NG Ignition Switch Position STARTER SIG ON OFF START ON REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P0617) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear DTCs. Drive the vehicle more than 25 mph (40 km/h) for 20 seconds or more. (e) Read DTCs. Result Display (DTC Output) Proceed to P0617 A No DTC output B B A REPLACE ECM CHECK FOR INTERMITTENT PROBLEMS ES–299 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0630 VIN not Programmed or Mismatch - ECM / PCM DESCRIPTION DTC P0630 is set if the Vehicle Identification Number (VIN) is not stored in the ECM or the input VIN is not accurate. Input the VIN with the intelligent tester. DTC No. DTC Detection Condition • • P0630 Trouble Area VIN not stored in ECM Input VIN in ECM not accurate ECM MONITOR STRATEGY Related DTCs P0630: VIN not programmed Required Sensors/Components (Main) ECM Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.325 seconds MIL Operation Immediate Sequence of Operation None ES TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present None Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE 1 READ CURRENT DTC (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0630 A P0630 and other DTCs B If any DTCs other than P0630 are output, troubleshoot those DTCs first. ES–300 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: If P0630 is set, the VIN must be input to the ECM using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are set, check them first. B GO TO DTC CHART A 2 INPUT VIN WITH INTELLIGENT TESTER (a) Input VIN with the intelligent tester (See page ES-12). ES NEXT END ES–24 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM READINESS MONITOR DRIVE PATTERN 1. ES PURPOSE OF READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emissionrelated components, and indicate any detected abnormalities with Diagnostic Trouble Codes (DTC). Since various components need to be monitored during different driving conditions, the OBD II system is designed to run separate monitoring programs called Readiness Monitors. • The intelligent tester's software must be version 9.0 or newer to view the Readiness Monitor Status. To view the status, Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. • When the Readiness Monitor status reads COMPL (complete), the necessary conditions have been met for running the performance tests for that Readiness Monitor. • A generic OBD II scan tool can also be used to view the Readiness Monitor status. HINT: Many state Inspection and Maintenance (I/M) programs require a vehicle's Readiness Monitor status to show COMPL before beginning emissions tests. The Readiness Monitor will be reset to INCMPL (incomplete) if: • The ECM has lost battery power or blown a fuse. • DTCs have been cleared. • The conditions for running the Readiness Monitor have not been met. If the readiness monitor status shows INCMPL, follow the appropriate readiness monitor drive pattern to change the status to COMPL. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: The following drive patterns are the fastest method of completing all the requirements necessary for making the readiness monitor status read "complete". If forced to momentarily stop a drive pattern due to traffic or other factors, the drive pattern can be resumed. Upon completion of the drive pattern, in most cases, the readiness monitor status will change to "complete". Sudden changes in vehicle load and speed, such as driving up and down hills and/or sudden acceleration, hinder readiness monitor completion. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–25 Contents: TITLE STEP(s) CATALYST MONITOR Procedure "A" EVAP MONITOR Procedure "B", "C" AIR-FUEL RATIO (A/F) AND OXYGEN SENSOR (O2S) MONITOR Procedure "D" OXYGEN SENSOR HEATER MONITOR Procedure "E" 2. CATALYST MONITOR (ACTIVE AIR FUEL RATIO CONTROL TYPE) (Procedure "A") Vehicle Speed Between [B] ES 40 and 70 mph (64 and 113 km/h) Idling [A] Ignition Switch ON Warm up 10 minutes Time (Note: Even when vehicle stops during pattern, test can be resumed.) A115372E38 3. (a) Preconditions The monitor will not run unless: – The MIL is OFF (b) Drive Pattern (1) Connect the intelligent tester. (2) Turn the ignition switch ON. (3) Turn the intelligent tester ON. (4) Clear DTC (if set) (See page ES-35). (5) Start the engine and warm it up [A]. (6) Drive vehicle at between 40 to 70 mph (64 and 113 km/h) for at least 10 minutes [B]. NOTICE: This test will not be completed if the vehicle is driven under absolutely constant speed, such as with cruise control activated. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), extend the driving time. EVAP SYSTEM MONITOR (KEY OFF TYPE) (a) Preconditions The monitor will not run unless: ES–26 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM – – – – ES 4. The fuel tank is less than 90% full. The altitude is less than 8,000 ft (2,450 m). The vehicle is stationary. The engine coolant temperature is between 4.4 and 35°C (40 and 95°F). – The intake air temperature is between 4.4 and 35°C (40 and 95°F). – Vehicle was driven in an urban area (or on a freeway) for 10 minutes or more. (b) Monitor Conditions (1) Turn the ignition switch OFF and wait for 6 hours. HINT: Do not start the engine until checking Readiness Monitor status. If the engine is started, the step described above must be repeated. (c) Monitor Status (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) Turn the tester or scan tool ON. (4) Check the Readiness Monitor status displayed on the tester or scan tool. If the status does not switch to COMPL (complete), restart the engine, make sure that the preconditions have been met, and then perform the Monitor Conditions again. AIR FUEL RATIO (A/F) AND HEATED OXYGEN SENSOR (HO2) MONITOR (ACTIVE AIR FUEL RATIO CONTROL TYPE) (a) Preconditions The monitor will not run unless: – 2 minutes or more have elapsed since the engine was started. – The Engine Coolant Temperature (ECT) is 75°C (167°F) or higher. – Air fuel ratio feedback control is performed. – Fuel-cut control is performed for 8 seconds or more (for the Rear HO2 Sensor Monitor). (b) Drive Pattern for front A/F sensor and rear HO2 sensor (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON. (3) Turn the tester ON. (4) Clear DTCs (if set) (See page ES-35). (5) Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher [A]. (6) Drive the vehicle at 40 mph (64 km/h) or more for at least 10 minutes [B]. (7) Change the transmission to 2nd gear [C]. (8) Accelerate the vehicle to 30 mph (48 km/h) or more by depressing the accelerator pedal for at least 10 seconds [D]. ES–27 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (9) Soon after performing the step above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal, in order to execute fuel-cut control [E]. (10)Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) [F]. (11)Repeat steps from [D] through [F] above at least 3 times in one driving cycle [G]. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. (2) If the status does not switch to COMPL (complete), make sure that the preconditions have been met, and then perform steps from [A] through [G] in "Drive Pattern" procedures above. Monitor Drive Pattern Accelerator Pedal Released (Fuel-cut) ETC: 75°C (167°F) or higher Vehicle Speed Accelerator Pedal Depressed [B] 40 to 75 mph (64 to 120 km/h) 30 mph (48 km/h) or more [A] At least 3 times [D] [E] [F] 6 mph (10 km/h) [C] Idling Time Warming up 10 minutes or more 10 seconds 4 seconds or more or more A115374E05 ES ES–28 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. AIR FUEL RATIO (A/F) AND HEATED OXYGEN (HO2) SENSOR HEATER MONITOR (FRONT A/F AND REAR HO2 SENSOR TYPE) 25 mph (40 km/h) ES Idling Ignition Switch OFF Over 500 seconds Over 2 minutes A121604E01 (a) Preconditions The monitor will not run unless: – The MIL is OFF (b) Drive Pattern 1. Connect the intelligent tester to the DLC3 [A]. 2. Turn the ignition switch ON [B]. 3. Turn the tester ON [C]. 4. Clear DTCs (if set) (See page ES-35) [D]. 5. Start the engine [E]. 6. Start the engine and allow it to idle for 500 seconds or more [F]. 7. Drive the vehicle at 25 mph (40 km/h) or more for at least 2 minutes [G]. (c) Monitor Status (1) Check the Readiness Monitor status displayed on the tester. If the status does not switch to COMPL (complete), make sure that the preconditions of the readiness monitor on the scan tool display. If readiness status did not switch to complete, ensure the preconditions are met, turn the ignition switch OFF and then repeat steps [E] and [G]. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0657 ES–301 Actuator Supply Voltage Circuit / Open DESCRIPTION The ECM monitors the output voltage to the throttle actuator. This self-check ensures that the ECM is functioning properly. The output voltage usually is 0 V when the ignition switch is turned OFF. If the output voltage is higher than 7 V when the ignition switch is turned OFF, the ECM will illuminate the MIL and set a DTC when the ignition switch is turned ON. DTC No. DTC Detection Condition Trouble Area P0657 Throttle actuator power supply error ECM MONITOR STRATEGY Related DTCs None Required sensors / components (main) ECM Required sensors / components (sub) Throttle actuator Frequency of operation Once per driving cycle Duration Within 1 second MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Ignition switch From ON to OFF TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply 7 V or more INSPECTION PROCEDURE 1 CHECK DTC (a) Clear DTC. (b) Turn the ignition switch OFF. (c) Disconnect the cable from the negative battery terminal and wait for 1 minute. (d) Connect the cable to the negative battery terminal. (e) Turn the ignition switch ON for 10 seconds. (f) Turn the ignition switch OFF. (g) Turn the ignition switch ON. (h) Check DTC. OK: P0657 is not present. NG OK INTERMITTENT PROBLEMS REPLACE ECM ES ES–302 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1340 Camshaft Position Sensor "A" (Bank 1 Sensor 2) DTC P1341 Camshaft Position Sensor "A" (Bank 1 Sensor 2) DESCRIPTION ES The camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The camshaft drive gear (LH) has 3 teeth on its inner circumstance. When the camshaft gear rotates, air gap changes between the protrusion on the gear and the pickup coil. The change affects the magnetic field and results in changes in the resistance of the MRE element. The crankshaft signal plate has 32 teeth and is mounted on the crankshaft. The crankshaft position sensor generates 32 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. DTC No. P1340 P1341 DTC Detection Condition Trouble Area No camshaft position sensor signal to ECM during cranking (2 trip detection logic) No camshaft position sensor signal to ECM with engine speed 600 rpm or more • • • • Open or short in camshaft position sensor circuit Camshaft position sensor Camshaft timing pulley LH ECM MONITOR DESCRIPTION The camshaft position sensor (G signal) consists of a magnet and MRE element. The camshaft drive gear has 5 teeth on its inner circumference. When the camshaft gear rotates, air gap changes between the protrusion on the gear and the pickup coil. The change affects the magnetic field and results in changes in the resistance of the MRE element. The crankshaft angle sensor plate has 32 teeth and outputs 32 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and actual crankshaft angle and engine speed by NE signal. MONITOR STRATEGY Related DTCs P1340: Camshaft position sensor range check P1340: Camshaft position / Crankshaft position misalignment P1341: Camshaft position sensor malfunction Required Sensors/Components (Main) Camshaft position sensor Required Sensors/Components (Related) Crankshaft position sensor, Engine speed sensor Frequency of Operation Continuous Duration 5 seconds MIL Operation 2 driving cycles: Camshaft position sensor range check Immediate: Camshaft position / Crankshaft position misalignment and camshaft position sensor malfunction Sequence of Operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None Camshaft position sensor range check: Starter ON Minimal battery voltage while starter ON Less than 11 V Camshaft position / Crankshaft position misalignment: Engine RPM 600 rpm or more ES–303 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Starter OFF Camshaft position sensor malfunction: Starter After OFF to ON timing TYPICAL MALFUNCTION THRESHOLDS Camshaft position sensor range check: Camshaft position signal No signal Camshaft position / Crankshaft position misalignment: Camshaft position and crankshaft position phase Misaligned Camshaft position sensor malfunction: Camshaft position and crankshaft position phase Misaligned Camshaft position signal per 2 revolutions of crankshaft 12 signals or more ES COMPONENT OPERATING RANGE • Camshaft position sensor signal • Camshaft position sensor voltage fluctuates when the camshaft rotates 3 signals per revolution of crankshaft WIRING DIAGRAM Refer to DTC P0335 (See page ES-195). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK HARNESS AND CONNECTOR (SENSOR POWER SOURCE) Wire Harness Side Camshaft Position Sensor Connector (a) Disconnect the C1 camshaft position sensor connector. (b) Turn the ignition switch ON. (c) Measure the voltage between terminal 3 of the camshaft position sensor connector and body ground. Standard voltage Tester Connection Specified Condition C1-3 - Body ground 4.5 to 5.0 V (d) Reconnect the camshaft position sensor connector. C1 NG Front View A115895E01 REPAIR OR REPLACE HARNESS OR CONNECTOR ES–304 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 2 CHECK ECM TERMINAL VOLTAGE (a) Inspect the ECM using an oscilloscope. (1) While the engine is idling, check the waveform between the terminals of the ECM connector. Standard voltage ECM Connector E6 ES G2+ 2 V/DIV. OK *1 *3 Specified Condition G2+ (E6-19) - G2- (E6-29) Correct waveform is as shown HINT: • *1: Crank angle • *2: 180° • *3: 120° • *4: 60° G2- REPLACE ECM *4 *3 *2 Tester Connection *2 *4 200 ms./DIV. A115714E01 NG 3 CHECK HARNESS AND CONNECTOR (ECM - CAMSHAFT POSITION SENSOR) Wire Harness Side Camshaft Position Sensor Connector (a) Disconnect the C1 Camshaft position sensor connector. (b) Disconnect the E6 ECM connector. (c) Measure the resistance between wire harness side connectors. Standard resistance Tester Connection C1 Camshaft position sensor (C1-2) G2+ (E6-19) Camshaft position senssor (C1-1) G2- (E6-29) Front View ECM Connector E6 Camshaft position sensor (C1-2) or G2+ (E6-19) - Body ground Camshaft position sensor (C1-1) or G2- (E6-29) - Body ground Specified Condition Below 1 Ω 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the Camshaft position sensor connector. NG G2+ G2A115715E01 REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–305 OK 4 INSPECT SENSOR INSTALLATION (a) Check the camshaft position sensor installation. OK: The camshaft position sensor is installed properly. NG REPAIR OR REPLACE SENSOR Clearance OK NG ES BR03795E10 OK 5 INSPECT CAMSHAFT TIMING PULLEY LH (SIGNAL PLATE TOOTH) NG OK REPLACE CAMSHAFT POSITION SENSOR REPLACE CAMSHAFT TIMING PULLEY LH ES–306 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1440 Secondary Air Injection Vacuum Switching Valve Circuit Malfunction Bank 1 DTC P1443 Secondary Air Injection Vacuum Switching Valve Circuit Malfunction Bank 2 DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. P1440 ES P1443 DTC Detection Condition Trouble Area AIV1 terminal voltage becomes less than half of the +B voltage while the VSV for air injection system is not operating. (1 trip detection logic) • AIV2 terminal voltage becomes less than half of the +B voltage while the VSV for air injection system is not operating. (1 trip detection logic) • • • • • • • Open or short in VSV for air injection system circuit (bank 1) VSV power source VSV for air injection system (bank 1) ECM Open or short in VSV for air injection system circuit (bank 2) VSV power source VSV for air injection system (bank 2) ECM MONITOR DESCRIPTION The ECM detects an open or short in the circuit of the VSV for air injection system according to the AIV1 (AIV2) terminal voltage, stores the DTC, and then illuminates the MIL. When the AIV1 (AIV2) terminal voltage is less than half of the +B voltage while the VSV for air injection system is not operating, the ECM determines it as a malfunction. MONITOR STRATEGY Related DTCs P1440: Secondary air injection system control valve circuit (bank 1) range check P1443: Secondary air injection system control valve circuit (bank 2) range check Required sensors/components VSV for air injection control Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None P1440: Engine Running No. 2 air switching valve (bank 1) Not operating P1443: Engine Running No. 2 air switching valve (bank 2) Not operating TYPICAL MALFUNCTION THRESHOLDS P1440: No. 2 air switching valve (bank 1) output terminal level Low 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–307 P1443: No. 2 air switching valve (bank 2) output terminal level Low WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 ES CHECK HARNESS AND CONNECTOR (AIR INJECTION SYSTEM POWER SOURCE) (a) Disconnect the V12 or V13 VSV for air injection system connector. (b) Turn the ignition switch ON. (c) Measure the voltage between terminal 1 of the VSV connector and body ground. Standard: 9 V or more (d) Reconnect the VSV for air injection system connector. Wire Harness Side V12 V13 VSV for Air Injection System Connector G032727E15 OK NG REPAIR AIR INJECTION SYSTEM POWER SOURCE CIRCUIT ES–308 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (ECM - VSV FOR AIR INJECTION SYSTEM) Wire Harness Side VSV for Air Injection Control Connector (a) Disconnect the E4 ECM connector. (b) Disconnect the VSV for air injection control connector. (c) Measure the resistance between the VSV connector and ECM. Standard resistance V12 Tester connection Specified condition AIV1 (E4-27) - V13-2 Below 1 Ω AIV2 (E4-26) - V12-2 Below 1 Ω V13 (d) Measure the resistance between the VSV connector and body ground. Standard resistance ES ECM Connector E4 Tester connection Specified condition AIV1 (E4-27) or V13-2 - Body ground 10 kΩ or higher AIV2 (E4-26) or V12-2 - Body ground 10 kΩ or higher (e) Reconnect the ECM connector. (f) Reconnect the VSV for air injection control connectors. NG AIV1 REPAIR OR REPLACE HARNESS OR CONNECTOR AIV2 A121617E07 OK 3 CHECK VSV (RESISTANCE) (a) Disconnect the V12 or V13 VSV for air injection system connector. (b) Disconnect the 2 vacuum hoses from the VSV. (c) Measure the resistance of the VSV terminals. Standard resistance Tester Connection Specified Condition 1-2 33 to 39 Ω at 20°C (68°F) 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher A115365 (d) Reconnect the VSV for air injection system connector. (e) Reconnect the vacuum hose. NG OK REPLACE ECM REPLACE VSV 2UZ-FE ENGINE CONTROL SYSTEM – VVT SENSOR ES–489 VVT SENSOR INSPECTION 1. INSPECT VVT SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold: 835 to 1,400 Ω Hot: 1,060 to 1,645 Ω NOTICE: "Cold" and "Hot" above mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). ES ES–309 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1441 Stuck Open in Secondary Air Injection Vacuum Switching Valve Bank 1 DTC P1444 Stuck Open in Secondary Air Injection Vacuum Switching Valve Bank 2 DTC P2440 Secondary Air Injection System Switching Valve Stuck Open Bank1 DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. DTC Detection Condition Trouble Area P1441 No. 2 air switching valve (bank 1) stuck open: The pressure sensor detects exhaust pulsation, when both of No. 2 air switching valve OFF (and air switching valve ON). (2 trip detection logic) • • • • VSV for air injection system circuit (bank 1) No. 2 air switching valve (bank 1) VSV for air injection system (bank 1) ECM P1444 No. 2 air switching valve (bank 2) stuck open: The pressure sensor detects exhaust pulsation, when both of No. 2 air switching valve OFF (and air switching valve ON). (2 trip detection logic) • • • • VSV for air injection system circuit (bank 2) No. 2 air switching valve (bank 2) VSV for air injection system (bank 2) ECM P2440 No. 2 air switching valve stuck open: The pressure sensor detects exhaust pulsation when the system is not operating (both of No. 2 air switching valve OFF, and air switching valve OFF and air pump OFF). This DTC means air switching valve and "No. 2 air switching valve bank 1 or bank 2" are stuck open. (1 trip detection logic) • • • • • • Air switching valve (ASV) No. 2 air switching valve (Bank 1 and/or 2) VSV for air injection system (bank 1 and/or 2) Air injection control driver (AID) Air injection control driver circuit ECM MONITOR DESCRIPTION The ECM detects pressure change with the pressure sensor to determine malfunctioning parts in the system, and stores the DTCs. The ECM measures pressure and/or exhaust pulsation of the system at 6 points, A to F, when the air injection system is in operation or when not in operation. When the pressure is high, the ECM determines that the pump operates. When exhaust pulsation is detected, the ECM determines that the Air Switching Valve (ASV) is open. The ECM determines malfunction parts based on the measured value, and stores the DTCs. Points A and B: ECM detects pressure changes (decrease), and determines that the No. 2 Air Switching Valve (No. 2 ASV) is open. Points C and F: ECM detects pressure and exhaust pulsation, and determines the pressure pattern of the system. Point D: ECM operates the system, as indicated by the dashed lines, to determine which of the No. 2 ASV is malfunctioning only when pressure changes cannot be detected at point A or B. Point E: ECM detects exhaust pulsation to determine the condition of the system. ES ES–310 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor Operation Outline Running ES Engine OFF Air Pump ON OFF ASV (Electromagnetic Type) ON No. 2 ASV (Bank 1) (Vacuum Type)* ON OFF No. 2 ASV (Bank 2) (Vacuum Type)* ON OFF OFF System Air Pressure A B C D E F *: No. 2 ASV opens alternately per trip. A115364E02 Pressure condition in Secondary Air Injection System (Point C and F) Pattern 1: Air Pump ON Air Switching Valve and No. 2 Air Switching Valve Open Pressure 1 kPa or more Pulsation detection Exhaust gas pulsation detected Pattern 2: Air Pump OFF Air Switching Valve and No. 2 Air Switching Valve Open Pressure Less than 5 kPa Pulsation detection Exhaust gas pulsation detected Air Pump ON Pattern 3: Air Switching Valve and No. 2 Air Switching Valve Closed Pressure 1 kPa or more Pulsation detection Slight pulsation detected Air Pump OFF Pattern 4: Air Switching Valve and No. 2 Air Switching Valve Closed Pressure Less than 5 kPa Pulsation detection Not detected ES–311 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Judgment and decision of failure mode: Monitor Judgment C F A B D E DTCs that may be set Pattern 1 Pattern 1 Pressure changed Pressure changed - No pulsation detected P2444, P1441 and P1444 Pattern 1 Pattern 1 No pressure changed Pressure changed - No pulsation detected P2444 and "P1441 or P1444" Pattern 1 Pattern 1 Pressure changed No pressure changed Pulsation detected No pulsation detected P2444, P1441 and P1444 Pattern 1 Pattern 1 No pressure changed No pressure changed Pulsation detected No pulsation detected P2444, P1441 and P1444 Pattern 1 Pattern 2 Pressure changed Pressure changed - No pulsation detected P1441 and P1444 Pattern 1 Pattern 2 No pressure changed Pressure changed - No pulsation detected P1441 or P1444 Pattern 1 Pattern 2 Pressure changed No pressure changed Pulsation detected No pulsation detected P1441 and P1444 Pattern 1 Pattern 2 No pressure changed No pressure changed Pulsation detected No pulsation detected P1441 and P1444 Pattern 1 Pattern 3 Pressure changed Pressure changed - No pulsation detected P2444 Pattern 1 Pattern 3 No pressure changed Pressure changed - No pulsation detected P2444 and "P1442 or P1445" Pattern 1 Pattern 3 Pressure changed No pressure changed No pulsation detected No pulsation detected P2444 and "P1442 or P1445" Pattern 1 Pattern 3 No pressure changed No pressure changed No pulsation detected No pulsation detected P2444, P1442 and P1444 Pattern 1 Pattern 4 Pressure changed Pressure changed - No pulsation detected Normal Pattern 1 Pattern 4 Pressure changed No pressure changed Pulsation detected No pulsation detected Normal Pattern 1 Pattern 4 Pressure changed No pressure changed No pulsation detected No pulsation detected P1442 or P1445 Pattern 1 Pattern 4 No pressure changed Pressure changed - No pulsation detected P1442 or P1445 Pattern 1 Pattern 4 No pressure changed No pressure changed Pulsation detected No pulsation detected P1442 or P1445 Pattern 1 Pattern 4 No pressure changed No pressure changed No pulsation detected No pulsation detected P1442 and P1445 Pattern 2 - No pressure changed No pressure changed - - P2445 Pattern 3 Pattern 3 No pressure changed No pressure changed No pulsation detected No pulsation detected P2441, P2444, P1442 and P1445 Pattern 3 Pattern 4 No pressure changed No pressure changed No pulsation detected No pulsation detected P2441, P1442 and P1445 Pattern 4 - No pressure changed No pressure changed - - P2445 - - - - - Pulsation detected P2440 and "P1441 or P1444" MONITOR STRATEGY Related DTCs P1441 Air valve bank 1 open stuck P1444 Air valve bank 2 open stuck P1441 and P1444 Air valve bank 1 and bank 2 open stuck P2440 Air valve open stuck P2440 Air valve bank 1 and bank 2 open stuck Required sensors/Components (main) AIR valve, AIR VSV bank 1, AIR VSV bank 2 ES ES–312 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/Components (sub) AIR pressure sensor Frequency of operation Once per driving cycle Duration Within 20 seconds MIL operation 2 driving cycles: P1441and P1444 Immediate: P2440 Sequence operation None TYPICAL ENABLING CONDITIONS All: ES This monitor runs whenever these DTCs are not present • • • • • • • • • • • • • • • • • • • • • • • • • P0010, P0020: VVT system P0011: VVT System 1 - Advance P0012: VVT System 1 - Retard P0016, P0018: VVT System - Misalignment P0021: VVT System 2 - Advance P0022: VVT System 2 - Retard P0031, P0032, P0051, P0052: Front A/F sensor heater P0100 - P0103: MAF sensor P0110 - P0113: IAT sensor P0115 - P0118: ECT sensor P0120 - P0223, P2125: TP sensor P0125: Closed loop P0171 - P0175: Fuel trim P0300 - P0308: Misfire P0327 - P0333: Knock sensor P0335: CKP sensor P0340 - P0346: VVT sensor P0351 - P0358: Igniter P0445 - P0446: EVAP system P0450 - P0453: EVAP press sensor P0500: VSS P2196, P2198: A/F sensor - rationality P2237, P2240: A/F sensor - open P2430 - P2433: AIR pressure sensor P2A00, P2A03: A/F sensor - slow response Case 1: Atmospheric pressure 45 kPa (420 mmHg) or higher Battery voltage 10.5 V or higher Case 2: Atmospheric pressure 45 kPa (420 mmHg) or higher Battery voltage 10.5 V or higher AIR pump OFF Time after engine start 10 seconds or more AIR valve bank 1 OFF AIR valve bank 2 OFF AIR status OFF Engine load 0 % or more Intake air amount 40 g/sec. or more IAT at engine start -15°C (5°F) or higher ECT at engine start Lower than 5°C (41°F) AIR valve ON Engine RPM Lower than 3,750 rpm Case 3: Cumulative intake air amount 109 g/sec. or more AIR pump OFF AIR valve OFF AIR valve bank 1 OFF 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM AIR valve bank 2 OFF Engine RPM Lower than 3,750 rpm AIR status OFF ES–313 AIR monitor runs in accordance with the monitor sequence 1 to 5 Monitor Sequence 1 Idle ON AIR status ON AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF -AIR valve bank 2 ON Monitor Sequence 2 Idle ON AIR status ON AIR valve ON AIR VSV bank 1 ON AIR VSV bank 2 ON Monitor Sequence 3 Engine RPM Less than 3,750 rpm AIR status ON AIR pump ON AIR valve ON AIR valve bank 1 ON AIR valve bank 2 ON Monitor Sequence 4-1 Runs when AIR pressure did not change at monitor sequence 2 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF -AIR valve bank 2 ON Monitor Sequence 4-2 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve OFF AIR VSV bank 1 OFF AIR VSV bank 2 OFF Monitor Sequence 5 ES ES–314 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve ON AIR VSV bank 1 OFF AIR VSV bank 2 OFF TYPICAL MALFUNCTION THRESHOLDS P1441 AIR valve bank 1 open stuck: ES When both conditions below are met: Condition 1 and 2 1. When one of the following conditions is met: Condition (a), (b) or (c) (a) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 20 kPa or more AIR pressure Less than 5 kPa (b) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 30 kPa or more AIR pressure 5 kPa or more (c) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 20 kPa or more AIR pressure Less than 5 kPa 2. When one of following conditions is met: Condition (a), (b) or (c) (a) When both conditions below are met: Condition (1) or (2) (1) AIR pressure change at monitor sequence 1 2.5 kPa or more (2) AIR pressure change at monitor sequence 2 2.5 kPa or more (b) AIR pressure change at monitor sequence 1 (for AIR valve bank 1) Less than 1 kPa (c) AIR pressure change at monitor sequence 2 (for AIR valve bank 1) Less than 1 kPa P1444 AIR valve bank 2 open stuck: When both conditions below are met: Condition 1 and 2 1. When one of the following conditions is met: Condition (a), (b) or (c) (a) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 20 kPa or more AIR pressure Less than 5 kPa (b) When both conditions below are met: Condition (1) and (2) 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 30 kPa or more AIR pressure 5 kPa or more (c) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - Cumulative pressure pulsation 15 kPa or more AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - Cumulative pressure pulsation 20 kPa or more AIR pressure Less than 5 kPa 2. When one of following conditions is met: Condition (a), (b) or (c) (a) When both conditions below are met: Condition (1) or (2) (1) AIR pressure change at monitor sequence 1 2.5 kPa or more (2) AIR pressure change at monitor sequence 2 2.5 kPa or more (b) AIR pressure change at monitor sequence 1 (for AIR valve bank 2) Less than 1 kPa (c) AIR pressure change at monitor sequence 2 (for AIR valve bank 2) Less than 1 kPa ES–315 P1441 and P1444 AIR valve bank 1 and bank 2 open stuck: Cumulative pressure pulsation 100 kPa or more P2440 AIR valve open stuck: When both of conditions are met (during AIR ON): Condition 1 and 2 1. Cumulative pressure pulsation 15 kPa or more 2. AIR pressure Less than 1 kPa Cumulative pressure pulsation during monitor sequence 4-2 20 kPa or more P2440 AIR valve bank 1 and bank 2 open stuck: Cumulative pressure pulsation 100 kPa or more MONITOR RESULT Refer to Checking Monitor Status (See page ES-17). WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO SECONDARY AIR INJECTION SYSTEM DTCS) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. ES ES–316 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed To "P1441 and/or P1444" and P2440 A P1441 and/or P1444 B "P1441 and/or P1444 and/or P2440" and other DTCs C HINT: If any DTCs other than P1441, P1444 or P2440 are output, troubleshoot those DTCs first. B ES C Go to step 7 GO TO DTC CHART A 2 CHECK AIR SWITCHING VALVE (OPERATION) (a) Remove the intake manifold (See page ES-501). (b) Remove the Air Switching Valve (ASV). (c) Blow air into port A and check that air is not discharged from port B. OK: Not discharged Air Port A Port B G032728E01 Port B Air Battery (d) Apply battery positive voltage across the terminals. (e) Blow air into port A and check that air is discharged from port B. OK: Discharged NG Port A G032729E02 OK REPLACE AIR SWITCHING VALVE ES–317 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK AIR SWITCHING VALVE (VOLTAGE) (a) (b) (c) (d) Wire Harness Side A47 Remove the intake manifold (See page ES-501). Disconnect the A47 ASV connector. Turn the ignition switch ON. Measure the voltage between terminal 1 of the air switching valve connector and body ground. Standard voltage ASV Connector G032727E10 Tester Connection Specified Condition A47-1 - Body ground Below 1.0 V (e) Reconnect the ASV connector. NG Go to step 4 ES OK CHECK FOR INTERMITTENT PROBLEMS 4 CHECK HARNESS AND CONNECTOR (AIR INJECTION CONTROL DRIVER - AIR SWITCHING VALVE) Wire Harness Side Air Injection Control Driver Connector A44 (a) (b) (c) (d) (e) Remove the intake manifold (See page ES-501). Disconnect the A44 air injection driver connector. Disconnect the A47 air switching valve connector. Disconnect the battery positive terminal cable. Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection Specified Condition VV (A44-6) - A47-1 Below 1 Ω VV (A44-6) or A47-1 - Battery positive terminal cable 10 kΩ or higher VV (f) Reconnect the air injection driver connector. (g) Reconnect the ASV connector. Air Switching Valve Connector NG A47 A121615E04 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–318 5 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR INJECTION CONTROL DRIVER (VOLTAGE) (a) Disconnect the A44 Air Injection Control Driver (AID) connector. (b) Turn the ignition switch ON. (c) Measure the voltage between terminal 3 (SIV) of the AID connector and body ground. Standard voltage Wire Harness Side A44 Tester Connection Specified Condition SIV (A44-3) - Body ground 10 V or more SIV AID Connector G032721E22 (d) Reconnect the AID connector. NG ES Go to step 6 OK REPLACE AIR INJECTION CONTROL DRIVER 6 CHECK HARNESS AND CONNECTOR (AIR INJECTION CONTROL DRIVER - ECM) (a) Disconnect the air injection driver connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Wire Harness Side Air Injection Control Driver Connector Tester Connection Specified Condition SIV (A44-3) - AIRV (E8-4) Below 1 Ω SIV (A44-3) or AIRV (E8-4) - Body ground 10 kΩ or higher A44 SIV (d) Reconnect the air injection driver connector. (e) Reconnect the ECM connector. ECM Connector E8 NG AIRV A121716E06 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 ES–319 CHECK NO. 2 AIR SWITCHING VALVE (OPERATION) (a) (b) (c) (d) A116419 Air switching valve No. 2 operation Start the engine and warm it up. Turn the ignition switch OFF. Connect the intelligent tester to the DLC3 with CAN VIM. Start the engine and push the intelligent tester main switch ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL / OPERATION 5 and 6. HINT: OPERATION 5: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: CLOSE OPERATION 6: AP: ON; EASV: OPEN; ASV1: CLOSE; ASV2: OPEN NOTICE: • This test only allows technicians to operate the AIR system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. (f) Read values of the A/F BANK1 and BANK2 on the intelligent tester. Result Air fuel ratio Open 18 or more Closed Approximately 14.5 HINT: • When the No. 2 ASV operates normally, the A/F value is 18 or more when the valve is open, and approximately 14.5 when the valve is closed. • Perform the following procedures only on the bank of which the valve is not closed. NEXT ES ES–320 8 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK VSV (FOR AIR INJECTION SYSTEM) Port A A121720E01 ES (a) Turn the ignition switch OFF. (b) Disconnect the vacuum hose from the VSV for air injection system. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Start the engine and turn the tester ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL / OPERATION 1. (f) At this time, check that no negative pressure generates at port A of the VSV. HINT: OPERATION 1: AP: OFF; EASV: CLOSE; ASV1: CLOSE; ASV2: CLOSE NOTICE: • This test only allows technicians to operate the AIR system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch to OFF when the AIR INJ CHECK operation finishes. OK: No negative pressure is generated. (g) Reconnect the vacuum hose. NG Go to step 10 OK 9 CHECK NO. 2 AIR SWITCHING VALVE (OPERATION) (a) Remove the No. 2 air switching valve. (b) Blow air into port B and check that air is not discharged from port C. OK: Not discharged from port C Port A Port C Air Port B G032732E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–321 (c) Apply vacuum 30 kPa (225 mmHg) to port A, blow air into port B and check that air is discharged from port C. OK: Discharged from port C Port A NG REPLACE NO. 2 AIR SWITCHING VALVE Port B Air Port C G032733E01 OK CHECK FOR INTERMITTENT PROBLEMS 10 ES CHECK VSV (FOR AIR INJECTION SYSTEM) (a) Disconnect the 2 vacuum hoses. (b) Disconnect the VSV for air injection system connector. (c) Blow air into port B and check that air does not flow from port A. OK: Air does not flow from port A (d) Apply battery positive voltage across the terminals. Then blow air into port B and check that air flows from port A. OK: Air flows from port A Port A Air NG Port A Air A138066E01 OK REPLACE VSV ES–322 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 CHECK HARNESS AND CONNECTOR (ECM - VSV FOR AIR INJECTION SYSTEM) Wire Harness Side VSV for Air Injection Control Connector V12 (a) Remove the intake manifold (See page ES-501). (b) Disconnect the E4 ECM connector. (c) Disconnect the V12 and V13 VSV for air injection system control connector. (d) Measure the resistance between the VSV connector and ECM. Standard resistance V13 ES Tester connection Specified condition AIV1 (E4-27) - V13-2 Below 1 Ω AIV2 (E4-26) - V12-2 Below 1 Ω (e) Measure the resistance between the VSV connector and body ground. Standard resistance ECM Connector E4 Tester connection Specified condition AIV1 (E4-27) or V13-2 - Body ground 10 kΩ or higher AIV2 (E4-26) or V12-2 - Body ground 10 kΩ or higher (f) Reconnect the ECM connector. (g) Reconnect the VSV connector. NG AIV1 AIV2 A121617E07 OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–323 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1442 Stuck Close in Secondary Air Injection Vacuum Switching Valve Bank 1 DTC P1445 Stuck Close in Secondary Air Injection Vacuum Switching Valve Bank 2 DTC P2441 Secondary Air Injection System Switching Valve Stuck Close Bank1 DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. DTC Detection Condition Trouble Area • • P1442 No. 2 air switching valve (bank 1) stuck closed: No pressure change (decrease) after the ECM sends an open No. 2 air switching valve (bank 1) signal. (2 trip detection logic) • • • • • • P1445 No. 2 air switching valve (bank 2) stuck closed: No pressure change (decrease) after the ECM sends an open No. 2 air switching valve (bank 2) signal. (2 trip detection logic) • • • • • P2441 Air switching valve stuck closed: The pressure sensor does not detect exhaust pulsation when system operates. (All of air switching valve ON) This DTC means either of the following conditions is met. 1. Electromagnetic air switching valve stuck closed. 2. Both of "No. 2 air switching valve (bank 1)" and "No. 2 air switching valve (Bank 2)" are stuck closed. (2 trip detection logic) • • • • • • • • VSV for air injection system circuit (bank 1) Vacuum hose (VSV for air injection system - No. 2 air switching valve) Air injector pipe (No. 2 air switching valve - exhaust manifold) No. 2 air switching valve (bank 1) VSV for air injection system (bank 1) ECM VSV for air injection system circuit (Bank 2) Vacuum hose (VSV for air injection system - No. 2 air switching valve ) Air injector pipe (No. 2 air switching valve - exhaust manifold) No. 2 air switching valve (bank 2) VSV for air injection system (bank 2) ECM Vacuum hoses (Throttle body - VSVs for air injection system) Air switching valve Air injector pipe (No. 2 air switching valve - exhaust manifold) Air injection hose No. 2 air switching valve (bank 1 and/or 2) VSV for air injection system (bank 1 and/or 2) Air injection control driver Air injection control driver circuit ECM MONITOR DESCRIPTION Refer to DTC P1441, P1444 and P2440 (See page ES-304). MONITOR STRATEGY Related DTCs (Case 1) P1442 AIR VSV stuck close bank 1 (Case 2) P1445 AIR VSV stuck close bank 2 (Case 3) P2441 AIR valve stuck close Required sensors/Components (main) AIR valve, AIR VSV bank 1, AIR VSV bank 2 Required sensors/Components (sub) AIR pressure sensor Frequency of operation Once per driving cycle Duration Within 20 seconds MIL operation 2 driving cycles Sequence operation None ES ES–324 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL ENABLING CONDITIONS This monitor runs whenever these DTCs are not present • • • • • • • • • • • • • • • • • • • • • • • • • Atmospheric pressure 45 kPa (420 mmHg) or more Battery voltage 10.5 V or higher ES P0010, P0020: VVT system P0011: VVT System 1 - Advance P0012: VVT System 1 - Retard P0016, P0018: VVT System - Misalignment P0021: VVT System 2 - Advance P0022: VVT System 2 - Retard P0031, P0032, P0051, P0052: Front A/F sensor heater P0100 - P0103: MAF sensor P0110 - P0113: IAT sensor P0115 - P0118: ECT sensor P0120 - P0223, P2125: TP sensor P0125: Closed loop P0171 - P0175: Fuel trim P0300 - P0308: Misfire P0327 - P0333: Knock sensor P0335: CKP sensor P0340 - P0346: VVT sensor P0351 - P0358: Igniter P0445 - P0446: EVAP system P0450 - P0453: EVAP press sensor P0500: VSS P2196, P2198: A/F sensor - rationality P2237, P2240: A/F sensor - open P2430 - P2433: AIR pressure sensor P2A00, P2A03: A/F sensor - slow response AIR monitor runs in accordance with the monitor sequence 1 to 5 Monitor Sequence 1 Idle ON AIR status ON AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF -AIR valve bank 2 ON Monitor Sequence 2 Idle ON AIR status ON AIR valve ON AIR VSV bank 1 ON AIR VSV bank 2 ON Monitor Sequence 3 Engine RPM Less than 3,750 rpm AIR status ON AIR pump ON AIR valve ON AIR valve bank 1 ON AIR valve bank 2 ON Monitor Sequence 4-1 Runs when AIR pressure did not change at monitor sequence 2 Engine RPM Less than 3,750 rpm 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM AIR status OFF AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF -AIR valve bank 2 ON ES–325 Monitor Sequence 4-2 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve OFF AIR VSV bank 1 OFF AIR VSV bank 2 OFF Monitor Sequence 5 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve ON AIR VSV bank 1 OFF AIR VSV bank 2 OFF TYPICAL MALFUNCTION THRESHOLDS P1442 AIR valve bank 1 close stuck When both conditions below are met: Condition 1 and 2 1. When one of following conditions is met: Condition (a), (b), (c) or (d) (a) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 30 kPa - AIR pressure 5 kPa or more (b) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 20 kPa - AIR pressure Less than 5 kPa (c) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 30 kPa - AIR pressure 5 kPa or more ES ES–326 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) When both conditions below are met: Condition (1) or (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 20 kPa - AIR pressure Less than 5 kPa 2. When one of following conditions is met: Condition (a), (b) or (c) (a) AIR pressure change at monitor sequence 1 (for AIR valve bank1) Less than 1 kPa (b) AIR pressure change at monitor sequence 2 (for AIR valve bank1) Less than 1 kPa (c) Cumulative pressure pulsation during monitor sequence 4-1 (for AIR valve bank 1) Less than 15 kPa P1445 AIR valve bank 2 close stuck ES When both conditions below are met: Condition 1 and 2 1. When one of following conditions is met: Condition (a), (b), (c) or (d) (a) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure 1 kPa or more (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 30 kPa - AIR pressure 5 kPa or more (b) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure 1 kPa or more (2) When both conditions below are met: - - Cumulative pressure pulsation Less than 20 kPa - AIR pressure Less than 5 kPa (c) When both conditions below are met: Condition (1) and (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 30 kPa - AIR pressure 5 kPa or more (d) When both conditions below are met: Condition (1) or (2) (1) When both conditions below are met (during AIR ON): - - Cumulative pressure pulsation Less than 15 kPa - AIR pressure Less than 1 kPa (2) When both conditions below are met (during AIR OFF): - - Cumulative pressure pulsation Less than 20 kPa - AIR pressure Less than 5 kPa 2. When one of following conditions is met: Condition (a), (b) or (c) (a) AIR pressure change at monitor sequence 1 (for AIR valve bank2) Less than 1 kPa (b) AIR pressure change at monitor sequence 2 (for AIR valve bank2) Less than 1 kPa (c) Cumulative pressure pulsation during monitor sequence 4-1 (for AIR valve bank 2) Less than 15 kPa P2441 AIR valve close stuck When both conditions below are met (during AIR ON) Condition 1 and 2 ES–327 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. Cumulative pressure pulsation Less than 15 kPa 2. AIR pressure 1 kPa or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO SECONDARY AIR INJECTION SYSTEM DTCS) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to "P1442 and/or P1445" and P2441 A P1442 and/or P1445 B "P1442 and/or P1445 and/or P2441" and other DTCs C HINT: If any DTCs other than P1441 and/or P1444 and P2440 are output, troubleshoot those DTCs first. B C A Go to step 5 GO TO DTC CHART ES ES–328 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK VACUUM HOSES (THROTTLE BODY - VSV FOR AIR INJECTION SYSTEM) (a) Check that the vacuum hoses between the throttle body and VSV for air injection system are securely connected. OK: The vacuum hoses are securely connected. (b) Inspect the vacuum hoses for blockages and damage. OK: The vacuum hoses have no blockages and damage. A121722 ES NG REPAIR OR REPLACE VACUUM HOSES OK 3 CHECK PIPES AND HOSES (CONNECTION OF AIR INJECTION SYSTEM) G032737E01 (a) Remove the intake manifold (See page ES-501). (b) Check all pipes and hoses of the air injection system. OK: All air injection pipes and hoses are securely connected. (c) Check all pipes and hoses of the air injection system for blockage or damage. OK: All air injection pipes or hoses have no blockages or damage. NG REPAIR OR REPLACE AIR INJECTION SYSTEM PIPING AND HOSES OK 4 CHECK AIR SWITCHING VALVE (OPERATION) (a) Remove the intake manifold (See page ES-501). (b) Remove the Air Switching Valve (ASV). (c) Blow air into port A and check that air is not discharged from port B. OK: Not discharged Air Port A Port B G032728E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–329 (d) Apply battery positive voltage across the terminals. (e) Blow air into port A and check that air is discharged from port B. OK: Discharged Port B Air Battery NG Port A REPLACE AIR SWITCHING VALVE AND GO TO STEP 6 G032729E02 OK 5 CHECK NO. 2 AIR SWITCHING VALVE (OPERATION) (a) (b) (c) (d) A116419 Start the engine and warm it up. Turn the ignition switch OFF. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and push the intelligent tester main switch ON. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL / OPERATION 5 and 6. HINT: OPERATION 5: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: CLOSE OPERATION 6: AP: ON; EASV: OPEN; ASV1: CLOSE; ASV2: OPEN NOTICE: • This test only allows technicians to operate the AIR system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. (f) Read values of the A/F BANK1 and BANK2 on the intelligent tester. Result Air switching valve No. 2 operation Air fuel ratio Open 18 or more Closed Approximately 14.5 ES ES–330 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • When the No. 2 ASV operates normally, the A/F value is 18 or more when the valve is open, and approximately 14.5 when the valve is closed. • Perform the following procedures only on the bank of which the valve is not open. NEXT 6 CHECK VSV (FOR AIR INJECTION SYSTEM) Port A ES A121723E01 (a) Turn the ignition switch OFF. (b) Disconnect the vacuum hoses from the VSV for the air injection system. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Start the engine and turn the tester ON. (e) When the air switching valve is operated using the intelligent tester, check that negative pressure from port A. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL / OPERATION 2. HINT: OPERATION 2: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: OPEN NOTICE: • This test only allows technicians to operate the AIR system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. OK: Negative pressure from port A (g) Reconnect the vacuum hose. NG OK Go to step 10 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 ES–331 CHECK VACUUM HOSES (AIR SWITCHING VALVE - VSV FOR AIR INJECTION SYSTEM) (a) Check that the vacuum hoses between the No. 2 air switching valve(s) and VSV for the air injection system are securely connected. OK: The vacuum hose(s) are securely connected. (b) Check the vacuum hoses for blockages and damage. OK: The vacuum hoses have no blockages and damage. A121724 NG REPAIR OR REPLACE VACUUM HOSES ES OK 8 CHECK NO. 2 AIR SWITCHING VALVE (OPERATION) (a) Remove the No. 2 air switching valve. Port A Port C Air Port B G032732E01 (b) Blow air into port B and check that air is not discharged from port C. OK: Not discharged from port C (c) Apply vacuum 30 kPa (225 mmHg) to port A, blow air into port B and check that air is discharged from port C. OK: Discharged from port C Port A Port B Air OK Port C G032733E01 NG REPLACE NO. 2 AIR SWITCHING VALVE ES–332 9 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR INJECTION PIPE (NO. 2 AIR SWITCHING VALVE - EXHAUST MANIFOLD) (a) Check that the air injection pipe between the No. 2 air switching valve(s) and exhaust manifold are securely connected. OK: The air injection pipe is securely connected. (b) Check the air injection pipe for blockages and damage. OK: The air injection pipe has no blockages and damage. G032739E01 ES NG REPAIR OR REPLACE AIR INJECTION PIPE OK CHECK FOR INTERMITTENT PROBLEMS 10 CHECK VSV (FOR AIR INJECTION SYSTEM) (a) Disconnect the 2 vacuum hoses. (b) Disconnect the VSV for the air injection system connector. (c) Blow air into port B. Check that air does not flow from port A. OK: Air does not flow from port A (d) Apply battery positive voltage across the terminals. Then blow air into port B and check that air flows from port A. OK: Air flows from port A A Air NG A Air A138067E01 OK REPLACE ECM REPLACE VSV 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1613 ES–333 Secondary Air Injection Driver Malfunction DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. DTC Detection Condition Trouble Area P1613 Either of following condition (a) or (b) is met: (a) Both of following conditions are met (1 trip detection logic): – While either of air pump or air switching valve does not operate – Air injection control driver outputs normal signal (80 % duty signal) (b) Following condition is met (1 trip detection logic): – Air injection control driver outputs abnormal duty signal (duty signal excluding 0, 20, 40, 60, 80, 100 %) P1613 Both of following conditions are met (1 trip detection logic): (a) While air injection system operating (Air pump ON and all ASV ON) (b) Air injection control driver outputs air pump malfunction signal (0 % duty signal) P1613 Air injection control driver outputs abnormal duty signal (100 % duty signal) (1 trip detection logic) • • Air injection control driver (AID) Open in air injection control driver ground circuit • • • • • Short in diagnostic information signal circuit (AID - ECM) Open or short in air pump and air switching valve command signal circuit (AID - ECM) Air injection control driver (AID) Open in air injection control driver ground circuit ECM • • • • Open or short in AID power source circuit Open in diagnostic information signal circuit (AID - ECM) Air injection control driver (AID) ECM MONITOR DESCRIPTION When the air injection system operation is required while the engine is warming up, the ECM transmits command signals to the Air Injection Control Driver (AID) to drive the air pump and Air Switching Valve (ASV). AID detects an open and short in the air pump and air switching valve circuit according to the terminal voltage and sends a signal as the diagnostic information to the ECM. If the air injection system drive circuit or the AID itself has a malfunction, the AID sends a malfunction signal (duty signal) as a diagnostic information signal to the ECM (when the system is normal, a system normal signal is sent). The ECM sets the DTC based on the diagnostic information from the AID. Example: 1. The duty ratio of the diagnostic information signal output from AID is 0 or 100 % (remains at 0 V or battery voltage). 2. The duty ratio of the diagnostic signal from the AID shows an impossible ratio (other than 0, 20, 40, 60, 80, 100 %). 3. The AID outputs the normal signal (normal duty signal: 80 %) while the system is not operating. MONITOR STRATEGY Related DTCs P1613: Secondary air injection system control module range check Required sensors/components Air injection control driver Frequency of operation Continuous Duration 3 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present None ES ES–334 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 1: Battery voltage 8 V or more Ignition switch ON Starter OFF Case 2: Either of following conditions is met Condition 1 or 2 1. Air pump Not operating 2. Air switching valve Not operating Battery voltage 8 V or more Ignition switch ON Starter OFF Case 3: ES Air pump Operating Air switching valve Operating Battery voltage 8 V or more Ignition switch ON Starter OFF Case 4: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: One of the following conditions is met Condition 1, 2, 3 or 4 1. Diagnostic signal duty ratio from air injection control driver 1 to 10 % 2. Diagnostic signal duty ratio from air injection control driver 30 % 3. Diagnostic signal duty ratio from air injection control driver 49 % 4. Diagnostic signal duty ratio from air injection control driver 91 to 99 % Case 2: Diagnostic signal duty ratio from air injection control driver 70 to 90 % Case 3: Diagnostic signal duty ratio from air injection control driver 0% Case 4: Diagnostic signal duty ratio from air injection control driver 100 % COMPONENT OPERATING RANGE Diagnostic signal duty ratio from air injection control driver WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). 70 to 90 % when secondary air injection system is operating and 0 % when secondary air injection system is not operating 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–335 INSPECTION PROCEDURE HINT: The diagnostic information output from the Air Injection Control Driver (AID) can be confirmed by connecting an oscilloscope to the diagnostic information terminal of the AID. A trouble area search can be narrowed by reading the waveform on the oscilloscope when performing the AIR system intrusive operation function provided in the SYSTEM CHECK. 1. Start the engine and warm it up. 2. Turn the ignition switch OFF. 3. Connect the intelligent tester to the DLC3 with CAN VIM. 4. Connect an oscilloscope probe to the AIDI terminal of the ECM. ECM Connector ES E1 AIDI G035614E71 5. Start the engine and turn the tester ON. 6. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ SYSTEM. 7. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL / OPERATION 1 and 2. AIR INJ CHECK AIR PUMP ON EASV OPEN ASV1 OPEN ASV2 OPEN A/F BANK1 19.05 A/F BANK2 19.05 PRESSURE 17kPa-g PULSATION 25.39kPa-g AI STATUS OK Remaining Time 05 sec. Press [EXIT] to quit A133735 HINT: OPERATION 1: AP: OFF; EASV: CLOSE; ASV1: CLOSE; ASV2: OFF OPERATION 2: AP: ON; EASV: OPEN; ASV1: OPEN; ASV2: OPEN ES–336 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8. Monitor the voltage output of the AID (duty ratio signal). Example: 80% Duty Signal 5 V/DIV. GND 20 msec./DIV. ES A116420E03 Oscilloscope range Item Content Terminal CH1: AIDI - E1 Equipment Setting 5 V/DIV., 20 to 40 msec./DIV. Condition Idling NOTICE: • This AIR INJECTION CHECK only allows technicians to operate the AIR system for 5 seconds. Furthermore, the check can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between checks. While the AIR system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • Performing the AIR INJ CHECK over and over again may cause damage in the secondary air injection system. If necessary, wait several minutes between tests to prevent overheating the system. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. AID Diagnostic Signal Waveform ECM Command DTC (ECM Output) Suspected Trouble Area • • 100 % Duty Ratio See waveform 1 Any Air Injection (AIR) System operation P1613 • • • 0 % Duty Ratio See waveform 2 AIR System: ON (Air pump ON, ASV ON) P1613 • • • • AIR System: OFF (Air pump OFF, ASV OFF) - Open in diagnostic signal circuit Air Injection Control Driver (AID) Open in AID +B circuit (AID power source) Short between +B circuit and diagnostic signal circuit Open or short in air pump or Air Switching Valve (ASV) command signal circuit (ECM - AID) Open in AID ground circuit Short between diagnostic signal circuit and body ground AID ECM Normal ES–337 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM AID Diagnostic Signal Waveform DTC (ECM Output) ECM Command Suspected Trouble Area • • Air Pump: ON P0418 • • • 20 % Duty Ratio See waveform 3 • Air Pump: OFF P0418 • • • • • • ASV: ON P0412 • • • 40 % Duty Ratio See waveform 4 • ASV: OFF 80 % Duty Ratio See waveform 5 Excluding Above (excluding 0, 20, 40, 80, 100 % duty) P0412 Short between air pump drive circuit and body ground Harness & connector (AID Pump) Air Pump AID ECM Open in air pump drive circuit (AID - Pump), or short between air pump drive circuit and +B Harness & connector (AID Pump) Air Pump AID ECM Short between ASV drive circuit and body ground Harness & connector (AID ASV) ASV AID ECM • • • Open in ASV drive circuit (AID - ASV), or short between ASV drive circuit and +B Harness & connector (AID ASV) AID ASV ECM AID ECM • AIR System: OFF (Air pump OFF, ASV OFF) P1613 • • AIR System: ON (Air pump ON, ASV ON) - Normal - P1613 • • 1. Almost Same as Battery Voltage +B GND A112066E01 Waveform 1 100 % Duty Ratio AID Open in AID ground circuit ES ES–338 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. Waveform 2 0 % Duty Ratio 3. Waveform 3 20 % Duty Ratio 4. Waveform 4 40 % Duty Ratio 5. Waveform 5 80 % Duty Ratio +B Fixed at Low Voltage GND A112067E01 20% ES +B GND A112068E01 40% +B GND A112069E01 80% +B GND A112070E01 HINT: • Using the AIR INJ CHECK operation of the SYSTEM CHECK provided in the intelligent tester function, conditions for air fuel ratio and pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. It helps technicians to troubleshoot the system when it is malfunctioning. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–339 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P1613) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P1613 A P1613 and other DTCs B HINT: If any DTCs other than P1613 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (AIDI VOLTAGE) (a) (b) (c) (d) (e) (f) E8 AIDI E118165E02 Results Suspected Trouble Areas • • Fixed at Low (1.6 V or less) even when AIR system ON (Air pump ON, ASV ON) Start the engine and warm it up. Turn the ignition switch OFF. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Start the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / AUTOMATIC. NOTICE: • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. (g) Measure the voltage between AIDI terminal of the ECM connector and body ground when the air injection system is ON and OFF. Result • • • • • Short between air pump or air switching valve command signal circuit and body ground Open in air pump command signal circuit (between ECM and AID) Open in ASV command signal circuit (between ECM and AID) Open in AID ground circuit (between AID and body ground) Diagnostic signal circuit ground short AID ECM Proceed to A ES ES–340 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Results Suspected Trouble Areas • ES Fixed at High (12 V or more) even when AIR system OFF (Air pump OFF, ASV OFF) • Other than above: • Fluctuating (duty signal excluding 20, 40, 80 %) • • • • • Proceed to Open in diagnostic signal circuit (ECM AID) Short between +B circuit and diagnostic signal circuit (ECM - AID) Open in AID power source circuit AID ECM B AID Open in AID ground circuit (between AID and body ground) C B Go to step 5 C Go to step 8 A 3 INSPECT ECM (AIRP AND AIRV VOLTAGE) AIRV (a) Turn the ignition switch ON. (b) Measure the voltage between terminal E8-25 (AIRP), E8-4 (AIRV) of the ECM connector and body ground. Standard voltage E8 Tester Connection AIRP (E8-25) - Body ground 10 V or more AIRV (E8-4) - Body ground 10 V or more AIRP E118166E02 OK Specified Condition NG REPLACE ECM ES–341 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER, AIR INJECTION CONTROL DRIVER - BODY GROUND) Wire Harness Side Air Injection Control Driver Connector (a) Disconnect the A44 air injection driver connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance A44 E DI SIV SIP Specified Condition 10 kΩ or higher SIV (A44-3) or AIRV (E8-4) - Body ground 10 kΩ or higher E (A44-1) - Body ground Below 1 Ω (d) Measure the voltage between terminals DI (A44-2) and E(A44-1) of the air injection driver wire harness side connectors. Standard voltage E8 AIRV AIRP Tester Connection SIP (A44-4) or AIRP (E8-25) - Body ground A121714E02 Tester Connection Specified Condition DI (A44-2) - E (A44-1) 9 V or more (e) Reconnect air injection driver connector. (f) Reconnect ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE AIR INJECTION CONTROL DRIVER 5 CHECK POWER SOURCE OF AIR INJECTION CONTROL DRIVER (a) Disconnect the A44 Air Injection Control Driver (AID) connector. (b) Turn the ignition switch ON. (c) Measure the voltage between the terminal +B (A44-5) and E (A44-1) of the AID connector. Standard voltage Wire Harness Side A44 E +B AID Connector G032721E23 OK NG Tester Connection Specified Condition +B (A44-5) - E (A44-1) 10 V or more REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–342 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT AIR INJECTION CONTROL DRIVER (DI TERMINAL VOLTAGE) (a) Disconnect the A44 AID connector. (b) Turn the ignition switch ON. (c) Measure the voltage between the terminal A44-2 (DI) of the AID connector and body ground. Standard voltage Wire Harness Side A44 DI Tester Connection Specified Condition DI (A44-2) - Body ground 10 V or more (d) Reconnect the AID connector. AID Connector G032721E24 OK ES REPLACE AIR INJECTION CONTROL DRIVER NG 7 CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER) Wire Harness Side Air Injection Control Driver Connector (a) Disconnect the A44 air injection driver connector. (b) Disconnect the E8 ECM connector. (c) Check the resistance between the wire harness side connectors. Standard resistance A44 DI +B AIDI A121715E02 REPLACE ECM Specified Condition Below 1 Ω DI (A44-2) or AIDI (E8-13) - +B (A44-5) 10 kΩ or higher NG E8 OK Tester Connection DI (A44-2) - AIDI (E8-13) REPAIR OR REPLACE HARNESS OR CONNECTOR ES–343 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 CHECK HARNESS AND CONNECTOR (AIR INJECTION DRIVER - BODY GROUND) (a) Disconnect the A44 AID connector. (b) Measure the resistance between the terminal E (A44-1) of the AID connector and body ground. Standard resistance Wire Harness Side A44 E Tester Connection Specified Condition E (A44-1) - Body ground Below 1 Ω (c) Reconnect the AID connector. AID Connector G032721E25 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES OK 9 REPLACE AIR INJECTION CONTROL DRIVER (a) Replace the AID. NEXT 10 CHECK WHETHER DTC OUTPUT RECURS (DTC P1613) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear the DTCs (See page ES-35). Start the engine. Perform ACTIVE TEST to operate the air injection system. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / AUTOMATIC. After operating the secondary air injection system, confirm the pending codes of the secondary air injection system by entering the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. NOTICE: • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. OK: DTC P1613 for the secondary air injection system is not output. NG GO TO DTC CHART ES–344 OK END ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–345 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2102 Throttle Actuator Control Motor Circuit Low DTC P2103 Throttle Actuator Control Motor Circuit High DESCRIPTION The throttle actuator is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM. This feedback allows the ECM to control the throttle actuator and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Conditions Trouble Areas P2102 Following conditions are met for 2 seconds (1 trip detection logic): • Throttle actuator duty-cycle is 80% or more • Throttle actuator current is below 0.5 A or less • • • Open in throttle actuator circuit Throttle actuator ECM P2103 Either of the following condition is met: • Hybrid IC diagnosis signal fail • Hybrid IC current limiter port fail • • • • • Short in throttle actuator circuit Throttle actuator Throttle valve Throttle bod ECM MONITOR DESCRIPTION The ECM monitors the flow of electrical current through the electronic throttle actuator, and detects malfunctions or open circuits in the throttle actuator based on the value of the electrical current. When the current deviates from the standard values, the ECM concludes that there is a fault in the throttle actuator. Or, if the throttle valve is not functioning properly (for example, stuck ON), the ECM concludes that there is a fault and illuminates the MIL and sets a DTC. Example: The ECM determines that the current has deviated from the standard values when one of the following is detected: 1) the current is more than 10 A, or 2) the actuator driving duty ratio exceeds 80% and the current is less than 0.5 A. Then the ECM turns on the MIL and a DTC is set. MONITOR STRATEGY Related DTCs P2102: Throttle actuator current (low current) P2103: Throttle actuator current (high current) Required Sensors/Components (Main) Throttle actuator (throttle body) Required Sensors/Components (Related) None Frequency of Operation Continuous Duration 2 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None P2102: Throttle actuator ON Duty ratio to open throttle actuator 80 % or more Throttle power supply 8 V or more Motor current change during latest 0.016 seconds Less than 0.2 A ES ES–346 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2103: Throttle actuator ON Either of the following conditions is met: Condition 1 or 2 1. Throttle actuator power supply 8 V or more 2. Throttle actuator power ON Battery voltage 8 V or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current Less than 0.5 A (when motor drive duty 80 % or more) P2103: ES When either condition below is met: Condition 1 or 2 1. Hybrid IC diagnosis signal Fail 2. Hybrid IC current limiter port Fail FAIL-SAFE When any of these DTCs, as well as other DTCs relating to Electronic Throttle Control System (ETCS) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 7° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned OFF. WIRING DIAGRAM Refer to DTC P0120 (See page ES-122). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT THROTTLE BODY ASSEMBLY (RESISTANCE OF THROTTLE ACTUATOR) (a) Disconnect the T2 throttle body assembly connector. (b) Measure the resistance of the throttle actuator. Standard resistance Component Side Throttle Actuator T2 NG M+ MA059778E37 Tester Connection Specified Condition M+ (T2-2) - M- (T2-1) 0.3 to 100 Ω at 20°C (68°F) REPLACE THROTTLE BODY ASSEMBLY ES–347 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 2 CHECK HARNESS AND CONNECTOR (THROTTLE ACTUATOR - ECM) Wire Harness Side Throttle Body Assembly Connector (a) Disconnect the T2 throttle body assembly connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection T2 M+ (T2-2) - M+ (E4-5) M- (T2-1) - M- (E4-4) M- E4 Front View M+ M+ (T2-2) or M+ (E4-5) - Body ground M- (T2-1) or M- (E4-4) - Body ground M- Below 1 Ω 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the throttle body assembly connector. ECM Connector NG M+ Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR A115716E02 OK 3 INSPECT THROTTLE BODY ASSEMBLY (VISUALLY CHECK THROTTLE VALVE) (a) Check between the throttle valve and the housing for foreign objects. Also check if the valve can open and close smoothly. OK: The throttle valve is not contaminated by foreign objects and can move smoothly. NG OK REPLACE ECM REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY ES ES–348 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2111 Throttle Actuator Control System - Stuck Open DTC P2112 Throttle Actuator Control System - Stuck Closed DESCRIPTION The throttle actuator is operated by the ECM, and it opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM to control the throttle actuator and set the throttle valve angle in response to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. ES DTC Detection Conditions Trouble Areas P2111 ECM tries to close throttle valve but throttle position is stuck (1 trip detection logic) • • • Throttle actuator Throttle body Throttle valve P2112 ECM tries to open throttle valve but throttle position is stuck (1 trip detection logic) • • • Throttle actuator Throttle body Throttle valve MONITOR DESCRIPTION The ECM determines that there is a malfunction in the ETCS when the throttle valve remains at a fixed angle despite a high drive current from the ECM. The ECM illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required Sensors/Components (Main) Throttle actuator motor Required Sensors/Components (Related) Throttle position sensor Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS All: Monitor will run whenever these DTCs are not present None P2111: System guard* ON Throttle actuator current 2 A or more Duty cycle to close throttle 80 % or more *: System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined ES–349 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2112: System guard* ON Throttle actuator current 2 A or more Duty cycle to open throttle 80 % or more *: System guard is ON when the following conditions are met - Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or more Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS TP sensor voltage change ES No change FAIL-SAFE When any of these DTCs, as well as other DTCs relating to Electronic Throttle Control System (ETCS) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 7°throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned OFF. WIRING DIAGRAM Refer to DTC P2102 (See page ES-341). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2111 OR P2112) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B ES–350 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If any DTCs other than P2111 or P2112 are output, troubleshoot those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK THROTTLE BODY (VISUALLY CHECK THROTTLE VALVE) (a) Check for foreign matter between the throttle valve and housing. If necessary, clean the throttle body. Also, check that the throttle valve moves smoothly. OK: No foreign matter between the throttle valve and the housing, and throttle valve can move smoothly. ES NG REPLACE THROTTLE BODY OK 3 CHECK WHETHER DTC OUTPUT RECURS (DTC P2111 OR P2112) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Clear the DTC (See page ES-35). (d) Start the engine, and depress and release the accelerator pedal quickly (fully open and close the throttle valve). (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (f) Read DTC. Result Display (DTC Output) Proceed to No DTC A P2111 and/or P2112 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–351 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2118 Throttle Actuator Control Motor Current Range / Performance DESCRIPTION The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is monitored and when the voltage is low (less than 4 V), the ECM concludes that the ETCS has a fault and current to the throttle actuator is cut. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the throttle actuator is cut. If repairs are made and the system has returned to normal, turn the ignition switch OFF. The ECM then allows current to flow to the throttle actuator so that the engine can be restarted. HINT: The ETCS does not use a throttle cable. ES ECM ETCS From Battery +BM +M Throttle Actuator Control Circuit -M Throttle Actuator ME01 A115751E01 DTC No. P2118 DTC Detection Condition Open in ETCS power source (+BM) circuit (1 trip detection logic) Trouble Area • • • Open in ETCS power source circuit ETCS fuse ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the electronic throttle motor +BM. When the power supply voltage drops below the threshold, the ECM concludes that the power supply has an open circuit. The MIL is turned on and a DTC is set. MONITOR STRATEGY Related DTCs P2118: Throttle actuator power supply Required Sensors/Components Throttle actuator, throttle valve, ETCS fuse Frequency of Operation Continuous Duration 0.8 seconds MIL Operation Immediate ES–352 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present None Battery voltage 8 V or more Actuator power ON TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage (+BM) Less than 4 V COMPONENT OPERATING RANGE ES Throttle actuator power supply voltage 9 to 14 V FAIL-SAFE When any of these DTCs, as well as other DTCs relating to Electronic Throttle Control System (ETCS) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 16° throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned OFF. WIRING DIAGRAM ECM GR 2 2 13 IC4 GR 7 +BM E8 Engine Room R/B ETCS 1 2 B Battery A074728E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–353 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 INSPECT FUSE (ETCS) Engine Room R/B: ETCS Fuse (a) Remove the ETCS fuse from the engine room relay block. (b) Measure the resistance of the ETCS fuse. Standard resistance: Below 1 Ω (c) Reinstall the ETCS fuse. NG REPLACE FUSE A072882E03 OK 2 READ VALUE OF INTELLIGENT TESTER (+BM VOLTAGE) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / +BM. Standard voltage: 9 to 14 V OK NG CHECK FOR INTERMITTENT PROBLEMS ES ES–354 3 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) Engine Room R/B: ETCS Fuse ES E8 (a) Remove the ETCS fuse from the engine room relay block. (b) Disconnect the E8 ECM connector. (c) Measure the resistance of the wire harness side connector between the ETCS fuse and ECM. Standard resistance Tester Connection Specified Condition Engine Room R/B (ETCS fuse terminal 2) - +BM (E8-7) Below 1 Ω Engine Room R/B (ETCS fuse terminal 2) or +BM (E8-7) - Body ground 10 kΩ or higher (d) Disconnect the battery positive terminal. (e) Measure the resistance of the wire harness side connector between the ETCS fuse and battery. Standard resistance +BM A139336E01 Tester Connection Specified Condition Engine Room R/B (ECTS fuse terminal 1) - Battery positive terminal Below 1 Ω Engine Room R/B (ETCS fuse terminal 1) or Battery positive terminal - Body ground 10 kΩ or higher (f) Reconnect the ECM connector. (g) Reinstall the ETCS fuse. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR ES–355 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC Throttle Actuator Control Throttle Body Range / Performance P2119 DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of the throttle actuator that operates the throttle valve, the throttle position sensor that detects the opening angle of the throttle valve, the accelerator pedal position sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system. The ECM operates the throttle actuator to position the throttle valve for proper response to driver inputs. The throttle position sensor detects the opening angle of the throttle valve and provides this signal to the ECM so that the ECM can regulate the throttle actuator. DTC No. P2119 DTC Detection Condition Trouble Area Throttle opening angle continues to vary greatly from target throttle opening angle (1 trip detection logic) • • ETCS ECM MONITOR DESCRIPTION The ECM determines the "actual" throttle angle based on the throttle position sensor signal. The "actual" throttle position is compared to the "target" throttle position commanded by the ECM. If the difference of these 2 values exceeds a specified limit, the ECM interprets this as a fault in the ETCS system. The ECM turns on the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P2119: ETCS malfunction Required Sensors/Components (Main) Throttle actuator motor Required Sensors/Components (Related) Throttle position sensor Frequency of Operation Continuous Duration 1 second MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever following DTCs are not present None System guard* ON *System guard is ON when the following conditions set - Throttle actuator ON Throttle actuator duty calculation Executing TP sensor Fail determined Throttle actuator current-cut operation Not executing Throttle actuator power supply 4 V or higher Throttle actuator Fail determined TYPICAL MALFUNCTION THRESHOLDS Either of following conditions A or B is met Condition 1 or 2 1. Commanded closed TP - current closed TP 0.3 V or more 2. Commanded open TP - current open TP 0.3 V or more ES ES–356 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE When any of these DTCs, as well as other DTCs relating to Electronic Throttle Control System (ETCS) malfunctions, are set, the ECM enters fail-safe mode. During fail-safe mode, the ECM cuts the current to the throttle actuator off, and the throttle valve is returned to a 16°throttle angle by the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing, in accordance with the accelerator pedal opening angle, to allow the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and gently, the vehicle can be driven slowly. Fail-safe mode continues until a pass condition is detected, and the ignition switch is then turned OFF. WIRING DIAGRAM Refer to DTC P2102 (See page ES-341). INSPECTION PROCEDURE ES HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTC OUTPUT (IN ADDITION TO DTC P2119) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P2119 A P2119 and other DTCs B HINT: If any DTCs other than P2119 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 CHECK WHETHER DTC OUTPUT RECURS (DTC P2119) (a) Connect the intelligent tester to the DLC3 with CAN VIM [A]. (b) Turn the ignition switch ON [B]. (c) Turn the tester ON [C]. (d) Clear DTCS [D]. (e) Allow the engine to idle for 15 seconds [E]. NOTICE: Exercise extreme care and take precautions at steps [F] and [G] below. Failure to do so may result in the vehicle unexpectedly rolling away. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–357 (f) Securely apply the parking brake and move the gear selector lever to the D position [F]. (g) While depressing the brake pedal securely, fully depress the accelerator pedal for 5 seconds [G]. (h) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES [H]. (i) Read DTCs [I]. HINT: The output voltage of the throttle position sensor can be checked during step [G] using the intelligent tester. Variations in the output voltage indicate that the throttle actuator is in operation. To check the output voltage using the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / THROTTLE POS #1. OK: No DTC output. NG OK NORMAL REPLACE THROTTLE BODY ES ES–358 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DTC P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation ES HINT: These DTCs relate to the Accelerator Pedal Position (APP) sensor. DESCRIPTION HINT: • This accelerator pedal position sensor is a non - contact type. • This ETCS (Electronic Throttle Control System) does not use a throttle cable. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal bracket and has 2 sensor circuits: VPA1 (main) and VPA2 (sub). The voltage, which is applied to terminals VPA1 and VPA2 of the ECM, varies between 0 V and 5 V in proportion to the operating angle of the accelerator pedal (throttle valve). A signal from VPA1 indicates the actual accelerator pedal opening angle (throttle valve opening angle) and is used for engine control. A signal from VPA2 conveys the status of the VPA1 circuit and is used to check the APP sensor itself. The ECM monitors the actual accelerator pedal opening angle (throttle valve opening angle) through the signals from VPA1 and VPA2, and controls the throttle actuator according to these signals. ES–359 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Accelerator Pedal Position Sensor Magnet Accelerator Pedal Position Sensor Output Voltage (V) ECM *1 IC No.1 *2 VPA EPA 5 3.7 to 4.4 VCPA 2.9 to 3.6 ES VPA2 EPA2 1.6 1.4 VCP2 25 IC No.2 0 Usable Range Accelerator Pedal Turning Angle(deg) Magnet *1 : Accelerator Pedal Fully Released *2 : Accelerator Pedal Fully Depressed A115889E01 DTC No. DTC Detection Condition Trouble Area P2120 Condition (a) continues for 0.5 second or more: (a) VPA is 0.4 V or less when accelerator pedal is fully released, or VPA is 4.8 V or more • • Accelerator Pedal Position (APP) sensor ECM P2122 Condition (a) continues for 0.5 second or more when accelerator pedal is fully released: (a) VPA is 0.4 V or less • • • • APP sensor Open in VCPA circuit Open or ground short in VPA circuit ECM P2123 Condition (a) continues for 2.0 seconds or more: (a) VPA is 4.8 V or more • • • APP sensor Open in EPA circuit ECM P2125 Condition (a) continues for 0.5 second or more: (a) (VPA2 is 1.2 V or less when accelerator pedal is fully released) or (VPA2 is 4.8 V or more and VPA is between 0.4 V and 3.45 V) • • APP sensor ECM P2127 VPA2 1.2 V or less for 0.5 seconds or more when accelerator pedal fully released • • • • APP sensor Open in VCP2 circuit Open or ground short in VPA2 circuit ECM P2128 Conditions (a) and (b) continue for 2.0 seconds or more (a) VPA2 4.8 V or more (b) VPA between 0.4 V and 3.45 V • • • APP sensor Open in EPA2 circuit ECM P2138 Condition (a) or (b) continues for 2.0 seconds or more (a) Difference between VPA and VPA2 0.02 V or less (b) VPA1 0.4 V or less and VPA2 1.2 V or less • • • Short between VPA and VPA2 circuits APP sensor ECM ES–360 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: After confirming DTC P2120, P2122, P2123, P2125, P2127, P2128 and P2138, use the intelligent tester or the OBD II scan tool to confirm the throttle valve opening percentage. Accelerator pedal position expressed as voltage Trouble Area ES Accelerator pedal released Accelerator pedal depressed ACCEL POS #1 ACCEL POS #2 ACCEL POS #1 ACCEL POS #2 VC circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V VPA circuit open or ground short 0 to 0.2 V 1.2 to 2.0 V 0 to 0.2 V 3.4 to 5.3 V VPA2 circuit open or ground short 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V E2 circuit open 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V HINT: • Accelerator pedal positions are expressed as voltages. • AP stands for Accelerator Pedal. MONITOR DESCRIPTION When VPA or VPA2 deviates from the standard, or the difference between the voltage outputs of the two sensors is less than threshold, the ECM concludes that there is a defect in the accelerator pedal position sensor. The ECM turns on the MIL and a DTC is set. Example: When the voltage output of the VPA is below 0.2 V or exceeds 4.8 V. MONITOR STRATEGY Related DTCs P2120: Accelerator Pedal Position (APP) sensor 1 range check (fluctuating) P2122: APP sensor 1 range check (low voltage) P2123: APP sensor 1 range check (high voltage) P2125: APP sensor 2 range check (fluctuating) P2127: APP sensor 2 range check (low voltage) P2128: APP sensor 2 range check (high voltage) P2138: APP sensor range check (correlation) Required Sensors/Components (Main) APP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 2.0 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present None Ignition switch ON Throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS P2120: Either of the following conditions is met: Condition 1 or 2 1. VPA1 voltage when VPA2 voltage is 0.04 V or more 0.4 V or less 2. VPA1 voltage 4.8 V or more P2122: VPA1 voltage when VPA2 voltage is 0.04 V or more 0.4 V or less 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–361 P2123: VPA1 voltage 4.8 V or more P2125: Either of the following conditions is met: Condition 1 or 2 1. VPA2 voltage when VPA1 is 0.04 V or more 1.2 V or less 2. VPA2 voltage when VPA1 is 0.4 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA1 0.04 V or more 1.2 V or less P2128: VPA2 voltage when VPA1 0.4 to 3.45 V 4.8 V or more P2138: Either of following conditions is met: Condition 1 or 2 Condition 1 - Difference between VPA1 and VPA2 voltages 0.02 V or less Condition 2 Condition (a) and (b) (a) VPA1 voltage 0.4 V or less (b) VPA2 voltage 1.2 V or less COMPONENT OPERATING RANGE VPA1 voltage 0.4 to 4.8 V VPA2 voltage 1.2 to 4.8 V Difference between VPA1 and VPA2 voltages More than 0.02 V FAIL-SAFE The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the remaining circuit is used to calculate the accelerator pedal opening to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. If a "pass" condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. ES ES–362 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A24 Accelerator Pedal Position Sensor VPA1 EP1 VCP1 ES VPA2 EP2 VCP2 ECM 6 W-R 34 IC4 W-R 18 VPA E8 5 LG-B 29 IC4 LG-B 20 E8 4 B-Y 26 IC4 B-Y EPA 26 VCPA E8 3 R-B 31 IC4 R-B 19 VPA2 E8 2 V-W 8 IC3 V-W 21 E8 W-L 9 IC3 W-L 1 EPA2 27 VCP2 E8 A152660E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2. (d) Read the values displayed on the tester. Standard voltage Accelerator Pedal Depressed Released FI07052E06 OK NG ACCEL POS #1 ACCEL POS #2 Released 0.5 to 1.1 V 1.5 to 2.9 V Depressed 2.5 to 4.6 V 3.5 to 5.5 V Go to step 5 ES–363 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR ECM) (a) Disconnect the A24 accelerator pedal position sensor connector. (b) Disconnect the E8 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Accelerator Pedal Position Sensor Connector VCP2 VPA1 A24 Front View Tester Connection Specified Condition VPA1 (A24-6) - VPA (E8-18) EP1 (A24-5) - EPA (E8-20) EP2 VCP1 (A24-4) - VCPA (E8-26) EP1 VPA2 ECM Connector Below 1 Ω VPA2 (A24-3) - VPA2 (E8-19) VCP1 EP2 (A24-2) - EPA2 (E8-21) E8 VCP2 (A24-1) - VCP2 (E8-27) Standard resistance (Check for short) VPA2 VPA EPA2 EPA VCP2 VCPA A115719E02 Tester Connection Specified Condition VPA1 (A24-6) or VPA (E8-18) - Body ground EP1 (A24-5) or EPA (E8-20) - Body ground VCP1 (A24-4) or VCPA (E8-26) - Body ground VPA2 (A24-3) or VPA2 (E8-19) - Body ground 10 kΩ or higher EP2 (A24-2) or EPA2 (E8-21) - Body ground VCP2 (A24-1) or VCP2 (E8-27) - Body ground (d) Reconnect the ECM connector. (e) Reconnect the accelerator pedal position sensor connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–364 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) Disconnect the A24 APP sensor connector. (b) Turn the ignition switch ON. (c) Measure the voltage of the E8 ECM connector. Standard voltage Accelerator Pedal Position Sensor Connector Tester Connection Specified Condition VCPA (E8-26) - EPA (E8-20) 4.5 to 5.0 V VCP2 (E8-27) - EPA2 (E8-21) A24 (d) Reconnect the APP sensor connector. NG ES VPA2 E8 REPLACE ECM VPA EPA2 ECM Connector EPA VCP2 VCPA A138089E01 OK 4 REPLACE ACCELERATOR PEDAL ROD ASSEMBLY (a) Replace accelerator pedal rod assembly (See page ES512). NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL POSITION SENSOR DTCS) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear DTCs (See page ES-35). Allow the engine to idle for 15 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. Result Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 or P2138 A No output B B SYSTEM OK 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–365 A REPLACE ECM ES ES–29 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE 2UZ-FE SFI SYSTEM Symptom Engine does not crank (does not start) No initial combustion (does not start) No complete combustion (does not start) Difficult to start (engine cranks normally) Difficult to start (with cold engine) Difficult to start (with hot engine) High engine idle speed (poor idling) Low engine idle speed (poor idling) Rough idling (poor idling) Hunting (poor idling) Hesitation/Poor acceleration (Poor driveability) Engine stalls during A/C operation Suspected Area See page 1. Cranking holding function circuit ES-469 2. Starter ST-12 3. Starter relay ST-19 4. VC output circuit ES-459 1. ECM power source circuit ES-454 2. VC output circuit ES-459 3. Fuel pump control circuit ES-463 4. ECM ES-510 Fuel pump control circuit ES-463 1. Starter signal circuit ES-290 2. Fuel pump control circuit ES-463 3. Compression EM-3 1. Starter signal circuit ES-290 2. Fuel pump control circuit ES-463 1. Starter signal circuit ES-290 2. Fuel pump control circuit ES-463 1. A/C signal circuit (compressor circuit) AC-82 2. ECM power source circuit ES-454 1. A/C signal circuit (compressor circuit) AC-82 2. Fuel pump control circuit ES-463 1. Compression EM-3 2. Fuel pump control circuit ES-463 1. ECM power source circuit ES-454 2. Fuel pump control circuit ES-463 1. ECM power source circuit ES-454 2. A/T faulty - 1. A/C signal circuit (Compressor circuit) AC-82 2. ECM ES-510 Surging (Poor driveability) Fuel pump control circuit ES-463 Unable to refuel/Difficult to refuel ORVR system - Engine stalls soon after starting Fuel pump control circuit ES-463 ES ES–30 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM 1. E4 7 6 5 4 ECM E5 3 2 17 16 15 14 13 12 11 10 9 1 8 7 6 5 4 3 E6 2 19 18 17 16 15 14 13 12 11 10 9 1 8 7 6 5 4 E7 3 2 1 17 16 15 14 13 12 11 10 9 8 6 5 4 E8 3 2 16 15 14 13 12 11 10 9 1 8 7 7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18 34 33 35 34 33 32 31 30 29 28 32 31 35 34 33 32 31 31 30 29 28 32 31 30 29 28 30 29 28 30 29 28 27 26 ES A121603E05 HINT: The standard normal voltage between each pair of ECM terminals is shown in the table below. The appropriate conditions for checking each pair of terminals are also indicated. The result of checks should be compared with the standard normal voltage for that pair of terminals, displayed in the STD Voltage column. The illustration above can be used as a reference to identify the ECM terminal locations. Symbols (Terminal No.) Wiring Color Terminal Description BATT (E8-3) - E1 (E6-1) L - W-B Battery (for measuring the battery voltage and for the ECM memory) Always 9 to 14 V +BM (E8-7) - E1 (E6-1) GR - W-B Power source of throttle motor Always 9 to 14 V IGSW (E8-9) - E1 (E6-1) B-O - W-B +B (E8-1) - E1 (E6-1) +B2 (E8-2) - E1 (E6-1) Condition STD Voltage Ignition switch Ignition switch ON 9 to 14 V B - W-B Power source of ECM Ignition switch ON 9 to 14 V B - W-B Power source of ECM Ignition switch ON 9 to 14 V EFI relay Ignition switch ON 9 to 14 V Power source for sensor (specific voltage) Ignition switch ON 4.5 to 5.5 V Mass air flow meter Idling, shift lever position P or N, A/C switch OFF 0.5 to 3.0 V MREL (E8-8) - E1 (E6-1) W-G - W-B VC (E4-23) - E2 (E4-28) L-R - BR VG (E4-30) - E2G (E4-29) W-R - B-W THA (E4-22) - E2 (E4-28) Y-B - BR Intake air temperature sensor Idling, Intake air temperature 20°C (68°F) 0.5 to 3.4 V THW (E4-21) - E2 (E4-28) R-L - BR Engine coolant temperature sensor Idling, Engine coolant temperature 80°C (176°F) 0.2 to 1.0 V VTA1 (E4-20) - E2 (E4-28) Y - BR Throttle position sensor (for engine control) Ignition switch ON, throttle valve fully closed 0.5 to 1.2 V VTA1 (E4-20) - E2 (E4-28) Y - BR Throttle position sensor (for engine control) Ignition switch ON, throttle valve fully open 3.2 to 4.8 V VTA2 (E4-19) - E2 (E4-28) R-B - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, throttle valve fully open 2.1 to 3.1 V VTA2 (E4-19) - E2 (E4-28) R-B - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, throttle valve fully open 4.5 to 5.5 V ES–31 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Color Terminal Description VPA (E8-18) - EPA (E820) Symbols (Terminal No.) W-R - LG-B Accelerator pedal position sensor (for engine control) Ignition switch ON, throttle valve fully closed Condition STD Voltage 0.5 to 1.1 V VPA (E8-18) - EPA (E820) W-R - LG-B Accelerator pedal position sensor (for engine control) Ignition switch ON, throttle valve fully open 2.6 to 4.5 V VPA2 (E8-19) - EPA2 (E821) R-B - V-W Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, throttle valve fully closed 1.2 to 2.0 V OC1+ (E6-17) - OC1- (E616) P - LG Camshaft timing oil control valve (OCV) Idling Pulse generation (See waveform 3) OC2+ (E6-15) - OC2- (E614) R-W - Y-R Camshaft timing oil control valve (OCV) Idling Pulse generation (See waveform 3) VV1+ (E6-25) - VV1- (E624) Y*1 - L*1 Variable valve timing (VVT) sensor (Bank 1) Idling Pulse generation (See waveform 4) VV2+ (E6-18) - VV2- (E628) R*1 - G*1 Variable valve timing (VVT) sensor (Bank 2) Idling Pulse generation (See waveform 4) M+ (E4-5) - E1 (E6-1) R*1 - W-B Throttle motor Idling Pulse generation (See waveform 7) M- (E4-4) - E1 (E6-1) G*1 - W-B Throttle motor Idling Pulse generation (See waveform 8) A1A+ (E5-22) - E1 (E6-1) Y*1 - W-B A/F sensor Ignition switch ON 3.3 V*2 A1A- (E5-30) - E1 (E6-1) BR*1 - W-B A/F sensor Ignition switch ON 3.0 V*2 A2A+ (E5-23) - E1 (E6-1) P*1 - W-B A/F sensor Ignition switch ON 3.3 V*2 A2A- (E5-31) - E1 (E6-1) L*1 - W-B A/F sensor Ignition switch ON 3.0 V*2 HA1A (E5-2) - E1 (E6-1) R-L - W-B A/F sensor heater Idling HA1A (E5-2) - E1 (E6-1) R-L - W-B A/F sensor heater Ignition switch ON HA2A (E5-1) - E1 (E6-1) B-W - W-B A/F sensor heater Idling HA2A (E5-1) - E1 (E6-1) B-W - W-B A/F sensor heater Ignition switch ON VPA2 (E8-19) - EPA2 (E821) R-B - V-W Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, throttle valve fully open 3.4 to 5.3 V VCPA (E8-26) - EPA (E820) B-Y - LG-B Power source of accelerator pedal position sensor (for VPA) Ignition switch ON 4.5 to 5.5 V VCP2 (E8-27) - EPA2 (E821) W-L - V-W Power source of accelerator pedal position sensor (for VPA2) Ignition switch ON 4.5 to 5.5 V OX1B (E4-18) - E1 (E6-1) B*1 - W-B Heated oxygen sensor Maintain engine speed at 2,500 rpm for 2 minutes after warming up Heated oxygen sensor heater Idling Heated oxygen sensor heater Ignition switch ON 9 to 14 V Injector Ignition switch ON 9 to 14 V OX2B (E5-33) - E1 (E6-1) W*1 - W-B HT1B (E4-1) - E1 (E6-1) G-Y - W-B HT2B (E5-5) - E1 (E6-1) P - W-B HT1B (E4-1) - E1 (E6-1) G-Y - W-B HT2B (E5-5) - E1 (E6-1) P - W-B #10 (E6-2) - E01 (E4-7) R-L - W-B #20 (E6-3) - E01 (E4-7) L - W-B #30 (E6-4) - E01 (E4-7) W - W-B #40 (E6-5) - E01 (E4-7) Y - W-B #50 (E6-6) - E01 (E4-7) G - W-B #60 (E6-7) - E01 (E4-7) R - W-B #70 (E4-3) - E01 (E4-7) W - W-B #80 (E4-2) - E01 (E4-7) BR - W-B Below 3.0 V 9 to 14 V Below 3.0 V 9 to 14 V Pulse generation (See waveform 10) Below 3.0 V ES ES–32 Symbols (Terminal No.) #10 (E6-2) - E01 (E4-7) ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Wiring Color Terminal Description Condition STD Voltage R-L - W-B #20 (E6-3) - E01 (E4-7) L - W-B #30 (E6-4) - E01 (E4-7) W - W-B #40 (E6-5) - E01 (E4-7) Y - W-B #50 (E6-6) - E01 (E4-7) G - W-B Injector Idling Pulse generation (See waveform 1) #60 (E6-7) - E01 (E4-7) R - W-B #70 (E4-3) - E01 (E4-7) W - W-B #80 (E4-2) - E01 (E4-7) BR - W-B KNK1 (E5-29) - EKNK (E5-28) G*1 - R*1 Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (See waveform 2) KNK2 (E5-21) - EKN2 (E520) W*1 - B*1 Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (See waveform 2) G2+ (E6-19) - G2- (E6-29) B-W Camshaft position sensor Idling Pulse generation (See waveform 5) NE+ (E6-21) - NE- (E6-20) L*1 - Y*1 Crankshaft position sensor Idling Pulse generation (See waveform 5) PRG (E4-34) - E1 (E6-1) Y-R - W-B VSV for EVAP Ignition switch ON SPD (E7-8) - E1 (E6-1) V-R - W-B Speed signal from combination meter Ignition switch ON, Rotate driving wheel slowly G-R - W-B Fuel pump relay Ignition switch ON 0 to 3.0 V Fuel pump control Ignition switch ON 9 to 14 V Ignition coil with igniter (ignition signal) Idling Ignition coil with igniter (ignition confirmation signal) Ignition switch ON Idling FPR (E6-30) - E1 (E6-1) FC (E8-10) - E1 (E6-1) GR-B - W-B 9 to 14 V Pulse generation (See waveform 6) IGT1 (E4-8) - E1 (E6-1) LG - W-B IGT2 (E4-15) - E1 (E6-1) LG-B - W-B IGT3 (E4-11) - E1 (E6-1) L-W - W-B IGT4 (E4-10) - E1 (E6-1) L-Y - W-B IGT5 (E4-13) - E1 (E6-1) B-L - W-B IGT6 (E4-12) - E1 (E6-1) G - W-B IGT7 (E4-14) - E1 (E6-1) G-W - W-B IGT8 (E4-9) - E1 (E6-1) G-B - W-B IGF1 (E4-24) - E1 (E6-1) R-Y - W-B IGF2 (E4-25) - E1 (E6-1) R-W - W-B IGF1 (E4-24) - E1 (E6-1) R-Y - W-B IGF2 (E4-25) - E1 (E6-1) R-W - W-B Ignition coil with igniter (ignition confirmation signal) STP (E8-15) - E1 (E6-1) G-Y - W-B Stop light switch Brake pedal depressed 7.5 to 14 V STP (E8-15) - E1 (E6-1) G-Y - W-B Stop light switch Brake pedal released Below 1.5 V ST1- (E8-16) - E1 (E6-1) R-L - W-B Stop light switch (opposite to STP terminal) Ignition switch ON, Brake pedal depressed Below 1.5 V ST1- (E8-16) - E1 (E6-1) R-L - W-B Stop light switch (opposite to STP terminal) Ignition switch ON, Brake pedal released 7.5 to 14 V STAR/NSW (E5-8) - E1 (E6-1) P - W-B Park/Neutral position switch Ignition switch ON, Shift lever position other than P and N 9 to 14 V STAR/NSW (E5-8) - E1 (E6-1) P - W-B Park/Neutral position switch Ignition switch ON, Shift lever position in P, N Below 3.0 V Pulse generation (See waveform 9) 4.5 to 5.5 V Pulse generation (See waveform 9) W (E7-30) - E1 (E6-1) R-B - W-B MIL Idling W (E7-30) - E1 (E6-1) R-B - W-B MIL Ignition switch ON Below 3.0 V 9 to 14 V ELS1 (E7-13) - E1 (E6-1) G - W-B Electric load Taillight switch ON, Defogger switch ON 7.5 to 14 V ELS2 (E7-12) - E1 (E6-1) Y-G - W-B Electric load Taillight switch OFF, Defogger switch OFF 0 to 1.5 V TACH (E7-1) - E1 (E6-1) B-W - W-B Engine speed Idling TC (E8-23) - E1 (E6-1) P-L - W-B Terminal TC of DLC3 Ignition switch ON Pulse generation (See waveform 11) 9 to 14 V ES–33 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage STA (E6-11) - E1 (E6-1) B-Y - W-B Starter signal Cranking STA (E6-11) - E1 (E6-1) B-Y - W-B Park/neutral position switch Shift lever position P or N, Ignition switch START 9 to 14 V STSW (E6-12) - E1 (E6-1) L-Y - W-B STA No. 2 fuse Shift lever position P or N, Ignition switch START 9 to 14 V VPMP (E8-5) - E1 (E6-1) R-G - W-B Canister closed valve Ignition switch ON 9 V to 14 V MPMP (E8-6) - E1 (E6-1) O - W-B Leak detection pump Vacuum pump OFF 0 V to 3 V MPMP (E8-6) - E1 (E6-1) O - W-B Leak detection pump Vacuum pump ON 9 V to 14 V PPMP (E8-22) - E1 (E6-1) R - W-B Vapor pressure sensor Ignition switch ON 3 V to 3.6 V AIV1 (E4-27) - E1 (E6-1) P - W-B VSV for air injection control (Bank 1) Ignition switch ON 9 to 14 V AIV2 (E4-26) - E1 (E6-1) L - W-B VSV for air injection control (Bank 2) Ignition switch ON 9 to 14 V AIRV (E8-4) - E1 (E6-1) Y - W-B AI driver (ASV control signal) Ignition switch ON 9 to 14 V G - W-B AI driver (Air pump control signal) Ignition switch ON 9 to 14 V Air pressure sensor Ignition switch ON 3 V to 3.6 V AIRP (E8-25) - E1 (E6-1) AIP (E4-32) - E1 (E6-1) W-L - W-B 6 V or higher HINT: • *1: Shielded • *2: The ECM terminal voltage is constant regardless of the output voltage from the sensor. (a) WAVEFORM 1 Fuel injector 20 V/DIV. ECM Terminal Names Between #10 (to #40) and E01 Tester Range 20 V/DIV., 20 msec./DIV. Condition Idling HINT: The wavelength becomes shorter as engine rpm increases. Ground 20 msec./DIV. A093279E06 (b) WAVEFORM 2 Knock sensor 1 V/DIV. GND 1 msec./DIV. A085286E15 ECM Terminal Name Between KNK1 and EKNK Between KNK2 and EKN2 Tester Range 1 V/DIV., 1 msec./DIV. Condition Maintain engine RPM at 2,000 rpm after engine warmed-up HINT: • The wavelength becomes shorter as engine rpm increases. • The waveforms and amplitudes displayed differ slightly depending on the vehicle. ES ES–34 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) WAVEFORM 3 Camshaft timing oil control valve (OCV) 0.2 V/DIV. ECM Terminal Name A Ground B Tester Range 0.2 V/DIV., 200 msec./DIV. Condition Accelerate slowly after engine warmedup HINT: In the DATA LIST, the items VVT OCV DUTY B1 and B2 show the duty ratio of voltage flowing to the OCV (see illustration). VVT OCV DUTY B1, B2 = A/B x 100 (%) 200 msec./DIV. A093281E07 (d) WAVEFORM 4 Variable Valve Timing (VVT) sensor (bank 1, 2) and Crankshaft position sensor 2 V/ DIV. ES Between OC1+ and OC1Between OC2+ and OC2- CH1 Ground CH2 Ground CH3 Ground ECM Terminal Name 20 msec./DIV. Crank Angle 60° Idle after engine warmed-up ECM Terminal Name 60° GND 120° 2 V/DIV., 20 msec./DIV. Condition (e) WAVEFORM 5 Camshaft position sensor and Crankshaft position sensor 2 V/DIV 120° Tester Range HINT: The wavelength becomes shorter as engine rpm increases. A085260E11 180° CH1: Between VV1+ and VV1CH2: Between VV2+ and VV2CH3: Between NE+ and NE- Between G2+ and G2- Tester Range 2 V/DIV, 200 msec./DIV Condition Idle after engine warmed up 180° HINT: The wavelength becomes shorter as the engine rpm increases. 200 msec./DIV A138873E01 (f) 5 V/DIV. Ground WAVEFORM 6 Vehicle speed signal ECM Terminal Name Between SPD2+ and SPD2- Tester Range 5 V/DIV., 10 msec./DIV. Condition Driving by 40 km/h (25 mph) HINT: The wavelength becomes shorter as engine rpm increases. 10 msec./DIV. A093224E18 ES–35 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (g) WAVEFORM 7 Throttle actuator positive terminal 5 V/DIV. ECM Terminal Name Between M+ and ME01 Tester Range 5 V/DIV., 1 msec./DIV. Condition Idle after engine warmed-up HINT: The duty ratio varies depending on the throttle opening operation. Ground 1 msec./DIV. A093274E10 (h) WAVEFORM 8 Throttle actuator negative terminal 5 V/DIV. ECM Terminal Name Between M- and ME01 Tester Range 5 V/DIV., 1 msec./DIV. Condition Idle after engine warmed-up HINT: The duty ratio varies depending on the throttle opening operation. Ground 1 msec./DIV. A093275E09 (i) 2 V/DIV. WAVEFORM 9 Igniter IGT signal (from ECM to igniter) and Igniter IGF signal (from igniter to ECM) (a) Ground ECM Terminal Name (a) Between IGT1 (to IGT8) and E1 (b) Between IGF1 (IGF2) and E1 Tester Range 2 V/DIV., 20 msec./DIV. (b) Ground Condition Idling HINT: The wavelength becomes shorter as engine rpm increases. 20 msec./DIV. A093278E14 (j) 0.2 V/DIV. WAVEFORM 10 Heated oxygen (HO2) sensor ECM Terminal Names Ground 200 msec./DIV. A088863E13 Between OX1B and E2 Tester Ranges 0.2 V/DIV., 200 msec./DIV. Conditions Engine speed maintained 2,500 rpm for 2 minutes after warming up sensor HINT: In the DATA LIST, item O2S B1S2 shows the ECM input values from the heated oxygen sensor. (k) WAVEFORM 11 Engine speed signal 5 V/DIV. Ground ECM Terminal Names Between TACH and E1 Tester Range 5 V/DIV., 10 msec./DIV. Condition Idling HINT: The wavelength becomes shorter as engine rpm increases. 10 msec./DIV. A093225E07 ES ES–366 DTC 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance P2121 DESCRIPTION HINT: This DTC relates to the Accelerator Pedal Position (APP) sensor. Refer to DTC P2120 (See page ES-353). ES DTC No. DTC Detection Condition Trouble Area P2121 Conditions (a) and (b) continue for 0.5 second: (a) Difference between VPA1 and VPA2 deviates from the standard (b) IDL is OFF • • APP sensor ECM MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has 2 sensor elements / signal outputs: VPA1 and VPA2. VPA1 is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA1. When the difference between the voltage outputs of VPA1 and VPA2 deviates from the standard, the ECM concludes the accelerator pedal position sensor has a malfunction. The ECM turns on the MIL and a DTC is set. MONITOR STRATEGY Related DTCs P2121: Accelerator pedal position (APP) sensor rationality Required Sensors/Components (Main) APP sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present None Either of the following conditions is met: Condition 1 or 2 1. Ignition switch ON 2. Throttle actuator power ON TYPICAL MALFUNCTION THRESHOLDS Difference between VPA1 voltage (learned value) and VPA2 voltage (learned value) Less than 0.4 V, or more than 1.2 V FAIL-SAFE The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the remaining circuit is used to calculate the accelerator pedal opening to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. ES–367 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM If a "pass" condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. WIRING DIAGRAM Refer to DTC P2120 (See page ES-357). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 ES CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2121) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P2121 A P2121 and other DTCs B HINT: If any DTCs other than P2121 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (ACCEL POS#1 AND ACCEL POS#2) Depressed Released FI07052E06 (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS#1 and ACCEL POS#2. (d) Read the voltage for the accelerator pedal position sensor data. Standard voltage Accelerator pedal operations ACCEL POS#1 Released 0.5 to 1.1 V 1.5 to 2.9 V Depressed 2.5 to 4.6 V 3.5 to 5.5 V OK ACCEL POS#2 CHECK FOR INTERMITTENT PROBLEMS ES–368 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 3 REPLACE ACCELERATOR PEDAL ASSEMBLY NEXT 4 CHECK WHETHER DTC OUTPUT RECURS (DTC P2121) (a) (b) (c) (d) (e) ES (f) Display (DTC Output) Proceed to P2121 A No output B B A REPLACE ECM Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear DTCs (See page ES-35). Allow the engine to idle for 15 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. Result CHECK FOR INTERMITTENT PROBLEMS 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–369 DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) DTC P2197 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1) DTC P2198 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1) DESCRIPTION HINT: • Although the DTC titles refer to the "oxygen sensor", these DTCs relate to the Air Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and located near the engine assembly. The A/F sensor generates voltage* that corresponds to the actual air fuel ratio. This sensor voltage is used to provide the ECM with feedback so that it can control the air fuel ratio. The ECM determines the deviation from the stoichiometric air fuel ratio level, and regulates the fuel injection time. If the A/F sensor malfunctions, the ECM is unable to control the air fuel ratio accurately. The A/F sensor is the planar type and is integrated with the heater, which heats the solid electrolyte (zirconia element). This heater is controlled by the ECM. When the intake air volume is low (the exhaust gas temperature is low), a current flows into the heater to heat the sensor, in order to facilitate accurate oxygen concentration detection. In addition, the sensor and heater portions are narrower than the conventional type. The heat generated by the heater is conducted to the solid electrolyte through the alumina, and the sensor activation is accelerated. In order to obtain a high purification rate of the carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxide (NOx) components in the exhaust gas, a TWC is used. For the most efficient use of the TWC, the air fuel ratio must be precisely controlled so that it is always close to the stoichiometric level. HINT: *: Value changes inside the ECM. Since the A/F sensor is the current output element, the current is converted to a voltage inside the ECM. Any measurements taken at the A/F sensor or ECM connectors will show a constant voltage. ES ES–370 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Monitored A/F Sensor Voltage Alumina Heater Solid Electrolyte (Zirconia Element) Element Platinum Electrode Cover ES Atmospheric Air Exhaust Gas A A Air Fuel Ratio A-A Section A107164E07 DTC No. DTC Detection Condition Trouble Area • P2195 P2197 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) Air Fuel Ratio (A/F) sensor voltage more than 3.8 V (b) Heated Oxygen (HO2) sensor voltage 0.15 V or more P2195 P2197 While fuel-cut operation performed (during vehicle deceleration), air fuel ratio (A/F) sensor current 3.6 mA or more for 3 seconds (2 trip detection logic) P2196 P2198 Conditions (a) and (b) continue for 2 seconds or more (2 trip detection logic): (a) A/F sensor voltage less than 2.8 V (b) HO2 sensor voltage less than 0.85 V P2196 P2198 While fuel-cut operation performed (during vehicle deceleration), air fuel ratio (A/F) sensor current less than 1.4 mA for 3 seconds (2 trip detection logic) • • • • • • Open or short in Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) circuit Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) heater A/F relay A/F sensor heater and relay circuits Air induction system Fuel pressure Fuel injector ECM • • A/F sensor ECM • • • • • • • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor (bank 1, 2 sensor 1) heater A/F relay A/F sensor heater and relay circuits Air induction system Fuel pressure Fuel injector ECM • • A/F sensor ECM • • HINT: • DTCs P2195 and P2196 indicate malfunctions related to bank 1 A/F sensor circuit. • DTCs P2197 and P2198 indicate malfunctions related to bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes No. 1 cylinder. • Bank 2 refers to the bank that includes No. 2 cylinder. • When any of these DTCs are set, check the A/F sensor output voltage by entering the following menus on the intelligent tester: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / AFS B1S1. • Short-term fuel trim values can also be read using the intelligent tester. ES–371 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • The ECM regulates the voltages at the A1A+, A2A+, A1A- and A2A- terminals of the ECM to a constant level. Therefore, the A/F sensor output voltage cannot be confirmed without using the intelligent tester. • If an A/F sensor malfunction is detected, the ECM sets a DTC. MONITOR DESCRIPTION • Sensor voltage detection monitor Under the air fuel ratio feedback control, if the A/F sensor output voltage indicates rich or lean for a certain period of time, the ECM determines that is a malfunction in the A/F sensor. The ECM illuminates the MIL and sets a DTC. Example: If the A/F sensor voltage output is less than 2.8 V (very rich condition) for 10 seconds, despite the HO2 sensor output voltage being less than 0.6 V, the ECM sets DTC P2196. Alternatively, if the A/F sensor output voltage is more than 3.8 V (very lean condition) for 15 seconds, despite the HO2 sensor output voltage being 0.15 V or more, DTC P2195 is set. • Sensor current detection monitor: A rich air-fuel mixture causes a low air-fuel ratio sensor current, and a lean air fuel mixture causes a high air-fuel ratio sensor current. Therefore, the sensor output becomes high during acceleration, and the sensor becomes low during deceleration. The ECM monitors the air-fuel ratio sensor current during fuel-cut and detects unusual current value. If the cumulative time sensor output exceeds 3 seconds, the ECM interprets a malfunction in the air-fuel ratio sensor and sets a DTC. Normal Condition: Malfunction Condition: (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (2) Approximately 2,500 rpm (1) Idling (1) Idling Engine RPM (1) Idling (1) Idling Engine RPM “Condition (3)” 0.76 V or More A/F Sensor A/F Sensor Voltage Voltage Fuel Cut Fuel Cut “Condition (1), (2)” Change When A/F sensor circuit malfunctioning, voltage at approximately 0.66 V output does not change A133737E01 ES ES–372 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P2195: A/F sensor (Bank 1) signal stuck lean P2196: A/F sensor (Bank 1) signal stuck rich P2197: A/F sensor (Bank 2) signal stuck lean P2198: A/F sensor (Bank 2) signal stuck rich Required Sensors/Components A/F sensor Frequency of Operation Continuous Duration 5 seconds: A/F sensor signal stuck lean/rich 3 seconds: A/F sensor current (high/low side) MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS ES All The monitor will run whenever these DTCs are not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0037, P0038, P0057, P0058 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0136, P0156 (O2 Sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0455, P0456 (EVAP system) P0500 (VSS) P2440 (AIR control valve stuck open) P2441 (AIR control valve stuck close) P2444 (AIP stuck ON) P2445 (AIP stuck OFF) Sensor voltage detection monitor: Time after engine start 30 seconds or more Fuel system status closed-loop Sensor current detection monitor P2195, P2196, P2197 and P2198 Battery voltage 11 V or more Atmospheric pressure 76 kPa (570 mmHg) or higher Air-fuel ratio sensor status Activated ECT 75°C (167°F) or more Continuous time of fuel cut 3 to 10 seconds TYPICAL MALFUNCTION THRESHOLDS Sensor voltage detection monitor (Lean side malfunction P2195, P2197): A/F sensor voltage More than 3.8 V Rear HO2S voltage Rises from less than 0.21 V to 0.59 V or more Sensor voltage detection monitor (Rich side malfunction P2196, P2198): A/F sensor voltage Less than 2.8 V Rear HO2S voltage Falls from 0.59 V or more to less than 0.21 V Sensor current detection monitor (High side malfunction P2195, P2197): Air-fuel ratio sensor current 3.6 mA or more Sensor current detection monitor (Rich side malfunction P2196, P2198): Air-fuel ratio sensor current Less than 1.4 mA ES–373 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR RESULT Detailed information on CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM ECM 35 IC4 W-G 8 E8 MREL W-G A12 A/F Sensor (Bank 1 Sensor 1) ES (*1) B W 2 +B AF- BR 4 30 E5 A1A- B-R 2 2 3 2 1 5 1 EFI Relay 5 2 Y 3 R-L L W-B 2 2 W 2 2 EFI A/F HTR 1 (*1) W +B AF4 C 2 L 4 IM1 W 2 W 1 HT AF+ P 3 B-W J/C 1 E5 HA2A W-B E B J2 J28 J/C B J3 Battery 23 E5 A2A+ 9 IC4 W-B B J2 31 E5 A2A- C W Engine Room R/B B J26 J/C W-B 1 2 E5 HA1A 2 C B-R 22 E5 A1A+ A13 A/F Sensor (Bank 2 Sensor 1) 2 2 1 W A/F HTR Relay 3 2 2 Engine Room R/B 2 HT AF+ E EB W-B ED *1: Shielded A130714E02 ES–374 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRMATION DRIVING PATTERN This confirmation driving pattern is used in the following diagnostic troubleshooting inspection procedure when using the intelligent tester. Monitor Drive Pattern ECT: 70°C (158°F) or more Vehicle Speed Accelerator Pedal Depressed At least 3 times Between 38 and 75 mph (60 and 120 km/h) [I] 40 mph (64 km/h) or more [G] Accelerator Pedal Released (Fuel-cut) [J] [K] ES [E] Idling 6 mph (10 km/h) [H] Warming up 10 seconds or 4 seconds or more more 10 minutes or more Time Refer to figure below A107162E20 Driving Pattern Detail for [H] through [K] Cumulative Detection Period “t” = t1 + t2 + t3 = 3 seconds or more Reference Engine RPM Delay Detection Period t1 [I] [J] [K] 2,500 rpm 1,000 rpm Idling t2 [H] t3 Time Idling 4 seconds or more 4 seconds or more 4 seconds or more A107163E13 1. 2. 3. 4. 5. 6. Connect the intelligent tester to the DLC3 with CAN VIM [A]. Turn the ignition switch ON [B]. Turn the tester ON [C]. Clear DTCs (See page ES-35) [D]. Start the engine, and warm it up until the ECT reaches 75°C (167°F) or higher [E]. On the intelligent tester, enter the following menus to check the fuel-cut status: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / FC IDLE [F]. ES–375 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 7. Drive the vehicle at between 38 mph (60 km/h) and 75 mph (120 km/h) for at least 10 minutes [G]. 8. Change the transmission to 2nd gear [H]. 9. Drive the vehicle at proper vehicle speed to perform fuel-cut operation [I]. HINT: Fuel-cut is performed when the following conditions are met: • Accelerator pedal fully released. • Engine speed is 2,500 rpm or more (fuel injection returns at 1,000 rpm). 10.Accelerate the vehicle to 40 rpm (64 km/h) or more by depressing the accelerator pedal for at least 10 seconds [J]. 11.Soon after performing step [J] above, release the accelerator pedal for at least 4 seconds without depressing the brake pedal in order to execute fuel-cut control [K]. 12.Allow the vehicle to decelerate until the vehicle speed declines to less than 6 mph (10 km/h) [L]. 13.Repeat steps from [I] through [L] above at least 3 times in one driving cycle [M]. HINT: Completion of all A/F sensor monitors is required to change the value in TEST RESULT. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. INSPECTION PROCEDURE HINT: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. ES ES–376 Case 1 2 ES 3 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus on the tester: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. HINT: • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. • A low A/F sensor voltage could be caused by a rich air fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air fuel mixture. Check for conditions that would cause the engine to run lean. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P2195, P2196, 2197 OR P2198) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON. Turn the tester ON Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. ES–377 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Display (DTC Output) Proceed to P2195, P2196, P2197, or P2198 A P2195, P2196, P2197, or P2198 and other DTCs B HINT: If any DTCs other than P2195, P2196, P2197 or P2198 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (TEST VALUE OF A/F SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear DTCs (See page ES-35). Allow the vehicle to drive in accordance with the drive pattern described in the CONFIRMATION DRIVING PATTERN. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR STATUS. (f) Check the the status of O2S MON is COMPL. If the status is still INCMPL, drive the vehicle according to the driving pattern again. HINT: • AVAIL indicates that the component has not been monitored yet. • COMPL indicates that the component is functioning normally. • INCMPL indicates that the component is malfunctioning. (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT / RANGE B1S1; then press the ENTER button. (h) Check the test value of the A/F sensor output current during fuel-cut. Result Test Value Proceed to Within normal range (1.4 mA or more, and less than 3.6 mA) A Outside normal range (Less than 1.4 mA, or 3.6 mA or more) B B Go to step 20 A 3 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3 with CAN VIM. Start the engine. Turn the tester ON. Warm up the Air Fuel Ratio (A/F) sensor at an engine speed of 2,500 rpm for 90 seconds. ES ES–378 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA / AFS B1S1 or AFS B2S1 and ENGINE SPD. (f) Check the A/F sensor voltage three times, when the engine is in each of the following conditions: Operation Steps ES Step Condition (1) While idling (check for at least 30 seconds) (2) At an engine speed of approximately 2,500 rpm (without any sudden changes in engine speed) (3) Raise the engine speed to 4,000 rpm and then quickly release the accelerator pedal so that the throttle valve is fully closed. Standard voltage Condition A/F Sensor Voltage Variation Reference (1) and (2) Changes at approximately 0.66 V Between 0.62 and 0.7 V (3) Increases to 0.76 V or more This occurs during engine deceleration (when fuel-cut performed) HINT: • For more information, see the diagrams below. Malfunction Condition: Normal Condition: (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (2) Approximately 2,500 rpm (1) Idling (1) Idling (1) Idling Engine RPM Engine RPM A/F Sensor Voltage A/F Sensor Voltage Fuel-cut Fuel-cut “Condition (1), (2)” Change at approximately 0.66 V (1) Idling “Condition (3)” 0.76 V or more When A/F sensor circuit malfunctioning, voltage output does not change A107161E13 • If the output voltage of the A/F sensor remains at approximately 0.66 V (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have an open circuit (this will also happen if the A/F sensor heater has an open circuit). ES–379 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • If the output voltage of the A/F sensor remains at either approximately 0.76 V or more, or 0.56 V or less (see Malfunction Condition diagram) under any conditions, including those above, the A/F sensor may have a short circuit. • The ECM stops fuel injection (fuel cut) during engine deceleration. This causes a lean condition and results in a momentary increase in the A/F sensor output voltage. • The ECM must establish a closed throttle valve position learning value to perform fuel cut. If the battery terminal has been reconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle valve position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 0.56 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally. • The A/F sensor is a current output element; therefore, the current is converted into a voltage inside the ECM. Measuring the voltage at the connectors of the A/F sensor or ECM will show a constant voltage result. NG Go to step 10 OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Result Display (DTC Output) Proceed to P2195, P2196, P2197, or P2198 A No output B B A Go to step 9 ES ES–380 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE AIR FUEL RATIO SENSOR NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. ES Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197, or P2198 B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 9 CONFIRM WHETHER VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS YES DTC CAUSED BY RUNNING OUT OF FUEL 10 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Measure the resistance of the A/F sensor connector. Standard resistance Component Side A/F Sensor A12 A13 HT +B AF- Specified Condition HT (1) - +B (2) 1.8 Ω to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. AF+ Front View A085152E60 OK Tester Connection NG REPLACE AIR FUEL RATIO SENSOR ES–381 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 11 INSPECT A/F RELAY (a) Remove the A/F relay from the engine room relay block. (b) Measure the resistance of the A/F relay. Standard resistance B016200E02 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the A/F relay. NG REPLACE A/F RELAY ES OK 12 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch to ON. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side A/F Sensor Connector A12 HT +B AF- ECM Connector E5 HA1A HA2A A2A+ A1A+ A2A- A1A- Specified Condition Between 9 V and 14 V (d) Turn the ignition switch to OFF. (e) Disconnect the E5 ECM connector. (f) Check the resistance. Standard resistance (Check for open) A13 AF+ Tester Connection +B (2) - Body ground Tester Connection Specified Condition HT (A12-1) - HA1A (E5-2) HT (A13-1) - HA2A (E5-1) Below 1 Ω AF+ (A12-3) - A1A+ (E5-22) AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A12-4) - A1A- (E5-30) AF- (A13-4) - A2A- (E5-31) Below 1 Ω Standard resistance (Check for short) A121613E02 Tester Connection Specified Condition HT (A12-1) or HA1A (E5-2) - Body ground HT (A13-1) or HA2A (E5-1) - Body ground 10 kΩ or higher AF+ (A12-3) or A1A+ (E5-22) - Body ground AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher (g) Reconnect the A/F sensor connector. (h) Reconnect the ECM connector. ES–382 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (Bank 1 Sensor 1 System Diagram) A/F HEATER A/F Sensor ECM A/F Heater Fuse Heater +B From Battery HT HA1A AF+ A1A+ Sensor AF- A1A- ES Duty Control From EFI Relay A118002E16 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 13 CHECK AIR INDUCTION SYSTEM (a) Check the air induction system for vacuum leakage. OK: No leakage from air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 14 CHECK FUEL PRESSURE (a) Check the fuel pressure (See page FU-6). NG REPAIR OR REPLACE FUEL SYSTEM OK 15 INSPECT FUEL INJECTOR (a) Check the injector injection (whether fuel volume is high or low, and whether injection pattern is poor). NG REPLACE FUEL INJECTOR ES–383 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 16 REPLACE AIR FUEL RATIO SENSOR NEXT 17 PERFORM CONFIRMATION DRIVING PATTERN NEXT 18 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Read DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197 or P2198 B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 19 CONFIRM WHETHER VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS YES DTC CAUSED BY RUNNING OUT OF FUEL 20 REPLACE AIR FUEL RATIO SENSOR NEXT 21 PERFORM CONFIRMATION DRIVING PATTERN NEXT 22 CHECK WHETHER DTC OUTPUT RECURS (DTC P2195, P2196, P2197 OR P2198) (a) Connect the intelligent tester to the DLC3 with CAN VIM. ES ES–384 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the ignition switch ON and turn the tester ON. (c) Read DTCs using the intelligent tester. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to No output A P2195, P2196, P2197 or P2198 (A/F sensor pending DTCs) B B A ES END REPLACE ECM ES–490 2UZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES ENGINE UNDER COVER ASSEMBLY REAR 29 (296, 21) N*m (kgf*cm, ft.*lbf) : Specified torque A119814E01 2UZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–491 ES CRANKSHAFT POSITION SENSOR 6.5 (65, 58 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A119819E02 ES–385 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2237 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 1 Sensor 1) DTC P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) DTC P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) DTC P2240 Oxygen (A/F) Sensor Pumping Current Circuit / Open (Bank 2 Sensor 1) DTC P2241 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 2 Sensor 1) DTC P2242 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 2 Sensor 1) DTC P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) DTC P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) DTC P2255 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 2 Sensor 1) DTC P2256 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 2 Sensor 1) DESCRIPTION HINT: • Although the DTC titles refer to the "oxygen sensor", these DTCs relate to the Air Fuel Ratio (A/F) sensor. • Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and is located near the engine assembly. Refer to DTC P2195 (See page ES-364). DTC No. P2237 P2238 DTC Detection Condition Open in the circuit between terminals AF+ and AF- of the A/F sensor while engine is running (2 trip detection logic) Trouble Area • • • Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) ECM ES ES–386 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition • P2238 P2241 • Case 1: Condition (a) or (b) continues for 5.0 seconds or more (1 trip detection logic): (a) AF+ voltage 0.5 V or less (b) (AF+) - (AF-) = 0.1 V or less Case 2: A/F sensor admittance: Less than 0.0221/Ω (2 trip detection logic) Trouble Area • • • • • • • P2239 P2242 AF+ voltage more than 4.5 V for 5.0 seconds or more (2 trip detection logic) • • • • • • ES P2252 P2255 AF- voltage 0.5 V or less for 5.0 seconds or more (2 trip detection logic) • • • • • • P2253 P2256 AF- voltage more than 4.5 V for 5.0 seconds or more (2 trip detection logic) • • • • • Open or short in Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) circuit Air Fuel Ratio (A/F) sensor (bank 1, 2 sensor 1) Air Fuel Ratio (A/F) sensor heater (bank 1, 2 sensor 1) A/F relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F relay A/F sensor heater and relay circuits ECM Open or short in A/F sensor (bank 1, 2 sensor 1) circuit A/F sensor (bank 1, 2 sensor 1) A/F sensor heater (bank 1, 2 sensor 1) A/F relay A/F sensor heater and relay circuits ECM HINT: • DTCs P2238, P2239, P2252 and P2253 indicate malfunctions related to bank 1 A/F sensor circuit. • DTCs P2241, P2242, P2255 and P2256 indicate malfunctions related to bank 2 A/F sensor circuit. • Bank 1 refers to the bank that includes No. 1 cylinder. • Bank 2 refers to the bank that includes No. 2 cylinder. MONITOR DESCRIPTION These DTCs are output when there is an open or short in the A/F sensor circuit, or if A/F sensor output drops. To detect these problems, the voltage of the A/F sensor is monitored when turning the ignition switch to the ON position, and the admittance (admittance is an electrical term that indicates the ease of flow of current) is checked while driving. If the voltage of the A/F sensor is between 0.6 V and 4.5 V, it is considered normal. If the voltage is outside of the specified range, or the admittance is less than the standard value, the ECM will determine that there is a malfunction in the A/F sensor. If the same malfunction is detected in the next driving cycle, the MIL is illuminated and a DTC is set.. MONITOR STRATEGY Related DTCs P2237: A/F sensor (Bank 1) open circuit between AF+ and AFP2238: A/F sensor (Bank 1) low impedance P2238: A/F sensor (Bank 1) short circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and GND P2239: A/F sensor (Bank 1) short circuit between AF+ and +B P2240: A/F sensor (Bank 2) open circuit between AF+ and AFP2241: A/F sensor (Bank 2) low impedance P2241: A/F sensor (Bank 2) short circuit between AF+ and AFP2241: A/F sensor (Bank 2) short circuit between AF+ and GND P2242: A/F sensor (Bank 2) short circuit between AF+ and +B P2252: A/F sensor (Bank 1) short circuit between AF- and GND P2253: A/F sensor (Bank 1) short circuit between AF- and +B P2255: A/F sensor (Bank 2) short circuit between AF- and GND P2256: A/F sensor (Bank 2) short circuit between AF- and +B 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Required Sensors/Components (Main) A/F sensor Required Sensors/Components (Related) - Frequency of Operation Continuous Duration 10 seconds MIL Operation 2 driving cycles Sequence of Operation None ES–387 TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present P0031, P0032, P0051, P0052: A/F sensor heater P0100 - P0103: MAF sensor P0110 - P0113: IAT sensor P0115 - P0118, P0125: ECT sensor P0120 - P0223, P2135: TP sensor P0125: Insufficient ECT for Closed Loop P0171, P0172: Fuel trim P0300 - P0308: Misfire P0335: CKP sensor P0455, P0456: EVAP system P0500: VSS P2440: AIR control valve stuck open P2441: AIR control valve stuck close P2444: AIP stuck On P2445: AIP stuck Off A/F sensor - Open circuit between AF+ and AFBattery voltage 13.5 V or more Engine Running Estimated sensor temperature 450 to 550°C (842 to 1022°F) for P2237 and P2240 A/F sensor - Low impedance Engine coolant temperature 0°C (0°F) or higher [Closed loop enabling ECT] Estimated sensor temperature 700 to 800°C (1292 to 1472°F) for P2238 and P2241 Fuel cut Not executed Others: Battery voltage 11 V or more Ignition switch ON Time after ignition switch is OFF to ON 5 seconds or more TYPICAL MALFUNCTION THRESHOLDS P2237 and P2240: A/F sensor admittance Below 0.002 1/Ω P2238 and P2241: When one of the following conditions is met: Condition 1, 2 or 3 1. Sensor admittance Less then 0.022 1/Ω 2. AF+ voltage 0.5 V or less 3. Difference of AF+ and AF- Less than 0.1 V P2239 and P2242: AF+ terminal voltage More than 4.5 V P2252 and P2255: AF- terminal voltage 0.5 V or less P2253 and P2256: AF- terminal voltage More than 4.5 V ES ES–388 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE Sensor admittance 0.022 1/Ω or more AF+ voltage 0.6 to 4.5 V AF- voltage 0.6 to 4.5 V Difference of AF+ and AF- 0.11 to 0.8 V WIRING DIAGRAM Refer to DTC P2195 (See page ES-368). INSPECTION PROCEDURE ES HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard voltage Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 or AFS B2S1 (A/F) +25 % Rich Less than 3.0 AFS B1S1 or AFS B2S1 (A/F) -12.5 % Lean More than 3.35 O2S B1S2 or O2S B2S2 (HO2) +25 % Rich More than 0.55 O2S B1S2 or O2S B2S2 (HO2) -12.5 % Lean Less than 0.4 NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. ES–389 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 1 2 3 4 A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Areas - • • • A/F sensor A/F sensor heater A/F sensor circuit ES • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) • Following the A/F CONTROL procedure enables technicians to check and graph the output voltages of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–390 1 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Disconnect the E5 ECM connector. (c) Check the resistance. Standard resistance (Check for open) Wire Harness Side A/F Sensor Connector A12 HT +B AF+ AF- A13 ECM Connector A2A+ A1A+ A2A- A1A- Below 1 Ω AF- (A12-4) - A1A- (E5-30) AF- (A13-4) - A2A- (E5-31) Below 1 Ω Tester Connections Specified Conditions AF+ (A12-3) or A1A+ (E5-22) - Body ground AF+ (A13-3) or A2A+ (E5-23) - Body ground 10 kΩ or higher AF- (A12-4) or A1A- (E5-30) - Body ground AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher E5 HA2A Specified Conditions Standard resistance (Check for short) ES HA1A Tester Connections AF+ (A12-3) - A1A+ (E5-22) AF+ (A13-3) - A2A+ (E5-23) A121613E02 Reference (Bank 1 Sensor 1 System Diagram) A/F HEATER A/F Sensor ECM A/F Heater Fuse From Battery Heater +B HT HA1A AF+ A1A+ Sensor AF- A1A- Duty Control From EFI Relay A118002E16 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–391 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 REPLACE AIR FUEL RATIO SENSOR NEXT 3 CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the tester ON. (c) Clear the DTCs (See page ES-35) (d) Start the engine. (e) Allow the engine to idle for 5 minutes or more. (f) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (g) Read pending DTCs. Result Display (DTC Output) Proceed to No output A P2237, P2238, P2239, P2240, P2241, P2242, P2252, P2253, P2255 or P2256 B B A END REPLACE ECM ES ES–392 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2401 Evaporative Emission Leak Detection Pump Stuck OFF DTC P2402 Evaporative Emission Leak Detection Pump Stuck ON DTC SUMMARY DTC No. Monitoring Item Malfunction Detection Condition Leak detection pump stuck OFF Leak detection pump creates negative pressure through reference orifice, and EVAP system pressure measured to determine leak criterion. Reference leak pressure standard is measured at the start and at the end of the leak check. If system pressure higher than -1.06 kPa (-7.93 mmHg)*, or lower than -4.85 kPa (-36.38 mmHg)*, ECM determines that leak detection pump stuck OFF. ES P2401 P2402 Leak detection pump stuck ON Leak detection pump creates negative pressure through reference orifice, and EVAP system pressure measured to determine leak criterion. If system pressure higher than -1.06 kPa (-7.93 mmHg)*, or lower than -4.85 kPa (-36.38 mmHg)*, ECM determines that leak detection pump stuck ON. Trouble Area • • • • • • Detection Timing Detection Logic Canister pump module (reference orifice, leak detection pump, vent valve) Connector/wire harness (canister pump module ECM) ECM Ignition switch OFF 2 trip Canister pump module (reference orifice, leak detection pump, vent valve) Connector/wire harness (canister pump module ECM) ECM Ignition switch OFF 2 trip *: The threshold values vary according to the atmospheric pressure measured in operation A. The values described in the table above are based on an atmospheric pressure of 100 kPa (750.1 mmHg). HINT: The leak detection pump is built into the canister pump module. DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-425). INSPECTION PROCEDURE Refer to the EVAP system (See page ES-430). ES–393 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Description Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion (reference pressure) measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion (reference pressure) measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operation *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES ES–394 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation B, E: Operation A: Atmospheric Pressure Measurement 0.02 Inch Leak Criterion Measurement Purge VSV: OFF Canister Fuel Tank OFF OFF (vent) Vent Valve: OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter ON Leak Detection Pump: OFF ES Reference Orifice (0.02 Inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E05 ES–395 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P2401: Leak detection pump stuck OFF In operation B, the leak detection pump creates negative pressure (vacuum) through the reference orifice. The EVAP system pressure is then measured by the ECM using the canister pressure sensor to determine the 0.02 inch leak criterion. If the pressure is higher than -1.06 kPa (-7.95 mmHg)* or lower than -4.85 kPa (-36.38 mmHg)*, the ECM interprets this as the leak detection pump being stuck OFF (not operating). The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The values described above are based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Leak Detection Pump Stuck OFF ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent ON Vacuum Pump EVAP Pressure Malfunction Positive Negative 0.02 Inch Leak Criterion OK Sequence A B C D E Time (Second) 10 60 Within 900 10 60 A106064E08 2. P2402: Vacuum pump stuck ON In operation B, the vacuum pump creates negative pressure (vacuum) through the reference orifice. The EVAP system pressure is then measured by the ECM using the canister pressure sensor to determine the 0.02 inch leak criterion. If the pressure is higher than -1.06 kPa (-7.95 mmHg)* or lower than -4.85 kPa (-36.38 mmHg)*, the ECM interprets this as the vacuum pump being stuck ON (operating all the time). The ECM illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The values described above are based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. HINT: The detection logic of DTCs P2401 and P2402 is the same because in both cases the 0.02 inch leak criterion measured in operation B is compared to the atmospheric pressure registered in operation A. The ECM calculates the difference between these pressures by deducting [the 0.02 inch leak criterion] from [the stored atmospheric pressure], and uses this to monitor the EVAP system pressure change. ES ES–396 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP Pressure When Leak Detection Pump Stuck ON ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent ON Vacuum Pump EVAP Pressure OK Positive ES Negative Malfunction 0.02 Inch Leak Criterion Sequence Time (Second) A B C D E 10 60 Within 900 10 60 A106065E07 MONITOR STRATEGY Related DTCs P2401: Vacuum pump stuck OFF P2402: Vacuum pump stuck ON Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Within 2 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or higher Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool Both of the following conditions are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–397 TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. One of the following conditions set Condition 1, 2, 3, 4 or 5 1. EVAP pressure just after reference pressure measurement start -1 kPa (7.5 mmHg) or higher 2. Reference pressure Less than -4.85 kPa (726 mmHg) 3. Reference pressure -1.05 kPa (754 mmHg) or higher 4. Reference pressure Not saturated 5. Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) or more MONITOR RESULT Refer to detailed information on CHECKING MONITOR STATUS (See page ES-17). ES ES–398 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2419 Evaporative Emission Pressure Switching Valve Stuck ON DTC P2420 Evaporative Emission Pressure Switching Valve Stuck OFF DTC SUMMARY DTC No. Monitoring Items ES P2419 P2420 Vent valve stuck closed Vent valve stuck open (vent) Malfunction Detection Conditions Vacuum pump creates negative pressure through 0.02 inch orifice and EVAP system pressure measured to determine leak pressure standard. If system pressure higher than -1.06 kPa (-7.95 mmHg)* 4 seconds after vacuum pump turned ON, ECM determines that vent valve stuck closed. Vacuum pump creates negative pressure through 0.02 inch orifice and EVAP system pressure measured to determine leak pressure standard. 0.02 inch leak pressure standard is measured at the start and at the end of the leak check. If system pressure does not increase by more than 0.3 kPa (2.25 mmHg) within 10 seconds when vent valve turned ON, ECM determines that vent valve stuck closed. Trouble Areas • • • • • • Detection Timing Detection Logic Pump module Connector / Wire harness (Pump module - ECM) ECM Ignition switch OFF 2 trip Pump module Connector / Wire harness (Pump module - ECM) ECM Ignition switch OFF 2 trip *: The threshold valve varies according to the atmospheric presser measured in operation A. The value described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. HINT: The vent value is built into the pump module. DESCRIPTION The circuit description can be found in the Evaporative Emission (EVAP) system (See page ES-425). INSPECTION PROCEDURE Refer to the EVAP system (See page ES-430). ES–399 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after ignition switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion (reference pressure) measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion (reference pressure) measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES ES–400 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation B, E: Operation A: Atmospheric Pressure Measurement 0.02 Inch Leak Criterion Measurement Purge VSV: OFF Canister Fuel Tank OFF OFF (vent) Vent Valve: OFF (vent) Canister Pump Module Canister Pressure Sensor Canister Filter ON Leak Detection Pump: OFF ES Reference Orifice (0.02 Inch) Operation C: EVAP System Pressure Measurement Operation D: Purge VSV Monitor ON (closed) OFF Atmospheric Pressure ON ON (closed) Negative Pressure ON ON A112612E05 ES–401 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P2419: Vent valve stuck closed In operation B, the leak detection pump creates negative pressure (vacuum) through the reference orifice. The EVAP system pressure is then measured by the ECM using the canister pressure sensor to determine the 0.02 inch leak criterion. If the pressure exceeds -1.06 kPa (-7.95 mmHg)* 4 seconds after the leak detection pump is turned ON, the ECM interprets this as the vent valve being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). *: The threshold varies according to the atmospheric pressure measured in operation A. The values described above is based on an atmospheric pressure of 100 kPa (750.1 mmHg): absolute pressure. EVAP Pressure when Vent Valve Stuck OFF: ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure Malfunction Positive Negative 0.02 Inch Leak Criterion OK 4 seconds Sequence A B C D E Time (Second) 10 60 Within 900 10 60 A106066E03 ES ES–402 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P2420: Vent valve stuck open (vent) In operation C, the vent valve turns ON (closes) and the EVAP system pressure is then measured by the ECM using the canister pressure sensor to conduct an EVAP leak check. If pressure does not drop when the vent valve is open, the ECM interprets this as the vent valve being stuck open. The ECM illuminates the MIL and sets the DTC. EVAP Pressure when Vent Valve Stuck OFF: ON: Open ON Purge VSV OFF: Closed Vent Valve ES ON: Closed ON OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Negative OK 0.02 Inch Leak Criterion Malfunction Sequence Time (Second) A B C D E 10 60 Within 900 10 60 A106067E03 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration 2 minutes MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or higher Vehicle speed Less than 2.5 mph (4 km/h) Ignition switch OFF Time after key off 5 or 7 or 9.5 hours EVAP pressure sensor malfunction (P0450, P0452, P0453) Not detected EVAP canister purge valve Not operated by scan tool EVAP canister vent valve Not operated by scan tool EVAP leak detection pump Not operated by scan tool 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Both of the following condition are met before key off Condition 1 and 2 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–403 TYPICAL MALFUNCTION THRESHOLDS 1. P2419: Vent valve stuck closed "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. One of following conditions set - 1. EVAP pressure just after reference pressure measurement start -1 kPa (-7.5 mmHg) or higher 2. Reference pressure Less than -4.85 kPa (726 mmHg) 3. Reference pressure -1.05 kPa (-7.93 mmHg) or higher 4. Reference pressure Not saturated 5. Difference between first reference pressure and second reference pressure 0.7 kPa (5.25 mmHg) or more 2. P2420: Vent valve stuck open (vent) EVAP pressure change after EVAP canister vent valve is ON Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT Refer to detailed information on CHECKING MONITOR STATUS (See page ES-17). ES ES–404 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2430 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Bank1 DTC P2431 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Range / Performance Bank1 DTC P2432 Secondary Air Injection System Air Flow / Pressure Sensor Circuit Low Bank1 DTC P2433 Secondary Air Injection System Air Flow / Pressure Sensor Circuit High Bank1 DTC ES DESCRIPTION DTC No. DTC Detection Condition Trouble Area P2430 While the engine is running, if voltage output of the pressure sensor indicates 0.1V or less, or indicates 4.8 V or more. (1 trip detection logic) • • • Pressure sensor Open or short in pressure sensor circuit ECM P2431 The pressure sensor indicates less than 45 kPa (338 mHg), or more than 135 kPa (1013 mHg). (1 trip detection logic) • • • Pressure sensor Open or short in pressure sensor circuit ECM P2432 While the engine is running, if voltage output of pressure sensor remains below 0.1 V. (1 trip detection logic) • • • Pressure sensor Open or short in pressure sensor circuit ECM P2433 While the engine is running, if voltage output of the pressure sensor remains above 4.8 V. (1 trip detection logic) • • • Pressure sensor Open or short in pressure sensor circuit ECM MONITOR DESCRIPTION The ECM observes the pressure in the secondary air passage using the pressure sensor located on the air switching valve in the secondary air injection system. If there is a defect in the sensor or the sensor circuit, the voltage level will deviate from the normal operating range, the ECM interprets this deviation as a defect in the pressure sensor circuit and sets a DTC. Pressure Sensor VC AIP E2 ECM VC 3 23 2 32 1 28 AIP E2 A115345E02 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–405 MONITOR STRATEGY Related DTCs P2430: Air flow/pressure sensor circuit range check (Fluctuating) P2431: Air flow/pressure sensor circuit rationality P2432: Air flow/Pressure sensor circuit range check (Low voltage) P2433: Air flow/pressure sensor circuit range check (High voltage) Required sensors/Components Pressure sensor Frequency of operation Continuous Duration P2430, P2432, P2433: 0.5 second P2431: 5 second MIL operation P2430, P2432, P2433: Immediate P2431: 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS ES The monitor will run whenever this DTC is not present None Starter OFF Time after starter turned from ON to OFF 2 seconds or more Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS P2430: Air pressure sensor voltage Less than 0.1 V, or more than 4.8 V P2431: Air pressure Less than 45 kPa (338 mmHg), or more than 135 kPa (1013 mmHg) P2432: Air pressure sensor voltage Less than 0.1 V P2433: Air pressure sensor voltage More than 4.8 V ES–406 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM A45 Air Pressure Sensor ECM 5V VC AIP 3 L-R 3 EB2 2 W-L 1 EB2 W-L 4 EB2 BR ES E2 1 BR L-R 23 VC E4 32 E4 AIP 28 E2 E4 A115928E02 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–407 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 CHECK HARNESS AND CONNECTOR (PRESSURE SENSOR - ECM) (a) (b) (c) (d) Wire Harness Side Pressure Sensor Connector AIP Remove the intake manifold (See page ES-501). Disconnect the A45 pressure sensor connector. Disconnect the E4 ECM connector. Measure the resistance between the wire harness side connectors. Standard resistance A45 Tester Connection Specified Condition VC (A45-3) - VC (E4-23) E2 E4 Front View AIP (A45-2) - AIP (E4-32) VC Below 1 Ω E2 (A45-1) - E2 (E4-28) VC (A45-3) or VC (E4-23) - Body ground ECM Connector AIP (A45-2) or AIP (E4-32) - Body ground NG VC 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR E2 AIP A115720E02 OK 2 INSPECT PRESSURE SENSOR (a) Remove the intake manifold (See page ES-501). (b) Connect the pressure gauge to the pressure sensor as shown in the illustration. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Turn the ignition switch ON and push the intelligent tester main switch ON (Do not start engine). (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / AIR PMP PRS (A). (f) Check the pressure displayed on the intelligent tester fluctuates when applying the pressure to the pressure sensor with the pressure gauge. OK: Pressure fluctuates in response to the pressure applied with pressure gauge. NG OK REPLACE ECM REPLACE PRESSURE SENSOR ES ES–408 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2444 Secondary Air Injection System Pump Stuck On Bank1 DTC P2445 Secondary Air Injection System Pump Stuck Off Bank1 DESCRIPTION Refer to DTC P0412 (See page ES-214). DTC No. P2444 ES P2445 DTC Detection Condition Trouble Area Air pump stuck ON. The secondary air pressure is more than 5 kPa (38 mmHg) despite the ECM ordering the air pump to turn off. (2 trip detection logic) • • • • • Short in air pump circuit Air injection control driver (AID) Pressure sensor Open or short in pressure sensor circuit ECM Air pump stuck OFF or air injection volume is insufficient. The amount of air flow is below the criteria. (The secondary air pressure is less than specified value despite the ECM ordering the air pump turn ON.) (2 trip detection logic) • • • • • • • • • Air pump fuse Vacuum hose Air pump assembly Air injection control driver (AID) Open in air pump circuit Air injection system piping Pressure sensor Open or short in pressure sensor circuit ECM MONITOR DESCRIPTION P2444: The ECM observes the pressure in the secondary air passage using the pressure sensor located on the air switching valve in the secondary air injection system. The sensor measures the pressure in the secondary air passage and sends a signal to the ECM. If the pressure level from the sensor exceeds a certain level despite the ECM turning off the air pump, the ECM interprets this as a fault in the secondary air injection system and sets a DTC. P2445: The ECM calculates the amount of air flow within the secondary air system based on the output values of the pressure sensor and mass air flow meter. The ECM determines whether the amount of air flow is normal or not according to the calculated value. When the amount of air flow is below the criteria, the ECM stores the DTC and illuminates the MIL. MONITOR STRATEGY Related DTCs (Case 1) P2444 Air pump stuck ON (Case 2) P2445 Air pump stuck OFF (Case 3) P2445 Air insufficient (Case 4) P2445 Air pressure sensor stuck Required sensors/Components AIR valve, AIR VSV bank 1, AIR VSV bank 2 Required sensors/Components AIR pressure sensor Frequency of operation Continuous Duration Within 20 seconds MIL operation 2 driving cycles Sequence operation None 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–409 TYPICAL ENABLING CONDITIONS All: This monitor runs whenever these DTCs are not present • • • • • • • • • • • • • • • • • • • • • • • • • P0010, P0020: VVT system P0011: VVT System 1 - Advance P0012: VVT System 1 - Retard P0016, P0018: VVT System - Misalignment P0021: VVT System 2 - Advance P0022: VVT System 2 - Retard P0031, P0032, P0051, P0052: Front A/F sensor heater P0100 - P0103: MAF sensor P0110 - P0113: IAT sensor P0115 - P0118: ECT sensor P0120 - P0223, P2125: TP sensor P0125: Closed loop P0171 - P0175: Fuel trim P0300 - P0308: Misfire P0327 - P0333: Knock sensor P0335: CKP sensor P0340 - P0346: VVT sensor P0351 - P0358: Igniter P0445 - P0446: EVAP system P0450 - P0453: EVAP press sensor P0500: VSS P2196, P2198: A/F sensor - rationality P2237, P2240: A/F sensor - open P2430 - P2433: AIR pressure sensor P2A00, P2A03: A/F sensor - slow response Air pressure sensor stuck ECT at engine start Lower than 5°C (41°F) IAT at engine start -15°C (5°F) or higher Time that ECT is 80°C (176°F) or higher 10 to 60 minutes Cumulative intake air amount 109 g/sec. or more Monitor Sequence 3 Completed AIR valve OFF AIR valve bank 1 OFF AIR valve bank 2 OFF One of the following conditions is met - - Vehicle speed 80 km/h or more - Engine RPM 0 rpm or more - Throttle position 0° or more Other: Atmospheric pressure 45 kPa (420 mmHg) or more Battery voltage 10.5 V or higher AIR monitor runs in accordance with the monitor sequence 1 to 5 Monitor Sequence 1 Idle ON AIR status ON AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF ES ES–410 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM -AIR valve bank 2 ON Monitor Sequence 2 Idle ON AIR status ON AIR pump ON AIR valve ON AIR VSV bank 1 ON AIR VSV bank 2 ON Monitor Sequence 3 ES Engine RPM Less than 3,750 rpm AIR status ON AIR pump ON AIR valve ON AIR valve bank 1 ON AIR valve bank 2 ON Monitor Sequence 4-1 Runs when AIR pressure did not change at monitor sequence 2 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump ON AIR valve ON Either of following conditions 1 or 2 is met - 1. Both of the following conditions are met - -AIR valve bank 1 ON -AIR valve bank 2 OFF 2. Both of the following conditions are met - -AIR valve bank 1 OFF -AIR valve bank 2 ON Monitor Sequence 4-2 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve OFF AIR VSV bank 1 OFF AIR VSV bank 2 OFF Monitor Sequence 5 Engine RPM Less than 3,750 rpm AIR status OFF AIR pump OFF AIR valve ON AIR VSV bank 1 OFF AIR VSV bank 2 OFF TYPICAL MALFUNCTION THRESHOLDS P2444 AIR pump ON stuck AIR pressure during AIR OFF 5 kPa or more P2445 AIR pump OFF stuck AIR pressure during AIR ON Less than 1 kPa ES–411 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM P2445 AIR insufficient AIR amount 100 L/min. or less P2445 AIR pressure sensor stuck AIR pressure change 5 kPa or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). WIRING DIAGRAM Refer to DTC P0412 (See page ES-217). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2444 AND P2445) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES. (d) Read the DTCs. Result Display (DTC Output) Proceed to P2445 A P2444 B P2444 and P2445 "P2444 and P2445" and other DTCs C HINT: If any other codes besides P2444 or P2445 is output, perform the troubleshooting for those DTCs first. B C A Go to step 7 GO TO DTC CHART ES ES–412 2 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK AIR INJECTION SYSTEM PRESSURE (a) (b) (c) (d) AIR INJ CHECK AIR PUMP.....................ON EASV.......................OPEN ASV1.......................OPEN ASV2.......................OPEN A/F BANK1................OPEN A/F BANK2..................14.5 PRESSURE..............17kPa PULSATION.........25.39kPa AISTATUS.....................OK Remaining Time 05 sec. Press [ EXIT ] to quit A115721 ES Start the engine and warm it up. Turn the ignition switch OFF. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and push the intelligent tester main switch ON. (e) Start the engine. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL OPERATION / OPERATION 1 and 2. HINT: OPERATION 1: AP: OFF, EASV: CLOSE, ASV1: CLOSE, ASV2: CLOSE OPERATION 2: AP: ON, EASV: OPEN, ASV1: OPEN, ASV2: OPEN (g) Check that the PRESSURE on the intelligent tester. NOTICE: This test only allows technicians to operate the AI system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AI system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. Standard pressure Tester operation Pressure Operation 1 Less than 2.5 kPa Operation 2 5 to 8 kPa or more NG Go to step 4 OK 3 CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) (g) Start the engine and warm it up. Turn the ignition switch OFF. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Clear the DTCs (See page ES-35). Start the engine. Perform ACTIVE TEST to operate the air injection system. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / AUTOMATIC OPERATION 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–413 (h) After operating the secondary air injection system, confirm the pending codes for the secondary air injection system by entering the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. (i) Read DTC and check DTC. OK: DTC P2444 or P2445 for the secondary air injection system is not output. NG Go to step 4 OK CHECK FOR INTERMITTENT PROBLEMS ES 4 CHECK VACUUM HOSES (a) Remove the intake manifold (See page ES-501). (b) Check the vacuum hose connection between the pressure sensor and air switching valve. OK: The vacuum hose is securely connected. (c) Inspect the vacuum hose for blockage and damage. OK: The vacuum hose has no blockage and damage. Vacuum Hose G032743E01 NG REPAIR OR REPLACE VACUUM HOSES OK 5 READ VALUE OF INTELLIGENT TESTER (AIR VOLTAGE) Pressure Gauge Pressure Sensor G032742E01 (a) Remove the intake manifold (See page ES-501). (b) Connect the pressure gauge to the pressure sensor as shown in the illustration. (c) Connect the intelligent tester to the DLC3 with CAN VIM. (d) Turn the ignition switch ON and push the intelligent tester main switch ON (Do not start engine). (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / AIR PMP PRS. (f) Check that the pressure displayed on the intelligent tester fluctuates when applying the pressure to the pressure sensor with the pressure gauge. OK: Pressure fluctuates in response to the pressure applied with pressure gauge. NG OK REPLACE PRESSURE SENSOR ES–414 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK PIPING AND HOSES (CONNECTION OF ALL AIR INJECTION SYSTEM) G032737E01 (a) Remove the intake manifold (See page ES-501). (b) Check that all the pipes and hoses between the air pump and air switching valve are securely connected. OK: All air injection pipes and hoses are securely connected. (c) Check all pipes and hoses for blockages and damage. OK: All air injection pipes and hoses have no blockages and damage. NG ES REPAIR OR REPLACE AIR INJECTION SYSTEM PIPING AND HOSES OK 7 INSPECT AIR INJECTION CONTROL DRIVER (POWER SOURCE CIRCUIT) (a) Remove the intake manifold (See page ES-501). (b) Disconnect the A44 Air Injection Control Driver (AID) connectors. (c) Turn the ignition switch ON. (d) Measure the voltage between terminals A44-5 (+B) and A43-1 (BATT) of the AID and body ground. Standard voltage Wire Harness Side A44 AID Connector Tester Connection +B (A44-5) - Body ground E A43 Front View BATT (A43-1) - Body ground +B Specified Condition 10 V or more (e) Measure the resistance between the terminal A44-1 (E) of the AID and body ground. Standard resistance AID Connector (f) Tester Connection Specified Condition E (A44-1) - Body ground Below 1 Ω Reconnect the AID connector. BATT NG Front View A115722E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–415 INSPECT ECM (AIRP AND AIRV VOLTAGE) ECM Connector (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) When the air pump and air switching valve are operated using the intelligent tester, measure voltage between terminal E8-25 (AIRP) and E8-4 (AIRV) of the AID connector and body ground. Standard voltage E8 AIRV AIRP E118245E25 Tester Connection Air pump operation Specified Condition AIRP (E8-25) - Body ground ON 10 V or more AIRP (E8-25) - Body ground OFF 3.5 to 7.7 V* Tester Connection Air switching valve (ASV) operation (EASV) Specified Condition AIRV (E8-4) - Body ground OPEN 10 V or more AIRV (E8-4) - Body ground CLOSE 3.5 to 7.7 V* Standard voltage (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL OPERATION / OPERATION 1 and 2. HINT: OPERATION 1: AP: OFF, EASV: CLOSE, ASV1: CLOSE, ASV2: CLOSE OPERATION 2: AP: ON, EASV: OPEN, ASV1: OPEN, ASV2: OPEN NOTICE: This test only allows technicians to operate the AI system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AI system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. HINT: *: 35 to 55 % of the +B voltage. NG OK REPLACE ECM ES ES–416 9 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (AIR INJECTION CONTROL DRIVER - BODY GROUND) (a) (b) (c) (d) Wire Harness Side Air Injection Driver Connector A44 SIV Front View SIP A115723E02 ES Disconnect the A44 air injection driver connector. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. When the air pump and air switching valve are operated using the intelligent tester, measure the voltage between terminals A44-3 (SIV) and A44-4 (SIP) of the air injection driver connector and body ground. Standard voltage Tester Connection Air pump operation Specified Condition SIP (A44-4) - Body ground ON 10 V or more SIP (A44-4) - Body ground OFF 3.5 to 7.7 V* Tester Connection ASV operation (EASV) Specified Condition SIV (A44-3) - Body ground OPEN 10 V or more SIV (A44-3) - Body ground CLOSE 3.5 to 7.7 V* Standard voltage (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / AIR INJ CHECK / MANUAL OPERATION / OPERATION 1 and 2. HINT: OPERATION 1: AP: OFF, EASV: CLOSE, ASV1 : CLOSE, ASV2: CLOSE OPERATION 2: AP: ON, EASV: OPEN, ASV1: OPEN, ASV2: OPEN NOTICE: This test only allows technicians to operate the AI system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AI system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If the ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. *: 35 to 55 % of the +B voltage. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 10 ES–417 INSPECT AIR PUMP (OPERATION) Pressure Gauge Pressure Sensor A115725E01 (a) (b) (c) (d) Remove the hose between EASV and ASV. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON and turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / AIR INJ CHECK / MANUAL / OPERATION / OPERATION 2. (e) When the air pump is operated, check that air comes out from the air pump. HINT: OPERATION 2: AP: ON, EASV: CLOSE, ASV1: CLOSE, ASV2: CLOSE NOTICE: • This test only allows technicians to operate the AI system for 5 seconds. Furthermore, the test can be performed 4 times a trip. If the test is repeated, intervals of at least 30 seconds are required between tests. While the AI system operation using the intelligent tester is prohibited, the tester displays the prohibition (WAIT or ERROR). If ERROR (AI STATUS NG) is displayed on the tester, stop the engine for 10 minutes and then try again. • When performing the AIR INJ CHECK operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned ON or the engine running. • Turn the ignition switch OFF when the AIR INJ CHECK operation finishes. OK: Air comes out from the air pump NG OK CHECK WHETHER DTC OUTPUT NOT RECURS REPLACE AIR PUMP ES ES–418 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2610 ECM / PCM Internal Engine Off Timer Performance DTC SUMMARY DTC No. Monitoring Item P2610 Soak timer (built into ECM) Malfunction Detection Condition ECM internal malfunction Trouble Area ECM Detection Timing Detection Logic Engine running 2 trip DESCRIPTION ES The soak timer is built into the ECM. To ensure that the Evaporative Emission (EVAP) monitor values will be accurate, the soak timer counts 5 hours (+-15 minutes) from when the ignition switch is turned OFF. This allows the fuel to cool down, which stabilizes the Fuel Tank Pressure (FTP). When approximately 5 hours have passed, the ECM turns ON. Soak Timer Circuit ECM Ignition Switch IGSW EFI +B POWER SOURCE IC MREL Main Relay Control IC Soak Timer IC Battery A115729E09 MONITOR DESCRIPTION 5 hours after the ignition switch is turned OFF, the soak timer activates the ECM to begin the EVAP system monitor. While the engine is running, the ECM monitors the synchronization of the soak timer and the CPU clock. If the soak timer and CPU clock are not synchronized, the ECM interprets this as a malfunction, illuminates the MIL and sets the DTC (2 trip detection logic). MONITOR STRATEGY Related DTCs P2610: Soak timer (built into ECM) Required Sensors/Components ECM 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Frequency of Operation Once per driving cycle Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None ES–419 TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTC not present None Ignition switch ON Engine Running Battery voltage 8 V or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS Soak timer measurement when ECM CPU clock counts 10 minutes ES Less than 7 minutes or more than 13 minutes INSPECTION PROCEDURE HINT: • DTC P2610 is set if an internal ECM problem is detected. Diagnostic procedures are not required. ECM replacement is required. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 REPLACE ECM (a) Replace the ECM (See page ES-510). NEXT 2 CHECK WHETHER DTC OUTPUT RECURS (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Clear DTCs (See page ES-35). (d) Start the engine and wait for 10 minutes or more. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC / INFO / PENDING CODES. (f) If no pending DTC is displayed, the repair has been successfully completed. NEXT END ES–420 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) DTC P2A03 A/F Sensor Circuit Slow Response (Bank 2 Sensor 1) DESCRIPTION • • • • • ES DTC P2A00 indicates malfunctions related to the bank 1 A/F sensor. DTC P2A03 indicates malfunctions related to the bank 2 A/F sensor. Bank 1 refers to the bank that includes No. 1 cylinder. Bank 2 refers to the bank that includes No. 2 cylinder. Sensor 1 refers to the sensor mounted in front of the Three-Way Catalytic Converter (TWC) and is located near the engine assembly. Refer to DTC P2195 (See page ES-364). DTC No. DTC Detection Condition Trouble Area • P2A00 P2A03 Calculated test value for Air Fuel Ratio (A/F) sensor response rate deterioration level is less than threshold. • • Open or short in Air Fuel Ratio (A/F) sensor (sensor 1) circuit Air Fuel Ratio (A/F) sensor (sensor 1) ECM MONITOR DESCRIPTION After engine is warmed up, the ECM performs air fuel ratio feedback control to regulate the air fuel ratio at stoichiometric ratio. In addition, this vehicle performs Active Air Fuel Ratio (A/F) Control for approximately 10 seconds after preconditions are met in order to measure the A/F sensor response rate. During active air fuel ratio control, the ECM forcibly increases and decreases the injection volume a certain amount based on learned stoichiometric air fuel ratio during usual air fuel feedback control, and measures the A/F sensor response rate. The ECM receives a signal from the A/F sensor while performing active A/F control and uses it to calculate the A/F sensor response rate deterioration level. If the test value for A/F sensor response rate deterioration level is less than the threshold, the ECM interprets this as a malfunction, and sets the DTC. Air Fuel Ratio Sensor 10 Seconds ON Active A/F Control OFF Normal Malfunction A/F Sensor Output Increase Fuel Injection Volume Decrease A115363E02 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–421 MONITOR STRATEGY Related DTCs P2A00: Air fuel ratio (A/F) sensor (bank 1) slow response P2A03: Air fuel ratio (A/F) sensor (bank 2) slow response Required Sensors/Components (Main) A/F sensor Frequency of Operation Once per driving cycle Duration 10 to 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTCs not present P0031, P0032, P0051, P0052 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0171, P0172 (Fuel system) P0300 - P0308 (Misfire) P0335 (CKP sensor) P0455, P0456 (EVAP system) P0500 (VSS) P2196, P2198 (A/F sensor - rationality) P2237, P2240 (A/F sensor - open) P2440 (AIR control valve stuck open) P2441 (AIR control valve stuck close) P2444 (AIP stuck ON) P2445 (AIP stuck OFF) Active A/F control Performing Active A/F control is performed when the following conditions set - Battery Voltage 11 V or more ECT 75°C (167°F) or more Idle OFF Engine RPM Less than 4,000 rpm A/F sensor status Activated Fuel cut OFF Engine load 10 to 70 % Shift position 2nd or more Catalyst monitor Not executing Intake air amount 2.5 to 12 g/sec. TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level Less than 0.2 V MONITOR RESULT Detailed information on CHECKING MONITOR STATUS (See page ES-17). CONFIRMATION DRIVING PATTERN HINT: Performing this confirmation pattern will activate the air fuel ratio (A/F) sensor response monitor. ES ES–422 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Vehicle Speed Between [H] 25 and 75 mph (40 and 120 km/h) Idling [G] Ignition Switch OFF ES Warming up 3 minutes Time A115372E43 1. 2. 3. 4. 5. Connect the intelligent tester to the DLC3 with CAN VIM [A]. Turn the ignition switch ON [B]. Turn the tester ON [C]. Clear DTCs (if set) (See page ES-35) [D]. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / MONITOR RESULT [E]. 6. Check that RES RATE B1 S1 is INCOMPL [F]. 7. Start the engine and warm it up [G]. 8. Drive the vehicle at between 25 mph and 75 mph (40 km/h and 120 km/h) for 3 minutes. However, the vehicle should be driven at a constant speed [H]. 9. Check the monitor result values on the intelligent tester by entering the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO / TEST RESULT [I]. 10.If the values indicated on the tester do not change, perform READINESS MONITOR DRIVE PATTERN for the A/F sensor and the heated oxygen sensor (See page ES-20) [J]. HINT: Completion of all A/F sensor monitors are required to change the value in TEST RESULT. 11.Note the value of the Monitor Result [K]. 12.Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INO / PENDING CODES [L]. 13.Check if any pending DTCs are set [M]. WIRING DIAGRAM Refer to DTC P2195 (See page ES-368). INSPECTION PROCEDURE HINT: Intelligent tester only: Malfunctioning areas can be identified by performing the A/F CONTROL function provided in the ACTIVE TEST. The A/F CONTROL function can help to determine whether the Air Fuel Ratio (A/F) sensor, Heated Oxygen (HO2) sensor and other potential trouble areas are malfunctioning. The following instructions describe how to conduct the A/F CONTROL operation using the intelligent tester. 1. Connect the intelligent tester to the DLC3 with CAN VIM. ES–423 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. Start the engine and turn the tester ON. 3. Warm up the engine at an engine speed of 2,500 rpm for approximately 90 seconds. 4. On the intelligent tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 5. Perform the A/F CONTROL operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume). 6. Monitor the output voltages of the A/F and HO2 sensors (AFS B1S1 (AFS B2S1) and O2S B1S2 (O2S B2S2)) displayed on the tester. HINT: • The A/F CONTROL operation lowers the fuel injection volume by 12.5 % or increases the injection volume by 25 %. • Each sensor reacts in accordance with increases and decreases in the fuel injection volume. Standard: Tester Display (Sensor) Injection Volume Status Voltage AFS B1S1 (AFS B2S1) (A/F) +25 % Rich Less than 3.0 AFS B1S1 (AFS B2S1) (A/F) -12.5 % Lean More than 3.35 O2S B1S2 ( O2S B2S2) (HO2) +25 % Rich More than 0.55 O2S B1S2 (O2S B2S2) (HO2) -12.5 % Lean Less than 0.4 NOTICE: The Air Fuel Ratio (A/F) sensor has an output delay of a few seconds and the Heated Oxygen (HO2) sensor has a maximum output delay of approximately 20 seconds. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection volume +25 % -12.5 % Injection Volume +25 % -12.5 % Output Voltage Almost no reaction Output Voltage Almost no reaction Main Suspected Trouble Area - 1 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel injector Fuel pressure Gas leakage from exhaust system (Air fuel ratio extremely lean or rich) ES ES–424 ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • Following the A/F CONTROL procedure enables technicians to check and graph the voltage outputs of both the A/F and HO2 sensors. • To display the graph, enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL / USER DATA / AFS B1S1 and O2S B1S2 or AFS B2S1 and O2S B2S2. Then press the YES button and ENTER button, followed by the F4 button. HINT: • DTC P2A00 may be also set when the air fuel ratio is stuck rich or lean. • A low A/F sensor voltage could be caused by a rich air fuel mixture. Check for conditions that would cause the engine to run rich. • A high A/F sensor voltage could be caused by a lean air fuel mixture. Check for conditions that would cause the engine to run lean. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. 1 CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2A00 AND/OR P2A03) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A P2A00 and/or P2A03 and other DTCs B HINT: If any DTCs other than P2A00 and/or P2A03 are output, troubleshoot those DTCs first. B GO TO DTC CHART A 2 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A12 or A13 Air Fuel Ratio (A/F) sensor connector. (b) Measure the resistance of the A/F sensor connector. Standard resistance Component Side A/F Sensor A12 A13 HT +B AF- AF+ Tester Connection Specified Condition HT (1) - +B (2) 1.8 to 3.4 Ω at 20°C (68°F) HT (1) - AF- (4) 10 kΩ or higher (c) Reconnect the A/F sensor connector. Front View A085152E60 NG OK REPLACE AIR FUEL RATIO SENSOR ES–425 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A12 or A13 A/F sensor connector. (b) Turn the ignition switch ON. (c) Measure the voltage between the +B terminal of the A/F sensor connector and body ground. Standard voltage Wire Harness Side A/F Sensor Connector A12 A13 +B HT AF- AF+ Front View ECM Connector E5 Tester Connection Specified Condition +B (2) - Body ground 10 V or more (d) Turn the ignition switch OFF. (e) Disconnect the E5 ECM connector. (f) Measure the resistance. Standard resistance (Check for open) Tester Connection Specified Condition HT (A12-1) - HA1A (E5-2) HT (A13-1) - HA2A (E5-1) AF+ (A12-3) - A1A+ (E5-22) HA1A A2A+ A2A- HA2A AF+ (A13-3) - A2A+ (E5-23) Below 1 Ω AF- (A12-4) - A1A- (E5-30) A1A+ AF- (A13-4) - A2A- (E5-31) A1AA115727E02 Standard resistance (Check for short) Tester Connection Specified Condition HT (A12-1) or HA1A (E5-2) - Body ground HT (A13-1) or HA2A (E5-1) - Body ground AF+ (A12-3) or A1A+ (E5-22) - Body ground AF+ (A13-3) or A2A+ (E5-23) - Body ground AF- (A12-4) or A1A- (E5-30) - Body ground AF- (A13-4) or A2A- (E5-31) - Body ground 10 kΩ or higher ES ES–426 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference (Bank 1 Sensor 1 System Diagram) A/F HEATER A/F Sensor ECM A/F Heater Fuse Heater +B From Battery HT HA1A AF+ A1A+ Sensor AF- Duty Control A1A- ES From EFI Relay A118002E16 (g) Reconnect the A/F sensor connector. (h) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 PERFORM CONFIRMATION DRIVING PATTERN NEXT 5 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A No output B B A CHECK FOR INTERMITTENT PROBLEMS ES–427 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 REPLACE AIR FUEL RATIO SENSOR NEXT 7 PERFORM CONFIRMATION DRIVING PATTERN NEXT 8 CHECK WHETHER DTC OUTPUT RECURS (DTC P2A00 AND/OR P2A03) (a) Read DTCs using the intelligent tester. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Result Display (DTC Output) Proceed to P2A00 and/or P2A03 A No output B A B END CHECK EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (REFER TO DTC P0171 PROCEDURE) ES ES–428 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM EVAP System RELATED DTCS DTC No. Monitoring Items P043E Reference orifice clogged (built into canister pump module) P043F Reference orifice high-flow (built into canister pump module) P0441 • • • P0450 Canister pressure sensor (built into canister pump module) voltage abnormal fluctuation • ES P0451 • Purge VSV stuck closed Purge VSV stuck open Purge flow Canister pressure sensor (built into canister pump module) noising Canister pressure sensor stuck (built into canister pump module) P0452 Canister pressure sensor (built into canister pump module) voltage low P0453 Canister pressure sensor (built into canister pump module) voltage high P0455 EVAP gross leak P0456 EVAP small leak P2401 Leak detection pump stuck OFF (built into canister pump module) P2402 Leak detection pump stuck ON (built into canister pump module) P2419 Vent valve stuck closed (built into canister pump module) P2420 Vent valve stuck open (vent) (built into canister pump module) P2610 Soak timer (built into ECM) See procedure ES-237 ES-243 ES-251 ES-258 ES-387 ES-393 ES-413 If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. ES–429 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DTCs Malfunctioning Areas P043E P043F P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2401 P2419 P2420 P2402 Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor stuck Canister pressure sensor noise ES Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E06 NOTICE: If the 0.02 inch leak criterion difference between the first and second checks is greater than the specification, the DTCs corresponding to the 0.02 inch leak criterion (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored. ES–430 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION Location of EVAP (Evaporative Emission) System: Pump Module Pressure Sensor Vacuum Pump Vent Valve Purge VSV (Vacuum Switching Valve) Fuel Tank EVAP Hose Air Filter Canister (From Canister) ES Refueling Valve Breeding Pipe Purge Line EVAP Hose Fuel Tank Cap (To Throttle Body) Air Inlet Port A130715E01 EVAP System Circuit: Air Cleaner Throttle Valve ECM Soak Timer Intake Manifold Purge VSV Pump Module Canister Air Filter Refueling Valve Restrictor (0.08 inch) Roll-Over Valve Cut-Off Valve Fuel Tank A130686E01 NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–431 While the engine is running, if a predetermined condition (closed-loop etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. The following two monitors run to confirm appropriate EVAP system operation. 1. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the ignition switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the ignition switch is turned OFF, the monitor check starts 2.5 hours later. 2. Purge flow monitor The purge flow monitor consists of the two monitors. The 1st monitor is conducted every time and the 2nd monitor is conducted if necessary. • The 1st monitor While the engine is running and the purge Vacuum Switching Valve (VSV) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor. ES ES–432 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM • The 2nd monitor The vent valve turned OFF (open) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa (3.75 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. EVAP Purge Flow: Reference Orifice (0.02 inch) Refueling Valve Fuel Cap Canister Pressure Sensor To Atmosphere ES Purge VSV (ON) Fuel Tank Canister To Intake Manifold Canister Filter Vent Valve (OFF) ECM Leak Detection Pump (OFF) Canister Pump Module Soak Timer A122571E01 Components Operations Canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON, closed: OFF). Refueling valve Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08 inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and restrictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opens while refueling. Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours* (+-15 min) after ignition switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours* elapsed, ECM activates. Canister pump module Consists of (a) to (d) below. canister pump module cannot be disassembled. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Components ES–433 Operations (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When, ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. (d) Reference orifice Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump, to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. HINT: *: If the engine coolant temperature is not below 35°C after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35°C 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Canister Pump Module (fig. 1): Condition: Purge Flow Vent Valve: OFF (vent) : Airflow Condition: Leak Check To Canister Filter (Atmosphere): Canister Vent Valve: ON (closed) Reference Orifice Canister Pressure Sensor From Refueling Valve Leak Detection Pump: ON Leak Detection Pump: OFF A097611E07 ES ES–434 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification (fig. 2): Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (759.8mmHg) A115543E02 Soak Timer Circuit (fig.3) ECM Ignition Switch IGSW EFI +B POWER SOURCE IC MREL Main Relay Control IC Soak Timer IC Battery A115729E10 ES–435 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM 35 IC4 W-G J4 J/C L-W A A L-W W-G 17 L-W IC3 12 L-W IM1 2 2 1 IB2 BR 22 IM2 BR 28 E4 E2 L-R 42 IE1 L-R 7 IM2 L-R 23 E4 VC R 17 IE1 R 22 E8 PPMP R-G 11 IE1 R-G 5 E8 VPMP O 28 IE1 O 6 E8 MPMP L-W 3 EFI Relay 9 Engine Room R/B 3 8 5 1 2 W-B Engine Room R/B B J2 J/C Battery L B J3 ES 43 IE1 4 2 2 1 34 E4 PRG BR 2 B 2 Y-R Engine Room R/B L-W L4 EFI Canister Pump Module No. 2 1 1 C L-W C 2 A 2 2 V2 VSV (EVAP) J28 J/C 8 E8 MREL EFI 2 2 1 2 B W-B EB A133741E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. HINT: • Using the intelligent tester monitor results enables the EVAP system to be confirmed. • Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. ES–436 1 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the ignition switch OFF and wait for 10 seconds. Turn the ignition switch ON. Turn the ignition switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3 with CAN VIM. Turn the ignition switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II/ DTC INFO / CURRENT CODES. (g) Confirm DTCs and freeze frame data. If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. NOTICE: If the 0.02 inch leak criterion difference between the first and second checks is greater than the specification, the DTCs corresponding to the 0.02 inch leak criterion (P043E, P043F, P0441, P0455, P0456, P2401 and P2420) will all be stored. ES DTCs Malfunctioning Areas P043E P043F P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2401 P2419 P2420 P2402 Reference orifice clogged Reference orifice high-flow Purge VSV stuck open Purge VSV stuck closed Canister pressure sensor stuck Canister pressure sensor noise Canister pressure sensor low output Canister pressure sensor high output Gross leak Small leak Leak detection pump stuck OFF Leak detection pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) A106731E06 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–437 NEXT 2 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of five steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-35). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by entering the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed, perform the Monitor Confirmation (see "Diagnostic Help" menu). After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal. NEXT ES ES–438 3 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (MANUAL OPERATION) EVAP SYSTEM CHECK ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ES ON EVAP Pressure Positive Gross Leak Negative 0.02 Inch Leak Criterion [Second 0.02 Inch Leak Criterion] x 0.2 Small Leak No Leak Normal Pressure Steps 1/5 2/5 3/5 4/5 5/5 Time (Second) 10 60 Within 15 minutes 10 60 (Reference) A106735E06 NOTICE: • In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps are performed manually by the intelligent tester. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-35). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION. NEXT ES–439 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 PERFORM EVAP SYSTEM CHECK (STEP 1/5) ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON ES Canister Pressure Sensor Noise EVAP Pressure Positive Negative First Reference Pressure Steps OK 1/5 Time (Second) 10 (Reference) A106736E04 (a) Check the EVAP pressure in step 1/5. Result DTC No. * P0451 Test Results Suspected Trouble Areas Proceed to Virtually no variation in EVAP pressure Not yet determined A EVAP pressure fluctuates by +0.3 kPa (2.25 mmHg) or more Canister pressure sensor noise B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. B A Go to step 30 ES–440 5 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 1/5 TO 2/5) ON: Open ON Purge VSV OFF: Closed ON: Closed ES Vent Valve ON Leak Detection Pump ON OFF: Vent EVAP Pressure Positive Negative Leak Detection Pump Stuck ON 0.02 Inch Leak Criterion Steps Time (Second) 1/5 2/5 10 60 (Reference) A106737E04 (a) Check the EVAP pressure in step 1/5 and 2/5. Result DTC No. * Test Results - Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 inch leak criterion Suspected Trouble Areas Proceed to Not yet determined A P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Leak detection pump stuck ON B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. HINT: The first 0.02 inch leak criterion is the value determined in step 2/5. B A Go to step 23 ES–441 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 PERFORM EVAP SYSTEM CHECK (STEP 2/5) ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump EVAP Pressure ON ES Leak Detection Pump Stuck OFF Reference Orifice High-flow 4 seconds Positive Negative Vent Valve Stuck Closed 0.02 Inch Leak Criterion Steps Time (Second) OK 1/5 2/5 10 60 3/5 Within 15 minutes (Reference) A106738E04 HINT: Make a note of the pressures checked in the steps below. (a) Check the EVAP pressure 4 seconds after the leak detection pump is activated* [A}. (b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak criterion [B}. *: The leak detection pump begins to operate as step 1/5 proceeds to step 2/5. Result DTC No. * - Test Results Suspected Trouble Areas EVAP pressure in step [B] between -4.85 kPa and -1.06 kPa (-36.38 mmHg and -7.95 mmHg) Proceed to Not yet determined A • • B Reference orifice high-flow Leak detection pump stuck OFF P043F and P2401 EVAP pressure in step [B] -1.06 kPa (-7.95 mmHg) or more P043E EVAP pressure in step [B] below -4.85 kPa (-36.38 mmHg) Reference orifice clogged C P2419 EVAP pressure in step [A] more than -1.06 kPa (-7.95 mmHg) Vent valve stuck closed D *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. ES–442 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 11 C Go to step 30 D Go to step 19 A 7 ES PERFORM EVAP SYSTEM CHECK (STEP 2/5 TO 3/5) ON: Open ON Purge VSV OFF: Closed ON Vent Valve ON: Closed OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Negative Vent Valve Stuck Open (vent) 0.02 Inch Leak Criterion Steps 3/5 2/5 Time Within 15 minutes (Reference) A106739E04 (a) Check the EVAP pressure in step 3/5. Result DTC No. * Test Results Suspected Trouble Areas Proceed to EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 2/5 to step 3/5 Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/5 through 3/5 Canister pressure sensor malfunction (stuck) C - *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. ES–443 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 20 C Go to step 30 A 8 PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON: Open ON Purge VSV OFF: Closed ON: Closed Vent Valve ON OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Negative 0.02 Inch Leak Criterion Steps Time 3/5 Within 15 minutes (Reference) A106740E04 (a) Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds. (b) Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes (900 seconds). NEXT ES ES–444 9 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 4/5) ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ES ON: Open ON EVAP Pressure OK Positive Negative Purge VSV Stuck Closed 0.02 Inch Leak Criterion 4/5 Steps Time (Second) 10 (Reference) A106741E04 (a) Check the EVAP pressure in step 4/5. Result DTC No. * Test Results Suspected Trouble Areas Proceed to - EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Not yet determined A P0441 EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Problems in EVAP hose between purge VSV and intake manifold B P0441 Variation in EVAP pressure less than 0.3 kPa (2.25 mmHg) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. B Go to step 15 C Go to step 12 ES–445 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 10 PERFORM EVAP SYSTEM CHECK (STEP 5/5) ON: Open ON Purge VSV OFF: Closed Vent Valve ON Leak Detection Pump ON ON: Closed OFF: Vent ES EVAP Pressure Positive Gross Leak Negative 0.02 Inch Leak Criterion [Second 0.02 Inch Leak Criterion] x 0.2 Small Leak Second 0.02 Inch Leak Criterion No Leak 5/5 Steps 60 Time (Second) (Reference) A106735E07 (a) Check the EVAP pressure in step 5/5. (b) Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak criterion (step 5/5). Result DTC No. * Test Results - EVAP pressure (step 3/5) lower than second 0.02 inch leak criterion (step 5/5) Suspected Trouble Areas Not yet determined A P0441 and P0455 EVAP pressure (step 3/5) higher than [second 0.02 inch leak criterion (step 5/5) x 0.2] • • B P0456 EVAP pressure (step 3/5) higher than second 0.02 inch leak criterion (step 5/5) EVAP small leak Purge VSV stuck open EVAP gross leak Proceed to B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. A Go to step 36 B Go to step 12 ES–446 11 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM EVAP SYSTEM CHECK (STEP 3/5) ON: Open ON Purge VSV OFF: Closed Vent Valve OFF: Vent Leak Detection Pump ES ON: Closed ON ON Leak Detection Pump Stuck OFF EVAP Pressure Positive Negative Reference Orifice High-flow 0.02 Inch Leak Criterion Steps 2/5 3/5 Time Within 15 minutes (Reference) A106742E03 (a) Check the EVAP pressure in step 3/5. Result DTC No. * Test Results Suspected Trouble Areas Proceed to P043F EVAP pressure less than [0.02 inch leak criterion] measured at 2/5 Reference orifice high-flow A P2401 EVAP pressure almost same as [0.02 inch leak criterion] measured at 2/5 Leak detection pump stuck OFF B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in step 1. HINT: The first 0.02 inch leak criterion is the value determined in step 2/5. A Go to step 30 B Go to step 23 ES–447 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 12 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (PURGE VSV) Purge VSV Hose A115730E01 (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Disconnect the hose (connected to the canister) from the purge VSV. (c) Turn the ignition switch ON. (d) Using the tester, turn the purge VSV OFF (EVAP VSV: OFF). (e) Use your finger to confirm that the purge VSV has no suction. (f) Using the tester, turn the purge VSV ON (EVAP VSV: ON). (g) Use your finger to confirm that the purge VSV has suction. Result Test Results Suspected Trouble Areas Proceed to No suction when purge VSV turned OFF, and suction applied when turned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B • • C No suction when purge VSV turned ON Purge VSV stuck closed Problems with EVAP hose between purge VSV and intake manifold B Go to step 14 C Go to step 15 A 13 CHECK FUEL CAP (a) Check that the fuel cap is correctly installed. (1) Tighten the fuel cap until a few click sounds are heard. HINT: If an EVAP tester is available, use the tester to check the fuel cap. (b) Remove the fuel cap and install it onto the fuel cap adaptor. (c) Connect an EVAP tester pump hose to the adaptor, and pressurize the cap to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump. (d) Seal the adaptor and wait for 2 minutes. (e) Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel cap is normal. (f) Reinstall the fuel cap. Result Test Results Suspected Trouble Areas Proceed to Fuel cap correctly installed - A ES ES–448 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test Results Suspected Trouble Areas • • • Fuel cap loose No fuel cap ES 14 Proceed to Fuel cap improperly installed Defective fuel cap Fuel cap does not meet OEM specifications B - C A Go to step 29 B Go to step 27 C Go to step 28 INSPECT PURGE VSV Hose Purge VSV (a) Turn the ignition switch OFF. (b) Disconnect the V2 purge VSV connector. (c) Disconnect the hose (connected to the canister) from the purge VSV. (d) Start the engine. (e) Use your finger to confirm that the purge VSV has no suction. A115731E01 Result Test Results Suspected Trouble Areas Proceed to No suction ECM A Suction applied Purge VSV B (f) 15 Reconnect the purge VSV connector. A Go to step 35 B Go to step 31 CHECK EVAP HOSE (PURGE VSV - INTAKE MANIFOLD) Purge VSV Hose (a) Disconnect the hose (connected to the intake manifold) from the purge VSV. (b) Start the engine. (c) Use your finger to confirm that the hose has suction. A115730E01 Result Test Results Suspected Trouble Areas Proceed to Suction applied EVAP hose between purge VSV and intake manifold normal A ES–449 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Test Results • • No suction Suspected Trouble Areas Proceed to Intake manifold port EVAP hose between purge VSV and intake manifold B B Go to step 26 A 16 INSPECT DUTY PURGE VSV (a) Remove the purge VSV connector. (b) Apply battery voltage to the terminals of the purge VSV. (c) Using an air gun, confirm that air flows from port A to port B. Battery B A Air A133742E01 Result Test Results Suspected Trouble Areas Proceed to Air flows Purge VSV normal A No air flows Purge VSV B B Go to step 31 A 17 CHECK HARNESS AND CONNECTOR (POWER SOURCE OF PURGE VSV) (a) Disconnect the V2 purge VSV connector. (b) Turn the ignition switch ON. (c) Measure the voltage between terminal 2 of the purge VSV connector and the body ground. Wire Harness Side Purge VSV Connector V2 Front View A052933E30 Result Test Results Suspected Trouble Areas Proceed to Between 11 V and 14 V Normal A Other than result above Wire harness or connectors between purge VSV and ECM B (d) Reconnect the purge VSV connector. B Go to step 32 ES ES–450 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM A 18 CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V2 purge VSV connector. (b) Disconnect the E4 ECM connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Purge VSV Connector V2 Tester Connection Specified Condition V2-1 - PRG (E4-34) Below 1 Ω V2-1 or PRG (E4-34) - Body ground V2-1 - Body ground Front View ES 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the purge VSV connector. ECM Connector E4 OK Go to step 35 NG Go to step 32 PRG A115732E02 19 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE) ECM Connector E8 (a) Turn the ignition switch ON. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE). (c) Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. VPMP E118245E26 Result Test Results Suspected Trouble Areas Proceed to Between 9 V and 14 V when OFF Below 3 V when ON Vent valve A Below 3 V when OFF and ON ECM B A Go to step 22 B Go to step 35 ES–451 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 20 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR VENT VALVE) ECM Connector E8 (a) Turn the ignition switch ON. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE (ALONE). (c) Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. VPMP E118245E26 Result Test Results Suspected Trouble Areas Proceed to Below 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF Below 3 V when ON Vent valve B Between 9 V and 14 V when OFF and ON ECM C B Go to step 22 C Go to step 35 A 21 INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) (a) (b) (c) (d) L4 Wire Harness Side Canister Connector L4 Front View A115733E02 Turn the ignition switch OFF. Disconnect the L4 canister connector. Turn the ignition switch ON. Measure the voltage between terminal 9 of the canister connector and the body ground. ES ES–452 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to Between 9 V and 14 V Normal A Between 0 V and 3 V Power source wire harness of vent valve B B Go to step 32 A 22 INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) Charcoal Canister Assembly 9(+) 8(-) ES (a) Turn the ignition switch OFF. (b) Disconnect the L4 canister connector. (c) Apply the battery voltage to terminals 9 and 8 of the canister pump module. (d) Touch the canister pump module to confirm the vent valve operation. A115734E01 Result Test Results Suspected Trouble Areas Proceed to Operating Wire harness between vent valve and ECM A Not operating Vent valve B (e) Reconnect the canister connector. 23 A Go to step 32 B Go to step 30 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FOR CANISTER PUMP MODULE [LEAK DETECTION PUMP]) ECM Connector E8 (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). (b) Measure the voltage between MPMP terminal of the ECM connector and the body ground when the leak detection pump is turned ON and OFF using the tester. MPMP E118245E27 Result Test Results Suspected Trouble Areas Proceed to Between 0 V and 3 V when OFF Between 9 V and 14 V when ON ECM normal A Between 9 V and 14 V when OFF Between 0 V and 3 V when ON ECM B ES–453 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B Go to step 35 A 24 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) (b) (c) (d) Turn the ignition switch OFF. Disconnect the L4 canister connector. Turn the ignition switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). (e) Turn the leak detection pump ON. (f) Measure the voltage between terminal 1 of the canister connector and the body ground. L4 Wire Harness Side Canister Connector L4 Front View A115733E02 Result Test Results Suspected Trouble Areas Proceed to Between 9 V and 14 V Normal A Between 0 V and 3 V Wire harness between ECM and leak detection pump B (g) Reconnect the canister connector. B Go to step 32 A 25 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - GROUND) (a) Disconnect the L4 canister connector. (b) Turn the ignition switch OFF. (c) Measure the resistance of the wire harness side connectors between terminal 6 of the canister connector and the body ground. Wire Harness Side L4 Canister Connector Front View A085258E53 ES ES–454 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas Proceed to Below 1 Ω Leak detection pump A 10 kΩ or higher Wire harness between leak detection pump and body ground B (d) Reconnect the canister connector. 26 A Go to step 30 B Go to step 32 INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) (b) (c) (d) ES Turn the ignition switch OFF. Disconnect the EVAP hose from the throttle body. Start the engine. Use your finger to confirm that the port of the throttle body has suction. Result 27 Test Results Suspected Trouble Areas Proceed to Suction applied EVAP hose between intake manifold and purge VSV A No suction Intake manifold B A Go to step 33 B Go to step 34 CORRECTLY REINSTALL OR REPLACE FUEL CAP HINT: • When reinstalling the fuel cap, tighten it until a few click sounds are heard. • When replacing the fuel cap, use a fuel cap that meets OEM specifications, and tighten it until a few click sounds are heard. NEXT 28 Go to step 37 REPLACE FUEL CAP HINT: When installing the fuel cap, tighten it until a few click sounds are heard. NEXT 29 Go to step 37 LOCATE EVAP LEAK (a) Reinstall the fuel cap. (b) Disconnect the vent hose. ES–455 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister ES Disconnect the Vent Hose here. Fuel Cap A130688E01 (c) Connect the EVAP pressure tester tool to the canister with the adapter. Canister Pressure Gauge Air Filter Adapter A130689E01 (d) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg). (e) Apply soapy water to the piping and connecting parts of the EVAP system. (f) Look for areas where bubbles appear. This indicates leak point. (g) Repair or replace the leak point. ES–456 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Disconnect the hose between the canister and the fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks. NEXT 30 Go to step 37 REPLACE CANISTER ASSEMBLY (a) Replace the canister assembly. NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel or other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. ES NEXT 31 Go to step 37 REPLACE DUTY PURGE VSV (a) Disconnect the connector and hoses from the purge VSV. (b) Remove the purge VSV. (c) Install a new purge VSV. (d) Reconnect the connector and hose. NEXT 32 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 33 Go to step 37 REPLACE EVAP HOSE (INTAKE MANIFOLD - PURGE VSV) NEXT 34 Go to step 37 Go to step 37 INSPECT INTAKE MANIFOLD (EVAP PURGE PORT) (a) Remove the throttle body (See page ES-495). (b) Check that the EVAP purge port of the intake manifold is not clogged. If necessary, replace the intake manifold. NEXT Go to step 37 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 35 ES–457 REPLACE ECM (a) Replace the ECM (See page ES-510). NEXT 36 Go to step 37 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS (a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. NEXT 37 Go to step 37 PERFORM EVAP SYSTEM CHECK (AUTO OPERATION) NOTICE: • The EVAP SYSTEM CHECK (AUTO OPERATION) consists of five steps performed automatically by the intelligent tester. It takes a maximum of approximately 18 minutes. • Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90 % full because the cut-off valve may be closed, making the leak check of the fuel tank not possible. • Do not run the engine in this step. • When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35°C (95°F). (a) Clear the DTCs (See page ES-35). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the SYSTEM CHECK is completed, check for pending DTCs by entering the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is found, the repair has been successfully completed. NEXT COMPLETED CONFIRMATION DRIVING PATTERN HINT: After a repair, check Monitor Status by performing the key-off monitor confirmation and purge flow monitor confirmation described below. ES ES–458 1. ES 2. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Key-off monitor confirmation (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The fuel tank is less than 90 % full • The altitude is less than 8,000 ft (2,400 m) • The Engine Coolant Temperature (ECT) is between 4.4 to 35°C (40 to 95°F) • The Intake Air Temperature (IAT) is between 4.4 to 35°C (40 to 95°F) • The vehicle remains stationary (the vehicle speed is 0 km/h (0 mph)) (b) Monitor Conditions 1. Allow the engine to idle for at least 5 minutes. 2. Turn the ignition switch OFF and wait for 6 hours (8 or 10.5 hours). HINT: Do not Start the engine until checking MONITOR STATUS. If the engine is started, the steps described above must be repeated. (c) Monitor Status 1. Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. 2. Turn the ignition switch ON and turn the tester ON. 3. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 4. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again. Purge flow monitor confirmation (P0441) HINT: Perform this monitor confirmation after the key-off monitor confirmation shows COMPL (complete). (a) Preconditions The monitor will not run unless: • The vehicle has been driven for 10 minutes or more (in a city area or on a freeway) • The ECT is between 4.4 to 35°C (40 to 95°F) • The IAT is between 4.4 to 35°C (40 to 95°F) (b) Monitor Conditions 1. Release the pressure from the fuel tank by removing and reinstalling the fuel cap. 2. Warm the engine up until the ECT reaches more than 75°C (167°F). 3. Increase the engine speed to 3,000 rpm once. 4. Allow the engine to idle and turn the A/C ON for 1 minute. (c) Monitor Status 1. Turn the ignition switch OFF (where ON or the engine is running). 2. Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. 3. Turn the ignition switch ON and turn the tester ON. 4. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. 5. Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the "Monitor Conditions" procedures again. MONITOR RESULT Refer to CHECKING MONITOR STATUS (See page ES-17). ES–36 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSIS SYSTEM 1. ES DESCRIPTION When troubleshooting On-Board Diagnostics (OBD II) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the Data Link Connector 3 (DLC3) of the vehicle. Various data in the vehicle's Engine Control Module (ECM) can then be read. OBD II regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (a)The emission control systems components (b)The powertrain control components (which affect vehicle emissions) (c) The computer itself In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not recur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. FI00534E01 Intelligent Tester CAN VIM DLC3 A072434E01 2. To check the DTCs, connect the intelligent tester to the DLC3. The tester displays DTCs, freeze frame data, and a variety of engine data. The DTCs and freeze frame data can be erased with the tester (See page ES-48). In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, the Control Area Network (CAN) communication is used in this system. It minimizes the gap between technician skills and vehicle technology. CAN is a network which uses a pair of data transmission lines that span multiple ECUs and sensors. It allows high speed communication between the systems and simplifies the wire harness connections. The CAN Vehicle Interface Module (CAN VIM) must be connected with the intelligent tester to display any information from the ECM. The intelligent tester and ECM uses CAN communication signals to communicate. Connect the CAN VIM between the intelligent tester and DLC3. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, 2 trip detection logic is used to ensure accurate detection of malfunctions. Check mode is also available as an option for technicians. In check mode, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (intelligent tester only) (See page ES-36). ES–37 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. 4. 5. DLC3 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip). FREEZE FRAME DATA The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. DATA LINK CONNECTOR 3 (DLC3) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 1112131415 16 A082779E98 Symbol (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. ES ES–38 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 6. ES BATTERY VOLTAGE Battery voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. 7. MIL (Malfunction Indicator Lamp) (a) The MIL is illuminated when the ignition switch is first turned ON (the engine is not running). (b) The MIL should turn OFF when the engine is started. If the MIL remains illuminated, the diagnosis system has detected a malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the ignition switch is first turned ON, check the MIL circuit (See page ES-479 ). 8. ALL READINESS For the vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Enter the following menus: ENHANCED OBD II / MONITOR STATUS on the intelligent tester. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–459 ECM Power Source Circuit DESCRIPTION When the ignition switch is turned ON, the positive battery voltage is applied to terminal IGSW of the ECM and the EFI relay control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI relay. This signal causes current to flow to the coil, closing the contacts of the EFI relay and supplying power to terminal +B of the ECM. If the ignition switch is turned OFF, the ECM holds the EFI relay for a maximum of 2 seconds to allow for the initial setting of the throttle valve. ES ES–460 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM I18 Ignition Switch Driver Side J/B B-R 7 AM2 ES IG2 6 R B B-O 2 2 B B J31 B-O J/C 35 IC4 W-G B J32 B-O 5 AM2 EFI 2 1 EFI Relay 3 2 2 2 2 A J32 Engine Room R/B W-B J/C C J31 B J2 B 1 E8 +B 1 E6 E1 B 1 9 E8 IGSW 8 E8 MREL W-G B 2 1 11 1J L 2 2 IGN 6 1D ECM J8 J/C W-B J/C B B B J3 W-B Battery EB 11 IC4 EE A130724E01 ES–461 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK ECM (+B VOLTAGE) (a) Turn the ignition switch ON. (b) Measure the voltage of the ECM connectors. Standard voltage ECM Connector E6 E8 OK E1 (-) Tester Connection Specified Condition +B (E8-1) - E1 (E6-1) 9 to 14 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE +B (+) E118245E28 ES NG 2 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the wire harness side connector. Standard resistance ECM Connector E6 NG E1 G035617E07 Tester Connection Specified Condition E1 (E6-1) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK ECM (IGSW VOLTAGE) (a) Turn the ignition switch ON. (b) Measure the voltage of the ECM connectors. Standard voltage ECM Connector E6 E8 OK E1 (-) IGSW (+) E118245E29 NG Tester Connection Specified Condition IGSW (E8-9) - E1 (E6-1) 9 to 14 V Go to step 6 ES–462 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (IGN) (a) Remove the IGN fuse from the instrument panel junction block RH. (b) Measure the resistance of the IGN fuse. Standard resistance: Below 1 Ω Driver Side J/B: NG IGN Fuse REPLACE FUSE A072891E01 ES OK 5 INSPECT IGNITION SWITCH ASSEMBLY Component Side: Ignition Switch ACC I18 IG1 4 8 ST2 AM1 3 7 2 6 AM2 ST1 1 5 (a) Remove the lower finish panel. (b) Disconnect the I18 ignition switch connector. (c) Measure the resistance of the ignition switch. Standard resistance Switch position Tester Connection Specified Condition LOCK All Terminals 10 kΩ or higher IG2 Front View ACC 2-3 ON 2-3, 2-4 6-7 START 1-2, 2-4 6-7, 6-8 A087913E10 Below 1 Ω (d) Reconnect the ignition switch connector. NG REPLACE IGNITION SWITCH ASSEMBLY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - IGNITION SWITCH, IGNITION SWITCH - ECM) 6 CHECK ECM (MREL VOLTAGE) ECM Connector (a) Turn the ignition switch ON. (b) Measure the voltage of the ECM connectors. Standard voltage E1 (-) E6 E8 NG STSW (+) MREL (+) E118245E30 Tester Connection Specified Condition MREL (E8-8) - E1 (E6-1) 9 to 14 V REPLACE ECM ES–463 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 7 INSPECT FUSE (EFI) Engine Room R/B: EFI Fuse (a) Remove the EFI fuse from the engine room junction block. (b) Measure the resistance of the EFI fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE ES A072881E03 OK 8 INSPECT EFI RELAY (Marking: EFI) (a) Remove the EFI relay from the engine room junction block. (b) Measure the resistance of the EFI relay. Standard resistance B016200E03 Terminal Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) (c) Reinstall EFI relay. NG REPLACE EFI RELAY OK 9 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the E8 ECM connector. (b) Measure the resistance between the wire harness side connector and body ground. Standard resistance E8 ECM Connector Tester Connection Specified Condition MREL (E8-8) - Body ground Below 1 Ω (c) Reconnect the ECM connector. MREL A115739E02 NG CHECK FOR INTERMITTENT PROBLEMS OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–464 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM VC Output Circuit DESCRIPTION The ECM constantly generates 5 V power from the battery voltage supplied to the +B (BATT) terminal to operate the microprocessor. The ECM also provides this power to the sensors through the VC output circuit. ECM From MAIN Fuse ES From EFI Fuse Throttle Position Sensor, Camshaft Position Sensor, etc. (Sensors which have IC) BATT 5 V Constant Voltage Circuit +B Microprocessor VC Engine Coolant Temperature Sensor, Intake Air Temperature, etc. R A116143E03 When the VC circuit is short-circuited, the microprocessor in the ECM and sensors that are supplied power through the VC circuit are deactivated because the power is not supplied from the VC circuit. Under this condition, the system does not start up and the MIL does not illuminate even if the system malfunctions. HINT: Under normal conditions, the MIL is illuminated for several seconds when the ignition switch is first turned ON. The MIL goes off when the engine is started. WIRING DIAGRAM Refer to the following pages. • Throttle position sensor circuit (See page ES-122). • Canister pump module circuit (See page ES-430). • Secondary air injection pressure sensor circuit (See page ES-217). • Camshaft position sensor circuit (See page ES-195). INSPECTION PROCEDURE 1 CHECK MIL (a) Check that the Malfunction Indicator Lamp (MIL) lights up when turning the ignition switch ON. OK: MIL lights up OK SYSTEM OK ES–465 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG 2 CHECK CONNECTION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and intelligent tester ON. (c) Check the communication between the intelligent tester and ECM. Result Condition Proceed to Communication is possible A Communication is impossible B A GO TO MIL CIRCUIT B 3 INSPECT ECM E4 VC(+) (a) Turn the ignition switch ON. (b) Measure the voltage between E4-23 (VC) and E6-1 (E1) of the ECM connectors. Standard voltage: Voltage is not 5 V E6 E1(-) ECM Connector E118211E02 NEXT 4 CHECK MIL (THROTTLE POSITION SENSOR) (a) Disconnect the T2 throttle body connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Condition Proceed to MIL illuminates A MIL does not illuminate B A B REPLACE THROTTLE BODY ES ES–466 5 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MIL (CAMSHAFT POSITION SENSOR) (a) Disconnect the C1 camshaft position sensor connector. (b) Turn the ignition switch ON. (c) Check the MIL. Result Condition Proceed to MIL illuminates A MIL does not illuminate B A ES REPLACE CAMSHAFT POSITION SENSOR B 6 CHECK MIL (CANISTER PUMP MODULE) (a) (b) (c) (d) Remove the spare tire. Disconnect the L4 canister pump module connector. Turn the ignition switch ON. Check the MIL. L4 A121725E02 Result Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE CANISTER B 7 CHECK MIL (PRESSURE SENSOR) (a) (b) (c) (d) Remove the intake manifold (see page EM-84). Disconnect the A45 pressure sensor. Turn the ignition switch ON. Check the MIL. Result Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE AIR SWITCHING VALVE ES–467 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM B 8 CHECK HARNESS AND CONNECTOR (a) (b) (c) (d) (e) (f) E4 VC NG ECM Connector G035615E10 OK REPLACE ECM Disconnect the T2 throttle body connector. Disconnect the C1 camshaft position sensor connector. Disconnect the L4 canister pump module connector. Disconnect the A45 pressure sensor. Disconnect the E4 ECM connector. Measure the resistance of the wire harness side connector. Standard resistance (check for short) Tester Connection Specified Condition VC (E4-23) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR ES 2UZ-FE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ES–493 ENGINE COOLANT TEMPERATURE SENSOR INSPECTION 1. Acceptable RESISTANCE kΩ TEMPERATURE °C (°F) Z017274E14 INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 20°C (68°F): 2.32 to 2.59 kΩ 80°C (176°F): 0.310 to 0.326 kΩ NOTICE: If inspecting the water temperature sensor in water, prevent water from flowing into the terminals. After inspection, wipe the water off the sensor. ES ES–468 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel Pump Control Circuit DESCRIPTION Refer to DTC P0230 (See page ES-168). WIRING DIAGRAM Refer to DTC P0230 (See page ES-170). INSPECTION PROCEDURE 1 CHECK FUEL PUMP OPERATION (a) Check if there is pressure in the fuel inlet hose. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. ES OK Go to step 10 NG 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE CIRCUIT OPENING RELAY) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (d) Check the relay operation when it is operated by the intelligent tester. Standard: Operating sound can be heard from the relay. OK Go to step 5 NG 3 INSPECT CIRCUIT OPENING RELAY (Marking: C/OPN) (a) Remove the circuit opening relay from the engine room relay block. (b) Measure the resistance of the circuit opening relay. Standard resistance B016200E03 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) (c) Reinstall the circuit opening relay. NG REPLACE CIRCUIT OPENING RELAY ES–469 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 INSPECT ECM (FC VOLTAGE) (a) Turn the ignition switch ON. (b) Measure the voltage of the E8 and E6 ECM connectors. Standard voltage ECM Connector E6 E8 Tester Connection Specified Condition FC (E8-10) - E1 (E6-1) 9 to 14 V OK REPLACE ECM E1 (-) FC (+) ES E118245E31 NG CHECK AND REPAIR HARNESS OR CONNECTOR (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING RELAY - IGNITION SWITCH) 5 CHECK ECM POWER SOURCE CIRCUIT (a) Check the ECM Power Source Circuit (See page ES454). NG REPAIR OR REPLACE OK 6 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay from the engine room relay block. (b) Measure the resistance of the fuel pump relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A030519E02 (c) Reinstall the fuel pump relay. NG OK REPLACE FUEL PUMP RELAY ES–470 7 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUEL PUMP (a) Check the fuel pump operation (See page FU-17). NG REPLACE FUEL PUMP OK 8 CHECK HARNESS AND CONNECTOR (FUEL PUMP - FUEL PUMP RELAY, FUEL PUMP BODY GROUND) (a) Check the harness and connector between the fuel pump and fuel pump relay. (1) Disconnect the F14 fuel pump connector. (2) Remove the fuel pump relay from the engine room R/B. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: ES Fuel Pump Connector F14 Tester Connection Specified Condition Fuel pump (F14-4) - Engine room R/B (Fuel pump relay terminal 4) Below 1 Ω Front View Engine Room R/B: Standard resistance (Check for short) Fuel Pump Relay A138159E01 Tester Connection Specified Condition Fuel pump (F14-4) or Engine room R/B (Fuel pump relay terminal 4) - Body ground 10 kΩ or higher (b) Check the harness and connector between the fuel pump and body ground. (1) Disconnect the F14 fuel pump connector. (2) Measure the resistance between the wire harness side connector and body ground. Standard resistance (Check for open) Tester Connection Specified Condition Engine room R/B (Fuel pump relay terminal 5) Body ground Below 1 Ω NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR ES–471 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 CHECK HARNESS AND CONNECTOR (CIRCUIT OPENING RELAY - FUEL PUMP RELAY) (a) Remove the circuit opening relay from the engine room R/B. (b) Remove the fuel pump relay from the engine room R/B. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Engine Room R/B: Circuit Opening Relay Tester Connection Specified Condition Circuit opening relay (3) - Engine room R/B (Fuel pump relay terminal 3) Below 1 Ω Standard resistance (Check for short) Engine Room R/B: Tester Connection Specified Condition Circuit opening relay (3) or Engine room R/B (Fuel pump relay terminal 3) - Body ground 10 kΩ or higher (d) Reinstall the circuit opening relay. (e) Reinstall the fuel pump relay. NG REPAIR OR REPLACE HARNESS OR CONNECTOR Fuel Pump Relay A138160E01 OK CHECK AND REPAIR HARNESS OR CONNECTOR (EFI RELAY - CIRCUIT OPENING RELAY) 10 INSPECT FUEL PUMP RELAY (a) Remove the fuel pump relay from the engine room relay block. (b) Measure the resistance of the fuel pump relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A030519E02 (c) Reinstall the fuel pump relay. NG OK REPLACE FUEL PUMP RELAY ES ES–472 11 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUEL PUMP RESISTOR (RESISTANCE) Ohmmeter (a) Inspect the fuel pump resistor resistance. (1) Measure the resistance of the terminals. Resistance: 0.70 to 0.76 Ω at 20°C (68°F) NG REPLACE FUEL PUMP RESISTOR A072544E05 ES OK 12 CHECK HARNESS AND CONNECTOR (FUEL PUMP RELAY - FUEL PUMP RESISTOR, FUEL PUMP RESISTOR - FUEL PUMP) (a) Check the harness and connector between the fuel pump relay and fuel pump resistor. (1) Remove the fuel pump relay from the engine room R/B. (2) Disconnect the F8 fuel pump resistor connector. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Engine Room R/B: Fuel Pump Relay Wire Harness Side: Fuel Pump Resistor Connector Tester Connection Specified Condition Engine room R/B (Fuel pump relay terminal 5) Fuel pump resistor (F8-1) Below 1 Ω Standard resistance (Check for short) F8 Tester Connection Specified Condition Engine room R/B (Fuel pump relay terminal 5) or Fuel pump resistor (F8-1) - Body ground 10 kΩ or higher (4) Reinstall the fuel pump relay. (5) Reconnect the fuel pump resistor connector. (b) Check the harness and connector between the fuel pump resistor and fuel pump. (1) Disconnect the F8 fuel pump resistor connector. (2) Disconnect the F14 fuel pump connector. (3) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) Front View Wire Harness Side: Fuel Pump Connector F14 Tester Connection Specified Condition Fuel pump resistor (F8-2) - Fuel pump (F14-4) Below 1 Ω Standard resistance (Check for short) Front View A138161E01 Tester Connection Specified Condition Fuel pump resistor (F8-2) or Fuel pump (F14-4) Body ground 10 kΩ or higher (c) Reconnect the fuel pump resistor connector. 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–473 (d) Reconnect the fuel pump connector. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG REPAIR OR REPLACE HARNESS OR CONNECTOR ES ES–474 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Cranking Holding Function Circuit DESCRIPTION The starter is controlled by the ECM. When the ECM detects a start signal (STSW) from the ignition switch, this system monitors the engine speed (NE) and continues to operate the starter until it has determined that the engine has started (engine speed reaches approximately 500 rpm). If the engine is already running and the ignition switch is turned to START, the ECM will not operate the starter. ACC CUT Relay STA Relay EFI Ignition SW ES STSW AM2 ACC ST2 ACCR P STAR N ACCR ST2 Park/Neutral Starter Position SW ENG rpm STAR Battery ECM STSW STA A074731E04 ES–475 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM 7 8 AM2 ECM Driver Side J/B I18 Ignition SW G-B ST2 3 1D STA No. 2 2 1K 6 IM2 L-Y L-Y 12 E6 STSW R B-Y R 2 2 5 2 AM2 2 P 1 P1 Park / Neutral Position Switch 4 STA Relay 1 N P 3 B-Y 2 2 2 Engine Room R/B 5 B-Y A 2 Y-G ES 8 E5 STAR / NSW R B-Y J28 J/C W-B A 11 E6 STA A B-Y 6 EA1 B B J3 J/C Y-G 11 IM1 2 IC4 B 1 S2 1 S3 B-Y W-B Starter Battery EB B-Y G G J35 J/C A130725E01 ES–476 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK OPERATION OF ENGINE CRANKING (a) When turning the ignition switch to the START position check if the starter motor starts. OK CHECK FOR INTERMITTENT PROBLEMS NG 2 READ VALUE OF INTELLIGENT TESTER (STA SIGNAL) (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Enter the following menu: DIAGNOSIS / ENHANCED OBDII / DATA LIST / PRIMARY / STARTER SIG. (c) Confirm the starter signal status when the ignition switch is operated. ES OK Ignition Switch Position STARTER SIG ON OFF Start ON OK Go to step 5 NG 3 INSPECT ECM (STA AND STSW VOLTAGE) (a) Measure the voltage of the E6 ECM connector while cranking the engine (ignition switch is in the START position). Standard voltage ECM Connector E6 E1 (-) Tester Connection STA (E6-11) - E1 (E6-1) STSW (E6-12) - E1 (E6-1) Specified Condition 9 to 14 V STSW (+) STA (+) E118245E13 Result Terminal STSW Terminal STA 9 to 14 V 9 to 14 V A B 0V 0V B C A Proceed to C REPLACE ECM Go to step 9 ES–477 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 INSPECT PARK / NEUTRAL POSITION SWITCH (a) Disconnect the P1 park / neutral position switch connector. (b) Measure the resistance between each terminal shown below when the shift lever is moved to each position. Standard resistance Component Side Shift Position Tester Connection Park/Neutral Position Switch P 2 - 6, 4 - 5 R 1-2 N 2 - 9, 4 - 5 D 2-7 2 2-3 L 2-8 Specified Condition Below 1 Ω A093221E05 ES (c) Reconnect the park / neutral position switch connector. NG REPLACE PARK / NEUTRAL POSITION SWITCH OK CHECK AND REPAIR HARNESS OR CONNECTOR (PARK / NEUTRAL POSITION SWITCH - ECM) 5 INSPECT STARTER RELAY (a) Remove the starter relay from the engine room relay block. (b) Measure the resistance of the starter relay. Standard resistance B016200E03 Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage applied to terminals 1 and 2) (c) Reinstall the starter relay. NG OK Tester Connection REPLACE STARTER RELAY ES–478 6 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PARK / NEUTRAL POSITION SWITCH - STARTER RELAY, STARTER RELAY - BODY GROUND) (a) Check the harness and the connector between the park / neutral position switch connector and the starter relay. (1) Disconnect the P1 park/neutral position switch connector. (2) Remove the starter relay from the engine room relay block. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: P1 ES Tester Condition Specified condition Park/Neutral position switch (P1-5) Starter relay (1) Below 1 Ω Park/Neutral Position Switch Connector Standard resistance (Check for short) Engine Room R/B: Starter Relay A138162E01 Tester Condition Specified condition Park/Neutral position switch (P1-5) or Starter relay (1) Body ground 10 kΩ or higher (4) Reinstall the starter relay. (5) Reconnect the park/neutral position switch. (b) Check the harness and the connector between the starter relay and the body ground. (1) Remove the starter relay from the engine room relay block. (2) Measure the resistance between the starter relay and the body ground. Standard resistance (Check for open) Tester Condition Specified condition Starter relay (2) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 7 INSPECT ENGINE ROOM RELAY BLOCK (STARTER RELAY VOLTAGE) (a) Remove the Starter relay from the engine room relay block. (b) Measure the voltage of the engine room relay block and body ground. Standard voltage Engine Room R/B: Starter Relay A072892E01 Tester Connection Specified Condition Engine room relay block (Starter relay terminal 5) - Body ground 9 to 14 V (c) Reinstall the Starter relay. NG CHECK AND REPAIR HARNESS AND CONNECTOR (STARTER RELAY - BATTERY) ES–479 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 8 INSPECT STARTER ASSEMBLY (a) Inspect the starter assembly (See page ST-12). NG REPAIR OR REPLACE STARTER ASSEMBLY OK CHECK AND REPAIR HARNESS OR CONNECTOR (STARTER RELAY - STARTER, STARTER BATTERY) ES 9 INSPECT IGNITION SWITCH ASSEMBLY Component Side: Ignition Switch I18 IG1 ST2 ACC 4 8 AM1 3 7 AM2 Front View 2 6 ST1 1 5 (a) Remove the lower finish panel. (b) Disconnect the I18 ignition switch connector. (c) Measure the resistance of the connector terminals shown in the chart below. Standard resistance Switch Position Tester Connection Specified Condition LOCK All terminals 10 kΩ or higher ACC 2-3 ON 2-3 2 - 4, 6 - 7 START 1 - 2, 2 - 4 6 - 7, 6 - 8 IG2 A087913E10 Below 1 Ω (d) Reconnect the I18 ignition switch connector. NG REPLACE IGNITION SWITCH ASSEMBLY OK CHECK AND REPAIR HARNESS OR CONNECTOR (ECM - IGNITION SWITCH, IGNITION SWITCH BATTERY) ES–480 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM IACV Control Circuit DESCRIPTION This circuit opens and closes the Intake Air Control Valve (IACV) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 4,700 rpm or more and the throttle valve opening angle is 60° or more, the IACV is open (VSV: OFF). At all other times, the IACV is closed (VSV: ON). IACV IACV Closed (VSV: ON) Intake Manifold Throttle Valve Opening Angle (c) ES 60 4,700 Engine Speed (rpm) A054312E05 WIRING DIAGRAM ECM 35 IC4 W-G Engine Room R/B J4 J/C EFI No. 2 2 2 1 2 B L-W A 17 L-W IC3 L-W A 12 L-W IM1 C Engine Room R/B 3 5 1 2 2 V1 VSV (ACIS) J28 J/C C L-W 1 D D R 2 33 E4 ACIS Engine Room R/B EFI Relay 2 8 E8 MREL W-G 2 EFI L 2 2 2 2 1 W-B B B J2 J/C B J3 W-B EB Battery A133746E01 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–481 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (VACUUM SWITCHING VALVE) VSV is ON Air Port F Port E VSV is OFF Air Air Filter Port F Port E A067588E03 (a) Disconnect the vacuum hose from port F on the vacuum switching valve (for ACIS). (b) Connect the intelligent tester to the DLC3 with CAN VIM. (c) Start the engine. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1. Operate the ACIS VSV. (e) Check the VSV air flow when switching the VSV. OK Tester Condition Specified Condition VSV is ON Air from port E flows out through port F VSV is OFF Air from port E flows out through the air filter NG Go to step 4 OK 2 CHECK VACUUM HOSES (INTAKE MANIFOLD - VACUUM SWITCHING VALVE, VACUUM SWITCHING VALVE - INTAKE AIR CONTROL VALVE) (a) Check the condition of the vacuum hoses between the intake manifold, vacuum switching valve (for ACIS) and IACV. (1) The vacuum hoses are connected securely. (2) The vacuum hoses are not cracked or damaged. OK: The vacuum hoses are connected securely and not cracked or damaged. NG REPAIR OR REPLACE VACUUM HOSES OK 3 INSPECT INTAKE AIR CONTROL VALVE (a) Inspect the intake air control valve (See page IT-2). NG OK REPLACE ECM REPLACE INTAKE AIR CONTROL VALVE ES ES–482 4 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT VACUUM SWITCHING VALVE (OPERATION) (a) Check that air flows from port E to the air filter. (b) Apply positive (+) battery voltage across the terminals. (c) Check that air flows from port E to port F. Air Filter Air NG Port E REPLACE VACUUM SWITCHING VALVE ES Air Port E Battery Port F A108114E01 OK 5 CHECK HARNESS AND CONNECTOR (VACUUM SWITCHING VALVE - ECM, VACUUM SWITCHING VALVE - EFI NO. 2 FUSE) (a) Check the wire harness between the VSV for ACIS and connector the ECM connector. (1) Disconnect the V1 VSV for ACIS connector. (2) Disconnect the E6 and E4 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side VSV for ACIS Connector V1 Front View E4 ACIS E6 ECM Connector E1 A115740E02 Tester Connection Specified condition VSV for ACIS (V1-2) - ACIS (E4-33) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified condition VSV for ACIS (V1-2) or ACIS (E4-33) E1 (E6-1) 10 kΩ or higher (b) Check the wire harness between the VSV for ACIS connector and the EFI relay. (1) Disconnect the V1 VSV for ACIS connector. (2) Remove the EFI relay from the engine room relay block. (3) Measure the resistance between the wire harness side connectors. ES–483 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard resistance (Check for open) Tester Connection Specified condition VSV for ACIS (V1-1) - EFI relay terminal 3 of R/B Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM ES ES–484 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Circuit DESCRIPTION The Malfunction Indicator Lamp (MIL) is used to indicate the ECM's detection of a vehicle malfunction. The instrument panel GAUGE fuse provides the circuit with power and the ECM provides the circuit ground that illuminates the MIL. MIL operations should be checked visually: The MIL should be illuminated when the ignition switch is turned ON. If the MIL is always ON or OFF, use the intelligent tester and follow the procedures below to determine the cause of the problem. If the ECM detects trouble, the MIL illuminates. At this time, the ECM records a DTC in the memory. ES ES–485 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM R 7 Engine Room R/B 2 R-B AM2 30 E7 W ES I18 Ignition Switch 2 7 C8 AM2 IG2 6 1 Malfunction Indicator Lamp B-R 6 1D 2 Driver Side J/B GAUGE B 15 C10 4 1G Battery Combination Meter R-L A130726E01 ES–486 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CHECK THAT MILL IS ILLUMINATED (a) Perform troubleshooting in accordance with the chart below. Condition B Proceed to MIL remains ON A MIL does not illuminate B Go to step 5 A ES 2 CHECK WHETHER MIL TURNS OFF (a) Connect the intelligent tester to the DLC3 with CAN VIM. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Check whether any DTCs have been stored (See page ES-48). Note them down if necessary. (d) Clear the DTC (See page ES-35). (e) Check if the MIL turns off. OK: MIL should turn off. OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC NG 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the E7 ECM connector. (b) Turn the ignition switch ON. (c) Check that the MIL is not illuminated. OK: MIL is not illuminated. E7 OK ECM Connector REPLACE ECM G035618E23 NG 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Check the harness and connector. OK REPAIR OR REPLACE COMBINATION METER ES–487 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPAIR OR REPLACE HARNESS AND CONNECTOR 5 CHECK THAT MIL IS ILLUMINATED (a) Check that the MIL is illuminated when turning the ignition switch ON. OK: MIL is illuminated. OK SYSTEM OK ES NG 6 CHECK THAT ENGINE STARTS (a) Turn the ignition switch ON. (b) Start the engine. Result Result Proceed to Engine starts A Engine does not start* B HINT: *: The intelligent tester cannot communicate with the ECM. B GO TO VC OUTPUT CIRCUIT A 7 INSPECT COMBINATION METER (MIL CIRCUIT) (a) See the combination meter troubleshooting section (See page ME-4). NG REPAIR OR REPLACE COMBINATION METER OK CHECK AND REPLACE HARNESS OR CONNECTOR (COMBINATION METER - ECM) ES–488 2UZ-FE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR REMOVAL 1. DRAIN ENGINE COOLANT (See page CO-3) 2. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (See page EM-81) 3. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 4. REMOVE OIL COOLER PIPE (See page EM-85) 5. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO. 3 LH (See page EM-85) 6. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolt, stud bolt and camshaft position sensor. ES A134404 INSTALLATION A134404 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the camshaft position sensor with the bolt and stud bolt. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (b) Reconnect the camshaft position sensor connector. 2. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO. 3 LH (See page EM-90) 3. INSTALL OIL COOLER PIPE (See page EM-90) 4. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 5. ADD ENGINE COOLANT (See page CO-3) 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 7. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (See page EM-92) ES–492 2UZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR REMOVAL B003153 ES 1. REMOVE ENGINE UNDER COVER ASSEMBLY REAR 2. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the crank position sensor connector. (b) Remove the bolt and crankshaft position sensor. 2UZ-FE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–493 INSPECTION 1. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold: 1,630 to 2,740 Ω Hot: 2,065 to 3,225 Ω NOTICE: "Cold" and "Hot" above mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). INSTALLATION B003153 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install crank position sensor with bolt. Torque: 6.5 N*m (65 kgf*cm, 58 in.*lbf) (b) Reconnect the crank position sensor connector. 2. INSTALL ENGINE UNDER COVER ASSEMBLY REAR ES ES–496 2UZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY REMOVAL 1. DRAIN ENGINE COOLANT (See page CO-3) 2. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 nuts and throttle body cover subassembly. 3. REMOVE AIR CLEANER HOSE ASSEMBLY (a) Disconnect the vacuum hoses (for the P/S idle-up and fuel pressure regulator) and ventilation hose. (b) Remove the air cleaner hose assembly. 4. REMOVE THROTTLE W/MOTOR BODY ASSEMBLY (a) Disconnect the water by-pass hose, water by-pass hose No. 7 and the throttle position sensor connector. ES A133759 (b) Remove the 3 bolts and nut. (c) Remove the throttle body and the throttle body gasket. A133760 Ohmmeter INSPECTION M- 1. M+ INSPECT THROTTLE W/MOTOR BODY ASSEMBLY (a) Disconnect the throttle control motor connector. (b) Using an ohmmeter, measure the motor resistance between terminals M+ and M-. Motor resistance: 0.3 to 100 Ω at 20°C (68°F) A133758E01 INSTALLATION 1. A133760 INSPECT THROTTLE W/MOTOR BODY ASSEMBLY (a) Install a new gasket and the throttle body with the 3 bolts and nut. Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 2UZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–497 (b) Connect the water by-pass hose, water by-pass hose No. 7 and throttle position sensor connector. A133759 2. INSTALL AIR CLEANER HOSE ASSEMBLY 3. ADD ENGINE COOLANT (See page CO-3) 4. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 5. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (a) Install the throttle body cover sub-assembly with the 2 nuts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) ES ES–500 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR REMOVAL ES 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-6) 2. DRAIN ENGINE COOLANT (See page CO-3) 3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 nuts and throttle body cover subassembly. 4. REMOVE AIR CLEANER HOSE ASSEMBLY (a) Disconnect the vacuum hoses (for the power steering idle-up and fuel pressure regulator) and ventilation hose. (b) Remove the air cleaner hose assembly. 5. DISCONNECT FUEL HOSE (See page FU-10) 6. DISCONNECT FUEL HOSE NO.2 (See page EM-82) 7. DISCONNECT CONNECTORS FROM INTAKE MANIFOLD (a) Disconnect the throttle control connector. (b) Disconnect the purge VSV. (c) Disconnect the 8 injector connectors. (d) Disconnect the ECT sensor connector. (e) Disconnect the 2 VSV connectors for the air injection system. (f) Disconnect the 8 ignition coil connectors. (g) Disconnect the 2 air fuel ratio sensor connectors. 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 8. [B] ES–501 DISCONNECT HOSES FROM INTAKE MANIFOLD (a) Disconnect the vacuum hose [A] from the fuel pressure regulator. (b) Disconnect the PCV hoses [B] from the PCV valve on the LH cylinder head. (c) Disconnect the EVAP hose (from the charcoal canister) [C] from the purge VSV. (d) Disconnect the 2 vacuum hoses [D] from the VSV for the air injection system. [A] ES [C] [D] A134405E01 9. REMOVE INTAKE MANIFOLD (a) Disconnect the 2 water by-pass hoses from the throttle body. Water By-pass Hose A133761E01 (b) Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe. A133763 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–39 DTC CHECK / CLEAR NOTICE: • If no DTC appears in normal mode: On the OBD II scan tool or the intelligent tester, check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979). • When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of DTCs and freeze frame data. HINT: • DTCs stored in the ECM can be displayed on the intelligent tester. The intelligent tester can display current and pending DTCs. • The some DTCs are not set if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, malfunctions detected on only one occasion are stored as pending DTCs. Intelligent Tester 1. CAN VIM DLC3 A072434E01 2. CHECK DTC (Using the intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Check the DTC(s) and freeze frame data, and then write them down. (f) Check the details of the DTC(s) (See page ES-48). NOTICE: • When simulating a symptom with the OBD II scan tool (excluding intelligent tester) to check the DTCs, use the normal mode. For DTCs subject to "2 trip detection logic", perform either of the following actions. • Turn the ignition switch to OFF after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated again, the MIL illuminates and the DTCs are recorded in the ECM. • Check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool. FREEZE FRAME DATA (Using the OBD II scan tool or intelligent tester) (a) Connect the OBD II scan tool or intelligent tester to the DLC3. (b) Turn the ignition switch to ON. ES ES–40 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM 3. ES 4. (c) Use the OBD II scan tool or intelligent tester to check the DTCs and freeze frame data and then write them down. For the intelligent tester, enter the following menus: DIAGNOSIS / OBD/MOBD / FREEZE FRAME DATA. For the OBD II scan tool, see its instruction manual. CLEAR DTC (Using the OBD II scan tool or intelligent tester) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the intelligent tester For the intelligent tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its instruction manual. CLEAR DTC (Not using the OBD II scan tool or intelligent tester) (a) Remove the EFI and ETCS fuse from the engine room R/B for more than 60 seconds, or disconnect the battery terminal for more than 60 seconds. When disconnecting the battery terminal, perform the "INITIALIZE" procedure. ES–502 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR (c) Remove the bolt and nut holding the engine wire protector from the intake manifold and cylinder head. (d) Remove the 2 bolts and ground cables from the RH and LH cylinder heads. (e) Remove the bolt and V-bank cover bracket from the intake manifold. A133764 (f) Disconnect the engine wire from the engine hanger and wire bracket. ES A133765 (g) Remove the bolt and wire bracket from the intake manifold. (h) Remove the 6 bolts, 4 nuts, intake manifold assembly and 2 gaskets. 10. REMOVE AIR PUMP ASSEMBLY W/ BRACKET (See page EC-11) A133766 11. REMOVE KNOCK SENSOR (a) Disconnect the 2 knock sensor connectors. (b) Remove the 2 nuts and 2 knock sensors. A133767 INSPECTION 1. Ohmmeter A093606E07 INSPECT KNOCK SENSOR (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 1 (Ground) - 2 (Output) 120 to 280 kΩ at 20°C (68°F) If the result is not as specified, replace the knock sensor. 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–503 INSTALLATION Knock Sensor 2 1. INSTALL KNOCK SENSOR (a) Install the 2 knock sensors with the 2 nuts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the 2 knock sensor connectors. 2. INSTALL AIR PUMP ASSEMBLY W/ BRACKET (See page EC-12) Upper Engine Rear 0° to 10° ES Engine Rear Upper 0° to 10° Knock Sensor 1 A133768E01 3. INSTALL INTAKE MANIFOLD (a) Place 2 new gaskets on the intake manifold. A133769 (b) Place the intake manifold on the cylinder heads. (c) Install and uniformly tighten the 6 bolts and 4 nuts in several steps. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) A133770 ES–504 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR (d) Install the V-bank cover bracket to the intake manifold. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (e) Install the wire bracket to the intake manifold with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (f) Connect the engine wire to the engine hanger and wire bracket. A133771 (g) Connect the wire protector to the intake manifold and cylinder heads with the bolt and nut. (h) Install the 2 ground cables with the 2 bolts to the RH and LH cylinder heads. ES A133764 (i) Connect the 2 water by-pass hoses to the throttle body. (j) Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe. A133761 Wire Clamp A133763E01 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR 4. CONNECT HOSES FORM INTAKE MANIFOLD (a) Connect the vacuum hose [A] to the fuel pressure regulator. (b) Connect the PCV hose [B] to the PCV valve on the LH cylinder head. (c) Connect the EVAP hose (from the charcoal canister) [C] to the purge VSV. (d) Connect the 2 vacuum hoses [D] to the VSV for the air injection system. 5. CONNECT CONNECTORS FROM INTAKE MANIFOLD (a) Connect the throttle control connector. (b) Connect the 2 VSV connectors for the air injection system. (c) Connect the purge VSV connector. (d) Connect the 8 injector connectors. (e) Connect the ECT sensor connector. (f) Connect the 8 ignition coil connectors. (g) Connect the 2 air fuel ratio sensor connectors. [D] [A] [C] [B] A134405E02 ES–505 6. INSTALL FUEL HOSE NO.2 7. INSTALL FUEL HOSE (See page FU-13) 8. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 9. ADD ENGINE COOLANT (See page CO-3) 10. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 11. CHECK FOR FUEL LEAKS (See page FU-5) ES ES–494 2UZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY THROTTLE BODY 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY WATER BY-PASS HOSE ES VACUUM HOSE IDLE UP NO. 2 HOSE THROTTLE BODY GASKET 14 (143, 10) VENTILATION HOSE AIR CLEANER HOSE ASSEMBLY WATER BY-PASS HOSE NO. 7 THROTTLE W/MOTOR BODY ASSEMBLY THROTTLE POSITION SENSOR CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119859E01 2UZ-FE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–495 ON-VEHICLE INSPECTION 1. A133757 INSPECT THROTTLE BODY (a) Check for an operating sound. (1) Turn the ignition switch to the ON position. (2) When turning the accelerator pedal position sensor lever, listen to a running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See page ES-496), wiring and ECM. (b) Inspect the throttle position sensor. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) When turning the accelerator pedal position sensor lever to the full-open position, check the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA. Standard throttle valve opening percentage: 60% or more If the result is not as specified, check the accelerator pedal position sensor (See page ES-353), wiring and ECM. If the intelligent tester is not available, measure the voltage between the terminals (VTA1 - E2, VTA2 - E2) of the ECM connector (See page ES-27). (c) Inspect the air assist system. (1) Start the engine and check that the MIL does not light up. (2) Warm up the engine to the normal operating temperature. (3) Switch the A/C compressor from ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 +- 50 rpm NOTICE: Perform this inspection while no electrical load is applied. (d) Perform the driving test. ES 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–41 CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to normal mode, check mode is more sensitive to malfunctions. Therefore, check mode can detect the malfunctions that cannot be detected by normal mode. NOTICE: All the stored DTCs and freeze frame data are erased if: 1) the ECM is changed from normal mode to check mode or vice versa; or 2) the ignition switch is turned from ON to ACC or OFF while in check mode. Before changing modes, always check and make a note of any DTCs and freeze frame data. 1. CHECK MODE PROCEDURE (Using the intelligent tester) (a) Check and ensure the following conditions: (1) Positive (+) battery voltage of 11 V or more. (2) Throttle valve fully closed. (3) Transmission in the P or N position. (4) A/C switch OFF. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON. (e) Turn the tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / CHECK MODE. (g) Switch the ECM from normal mode to check mode. 0.13 seconds ON OFF 2. 0.13 seconds A076900E08 3. (h) Make sure the MIL flashes as shown in the illustration. (i) Start the engine. (j) Make sure the MIL turns OFF. (k) Simulate the conditions of the malfunction described by the customer. (l) Check DTCs and freeze frame data using the tester. CLEAR DTC (Using the intelligent tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the intelligent tester. For the intelligent tester: 1) enter the following menus: DIAGNOSIS ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. CLEAR DTC (Not using the intelligent tester) (a) Remove the EFI and ETCS fuse from the engine room R/B for more than 60 seconds, or disconnect the battery terminal for more than 60 seconds. When disconnecting the battery terminal, perform the "INITIALIZE" procedure. ES ES–42 2UZ-FE ENGINE CONTROL SYSTEM – SFI SYSTEM FAIL-SAFE CHART HINT: If any of the following codes are recorded, the ECM enters the fail-safe mode. DTC No. Fail-Safe Operation Fail-Safe Deactivation Conditions P0031, P0032, P0037, P0038, P0051, P0052, P0057 and P0058 The heater circuit in which an abnormality is detected is turned off Ignition switch OFF P0100, P0102 and P0103 Ignition timing is calculated from engine RPM and TP (Throttle Position) "Pass" condition detected P0110, P0112 and P0113 IAT (Intake Air Temperature) is fixed at 20°C (68°F) "Pass" condition detected P0115, P0117 and P0118 ECT (Engine Coolant Temperature) is fixed at 80°C (176°F) "Pass" condition detected P0120, P0121, P0122, P0123, P0220, P0222, P0223, P2102, P2103, P2111, P2112, P2118, P2119 and P2135 If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If the accelerator pedal is depressed quickly, the vehicle may speed up and slow down erratically. "Pass" condition detected and then the ignition switch turned OFF P0327, P0328, P0332 and P0333 Maximum ignition timing retardation Ignition switch OFF P0351, P0352, P0353, P0354, P0355, P0356, P0357 and P0358 Fuel is cut "Pass" condition detected P2120, P2121, P2122, P2123, P2125, P2127, P2128 and P2138 The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. "Pass" condition detected and then the ignition switch turned OFF P2440 and P1441 and/or P1444 Restrict the throttle opening angle: Ga is 30, 50, 100 g/ sec. or less "Pass" condition detected P1441 and P1444 Restrict the throttle opening angle: Ga is 30, 50, 100 g/ sec. or less "Pass" condition detected P1441 and P1444 Restrict the throttle opening angle: Ga is 30, 50, 100 g/ sec. or less "Pass" condition detected P2430, P2431, P2432 and P2433 Restrict the throttle opening angle: Ga is 30, 50, 100 g/ sec. or less "Pass" condition detected ES 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–497 KNOCK SENSOR 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY ES IDLE UP NO. 2 HOSE VACUUM HOSE VENTILATION HOSE AIR CLEANER HOSE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A119860E01 ES–498 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ENGINE WIRE 7.5 (76, 66 in.*lbf) ES ENGINE WIRE VSV FOR AIR INJECTION SYSTEM 18 (185, 13) INJECTOR CONNECTOR 18 (185, 13) WATER BY-PASS HOSE FUEL RETURN HOSE WATER BY-PASS HOSE NO. 7 FUEL HOSE INTAKE MANIFOLD FUEL PIPE CLAMP NO. 2 FUEL PIPE CLAMP NO. 1 VSV CONNECTOR FOR EVAP GASKET VACUUM HOSE 7.5 (76, 66 in.*lbf) WIRE BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE WIRE Non-reusable part A119820E04 2UZ-FE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–499 18 (185, 13) WATER BY-PASS PIPE SUB-ASSEMBLY 16 (163, 12) ES 16 (163, 12) O-RING AIR PUMP ASSEMBLY W/ BRACKET 20 (204, 15) KNOCK SENSOR 1 20 (204, 15) KNOCK SENSOR 2 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A130716E01 ES–510 2UZ-FE ENGINE CONTROL SYSTEM – ECM REMOVAL 1. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 (See page IP-9) 2. REMOVE GLOVE COMPARTMENT DOOR SUBASSEMBLY (See page IP-9) 3. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (See page IP-9) 4. REMOVE ECM (a) Disconnect the 5 ECM connector. (b) Remove the 3 nuts and ECM. (c) Remove the 2 screws and ECM bracket No. 1 from the ECM. (d) Remove the 2 screws and ECM bracket No. 2 from the ECM. ES A072553 INSTALLATION 1. INSTALL ECM (a) Install the ECM bracket No. 2 with the 2 screws to the ECM. (b) Install the ECM bracket No. 1 with the 2 screws to ECM. (c) Install the ECM with the 3 nuts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (d) Connect the 5 ECM connector. 2. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.2 3. INSTALL GLOVE COMPARTMENT DOOR SUBASSEMBLY 4. INSTALL INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 A072553 2UZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ES–513 INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD ASSEMBLY NOTICE: • Be care not to give a shock to the accelerator pedal assembly. • Be care not to disassemble the accelerator pedal assembly. (a) Install the accelerator pedal assembly with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect a accelerator pedal connector. ES A067127 ES–505 2UZ-FE ENGINE CONTROL SYSTEM – EFI RELAY EFI RELAY Ohmmeter 1 2 INSPECTION 1. 5 3 Battery A123026E02 INSPECT EFI RELAY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the E.F.I relay. ES ES–506 2UZ-FE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY Ohmmeter 1 2 1. 5 3 Battery A123026E02 ES INSPECTION INSPECT CIRCUIT OPENING RELAY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the circuit opening relay. ES–507 2UZ-FE ENGINE CONTROL SYSTEM – FUEL PUMP RELAY FUEL PUMP RELAY INSPECTION 1. INSPECT FUEL PUMP RELAY ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance Tester Connection Battery Ohmmeter Ohmmeter Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (Apply battery voltage to terminals 1 and 2) 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) If the result is not as specified, replace the fuel pump relay. A094494E01 ES ES–508 2UZ-FE ENGINE CONTROL SYSTEM – ECM ECM 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES ECM A119840E01 2UZ-FE ENGINE CONTROL SYSTEM – ECM ES–509 ES INSTRUMENT PANEL FINISH PANEL LOWER NO.2 GLOVE COMPARTMENT DOOR SUB-ASSEMBLY INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO. 2 B120192E02 2UZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ES–511 ACCELERATOR PEDAL 2UZ-FE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES ACCELERATOR PEDAL ROD ASSEMBLY (ACCELERATOR PEDAL POSITION SENSOR) A119840E02 ES–512 2UZ-FE ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ON-VEHICLE INSPECTION 1. ES INSPECT ACCELERATOR PEDAL POSITION SENSOR (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Check if the voltage (ACCEL POS) of the CURRENT DATA indicates the standard value. Accelerator pedal released: 0.5 to 1.1 V Accelerator pedal depressed: 2.6 to 4.5 V (d) Check if the voltage (ACCEL POS #2) of the CURRENT DATA indicates the standard value. Accelerator pedal released: 1.2 to 2.0 V Accelerator pedal depressed: 3.4 to 5.3 V If the intelligent tester is not available, measure the voltage between the terminals (VPA - EPA, VPA2 EPA2) of the ECM connector (See page ES-27). REMOVAL 1. A067127 REMOVE ACCELERATOR PEDAL ROD ASSEMBLY (a) Disconnect a accelerator pedal connector. (b) Remove the 2 nuts and accelerator pedal assembly. 2UZ-FE ENGINE MECHANICAL – DRIVE BELT EM–7 INSPECTION 1. P/S Pump INSTALLATION No. 2 Idler Tensioner 1. No. 1 Idler Generator Crankshaft INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the V belt from the tensioner pulley. Then check that nothing gets caught the tensioner by turning it clockwise and counterclockwise. (b) When a malfunction exists, replace the tensioner. INSTALL FAN AND GENERATOR V BELT (a) Set the V belt onto every parts except the No. 2 idler pulley, as shown in the illustration. (b) Loosen the V belt by turning the belt tensioner counterclockwise. (c) Set the V belt to the No. 2 idler pulley. A/C Compressor A053117E01 A C B A052038E01 (d) After installing a new belt, check that the mark is within the B range as shown in the illustration. EM EM–16 2UZ-FE ENGINE MECHANICAL – TIMING BELT REMOVAL Oil Cooler Hose 1. DRAIN ENGINE COOLANT (See page CO-3) 2. SEPARATE BATTERY NEGATIVE TERMINAL 3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 nuts and throttle body cover subassembly. 4. REMOVE AIR CLEANER HOSE ASSEMBLY 5. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 6. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 7. REMOVE FAN WITH FLUID COUPLING (a) Unfasten each clip and the 2 hose clamps, and then separate the 2 oil cooler hoses from the fan shroud. (b) Remove the 3 bolts and separate the fan shroud from the radiator. (c) Remove the 4 nuts and separate the fan with fluid coupling from the engine. (d) Remove the fan shroud and fan with fluid coupling together from the vehicle. (e) Remove the fan pulley. 8. SEPARATE VANE PUMP ASSEMBLY (a) Disconnect the vacuum hose. (b) Remove the nut, 2 bolts and vane pump assembly. HINT: Hang up the hoses instead of detaching. 9. REMOVE GENERATOR ASSEMBLY (See page CH-10) EM Hose Clamp A070463E01 A134361 10. SEPARATE COMPRESSOR (a) Disconnect the compressor connector. (b) Remove the nut, 3 bolts, compressor stay and compressor. HINT: Hang up the hoses instead of detaching. A134362 2UZ-FE ENGINE MECHANICAL – TIMING BELT EM–17 11. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the pulley bolt, cover plate and idler pulley. 12. REMOVE OIL COOLER PIPE (a) Disconnect the 3 hoses. (b) Remove the bolt, nut and oil cooler pipe. A072691 13. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH (a) Remove the grommet and separate the cam position sensor connector from the No. 3 timing belt cover sub-assembly LH. (b) Remove the 4 bolts and No. 3 timing belt cover subassembly LH. 14. REMOVE NO. 2 TIMING CHAIN OR BELT COVER (a) Remove the nut, 3 bolts and No. 2 timing belt cover. A014424 15. REMOVE NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Remove the 2 bolts and No. 2 timing belt cover subassembly. 16. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the bolt, 2 nuts and V-ribbed belt tensioner. 17. REMOVE FAN BRACKET SUB-ASSEMBLY (a) Remove the 2 nuts, 2 bolts and fan bracket subassembly. 18. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Using SST, remove the pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 SST A054468E02 (b) Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021) SST A054470E02 EM EM–18 2UZ-FE ENGINE MECHANICAL – TIMING BELT 19. REMOVE TIMING BELT NO. 1 COVER (a) Remove the 4 bolts and timing belt cover. A072694 20. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Remove the No. 1 crankshaft position sensor plate. EM A072696 21. REMOVE TIMING BELT (a) If reusing the timing belt, check the installation marks on the timing belt. (1) Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part. A054457 (b) Set the No. 1 cylinder to approx. 50° BTDC/ compression. (1) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Turn A054456E01 (2) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned. If not, turn the crankshaft 1 complete revolution (360°). A054458 2UZ-FE ENGINE MECHANICAL – TIMING BELT Approx. 50° Turn Timing Mark A054461E04 EM–19 (3) Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 50°. NOTICE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle. (c) Alternately loosen the 2 bolts, then remove the bolts, the chain tensioner and dust boot. EM A072697 (d) Using a SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by turning the camshaft timing pulley (RH bank) counterclockwise slightly. SST 09960-10010 (09962-01000, 09963-00350) (e) Disconnect the timing belt from the No. 1 timing belt idler and remove the timing belt. SST Slightly Turn A054459E02 EM–20 2UZ-FE ENGINE MECHANICAL – TIMING BELT INSTALLATION 1. Drain Hole Air Hole EM A053991E01 1 Tooth 1/2 Teeth A139497E01 INSTALL TIMING BELT (a) Check the No. 1 timing belt idler and No. 2 timing belt idler. (1) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler. (2) Check that the idler turns smoothly. If necessary, replace the idler. (b) Check the water pump. (1) Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump and timing belt. (2) Turn the pulley, and check that the water pump bearing moves smoothly. If necessary, replace the water pump. (c) Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No. 1 idler and No. 2 idler, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (d) Set the No. 1 cylinder to the TDC/compression. (1) Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates. HINT: By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy: 1/2 teeth turn for the left bank camshaft timing pulley 1 tooth turn for the right bank camshaft timing pulley 2UZ-FE ENGINE MECHANICAL – TIMING BELT EM–21 (2) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Turn A054465E01 A054463 (e) Install the timing belt. (1) Remove any oil or water on each pulley, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (2) Face the front mark (arrow) on the timing belt forward. (3) Put the timing belt on the crankshaft timing pulley. • Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (4) Put the timing belt on the No. 2 idler. (5) Put the timing belt on the camshaft timing pulley (LH bank). • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. (6) Put the timing belt on the water pump pulley. (7) Put the timing belt on the camshaft timing pulley (RH bank). • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. (8) Put the timing belt on the No. 1 idler. (f) 1.27 mm Hexagon Wrench A054983E02 Set the belt tensioner. (1) Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure. (2) Align the holes of the push rod and housing, and pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (3) Release the press. (4) Install the dust boot to the belt tensioner. EM EM–22 2UZ-FE ENGINE MECHANICAL – TIMING BELT (g) Install the belt tensioner. (1) Temporarily install the belt tensioner with the 2 bolts. (2) Alternately tighten the 2 bolts. Torque: 26 N*m (270 kgf*cm, 19 ft.*lbf) (3) Using pliers, remove the 1.27 mm hexagon wrench from the chain tensioner. 1.27 mm Hexagon Wrench A054462E02 (h) Check the valve timing. (1) Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise. EM Turn A054456E01 (2) Check that each pulley is aligned with each timing mark as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it. (3) Remove the crankshaft damper bolt. A054458 2. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Install the sensor plate as shown in the illustration. NOTICE: Take care not to install it in a wrong direction. 3. INSTALL TIMING BELT NO. 1 COVER (a) Install the timing belt cover with the 4 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) Front A053994E01 A072694 2UZ-FE ENGINE MECHANICAL – TIMING BELT 4. SST EM–23 INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Align the pulley set key with the key groove of the crankshaft damper. (b) Using SST and a hammer, tap in the crankshaft damper. SST 09223-46011 A054471E02 (c) Using SST, install the damper bolt. SST 09213-70011 (09213-70020), 09330-00021 Torque: 245 N*m (2,498 kgf*cm, 181 ft.*lbf) SST EM A054469E02 5. INSTALL FAN BRACKET SUB-ASSEMBLY (a) Install the idler pulley with the 2 bolts and 2 nuts. Torque: For 12 mm head 16 N*m (160 kgf*cm, 12 ft.*lbf) For 14 mm head 32 N*m (326 kgf*cm, 24 ft.*lbf) HINT: Each bolt length is as follows: 106 mm (4.17 in.) for 12 mm head (A) 114 mm (4.49 in.) for 14 mm head (B) 6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the belt tensioner with the bolt and 2 nuts. Torque: 16 N*m (160 kgf*cm, 11 ft.*lbf) HINT: Use a bolt 106 mm (4.17 in.) in length. 7. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Install the timing belt cover and fit the claws and pins into each part. (b) Install the timing belt cover with the 2 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) HINT: Use bolts 106 mm (4.17 in.) in length. B A A134365E03 A072692 A054467 EM–24 2UZ-FE ENGINE MECHANICAL – TIMING BELT 8. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH (a) Install the timing belt cover sub-assembly with the 4 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (b) Install the camshaft position sensor connector and grommet to the timing belt cover. 9. INSTALL NO. 2 TIMING CHAIN OR BELT COVER (a) Install the timing chain or belt cover with the nut and 3 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 10. INSTALL OIL COOLER PIPE (a) Install the oil cooler pipe with the bolt and nut. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (b) Connect the 3 hoses. 11. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the idler pulley and cover plate with the bolt. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) EM 12. INSTALL COMPRESSOR (a) Install the compressor with the stay, nut and 3 bolts. Torque: Bolt 47 N*m (475 kgf*cm, 34 ft.*lbf) Nut 25 N*m (255 kgf*cm, 18 ft.*lbf) A072691 13. INSTALL GENERATOR ASSEMBLY (See page CH-17) 14. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump assembly with the nut and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 15. INSTALL FAN WITH FLUID COUPLING (a) Install the fan pulley to the engine. (b) Put the fan with fluid coupling and fan shroud together into the engine room. (c) Install the fan shroud with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (d) Install the fan with fluid coupling with the 4 nuts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 16. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 17. INSTALL RADIATOR SUPPORT SEAL UPPER 18. INSTALL AIR CLEANER HOSE ASSEMBLY 19. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (a) Install the throttle body cover sub-assembly with the 2 nuts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 20. ADD ENGINE COOLANT (See page CO-3) 21. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 2UZ-FE ENGINE MECHANICAL – ENGINE EM–1 ENGINE ON-VEHICLE INSPECTION 1. INSPECT ENGINE COOLANT (See page CO-1) 2. INSPECT ENGINE OIL (See page LU-1) 3. INSPECT BATTERY SPECIFIC GRAVITY (See page CH-3) 4. INSPECT AIR CLEANER FILTER ELEMENT SUBASSEMBLY 5. INSPECT FAN AND GENERATOR V BELT HINT: As the belt tensioner coordinates belt tension automatically by its mechanism, you do not need to adjust it by yourself. (a) Check that the indicator mark on the automatic tensioner is within the A range as shown in the illustration. (b) When the mark is out of the standard range, replace the V belt with a new one. A C B 6. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-6) 7. WARM UP ENGINE 8. INSPECT IGNITION TIMING (a) When using the intelligent tester or OBD II scan tool: (1) Connect the intelligent tester or OBD II scan tool to the DLC3. HINT: Refer to the intelligent tester or OBD II scan tool operator's manual for further details. Ignition timing: 5 to 15° BTDC at idle (Transmission in neutral) (2) Disconnect the intelligent tester or OBD II scan tool from the DLC3. A052038E01 Intelligent Tester 1 DLC3 A134356E01 (b) When not using the intelligent tester or OBD II scan tool: (1) Remove the V-bank cover. (2) Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder. A072742 EM EM–2 2UZ-FE ENGINE MECHANICAL – ENGINE TAC (3) Using SST, connect the tachometer probe to terminal TAC of the DLC3. SST 09843-18030 Tachometer SST DLC3 Battery A075820E01 (4) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG TC EM DLC3 A075821E01 (5) Using the timing light, check the ignition timing. Ignition timing: 5 to 15° BTDC at idle (Transmission in neutral) (6) Remove the SST from the DLC3. (7) Disconnect the timing light from the engine. (8) Install the V-bank cover. A004459 Intelligent Tester 1 DLC3 A134356E01 9. INSPECT ENGINE IDLE SPEED (a) When using the intelligent tester or OBD II scan tool: (1) Connect the intelligent tester or OBD II scan tool to the DLC3. HINT: Refer to the intelligent tester or OBD II scan tool operator's manual for further details. (2) Run the engine at 2,500 rpm for approx. 90 seconds. (3) Check the idle speed. Idle speed: 700 +- 50 rpm If the idle speed is not as specified, check the air intake system. (4) Disconnect the intelligent tester or OBD II scan tool from the DLC3. 2UZ-FE ENGINE MECHANICAL – ENGINE TAC DLC3 Tachometer SST Battery A075820E01 EM–3 (b) When not using the intelligent tester or OBD II scan tool: (1) Using SST, connect the tachometer probe to terminal TAC of the DLC3. SST 09843-18030 HINT: Refer to the intelligent tester operator's manual for further details. (2) Run the engine at 2,500 rpm for approx. 90 seconds. (3) Check the idle speed. Idle speed: 700 +- 50 rpm (4) Remove the SST from the DLC3. (5) Disconnect the tachometer from the DLC3. 10. INSPECT COMPRESSION (a) Remove the V-bank cover sub-assembly. (b) Remove the air cleaner hose assembly. (c) Disconnect the throttle control motor connector. (d) Remove the 8 ignition coils. (e) Remove the 8 spark plugs. (f) Disconnect the 8 injector connectors. A074993 (g) Inspect the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole (Procedure "A"). (2) Fully open the throttle forcibly by hand. (3) While cranking the engine, measure the compression pressure (Procedure "B"). HINT: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. (4) Repeat procedures "A" to "B" for each cylinder. NOTICE: This measurement must be done as quickly as possible. Compression pressure: 1,373 kPa (14.0 kgf/cm2, 199 psi) or more Minimum pressure: 1,030 kPa (10.5 kgf/cm2, 149 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (5) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat procedures "A" to "B" for the cylinders with low compression. • If adding oil helps the compression, the piston rings and/or cylinder bore may be worn or damaged. • If pressure stays low, a valve may be sticking, seating is improper, or there may be leakage past the gasket. (h) Connect the 8 injector connectors. EM EM–4 2UZ-FE ENGINE MECHANICAL – ENGINE (i) (j) (k) (l) (m) Install the 8 spark plugs. Install the 8 ignition coils. Connect the throttle control motor connector. Install the air cleaner hose assembly. Install the V-bank cover sub-assembly. 11. INSPECT CO/HC HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. (a) Start the engine. (b) Sustain the engine speed at 2,500 rpm for approx. 180 seconds. EM A070520 CO HC Symptom (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Immediately check CO/HC concentration at idle and/or 2,500 rpm. HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (See page ES-135 and ES-364). (2) See the table below for possible causes, then inspect and correct the applicable causes if necessary. Cause Normal High Rough idle 1. Faulty ignitions: – Incorrect timing – Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinder Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks: – PCV hose – Intake manifold – Throttle body 2. Lean mixture causing misfire High High Rough idle Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system: – Faulty pressure regulator – Defective ECT sensor – Faulty ECM – Faulty injector – Faulty throttle position sensor – Faulty MAF sensor 2UZ-FE ENGINE MECHANICAL – CAMSHAFT EM–27 REMOVAL 1. REMOVE TIMING BELT HINT: (See page EM-18) 2. REMOVE IGNITION COIL ASSEMBLY (a) Disconnect the 4 ignition coil connectors. (b) Remove the 4 bolts and 4 ignition coils. 3. REMOVE CYLINDER HEAD COVER (for RH Side) (a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. 4. REMOVE CYLINDER HEAD COVER (for LH Side) (a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. Remove the cylinder head cover. 5. REMOVE CAMSHAFT TIMING PULLEY SUBASSEMBLY RH (a) Hold the camshaft with a wrench, and remove the 4 bolts and timing pulley. NOTICE: Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one. 6. REMOVE CAMSHAFT TIMING PULLEY SUBASSEMBLY LH (a) Hold the camshaft with a wrench, and remove the 4 bolts and timing pulley. NOTICE: Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one. A070489 EM A066672 Do not remove A134392E01 Do not remove A134395E01 EM–28 EM 2UZ-FE ENGINE MECHANICAL – CAMSHAFT Cut Part 7. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt, stud bolt and camshaft position sensor. 8. REMOVE CAMSHAFT (for RH Side) NOTICE: • As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. • Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration. Crankshaft pulley 45° Matchmarks A134393E01 (a) Bring the service bolt hole of the sub-gear upward by turning the hexagonal portion of the exhaust camshaft with a wrench. (b) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt Service Bolt Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm A054025E01 HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. (c) Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench. Approx. 10° A054026E01 2UZ-FE ENGINE MECHANICAL – CAMSHAFT 2 17 18 15 13 14 8 4 10 9 7 12 11 21 20 19 6 16 (d) Uniformly loosen and remove the 22 bearing cap bolts in several steps, in the order shown in the illustration. (e) Remove the oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter, and camshafts. HINT: Arrange the bearing caps in the correct order. 22 5 3 EM–29 1 A054151E01 (f) Mount the hexagonal portion of the camshaft in a vise. NOTICE: • Be careful not to damage the camshaft. • Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one. (g) Remove the screw plug and seal washer. Do not remove A054961E02 (h) Using a 10 mm hexagon wrench, remove the bolt. (i) Pull out the timing tube and drive gear from the camshaft. 10 mm Hexagon Wrench A054031E02 (j) 5 mm Hexagon Wrench 9. SST A054029E02 Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal. SST 09960-10010 (09962-01000, 09963-00500) NOTICE: Be careful not to damage the timing tube. REMOVE CAMSHAFT (for LH Side) NOTICE: • As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. • Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration. EM EM–30 2UZ-FE ENGINE MECHANICAL – CAMSHAFT (a) Bring the service bolt hole of the sub-gear upward by turning the hexagonal portion of the exhaust camshaft with a wrench. (b) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt Service Bolt Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm A054037E01 HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. (c) Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench. Align EM B002650E01 21 2 22 5 20 19 1 17 15 6 13 18 4 16 12 3 14 10 11 9 (d) Uniformly loosen and remove the 22 bearing cap bolts in several steps, in the order shown in the illustration. (e) Remove the oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter, and camshafts. HINT: Arrange the bearing caps in the correct order. 8 7 A054154E01 (f) Do not remove A054961E02 Mount the hexagonal portion of the camshaft in a vise. NOTICE: • Be careful not to damage the camshaft. • Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one. (g) Remove the screw plug and seal washer. 2UZ-FE ENGINE MECHANICAL – CAMSHAFT EM–31 (h) Using a 10 mm hexagon wrench, remove the bolt. (i) Pull out the timing tube and drive gear assembly from the camshaft. 10 mm Hexagon Wrench A054031E02 (j) 5 mm Hexagon Wrench Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal. SST 09960-10010 (09962-01000, 09963-00500) NOTICE: Be careful not to damage the timing tube. 10. REMOVE SEMICIRCULAR PLUG SST EM A054029E02 11. REMOVE CAMSHAFT SUB GEAR (a) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A002859 (b) Using SST, turn the sub gear clockwise and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Service Bolt Turn SST A002850E02 (c) Using snap ring pliers, remove the snap ring. (d) Remove the wave washer, sub gear and gear spring. HINT: Arrange the camshaft sub gears and gear spring (RH and LH sides). A054970 EM–32 2UZ-FE ENGINE MECHANICAL – CAMSHAFT (e) Using a vernier caliper, measure the gap distance of the gear spring. Gap distance: 18.2 to 18.8 mm (0.717 to 0.740 in.) If the gap distance is not as specified, replace the gear spring. 18.2 to 18.8 mm 12. REMOVE CAMSHAFT HOUSING PLUG A053870E01 INSTALLATION 1. [1] [2] Pin [3] EM INSTALL CAMSHAFT SUB GEAR (a) Install the gear spring [1], sub gear [2] and wave washer [3]. HINT: Attach the pins on the gears to the gear spring ends. Pin A054971E01 (b) Using snap ring pliers, install the snap ring. A002861 (c) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A002859 Service Bolt Sub Gear Main Gear SST Turn A002889E03 (d) Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise. Temporarily install a service bolt. (e) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt. SST 09960-10010 (09962-01000, 09963-00500) 2UZ-FE ENGINE MECHANICAL – CAMSHAFT 2. EM–33 INSTALL CAMSHAFT TIMING TUBE ASSEMBLY (a) Insert a new oil seal into the camshaft timing tube until it reaches the stopper. NOTICE: • Be careful of the installation direction. • Do not turn over the oil seal lip. Front A054032E01 (b) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts. (c) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps. SST 09960-10010 (09962-01000, 09963-00500) Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Be careful not to damage the timing tube. 5 mm Hexagon Wrench SST A054029E02 (d) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A003173 (e) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom. (f) Using a 10 mm hexagon wrench, install the bolt. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) (g) Install the seal washer and screw plug. Torque: 15 N*m (152 kgf*cm, 11 ft.*lbf) 10 mm Hexagon Wrench 3. A054031E02 INSTALL CAMSHAFT (for RH Side) NOTICE: • As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. • Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when installing the camshaft. Be sure to set the crankshaft pulley at the correct angle as shown in the illustration. EM EM–34 2UZ-FE ENGINE MECHANICAL – CAMSHAFT Crankshaft pulley 45° Cut Part Matchmarks A134393E01 (a) Apply engine oil to the thrust portion of the intake and exhaust camshafts. (b) Align the timing marks (1-dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts. (c) Set the timing marks (1-dot mark) of the camshaft drive and driven main gears at approx. 10° angle. Apporx. 10° EM A054974E01 (d) Apply seal packing to the camshaft housing plug. • Remove the old packing (FIPG) material. • Apply seal packing to the housing plug. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing A054975E01 (e) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration. NOTICE: Be careful of the installation direction. A054976 Seal Width 1.5 to 2.0 mm (f) Seal Packing Groove A072712E01 Apply seal packing to the front bearing cap. • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. 2UZ-FE ENGINE MECHANICAL – CAMSHAFT EM–35 • Apply seal packing to the bearing cap as shown in the illustration. Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall the cap. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Do not apply seal packing to the front bearing cap grooves. (g) Install the front bearing cap. HINT: The thrust position of the camshaft will be determined after installing the front bearing cap. (h) Install the other bearing caps in the order shown with the arrow mark facing forward. A054977 (i) Push in the camshaft setting oil seal. Push A054978E01 (j) E D C E A B E D E C A004469E01 Install new seal washers to the bearing cap bolts (A and B). (k) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E). NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C). HINT: Each bolt length is as follows: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E (l) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. EM EM–36 2UZ-FE ENGINE MECHANICAL – CAMSHAFT 21 8 5 14 9 17 10 3 4 11 15 7 13 1 12 6 19 20 (m) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration. Torque: For bolt C 7.5 N*m (76 kgf*cm, 66 in.*lbf) For others 16 N*m (163 kgf*cm, 12 ft.*lbf) 2 22 16 18 A054151E04 (n) Bring the service bolt installed in the driven subgear upward by turning the hexagonal portion of the camshaft with a wrench. (o) Remove the service bolt. 4. EM Service Bolt A054149E01 INSTALL CAMSHAFT (for LH Side) NOTICE: • As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out. • Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration. (a) Apply MP grease to the thrust portions of the camshafts. (b) Align the timing marks (2-dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts. A054979 (c) Apply seal packing to the camshaft housing plug. • Remove the old packing (FIPG) material. • Apply seal packing to the housing plug. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing A054975E01 2UZ-FE ENGINE MECHANICAL – CAMSHAFT EM–37 (d) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration. NOTICE: Be careful of the installation direction. B002649 Seal Packing Seal Width 1.5 to 2.0 mm Groove A072713E01 (e) Apply seal packing to the front bearing cap. • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. • Apply seal packing to the bearing cap as shown in the illustration. Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall the cap. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Do not apply seal packing to the front bearing cap grooves. (f) Install the front bearing cap. HINT: The thrust position of the camshaft will be determined after installing the front bearing cap. (g) Install the other bearing cap in the order shown with the arrow mark facing forward. A054981 EM EM–38 2UZ-FE ENGINE MECHANICAL – CAMSHAFT (h) Push in the camshaft setting oil seal. Push A054982E01 A (i) A E B B D E E E C E E E E E E E E EM D E E 1 Install a new seal washer to the bearing cap bolt (A and B). (j) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E). (k) Install the camshafts of the LH bank. NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C). HINT: Each bolt length is as follows: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E (l) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. C A054154E03 (m) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration. Torque: For bolt C 7.5 N*m (76 kgf*cm, 66 in.*lbf) For others 16 N*m (163 kgf*cm, 12 ft.*lbf) 21 2 10 3 4 6 14 9 5 17 7 22 12 13 11 15 19 18 8 20 16 A054154E04 (n) Bring the service bolt installed in the driven subgear upward by turning the hexagonal portion of the camshaft with a wrench. (o) Remove the service bolt. 5. Service Bolt A054152E01 INSPECT VALVE CLEARANCE (a) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance (See page EM-8). 2UZ-FE ENGINE MECHANICAL – CAMSHAFT 6. Seal Packing EM–39 INSTALL SEMICIRCULAR PLUG (for RH Side) (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the semicircular plug grooves. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent EM07143E01 (c) Install the 2 semicircular plugs to the cylinder heads. EM A070501E01 7. Seal Packing INSTALL SEMICIRCULAR PLUG (for LH Side) (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the semicircular plug grooves. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent EM07143E01 (c) Install the 4 semicircular plugs to the cylinder heads. 8. INSTALL CAMSHAFT POSITION SENSOR Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 9. INSTALL CAMSHAFT TIMING PULLEY SUB ASSEMBLY RH (a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley. (b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward. (c) Hold the hexagonal portion of the camshaft. (d) Using a 5 mm hexagon wrench, install the 4 bolts. Torque: 8.1 N*m (83 kgf*cm, 72 ft.*lbf) A070504E01 A134394 EM–40 2UZ-FE ENGINE MECHANICAL – CAMSHAFT 10. INSTALL CAMSHAFT TIMING PULLEY SUBASSEMBLY LH (a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley. (b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward. (c) Hold the hexagonal portion of the camshaft. (d) Using a 5 mm hexagon wrench, install the 4 bolts. Torque: 8.1 N*m (83 kgf*cm, 72 in.*lbf) A134396 EM A070502E01 A070505E01 11. INSTALL CYLINDER HEAD COVER (for RH Side) (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent (c) Install the gasket to the cylinder head cover. (d) Install the seal washer to the bolt. (e) Install the cylinder head cover with the 18 bolts. Uniformly tighten the bolts in several steps. Install the 2 cylinder head covers. Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) 12. INSTALL CYLINDER HEAD COVER (for LH Side) (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent (c) Install the gasket to the cylinder head cover. (d) Install the seal washer to the bolt. (e) Install the cylinder head cover with the 18 bolts. Uniformly tighten the bolts in several steps. Install the 2 cylinder head covers. Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) 13. INSTALL IGNITION COIL ASSEMBLY (a) Install the 4 bolts and ignition coil assembly. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 14. INSTALL TIMING BELT HINT: (See page EM-19) 2UZ-FE ENGINE MECHANICAL – DRIVE BELT EM–5 DRIVE BELT 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS EM FAN AND GENERATOR V BELT A119828E03 EM–6 2UZ-FE ENGINE MECHANICAL – DRIVE BELT REMOVAL 1. B000809 EM REMOVE FAN AND GENERATOR V BELT (a) Loosen the belt tension by turning the belt tensioner counterclockwise, and then remove the fan and generator V belt. HINT: The pulley bolt for the belt tensioner has left-hand thread. 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–45 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-10) 2. REMOVE TIMING BELT HINT: (See page EM-18) 3. REMOVE CAMSHAFT (for RH Side) (See page EM-28) 4. REMOVE CAMSHAFT (for LH Side) SST 09960-10010 (09962-01000, 09963-00500) 5. REMOVE TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Remove the bolt and transmission oil filler tube. 6. REMOVE OIL LEVEL GAGE GUIDE (a) Remove the bolt and oil level gauge guide. 7. REMOVE INTAKE MANIFOLD ASSEMBLY (See page ES-501) 8. REMOVE WATER INLET HOUSING (a) Remove the 2 bolts. (b) Remove the water inlet housing and O-ring from the engine. 9. REMOVE WATER BY-PASS JOINT FR (a) Remove the 4 nuts. (b) Remove the water by-pass joint and 2 gaskets. 10. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (a) Remove the bolt and water by-pass pipe. 11. REMOVE NO. 2 AIR SWITCHING VALVE (See page EC-18) 12. REMOVE WATER BY-PASS JOINT RR (a) Remove the 4 nuts, water by-pass joint and 2 gaskets. 13. REMOVE ENGINE WIRE 14. REMOVE NO. 2 REAR TIMING BELT PLATE RH (a) Remove the 2 bolts and No. 2 rear timing belt plate RH. 15. REMOVE REAR TIMING BELT PLATE RH (a) Remove the bolt, stud bolt and rear timing plate RH. 16. REMOVE NO. 2 REAR TIMING BELT PLATE LH (a) Remove the 2 bolts and No. 2 rear timing belt plate LH. 17. REMOVE REAR TIMING BELT PLATE LH (a) Remove the bolt and rear timing belt plate LH. 18. REMOVE FRONT EXHAUST PIPE (a) Remove the 2 bolts and separate the front exhaust pipe. EM EM–46 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 1 7 9 6 4 3 5 10 8 2 19. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Uniformly loosen the 10 cylinder head bolts in the order shown in the illustration. Remove the bolts and plate washers. NOTICE: • Cylinder head warpage or cracking could result from removing bolts in incorrect order. • Do not drop the plate washer for cylinder head bolt into portion A as shown in the illustration. If dropped into the portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. A EM A139498E01 A134397 (b) Remove the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is lifted off, pry off between the cylinder head and cylinder block with a screwdriver. NOTICE: • Be careful not to damage the contact surfaces of the cylinder head and cylinder block. • The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly. 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 2 8 10 5 3 4 6 9 7 1 EM–47 20. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH (a) Uniformly loosen the 10 cylinder head bolts in the order shown in the illustration. Remove the bolts and plate washers. HINT: • Cylinder head warpage or cracking could result from removing bolts in incorrect order. • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. A EM A139499E01 (b) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: • Be careful not to damage the contact surfaces of the cylinder head and cylinder block. • The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly. A134401 21. REMOVE CYLINDER HEAD GASKET 22. REMOVE NO. 2 CYLINDER HEAD GASKET INSPECTION 1. A003194 CLEAN CYLINDER BLOCK SUB-ASSEMBLY (a) Turn the crankshaft, and bring each piston to the top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. EM–48 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using compressed air. A134400 2. EM CHECK CYLINDER BLOCK FOR WARPAGE (a) Inspect for warpage. (1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and crankshaft bearing cap. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than the maximum, replace the cylinder block sub-assembly. Cylinder Head Side Crankshaft Bearing Cap Side A074955E02 (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block. A004853 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 3. EM–49 CLEAN CYLINDER HEAD SUB-ASSEMBLY (a) Clean the cylinder head. (1) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A053862 (2) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. EM A053863 (3) Using a valve guide bushing brush and solvent, clean all the guide bushes. P021861 (4) Using a soft brush and solvent, thoroughly clean the cylinder head. EM06325 EM–50 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 4. CHECK CYLINDER HEAD FOR WARPAGE (a) Inspect for warpage. (1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and the manifolds. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than the maximum, replace the cylinder head. EM A005592 (b) Inspect for cracks. (1) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. EM06327 5. Measuring Point 75 to 85 mm (2.95 to 3.35 in.) INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810 to 9.960 mm (0.3862 to 0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) If the diameter is less than the minimum, replace the bolt. A002827E01 INSTALLATION 1. A134400 INSTALL NO. 2 CYLINDER HEAD GASKET (a) Place a new cylinder head gasket in position on the cylinder block. HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank. 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–51 NOTICE: Be careful of the installation direction. (b) Place the cylinder head in position on the cylinder head gasket. 2. INSTALL CYLINDER HEAD GASKET (a) Place a new cylinder head gasket in position on the cylinder block. HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank. NOTICE: Be careful of the installation direction. (b) Place the cylinder head in position on the cylinder head gasket. 3. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression. (b) Install the cylinder head with the exhaust manifold to the cylinder block. HINT: • The cylinder head bolts are tightened in 2 progressive steps. • If any cylinder head bolt is broken or deformed, replace it. (c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (d) Install the plate washer to the cylinder head bolt. A134398 Timing Mark Timing Mark G039657E02 9 3 1 6 8 7 5 2 4 10 (e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. A A139500E01 EM EM–52 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD (f) Mark the front of the cylinder head bolt head with paint. (g) Retighten the cylinder head bolts by 90° in the order shown. (h) Retighten the cylinder head bolts by an additional 90°. (i) Check that the painted mark is now at a 180° angle to front. 90° 180° Painted Mark A011159E01 4. Timing Mark Timing Mark EM G039657E02 10 4 2 5 7 8 6 1 3 9 A A139501E01 INSTALL CYLINDER HEAD SUB-ASSEMBLY (a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression. (b) Install the cylinder head with the exhaust manifold to the cylinder block. HINT: • The cylinder head bolts are tightened in 2 progressive steps. • If any cylinder head bolt is broken or deformed, replace it. (c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. (d) Install the plate washer to the cylinder head bolt. (e) Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD EM–53 (f) Mark the front of the cylinder head bolt head with paint. (g) Retighten the cylinder head bolts by 90° in the order shown. (h) Retighten the cylinder head bolts by an additional 90°. (i) Check that the painted mark is now at a 180° angle to front. 90° 180° Painted Mark 5. INSTALL FRONT EXHAUST PIPE (a) Place a new gasket to the front exhaust pipe. (b) Install the 2 nuts and front exhaust pipe. Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 6. INSTALL REAR TIMING BELT PLATE LH (a) Install the bolt and rear timing belt plate LH. Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) 7. INSTALL NO. 2 REAR TIMING BELT PLATE LH (a) Install the 2 bolts and No. 2 rear timing belt plate LH. Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) A011159E01 8. INSTALL REAR TIMING BELT PLATE RH (a) Install the timing belt plate with the bolt and stud bolt. Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) 9. INSTALL NO. 2 REAR TIMING BELT PLATE RH (a) Install the timing belt plate with the 2 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) 10. INSTALL WATER BY-PASS JOINT RR (See page EM88) 11. INSTALL NO. 2 AIR SWITCHING VALVE (See page EC-19) 12. INSTALL WATER BY-PASS JOINT FR (See page EM88) 13. INSTALL WATER INLET HOUSING (See page CO-10) 14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (a) Install a new O-ring to the water by-pass pipe. (b) Apply soapy water to the O-ring. (c) Push in the water by-pass pipe end into the pipe hole of the water pump. (d) Install the water by-pass pipe with the bolt. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 15. INSTALL INTAKE MANIFOLD ASSEMBLY (See page ES-503) 16. INSTALL OIL LEVEL GAGE GUIDE (a) Install a new O-ring to the oil level gauge guide. (b) Install the oil level gauge guide with the bolt. Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) EM EM–54 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 17. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Install the transmission oil filler tube sub-assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 18. INSTALL CAMSHAFT (for LH Side) (See page EM-36) 19. INSTALL CAMSHAFT (for RH Side) (See page EM-33) 20. INSTALL TIMING BELT HINT: (See page EM-19) EM 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–7 VALVE CLEARANCE ADJUSTMENT 1. DRAIN ENGINE COOLANT (See page CO-3) 2. SEPARATE BATTERY NEGATIVE TERMINAL 3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY 4. REMOVE AIR CLEANER HOSE ASSEMBLY 5. REMOVE RADIATOR SUPPORT SEAL UPPER 6. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 7. REMOVE OIL COOLER PIPE (See page EM-85) 8. REMOVE IGNITION COIL ASSEMBLY 9. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH (See page EM-85) 10. REMOVE NO. 2 TIMING CHAIN OR BELT COVER (See page EM-85) 11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 9 bolts, 9 seal washers and cylinder head cover. 12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Disconnect the PCV hose. (b) Remove the 9 bolts, 9 seal washers and cylinder head cover. 13. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Turn the crankshaft pulley to align its notch with timing mark "0" of the No. 1 timing belt cover. A003330 (b) Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. A134357 EM EM–8 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE 14. INSPECT VALVE CLEARANCE (a) Check only the valves indicated. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust: 0.25 to 0.35 mm (0.010 to 0.014 in.) RH Cylinder Head EX IN LH Cylinder Head Front IN EM EX A005717E03 (b) Turn the crankshaft 1 complete revolution (360°) and align the camshaft timing marks. (c) Check only the valves indicated as shown in the illustration. Measure the valve clearance. RH Cylinder Head EX 15. ADJUST VALVE CLEARANCE (a) Remove the timing belt (See page EM-18). (b) Remove the camshafts (RH Bank) (See page EM28). (c) Remove the camshafts (LH Bank) (See page EM29). (d) Remove the valve lifter and adjusting shim. NOTICE: Be careful not to drop the adjusting shim into the cylinder head. IN Front LH Cylinder Head IN EX A004457E03 A002213 (e) Determine the replacement adjusting shim size according to the formula or charts on the following pages. (1) Using a micrometer, measure the thickness of the removed shim. (2) Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T: Thickness of removed shim 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE EM–9 A: Measured valve clearance N: Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) (3) Select a new shim with a thickness as close as possible to the calculated value. HINT: • Shims are available in 41 increments of 0.020 mm (0.0008 in.), from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.). • Refer to the new adjusting shim thickness table on the next 2 pages. EM EM–10 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Valve Lifter Selection Chart (Intake) 0.000 - 0.030 (0.0000 - 0.0012) 0.031 - 0.050 (0.0012 - 0.0020) 0.051 - 0.070 (0.0020 - 0.0028) 0.071 - 0.090 (0.0028 - 0.0035) 0.091 - 0.110 (0.0036 - 0.0043) 0.111 - 0.130 (0.0044 - 0.0051) 0.131 - 0.149 (0.0052 - 0.0059) 0.150 - 0.250 (0.0059 - 0.0098) 0.251 - 0.270 (0.0099 - 0.0106) 0.271 - 0.290 (0.0107 - 0.0114) 0.291 - 0.310 (0.0115 - 0.0122) 0.311 - 0.330 (0.0122 - 0.0130) 0.331 - 0.350 (0.0130 - 0.0138) 0.351 - 0.370 (0.0138 - 0.0146) 0.371 - 0.390 (0.0146 - 0.0154) 0.391 - 0.410 (0.0154 - 0.0161) 0.411 - 0.430 (0.0162 - 0.0169) 0.431 - 0.450 (0.0170 - 0.0177) 0.451 - 0.470 (0.0178 - 0.0185) 0.471 - 0.490 (0.0185 - 0.0193) 0.491 - 0.510 (0.0193 - 0.0201) 0.511 - 0.530 (0.0201 - 0.0209) 0.531 - 0.550 (0.0209 - 0.0217) 0.551 - 0.570 (0.0217 - 0.0224) 0.571 - 0.590 (0.0225 - 0.0232) 0.591 - 0.610 (0.0233 - 0.0240) 0.611 - 0.630 (0.0241 - 0.0248) 0.631 - 0.650 (0.0248 - 0.0256) 0.651 - 0.670 (0.0256 - 0.0264) 0.671 - 0.690 (0.0264 - 0.0272) 0.691 - 0.710 (0.0272 - 0.0280) 0.711 - 0.730 (0.0280 - 0.0287) 0.731 - 0.750 (0.0288 - 0.0295) 0.751 - 0.770 (0.0296 - 0.0303) 0.771 - 0.790 (0.0304 - 0.0311) 0.791 - 0.810 (0.0311 - 0.0319) 0.811 - 0.830 (0.0319 - 0.0327) 0.831 - 0.850 (0.0327 - 0.0335) 0.851 - 0.870 (0.0335 - 0.0343) 0.871 - 0.890 (0.0343 - 0.0350) 0.891 - 0.910 (0.0351 - 0.0358) 0.911 - 0.930 (0.0359 - 0.0366) 0.931 - 0.950 (0.0367 - 0.0374) 0.951 - 0.970 (0.0374 - 0.0382) 0.971 - 0.990 (0.0382 - 0.0390) 0.991 - 1.010 (0.0390 - 0.0398) 1.011 - 1.030 (0.0398 - 0.0406) 1.031 - 1.050 (0.0406 - 0.0413) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 EM Removed lifter thickness mm (in.) 2.000 (0.0787) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 08 06 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 08 Measured clearance mm (in.) 00 00 2.020 (0.0795) 00 00 00 2.040 (0.0803) 00 00 00 00 2.060 (0.0811) 02 00 00 00 00 2.080 (0.0819) 04 02 00 00 00 00 2.100 (0.0827) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 06 04 02 00 00 00 00 2.120 (0.0835) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 08 06 04 02 00 00 00 2.140 (0.0843) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 10 08 06 04 02 00 00 2.160 (0.0850) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 12 10 08 06 04 02 00 2.180 (0.0858) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 14 12 10 08 06 04 02 2.200 (0.0866) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 16 14 12 10 08 06 02 2.210 (0.0870) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 16 14 12 10 08 06 04 2.220 (0.0874) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 18 16 14 12 10 08 04 2.230 (0.0878) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 18 16 14 12 10 08 06 2.240 (0.0882) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 20 18 16 14 12 10 06 2.250 (0.0886) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 20 18 16 14 12 10 08 2.260 (0.0890) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 22 20 18 16 14 12 08 2.270 (0.0894) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 22 20 18 16 14 12 10 2.280 (0.0898) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 24 22 20 18 16 14 10 2.290 (0.0902) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 24 22 20 18 16 14 12 2.300 (0.0906) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 26 24 22 20 18 16 12 2.310 (0.0909) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 26 24 22 20 18 16 14 2.320 (0.0913) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 28 26 24 22 20 18 14 2.330 (0.0917) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 28 26 24 22 20 18 16 2.340 (0.0921) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 30 28 26 24 22 20 16 2.350 (0.0925) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 30 28 26 24 22 20 18 2.360 (0.0929) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 32 30 28 26 24 22 18 2.370 (0.0933) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 32 30 28 26 24 22 20 2.380 (0.0937) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 34 32 30 28 26 24 20 2.390 (0.0941) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 34 32 30 28 26 24 22 2.400 (0.0945) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 36 34 32 30 28 26 22 2.410 (0.0949) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 36 34 32 30 28 26 24 2.420 (0.0953) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 38 36 34 32 30 28 24 2.430 (0.0957) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 38 36 34 32 30 28 26 2.440 (0.0961) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 40 38 36 34 32 30 26 2.450 (0.0965) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 40 38 36 34 32 30 28 2.460 (0.0969) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 42 40 38 36 34 32 28 2.470 (0.0972) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 42 40 38 36 34 32 30 2.480 (0.0976) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 44 42 40 38 36 34 30 2.490 (0.0980) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 44 42 40 38 36 34 32 2.500 (0.0984) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 46 44 42 40 38 36 32 2.510 (0.0988) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 46 44 42 40 38 36 34 2.520 (0.0992) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 48 46 44 42 40 38 34 2.530 (0.0996) 80 80 80 78 76 74 72 70 68 66 64 62 60 48 46 44 42 40 38 36 2.540 (0.1000) 80 80 80 80 78 76 74 72 70 68 66 64 62 50 48 46 44 42 40 36 2.550 (0.1004) 80 80 80 78 76 74 72 70 68 66 64 62 50 48 46 44 42 40 38 2.560 (0.1008) 80 80 80 80 78 76 74 72 70 68 66 64 52 50 48 46 44 42 38 2.570 (0.1012) 80 80 80 78 76 74 72 70 68 66 64 52 50 48 46 44 42 40 2.580 (0.1016) 80 80 80 80 78 76 74 72 70 68 66 54 52 50 48 46 44 40 2.590 (0.1020) 80 80 80 78 76 74 72 70 68 66 54 52 50 48 46 44 42 2.600 (0.1024) 80 80 80 78 76 74 72 70 68 56 54 52 50 48 46 44 2.620 (0.1031) 80 80 80 78 76 74 72 70 58 56 54 52 50 48 46 2.640 (0.1039) 80 80 80 78 76 74 72 60 58 56 54 52 50 48 2.660 (0.1047) 80 80 80 78 76 74 62 60 58 56 54 52 50 2.680 (0.1055) 80 80 80 78 76 64 62 60 58 56 54 52 2.700 (0.1063) 80 80 80 78 66 64 62 60 58 56 54 2.720 (0.1071) 80 80 80 68 66 64 62 60 58 56 2.740 (0.1079) 80 80 70 68 66 64 62 60 58 2.760 (0.1087) 80 72 70 68 66 64 62 60 2.780 (0.1094) 74 72 70 68 66 64 62 2.800 (0.1102) A134420 EM–11 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE Valve Lifter Selection Chart (Exhaust) 0.000 - 0.030 (0.0000 - 0.0012) 0.031 - 0.050 (0.0012 - 0.0020) 0.051 - 0.070 (0.0020 - 0.0028) 0.071 - 0.090 (0.0028 - 0.0035) 0.091 - 0.110 (0.0036 - 0.0043) 0.111 - 0.130 (0.0044 - 0.0051) 0.131 - 0.150 (0.0052 - 0.0059) 0.151 - 0.170 (0.0059 - 0.0067) 0.171 - 0.190 (0.0067 - 0.0075) 0.191 - 0.210 (0.0075 - 0.0083) 0.211 - 0.230 (0.0083 - 0.0091) 0.231 - 0.249 (0.0091 - 0.0098) 0.250 - 0.350 (0.0098 - 0.0138) 0.351 - 0.370 (0.0138 - 0.0146) 0.371 - 0.390 (0.0146 - 0.0154) 0.391 - 0.410 (0.0154 - 0.0161) 0.411 - 0.430 (0.0162 - 0.0169) 0.431 - 0.450 (0.0170 - 0.0177) 0.451 - 0.470 (0.0178 - 0.0185) 0.471 - 0.490 (0.0185 - 0.0193) 0.491 - 0.510 (0.0193 - 0.0201) 0.511 - 0.530 (0.0201 - 0.0209) 0.531 - 0.550 (0.0209 - 0.0217) 0.551 - 0.570 (0.0217 - 0.0224) 0.571 - 0.590 (0.0225 - 0.0232) 0.591 - 0.610 (0.0233 - 0.0240) 0.611 - 0.630 (0.0241 - 0.0248) 0.631 - 0.650 (0.0248 - 0.0256) 0.651 - 0.670 (0.0256 - 0.0264) 0.671 - 0.690 (0.0264 - 0.0272) 0.691 - 0.710 (0.0272 - 0.0280) 0.711 - 0.730 (0.0280 - 0.0287) 0.731 - 0.750 (0.0288 - 0.0295) 0.751 - 0.770 (0.0296 - 0.0303) 0.771 - 0.790 (0.0304 - 0.0311) 0.791 - 0.810 (0.0311 - 0.0319) 0.811 - 0.830 (0.0319 - 0.0327) 0.831 - 0.850 (0.0327 - 0.0335) 0.851 - 0.870 (0.0335 - 0.0343) 0.871 - 0.890 (0.0343 - 0.0350) 0.891 - 0.910 (0.0351 - 0.0358) 0.911 - 0.930 (0.0359 - 0.0366) 0.931 - 0.950 (0.0367 - 0.0374) 0.951 - 0.970 (0.0374 - 0.0382) 0.971 - 0.990 (0.0382 - 0.0390) 0.991 - 1.010 (0.0390 - 0.0398) 1.011 - 1.030 (0.0398 - 0.0406) 1.031 - 1.050 (0.0406 - 0.0413) 1.051 - 1.070 (0.0414 - 0.0421) 1.071 - 1.090 (0.0422 - 0.0429) 1.091 - 1.110 (0.0430 - 0.0437) 1.111 - 1.130 (0.0437 - 0.0445) 1.131 - 1.150 (0.0445 - 0.0453) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 08 06 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 08 Measured clearance mm (in.) Removed lifter thickness mm (in.) 2.000 (0.0787) 00 00 2.020 (0.0795) 00 00 00 2.040 (0.0803) 00 00 00 00 2.060 (0.0811) 02 00 00 00 00 2.080 (0.0819) 04 02 00 00 00 00 2.100 (0.0827) 06 04 02 00 00 00 00 2.120 (0.0835) 08 06 04 02 00 00 00 00 2.140 (0.0843) 10 08 06 04 02 00 00 00 00 2.160 (0.0850) 12 10 08 06 04 02 00 00 00 00 2.180 (0.0858) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 14 12 10 08 06 04 02 00 00 00 00 2.200 (0.0866) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 16 14 12 10 08 06 04 02 00 00 00 00 2.210 (0.0870) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 16 14 12 10 08 06 04 02 00 00 00 00 2.220 (0.0874) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 18 16 14 12 10 08 06 04 02 00 00 00 2.230 (0.0878) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 18 16 14 12 10 08 06 04 02 00 00 00 2.240 (0.0882) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 20 18 16 14 12 10 08 06 04 02 00 00 2.250 (0.0886) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 20 18 16 14 12 10 08 06 04 02 00 00 2.260 (0.0890) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 22 20 18 16 14 12 10 08 06 04 02 00 2.270 (0.0894) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 22 20 18 16 14 12 10 08 06 04 02 00 2.280 (0.0898) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 24 22 20 18 16 14 12 10 08 06 04 00 2.290 (0.0902) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 24 22 20 18 16 14 12 10 08 06 04 02 2.300 (0.0906) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 26 24 22 20 18 16 14 12 10 08 06 02 2.310 (0.0909) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 26 24 22 20 18 16 14 12 10 08 06 04 2.320 (0.0913) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 28 26 24 22 20 18 16 14 12 10 08 04 2.330 (0.0917) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 28 26 24 22 20 18 16 14 12 10 08 06 2.340 (0.0921) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 30 28 26 24 22 20 18 16 14 12 10 06 2.350 (0.0925) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 30 28 26 24 22 20 18 16 14 12 10 08 2.360 (0.0929) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 32 30 28 26 24 22 20 18 16 14 12 08 2.370 (0.0933) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 32 30 28 26 24 22 20 18 16 14 12 10 2.380 (0.0937) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 34 32 30 28 26 24 22 20 18 16 14 10 2.390 (0.0941) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 34 32 30 28 26 24 22 20 18 16 14 12 2.400 (0.0945) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 36 34 32 30 28 26 24 22 20 18 16 12 2.410 (0.0949) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 36 34 32 30 28 26 24 22 20 18 16 14 2.420 (0.0953) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 38 36 34 32 30 28 26 24 22 20 18 14 2.430 (0.0957) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 38 36 34 32 30 28 26 24 22 20 18 16 2.440 (0.0961) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 40 38 36 34 32 30 28 26 24 22 20 16 2.450 (0.0965) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 40 38 36 34 32 30 28 26 24 22 20 18 2.460 (0.0969) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 42 40 38 36 34 32 30 28 26 24 22 18 2.470 (0.0972) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 54 42 40 38 36 34 32 30 28 26 24 22 20 2.480 (0.0976) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 44 42 40 38 36 34 32 30 28 26 24 20 2.490 (0.0980) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 56 44 42 40 38 36 34 32 30 28 26 24 22 2.500 (0.0984) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 58 46 44 42 40 38 36 34 32 30 28 26 22 2.510 (0.0988) 80 80 80 78 76 74 72 70 68 66 64 62 60 58 46 44 42 40 38 36 34 32 30 28 26 24 2.520 (0.0992) 80 80 80 80 78 76 74 72 70 68 66 64 62 60 48 46 44 42 40 38 36 34 32 30 28 24 2.530 (0.0996) 80 80 80 78 76 74 72 70 68 66 64 62 60 48 46 44 42 40 38 36 34 32 30 28 26 2.540 (0.1000) 80 80 80 80 78 76 74 72 70 68 66 64 62 50 48 46 44 42 40 38 36 34 32 30 26 2.550 (0.1004) 80 80 80 78 76 74 72 70 68 66 64 62 50 48 46 44 42 40 38 36 34 32 30 28 2.560 (0.1008) 80 80 80 80 78 76 74 72 70 68 66 64 52 50 48 46 44 42 40 38 36 34 32 28 2.570 (0.1012) 80 80 80 78 76 74 72 70 68 66 64 52 50 48 46 44 42 40 38 36 34 32 30 2.580 (0.1016) 80 80 80 80 78 76 74 72 70 68 66 54 52 50 48 46 44 42 40 38 36 34 30 2.590 (0.1020) 80 80 80 78 76 74 72 70 68 66 54 52 50 48 46 44 42 40 38 36 34 32 2.600 (0.1024) 80 80 80 78 76 74 72 70 68 56 54 52 50 48 46 44 42 40 38 36 34 2.620 (0.1031) 80 80 80 78 76 74 72 70 58 56 54 52 50 48 46 44 42 40 38 36 2.640 (0.1039) 80 80 80 78 76 74 72 60 58 56 54 52 50 48 46 44 42 40 38 2.660 (0.1047) 80 80 80 78 76 74 62 60 58 56 54 52 50 48 46 44 42 40 2.680 (0.1055) 80 80 80 78 76 64 62 60 58 56 54 52 50 48 46 44 42 2.700 (0.1063) 80 80 80 78 66 64 62 60 58 56 54 52 50 48 46 44 2.720 (0.1071) 80 80 80 68 66 64 62 60 58 56 54 52 50 48 46 2.740 (0.1079) 80 80 70 68 66 64 62 60 58 56 54 52 50 48 2.760 (0.1087) 80 72 70 68 66 64 62 60 58 56 54 52 50 2.780 (0.1094) 74 72 70 68 66 64 62 60 58 56 54 52 2.800 (0.1102) EM A134421 EM–12 2UZ-FE ENGINE MECHANICAL – VALVE CLEARANCE (f) Place a new adjusting shim on the valve. (g) Place the valve lifter. (h) Reinstall the camshafts (LH Bank) (See page EM36). (i) Reinstall the camshafts (RH Bank) (See page EM33). (j) Reinstall the timing belt (See page EM-19). (k) Recheck the valve clearance. 16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 18. INSTALL NO. 2 TIMING CHAIN OR BELT COVER (See page EM-90) 19. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH (See page EM-90) EM 20. INSTALL IGNITION COIL ASSEMBLY 21. INSTALL OIL COOLER PIPE (See page EM-90) 22. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 23. INSTALL RADIATOR SUPPORT SEAL UPPER 24. INSTALL AIR CLEANER HOSE ASSEMBLY 25. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY 26. CONNECT BATTERY NEGATIVE TERMINAL 27. ADD ENGINE COOLANT (See page CO-3) 2UZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–59 REMOVAL 1. REMOVE TIMING BELT HINT: (See page EM-18) 2. REMOVE CRANKSHAFT TIMING PULLEY (a) Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTICE: Do not turn the timing pulley. 3. REMOVE OIL PUMP SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use. SST A004445E01 Cut Position A004863E01 INSTALLATION 1. INSTALL OIL PUMP SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09316-60011 (09316-00011) 2. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the timing pulley set key with the key groove of the pulley. (b) Using SST and a hammer, tap in the timing pulley with the flange side facing inward. SST 09223-46011 3. INSTALL TIMING BELT HINT: (See page EM-19) SST A004864E02 Inward SST A004446E01 EM EM–13 2UZ-FE ENGINE MECHANICAL – TIMING BELT TIMING BELT 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS THROTTLE BODY COVER SUB-ASSEMBLY RADIATOR SUPPORT SEAL UPPER 7.5 (80, 66 in.*lbf) AIR CLEANER HOSE ASSEMBLY EM FAN SHROUD 5.0 (51, 44 in.*lbf) 29 (296, 11) FAN PULLEY FAN WITH FLUID COUPLING FAN AND GENERATOR V BELT 29 (296, 11) ENGINE UNDER COVER ASSEMBLY REAR NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) 29 (296, 11) A119828E02 EM–14 2UZ-FE ENGINE MECHANICAL – TIMING BELT VANE PUMP ASSEMBLY FAN BRACKET SUB-ASSEMBLY 43 (438, 32) 16 (160, 12) NO. 2 TIMING CHAIN OR BELT COVER EM 7.5 (80, 66 in.*lbf) 32 (330, 24) NO. 2 TIMING BELT COVER SUB-ASSEMBLY NO. 1 CHAIN TENSIONER ASSEMBLY 16 (160, 12) COVER PLATE 26 (270, 19) 39 (400, 29) NO. 2 IDLER PULLEY SUB-ASSEMBLY NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) OIL COOLER PIPE 47 (475, 34) COMPRESSOR 7.5 (80, 66 in.*lbf) 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque A119829E02 2UZ-FE ENGINE MECHANICAL – TIMING BELT EM–15 V-RIBBED BELT TENSIONER ASSEMBLY 16 (160, 12) 9.8 (100, 86 in.*lbf) 16 (160, 12) TIMING BELT NO. 1 COVER GENERATOR ASSEMBLY 39 (400, 29) 245 (2,500, 181 ) EM 39 (400, 29) 16 (160, 12) 7.5 (80, 66 in.*lbf) CRANKSHAFT DAMPER SUB-ASSEMBLY TIMING BELT NO. 1 CRANKSHAFT POSITION SENSOR PLATE N*m (kgf*cm, ft.*lbf) : Specified torque A119830E01 EM–66 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL REMOVAL EM 1. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See page AT-348) 2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See page AT-361) 3. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY (a) Using SST, hold the crankshaft. SST 09213-70011, 09330-00021 SST A134399E01 (b) Remove the 8 bolts, front spacer, drive plate and rear spacer. A004857 4. Cut Position REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use. A004858E01 INSTALLATION SST 1. A004859E01 INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL 2. EM–67 INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY (a) Using SST, hold the crankshaft. SST 09213-70011, 09330-00021 SST A134399E01 (b) Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Adhesive EM A004869E03 1 (c) Install the front spacer, drive plate and rear spacer on the crankshaft. (d) Install and uniformly tighten the 8 mounting bolts in several steps, in the order shown in the illustration. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt. 5 8 3 4 7 6 2 A004857E01 (e) Mark the mounting bolt with paint (Procedure "A"). (f) Retighten the mounting bolts by 90° in the order shown. (g) Check that the painted mark is now at a 90° angle to the mark placed in procedure "A". Painted Mark 90° 90° 3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See page AT-362) 4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See page AT-349) A087896E01 EM–25 2UZ-FE ENGINE MECHANICAL – CAMSHAFT CAMSHAFT 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS RH BANK: 6.0 (60, 53 in.*lbf) x9 CYLINDER HEAD COVER SUB-ASSEMBLY RH OIL FEED PIPE GASKET 16 (160, 12) CAMSHAFT SETTING OIL SEAL 16 (160, 12) EM 7.5 (80, 66 in.*lbf) BEARING CAP CAMSHAFT DRIVE GEAR BEARING CAP CAMSHAFT TIMING TUBE ASSEMBLY NO. 1 CAMSHAFT SUB-ASSEMBLY 7.5 (80, 66 in.*lbf) 78 (795, 58) SEAL WASHER NO. 2 CAMSHAFT SUB-ASSEMBLY CAMSHAFT GEAR SPRING 15 (152, 11) SCREW PLUG NO. 3 CAMSHAFT SUB GEAR 8.1 (83, 72 in.*lbf) CAMSHAFT TIMING PULLEY RH CAMSHAFT SUB GEAR WAVE WASHER CAMSHAFT SUB GEAR SHAFT SNAP RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119831E01 EM–26 2UZ-FE ENGINE MECHANICAL – CAMSHAFT LH BANK: x9 6.0 (60, 53 in.*lbf) CYLINDER HEAD COVER SUB-ASSEMBLY LH OIL FEED PIPE GASKET 16 (160, 12) BEARING CAP CAMSHAFT TIMING TUBE ASSEMBLY EM 16 (160, 12) CAMSHAFT SETTING OIL SEAL 7.5 (80, 66 in.*lbf) CAMSHAFT DRIVE GEAR 78 (795, 58) CAMSHAFT BEARING CAP SEAL WASHER 15 (152, 11) 7.5 (76, 66 in.*lbf) SCREW PLUG NO. 3 CAMSHAFT SUB-ASSEMBLY NO. 4 CAMSHAFT SUB-ASSEMBLY 8.1 (83, 72 in.*lbf) CAMSHAFT GEAR SPRING CAMSHAFT TIMING PULLEY LH NO. 3 CAMSHAFT SUB GEAR CAMSHAFT SUB GEAR WAVE WASHER 7.5 (80, 66 in.*lbf) CAMSHAFT SUB GEAR SHAFT SNAP RING CAMSHAFT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119832E01 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–81 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-10) 2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See page AT-348) 3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See page AT-361) 4. REMOVE HOOD SUB-ASSEMBLY (a) Disconnect the windshield washer hose. (b) Disconnect the hood dampers. (c) Remove the 4 bolts and hood sub-assembly. 5. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 nuts and throttle body cover subassembly. 6. REMOVE AIR CLEANER HOSE ASSEMBLY (a) Disconnect the vacuum hoses (for P/S idle up and for fuel pressure regulator) and ventilation hose. 7. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the intake air flow meter connector. (b) Disconnect the ground cable from the body. (c) Remove the air cleaner cap and air cleaner element. (d) Remove the 3 bolts and air cleaner assembly. 8. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY 9. REMOVE ENGINE UNDER COVER ASSEMBLY REAR 10. DRAIN ENGINE COOLANT (See page CO-3) 11. DRAIN ENGINE OIL (a) Remove the oil pan drain plug and drain the engine oil. (b) Clean the oil pan drain plug and install a new gasket and the drain plug. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 12. REMOVE RADIATOR ASSEMBLY HINT: (See page CO-14) 13. REMOVE FAN SHROUD (a) Disconnect the fasteners of the clamp and oil cooler hoses from the fan shroud in sequence. (b) Remove the fan shroud with fan. EM EM–82 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 14. DISCONNECT NO. 2 FUEL HOSE (a) Observe the following precautions when disconnecting the fuel tube connector: (1) Remove the No. 2 fuel pipe clamp. (2) Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. No. 2 Fuel Pipe Clamp A060083E22 (3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. A A EM A134358E01 (4) When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time. (5) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away. B012944 (6) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. Plastic Bag A134359E01 15. DISCONNECT FUEL HOSE (a) Observe the following precautions when disconnecting the fuel tube connector: (1) Remove the No. 1 fuel pipe clamp. (2) Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. No. 1 Fuel Pipe Clamp A060083E23 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–83 (3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. A A A134358E01 (4) When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time. (5) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away. B012944 (6) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. Plastic Bag 16. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 17. REMOVE FAN AND GENERATOR V BELT (See page EM-6) A134359E01 18. SEPARATE VANE PUMP ASSEMBLY (a) Disconnect the vacuum hose. (b) Remove the nut, 2 bolts and vane pump assembly. HINT: Hang up the hose instead of detaching. A134361 19. SEPARATE COMPRESSOR (a) Disconnect the compressor connector. (b) Remove the nut, 3 bolts, compressor stay and compressor. HINT: Hang up the hoses instead of detaching. A134362 EM EM–84 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 20. REMOVE FAN WITH FLUID COUPLING (a) Remove the 4 nuts and fan with fluid coupling. (b) Remove the fan pulley. 21. REMOVE TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Remove the bolt and transmission oil filler tube. A134363 22. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the bolt and oil level gauge guide. (b) Remove the O-ring. 23. DISCONNECT HEATER HOSE 24. SEPARATE ENGINE WIRE (a) Remove the front door scuff plate RH (See page IP6). (b) Remove the cowl side trim board RH (See page IP9). (c) Remove the glove compartment door (See page IP9). EM (d) Disconnect each connector for the ECM, fourwheel- drive-control ECU (4WD only) and instrument panel wire before pulling out the engine wire into the engine room. (e) Disconnect the 3 ground cables from the body. (f) Disconnect the No. 2 engine wire from the battery terminals (positive and negative) and engine room relay block. A070478 25. REMOVE ENGINE ASSEMBLY (a) Attach the engine chain hoist to the engine hangers. (b) Remove the 4 nuts and 4 bolts. (c) Lift the engine out of the vehicle slowly and carefully. HINT: Make sure that the engine is kept clear of all wiring hoses and cables. 26. REMOVE ENGINE WIRE (a) Disconnect the VSV connector. (b) Disconnect the solenoid connector. A070480 27. REMOVE INTAKE MANIFOLD ASSEMBLY (See page ES-501) 28. REMOVE NO. 2 WIRING HARNESS HEAT INSULATOR (a) Remove the 2 bolts and No. 2 wiring harness heat insulator. 29. REMOVE NO. 2 ENGINE WIRE (a) Remove the bolt and separate the ground cable wire. (b) Remove the nut, 2 bolts and No. 2 engine wire. 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–85 30. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT RH (a) Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front. 31. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH (a) Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front. 32. REMOVE GENERATOR ASSEMBLY (See page CH-10) 33. REMOVE HEATER HOSE 34. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY (See page EM-66) 35. REMOVE OIL COOLER PIPE (a) Disconnect the 3 hoses. (b) Remove the bolt, nut and oil cooler pipe. 36. REMOVE PUMP BRACKET (a) Remove the 4 bolts and pump bracket. 37. REMOVE NO. 3 TIMING BELT COVER SUBASSEMBLY LH (a) Remove the grommet and separate the cam position sensor connector from the No. 3 timing belt cover sub-assembly LH. (b) Remove the 4 bolts and No. 3 timing belt cover subassembly LH. A014424 38. REMOVE NO. 2 TIMING CHAIN OR BELT COVER (a) Remove the nut, 3 bolts and No. 2 timing belt cover. A134364 39. REMOVE NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Remove the 2 bolts and No. 2 timing belt cover subassembly. A054467 EM EM–86 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 40. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the bolt, 2 nuts and V-ribbed belt tensioner. A072692 41. REMOVE FAN BRACKET SUB-ASSEMBLY (a) Remove the 2 nuts, 2 bolts and fan bracket subassembly. 42. REMOVE IGNITION COIL ASSEMBLY (a) Remove the 8 bolts and 8 ignition coils. 43. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt, stud bolt and camshaft position sensor. EM A134365 44. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and crankshaft position sensor. 45. REMOVE VVT SENSOR (a) Remove the 2 bolts and VVT sensors. 46. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (a) Remove the wire clamp. (b) Remove the bolt and water by-pass. (c) Remove the O-ring from the water by-pass pipe sub-assembly. 47. REMOVE NO. 2 AIR SWITCHING VALVE (See page EC-18) A134366 48. REMOVE WATER BY-PASS JOINT RR (a) Remove the 4 nuts and water by-pass joint. (b) Remove the 2 gaskets from the water by-pass joint. 49. REMOVE AIR PUMP ASSEMBLY WITH BRACKET (See page EC-11) 50. REMOVE STARTER ASSEMBLY (a) Disconnect the No. 2 engine wire. (b) Remove the 2 bolts and starter assembly. A134367 51. REMOVE KNOCK SENSOR (See page ES-502) 52. REMOVE WATER INLET HOUSING (See page EM-45) EM–41 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS ENGINE WIRE ENGINE WIRE PROTECTOR 18 (185, 13) 7.5 (76, 66 in.*lbf) EM VSV FOR AIR INJECTION SYSTEM WATER BY-PASS JOINT RR WATER BY-PASS HOSE 18 (185, 13) GASKET NO. 7 WATER BY-PASS HOSE NO. 2 FUEL HOSE INTAKE MANIFOLD ASSEMBLY NO. 2 FUEL PIPE CLAMP FUEL HOSE WATER BY-PASS PIPE SUB-ASSEMBLY NO. 1 FUEL PIPE CLAMP 18 (185, 13) GASKET 7.5 (76, 66 in.*lbf) O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119835E01 EM–42 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD NO. 2 AIR TUBE 10 (102, 7) 10 (102, 7) GASKET O-RING 18 (185, 13) NO. 2 AIR SWITCHING VALVE NO. 3 AIR TUBE 18 (185, 13) EM GASKET 10 (102, 7) WATER BY-PASS JOINT FR WATER INLET HOUSING GASKET NO. 2 REAR TIMING BELT PLATE RH 7.5 (80, 66 in.*lbf) IGNITION COIL 7.5 (80, 66 in.*lbf) REAR TIMING BELT PLATE RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A130723E01 EM–43 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD 6.0 (60, 53 in.*lbf) x9 CYLINDER HEAD COVER SUB-ASSEMBLY GASKET CAMSHAFT TIMING OIL CONTROL VALVE 16 (160, 12) 7.5 (80, 66 in.*lbf) 7.5 (76, 66 in.*lbf) O-RING 16 (160, 12) BEARING CAP EM CAMSHAFT (WITH TIMING TUBE) BEARING CAP *1 NO. 2 CAMSHAFT (WITH SUB GEAR) 1st: 40 (408, 30) 2nd: Turn 90° 3rd: Turn 90° x10 SEMICIRCULAR PLUG OIL CONTROL VALVE FILTER CAMSHAFT HOUSING PLUG ENGINE HANGER 16 (160, 12) CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET *1: See paragraph INSTALLATION N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119834E01 EM–44 2UZ-FE ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD COVER SUB-ASSEMBLY LH 6.0 (60, 53 in.*lbf) x9 GASKET 7.5 (76, 66 in.*lbf) 16 (160, 12) CAMSHAFT TIMING OIL CONTROL VALVE EM 16 (160, 12) BEARING CAP O-RING NO. 4 CAMSHAFT SUB-ASSEMBLY (WITH SUB GEAR) BEARING CAP NO. 3 CAMSHAFT SUB-ASSEMBLY (WITH TIMING TUBE) x10 CAMSHAFT HOUSING PLUG *1 1st: 40 (408, 30) 2nd: Turn 90° OIL CONTROL VALVE FILTER 3rd: Turn 90° ENGINE HANGER SEMICIRCULAR PLUG 37 (380, 27) CYLINDER HEAD GASKET CYLINDER HEAD SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part *1: See paragraph INSTALLATION A119837E01 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–87 53. REMOVE WATER BY-PASS JOINT FR (a) Remove the 4 nuts, water by-pass joint and 2 gaskets. 54. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Remove the 4 bolts and No. 1 exhaust manifold heat insulator. (b) Disconnect the oxygen sensor connector. (c) Remove the 8 nuts and exhaust manifold subassembly. A134368 55. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Remove the 4 bolts and No. 2 exhaust manifold heat insulator. (b) Disconnect the oxygen sensor connector. (c) Remove the 8 nuts and exhaust manifold subassembly. 56. REMOVE OIL COOLER ASSEMBLY (a) Remove the 2 bolts and nut. (b) Remove the oil cooler assembly with bracket and gasket. 57. REMOVE VENTILATION VALVE SUB-ASSEMBLY (a) Remove the ventilation valve cover. (b) Remove the ventilation valve sub-assembly. 58. REPLACE PARTIAL ENGINE ASSEMBLY INSTALLATION 1. INSTALL VENTILATION VALVE SUB-ASSEMBLY (a) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent B016488 (b) Install the ventilation valve. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) HINT: After tightening the valve to the specified torque, turn the ventilation valve clockwise with the port facing in the direction indicated in the illustration. (c) Install the ventilation valve cover to the ventilation valve. (d) Connect the ventilation hose to the ventilation valve. 15 to 25° A072725E01 2. INSTALL OIL COOLER ASSEMBLY (a) Place a new gasket into the groove of the oil cooler. (b) Apply a light coat of engine oil to the gasket. (c) Install the oil cooler assembly with the 2 bolts and nut. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) EM EM–88 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Place a new gasket on the cylinder head. NOTICE: Be careful of the installation direction. (b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in diagonally. Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf) (c) Install the heat insulator with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Place a new gasket on the cylinder head. NOTICE: Be careful of the installation direction. (b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts diagonally. Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf) (c) Install the heat insulator with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 5. INSTALL WATER BY-PASS JOINT FR (a) With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side. (b) Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 6. INSTALL WATER INLET HOUSING (See page CO-10) 7. INSTALL KNOCK SENSOR (See page ES-502) 8. INSTALL STARTER ASSEMBLY (a) Install the starter assembly with the 2 bolts. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (b) Connect the No. 2 engine wire. Torque: 9.8 N*m (100 kgf*cm, 7.2 ft.*lbf) 9. INSTALL AIR PUMP ASSEMBLY WITH BRACKET (See page EC-12) A134369 EM A134370 Flat Area A070482E01 10. INSTALL WATER BY-PASS JOINT RR (a) With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side. (b) Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) Flat Area 11. INSTALL NO. 2 AIR SWITCHING VALVE (See page EC-19) A070482E01 12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (a) Install a new O-ring to the water by-pass pipe. (b) Apply soapy water to the O-ring. 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–89 (c) Push in the water by-pass pipe end into the pipe hole of the water pump. (d) Install the water by-pass pipe with the bolt. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 13. INSTALL VVT SENSOR (a) Install the VVT sensors with the 2 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) A134371 14. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the crankshaft position sensor with the bolt. Torque: 6.5 N*m (65 kgf*cm, 58 in.*lbf) 15. INSTALL CAMSHAFT POSITION SENSOR (a) Install the camshaft position sensor with the bolt and the stud bolt. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 16. INSTALL IGNITION COIL ASSEMBLY (a) Install the 8 ignition coils with the 8 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 17. INSTALL FAN BRACKET SUB-ASSEMBLY (a) Install the fan bracket with the 2 bolts and 2 nuts. Torque: 12 mm head 16 N*m (160 kgf*cm, 12 ft.*lbf) 14 mm head 32 N*m (326 kgf*cm, 24 ft.*lbf) A134365 18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the v-ribbed belt tensioner with the bolt and 2 nuts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) A072692 19. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Install the No. 2 timing belt cover sub-assembly with the 2 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) A054467 EM EM–90 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 20. INSTALL NO. 2 TIMING CHAIN OR BELT COVER (a) Install the timing chain or belt cover with the nut and 3 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) A134372 21. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH (a) Install the timing belt cover sub-assembly with the 4 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (b) Install the camshaft position sensor connector and grommet to the timing belt cover. EM A014424 22. INSTALL PUMP BRACKET (a) Install the pump bracket with the 4 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 23. INSTALL OIL COOLER PIPE (a) Install the oil cooler pipe with the bolt and nut. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (b) Connect the 3 hoses. 24. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY (See page EM-67) 25. INSTALL HEATER HOSE 26. INSTALL GENERATOR ASSEMBLY (See page CH-17) 27. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH (a) Install the engine-mounting bracket and enginemounting insulator with the 4 bolts. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 28. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH (a) Install the engine-mounting bracket and enginemounting insulator with the 4 bolts. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 29. INSTALL NO. 2 ENGINE WIRE (a) Install the engine wire protector with the nut and 2 bolts. (b) Connect the ground cable wire clamp with the bolt. 30. INSTALL NO. 2 WIRING HARNESS HEAT INSULATOR (a) Install the wiring harness heat insulator with the 2 bolts. Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) 31. INSTALL INTAKE MANIFOLD ASSEMBLY (See page ES-503) 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–91 32. INSTALL ENGINE WIRE 33. INSTALL ENGINE ASSEMBLY (a) Attach the engine chain hoist to the engine hangers. (b) Slowly lower the engine assembly into the engine compartment. (c) Attach the engine mounting brackets to the frame brackets. (d) Install the engine mounting brackets with the 4 nuts and 4 bolts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) (e) Remove the engine chain hoist. 34. INSTALL ENGINE WIRE 35. CONNECT HEATER HOSE 36. INSTALL OIL LEVEL GAUGE GUIDE (a) Install a new O-ring to the oil level gauge guide. (b) Install the oil level gauge guide with the bolt. Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 37. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (a) Install a new O-ring to the oil filler tube subassembly. (b) Install the transmission oil filler tube sub-assembly with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 38. INSTALL FAN WITH FLUID COUPLING (a) Install the fan pulley to the engine. (b) Install the fan with fluid coupling with the 4 nuts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) A134363 39. INSTALL COMPRESSOR (a) Install the compressor with the stay, nut and 3 bolts. Torque: Bolt 47 N*m (475 kgf*cm, 34 ft.*lbf) Nut 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Connect the compressor connector. A134362 EM EM–92 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 40. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump assembly with the nut and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 41. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 42. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 43. CONNECT FUEL HOSE A134361 44. CONNECT NO. 2 FUEL HOSE 45. INSTALL FAN SHROUD (a) Install the fan shroud with the fan into the engine room. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 46. INSTALL RADIATOR ASSEMBLY (See page CO-14) EM 47. ADD ENGINE COOLANT (See page CO-3) 48. ADD ENGINE OIL 49. INSTALL ENGINE UNDER COVER ASSEMBLY REAR 50. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY 51. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner assembly with the 3 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) (b) Connect the wire harness clamp and the ground cable. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 52. INSTALL AIR CLEANER HOSE ASSEMBLY 53. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (a) Install the throttle body cover sub-assembly with the 2 nuts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 54. INSTALL HOOD SUB-ASSEMBLY (a) Install the hood with the 4 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the hood damper. Torque: 18 N*m (180 kgf*cm, 13 ft.*lbf) (c) Connect the windshield washer hose. 55. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: (See page AT-349) 56. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: (See page AT-362) 57. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-4) 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–93 58. CHECK FOR EXHAUST GAS LEAKAGE 59. CHECK FOR FUEL LEAK (See page FU-5) 60. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: (See page AT-304) 61. CHECK FOR ENGINE OIL LEAKAGE EM 2UZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–55 ENGINE FRONT OIL SEAL 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS THROTTLE BODY COVER SUB-ASSEMBLY RADIATOR SUPPORT SEAL UPPER 7.5 (80, 66 in.*lbf) AIR CLEANER HOSE ASSEMBLY EM FAN SHROUD 5.0 (51, 44 in.*lbf) 29 (296, 21) FAN PULLEY FAN WITH FLUID COUPLING FAN AND GENERATOR V BELT 29 (296, 21) ENGINE UNDER COVER ASSEMBLY REAR NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 29 (296, 21) A119828E04 EM–56 2UZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL VANE PUMP ASSEMBLY FAN BRACKET SUB-ASSEMBLY 43 (438, 32) 16 (160, 12) NO. 2 TIMING CHAIN OR BELT COVER EM 7.5 (80, 66 in.*lbf) 32 (330, 24) NO. 2 TIMING BELT COVER SUB-ASSEMBLY 16 (160, 12) COVER PLATE NO. 1 CHAIN TENSIONER ASSEMBLY 26 (270, 19) 39 (400, 29) NO. 2 IDLER PULLEY SUB-ASSEMBLY NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) OIL COOLER PIPE 47 (475, 34) COMPRESSOR 7.5 (80, 66 in.*lbf) 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque A119829E03 2UZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–57 V-RIBBED BELT TENSIONER ASSEMBLY 16 (160, 12) 9.8 (100, 86 in.*lbf) 16 (160, 12) TIMING BELT NO. 1 COVER GENERATOR ASSEMBLY 39 (400, 29) 245 (2,500, 181 ) EM 39 (400, 29) 16 (158, 11) 7.5 (80, 66 in.*lbf) CRANKSHAFT DAMPER SUB-ASSEMBLY TIMING BELT NO. 1 CRANKSHAFT POSITION SENSOR PLATE N*m (kgf*cm, ft.*lbf) : Specified torque A119830E02 EM–58 2UZ-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM OIL PUMP SEAL CRANKSHAFT TIMING PULLEY Non-reusable part A119825E01 EM–60 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL ENGINE REAR OIL SEAL 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS 2WD: NO. 1 OIL COOLER INLET TUBE NO. 1 OIL COOLER OUTLET TUBE 5 (50, 43 in.*lbf) 34 (346, 25) AUTOMATIC TRANSMISSION ASSEMBLY 71 (720, 53) TRANSMISSION CONTROL CABLE 71 (720, 53) 71 (720, 53) EM 37 (380, 35) x6 12 (122, 9) 48 (490, 35) TORQUE CONVERTER CLUTCH ASSEMBLY 12 (122, 9) 71 (720, 53) 37 (380, 35) FLYWHEEL HOUSING UNDER COVER 18 (184, 13) NO. 1 ENGINE MOUNTING INSULATOR REAR 65 (663, 48) 72 (734, 53) 65 (663, 48) NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY FRONT SUSPENSION MEMBER BRACKET 72 (734, 53) 18 (184, 13) 33 (336, 24) 33 (336, 24) 33 (336, 24) FRONT SUSPENSION MEMBER BRACKET LH 33 (336, 24) N*m (kgf*cm, ft.*lbf) : Specified torque C119722E04 EM–61 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL 48 (490, 35) GASKET 48 (490, 35) EXHAUST PIPE GASKET 62 (630, 46) 62 (630, 46) GASKET EM 88 (900, 65) PROPELLER SHAFT ASSEMBLY 88 (900, 65) 29 (296, 21) 29 (296, 21) 29 (296, 21) ENGINE UNDER COVER REAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119723E02 EM–62 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL 4WD: TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY ATF LEVEL GAUGE PROPELLER SHAFT ASSEMBLY 12 (122, 9) 88 (900, 65) NO. 1 OIL COOLER INLET TUBE EM TRANSFER ASSEMBLY NO. 1 OIL COOLER OUTLET TUBE 5 (50, 43 in.*lbf) 34 (346, 25) AUTOMATIC TRANSMISSION ASSEMBLY 71 (720, 53) 48 (490, 35) 12 (122, 9) TRANSMISSION CONTROL CABLE FLYWHEEL HOUSING UNDER COVER TORQUE CONVERTER CLUTCH ASSEMBLY 18 (184, 13) 88 (900, 65) PROPELLER SHAFT ASSEMBLY FRONT 88 (900, 65) N*m (kgf*cm, ft.*lbf) : Specified torque C119729E04 EM–63 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EXHAUST PIPE NO. 1 ENGINE MOUNTING INSULATOR REAR GASKET 48 (490, 35) 65 (663, 48) NO. 3 FRONT CROSSMEMBER SUB-ASSEMBLY GASKET 62 (630, 46) FRONT SUSPENSION MEMBER BRACKET 72 (734, 53) 33 (336, 24) 33 (336, 24) FRONT SUSPENSION MEMBER RACKET LH ENGINE UNDER COVER REAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119730E03 EM EM–64 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL ENGINE REAR OIL SEAL 49 (500, 36) CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY ENGINE REAR OIL SEAL RETAINER 16 (160, 11) O-RING 31 (311, 23) EM x7 8.0 (82, 71 in.*lbf) O-RING 49 (500, 36) 16 (160, 11) OIL PUMP ASSEMBLY OIL PUMP SEAL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY CRANKSHAFT TIMING PULLEY 18 (184, 13) 21 (214, 15) GASKET x5 18 (184, 13) WATER PUMP ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part A119825E04 2UZ-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–65 GASKET OIL STRAINER SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) EM OIL PAN SUB-ASSEMBLY (NO. 1) 7.5 (76, 66 in.*lbf) 28 (290, 31) OIL PAN BAFFLE PLATE 7.5 (76, 66 in.*lbf) NO. 2 OIL PAN SUB-ASSEMBLY GASKET x17 N*m (kgf*cm, ft.*lbf) : Specified torque 39 (398, 29) OIL PAN DRAIN PLUG 7.5 (76, 66 in.*lbf) Non-reusable part A119930E03 EM–68 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS THROTTLE BODY COVER SUB-ASSEMBLY HOOD SUB-ASSEMBLY THROTTLE WITH MOTOR BODY ASSEMBLY CONNECTOR 7.5 (80, 66 in.*lbf) 18 (180, 13) HOOD DAMPER EM 13 (133, 10) 12 (125, 9) AIR CLEANER ASSEMBLY AIR CLEANER HOSE ASSEMBLY ENGINE UNDER COVER ASSEMBLY REAR NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque 29 (296, 21) 29 (296, 21) A119814E02 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–69 RADIATOR SUPPORT SEAL UPPER 5.0 (51, 44 in.*lbf) RADIATOR ASSEMBLY EM FAN SHROUD NO. 1 OIL COOLER INLET HOSE 13 (130, 9) NO. 1 TRANSMISSION OIL COOLER HOSE FAN WITH FLUID COUPLING FAN PULLEY 29 (296, 21) FAN AND GENERATOR V BELT N*m (kgf*cm, ft.*lbf) : Specified torque A119815E01 EM–70 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 4WD AUTOMATIC TRANSMISSION ASSEMBLY EM 88 (899, 65) PROPELLER SHAFT ASSEMBLY 37 (377, 27) for 14 mm Head 71 (724, 52) for 17 mm Head 88 (899, 65) PROPELLER SHAFT ASSEMBLY FRONT N*m (kgf*cm, ft.*lbf) : Specified torque A119816E01 EM–71 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 2WD 88 (899, 65) AUTOMATIC TRANSMISSION ASSEMBLY 37 (377, 27) for 14 mm Head 71 (724, 52) for 17 mm Head EM FRONT SUSPENSION MEMBER BRACKET OIL COOLER TUBE 12 (122, 9) DRIVE PLATE & RING GEAR SUB-ASSEMBLY 34 (347, 25) DRIVE PLATE SPACER REAR 1st: 30 (301, 22) 33 (336, 24) 2nd: Turn 90° 48 (489, 35) 33 (336, 24) DRIVE PLATE SPACER FRONT FRONT SUSPENSION MEMBER BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part FLYWHEEL HOUSING UNDER COVER A137102E01 EM–72 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY OIL LEVEL GAUGE GUIDE 12 (122, 9) VANE PUMP ASSEMBLY 43 (438, 32) 15 (155, 11) 43 (438, 32) 7.5 (76, 66 in.*lbf) EM 43 (438, 32) PUMP BRACKET EXHAUST MANIFOLD SUB-ASSEMBLY RH 44 (450, 33) GASKET NO. 1 EXHAUST MANIFOLD HEAT INSULATOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119817E01 EM–73 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EXHAUST PIPE ASSEMBLY FRONT 43 (438, 32) GASKET GASKET GASKET ENGINE MOUNTING INSULATOR FRONT 62 (632, 46) 62 (632, 46) EXHAUST MANIFOLD SUB-ASSEMBLY LH GASKET 36 (367, 27) 9.8 (100, 86 in.*lbf) 44 (450, 33) ENGINE MOUNTING INSULATOR FRONT GENERATOR ASSEMBLY 17 (175, 13) 36 (367, 27) 38 (387, 28) 39 (400, 29) 16 (158, 11) NO. 2 WIRING HARNESS HEAT INSULATOR 47 (475, 34) 39 (400, 29) 7.5 (76, 69 in.*lbf) COMPRESSOR COMPRESSOR STAY 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Non-reusable part A119818E01 EM EM–74 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY CAMSHAFT POSITION SENSOR 7.5 (80, 66 in.*lbf) EM 7.5 (80, 66 in.*lbf) NO. 2 TIMING CHAIN OR BELT COVER GASKET CRANKSHAFT POSITION SENSOR 6.5 (65, 58 in.*lbf) 7.5 (80, 66 in.*lbf) 18 (183, 13) OIL COOLER ASSEMBLY WITH OIL FILTER 7.5 (80, 66 in.*lbf) OIL COOLER PIPE NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH 7.5 (80, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119819E03 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–75 ENGINE WIRE VSV FOR AIR INJECTION SYSTEM 7.5 (76, 66 in.*lbf) ENGINE WIRE PROTECTOR 18 (185, 13) WATER BY-PASS HOSE NO. 2 FUEL HOSE NO. 7 WATER BY-PASS HOSE FUEL HOSE INTAKE MANIFOLD ASSEMBLY NO. 2 FUEL PIPE CLAMP NO. 1 FUEL PIPE CLAMP GASKET 7.5 (76, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119820E08 EM EM–76 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY NO. 2 AIR TUBE 10 (102, 7) 10 (102, 7) GASKET GASKET NO. 2 AIR SWITCHING VALVE EM O-RING 18 (185, 13) 18 (185, 13) NO. 3 AIR TUBE 10 (102, 7) GASKET WATER INLET HOUSING WATER BY-PASS JOINT FR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A130721E01 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–77 AIR PUMP ASSEMBLY WITH BRACKET 16 (163, 12) EM STARTER ASSEMBLY 18 (185, 13) 9.8 (100, 7.2) NO. 2 ENGINE WIRE O-RING WATER BY-PASS PIPE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119821E01 EM–78 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY KNOCK SENSOR 20 (204, 15) VVT SENSOR 7.5 (80, 66 in.*lbf) VENTILATION VALVE COVER EM 39 (400, 29) VENTILATION VALVE SUB-ASSEMBLY 7.5 (80, 66 in.*lbf) REAR TIMING BELT PLATE RH 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) REAR TIMING BELT PLATE LH IGNITION COIL ASSEMBLY NO. 2 REAR TIMING BELT PLATE LH 7.5 (80, 66 in.*lbf) CAMSHAFT POSITION SENSOR NO. 2 REAR TIMING BELT PLATE RH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A119927E01 EM–79 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY V-RIBBED BELT TENSIONER ASSEMBLY 16 (160, 12) 16 (160, 12) 16 (160, 12) EM FAN BRACKET SUB-ASSEMBLY 32 (326, 24) NO. 1 TIMING BELT COVER NO. 2 TIMING BELT COVER SUB-ASSEMBLY 245 (2,498, 181) COVER PLATE 7.5 (80, 66 in.*lbf) CRANKSHAFT DAMPER SUB-ASSEMBLY 39 (398, 24) DUST BOOT NO. 2 IDLER PULLEY SUB-ASSEMBLY NO. 1 CHAIN TENSHONER ASSEMBLY 26 (270, 19) N*m (kgf*cm, ft.*lbf) : Specified torque A119822E08 EM–80 2UZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY NO. 1 TIMING BELT IDLER SUB-ASSEMBLY PLATE WASHER 35 (352, 25) CAMSHAFT TIMING PULLEY EM 8.1 (83, 72 in.*lbf) 8.1 (83, 72 in.*lbf) TIMING BELT CRANKSHAFT TIMING PULLEY NO. 1 CRANKSHAFT POSITION SENSOR PLATE 35 (352, 25) NO. 2 TIMING BELT IDLER SUB-ASSEMBLY TIMING GEAR COVER SPACER N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 TIMING CHAIN COVER GASKET Precoated part A119928E01 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–107 DISASSEMBLY HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets, O-rings and oil seals with new ones. 1. REMOVE ENGINE HANGERS (a) Remove the 4 bolts and engine hangers. 2. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Remove the 2 water drain cocks. 3. REMOVE SPARK PLUG 4. REMOVE OIL FILLER CAP SUB-ASSEMBLY 5. REMOVE OIL FILLER CAP HOUSING (a) Remove the 2 nuts and oil filler cap housing. 6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. A072687 A072688 A072689 A072690 EM EM–108 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 8. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the pulley bolt, cover plate and idler pulley. 9. REMOVE NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Remove the 2 bolts and timing belt cover. A072691 EM A054467 10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the bolt, 2 nuts and belt tensioner. A072692 11. REMOVE FAN BRACKET SUB-ASSEMBLY (a) Remove the 2 bolts, 2 nuts and fan bracket. A134365 12. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Using SST, remove the pulley bolt. SST 09213-70011 (90105-08076), 09330-00021 SST A054468E03 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–109 (b) Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021) SST A054470E02 13. REMOVE NO. 1 TIMING BELT COVER (a) Remove the 4 bolts and timing belt cover. EM A072694 14. REMOVE TIMING GEAR COVER SPACER (a) Remove the cover spacer and gasket. A072695E01 15. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Remove No. 1 crankshaft position sensor plate. A072696E01 16. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) If reusing the timing belt, check the installation marks on the timing belt. (1) Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration. If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part. A054457 EM–110 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Turn A054456E01 (c) Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned. If not, turn the crankshaft 1 complete revolution (360°). EM A054008 Approx. 45° Turn Timing Mark A054461E05 17. REMOVE TIMING BELT (a) Set the No. 1 cylinder to approx. 45° BTDC/ compression. (1) Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 45°. NOTICE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle. (b) Alternately loosen the 2 bolts, then remove the bolts, chain tensioner and dust boot. A072697 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–111 (c) Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise. SST 09960-10010 (09962-01000, 09963-00350) (d) Disconnect the timing belt from the No. 1 timing belt idler and remove the timing belt. SST Slightly Turn A054459E02 18. REMOVE CAMSHAFT TIMING PULLEYS (a) Hold the crankshaft with a wrench, and remove the 8 bolts and 2 timing pulleys. RH Bank: EM LH Bank: A134373E01 19. REMOVE NO. 1 TIMING BELT IDLER SUBASSEMBLY (a) Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer. A072698 20. REMOVE NO. 2 TIMING BELT IDLER SUBASSEMBLY (a) Remove the bolt and idler. A072699 EM–112 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 21. REMOVE CRANKSHAFT TIMING PULLEY (a) Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTICE: Do not turn the timing pulley. 22. REMOVE NO. 2 REAR TIMING BELT PLATE RH (a) Remove the 2 bolts and No. 2 rear timing belt plate RH. SST A072700E01 23. REMOVE REAR TIMING BELT PLATE RH (a) Remove the bolt, stud bolt and rear timing belt plate RH. 24. REMOVE NO. 2 REAR TIMING BELT PLATE LH (a) Remove the 2 bolts and No. 2 rear timing belt plate LH. 25. REMOVE REAR TIMING BELT PLATE LH (a) Remove the bolt and rear timing belt plate LH. EM 26. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Service Bolt A054149E01 (a) Remove the camshafts of the RH bank. (1) In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench. (2) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. EM–113 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (3) Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench. A054150 2 17 18 15 13 14 8 22 5 20 19 6 4 16 10 9 7 12 11 21 3 (4) Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts. (5) Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts. 1 EM A054151E01 (b) Remove the camshafts on the LH bank. (1) In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench. (2) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: Service Bolt Thread diameter A054152E01 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has eliminated by the above operation. (3) Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench. Align A054153E02 EM–114 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 2 21 22 5 20 19 17 15 6 4 1 16 12 3 14 10 11 EM 13 18 8 9 7 27. REMOVE SEMICIRCULAR PLUG A054154E01 28. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several steps, in the order shown in the illustration. Likewise, loosen the 10 bolts on the other side. Remove the 20 cylinder head bolts and plate washers. NOTICE: • Cylinder head warpage or cracking may result from removing bolts in incorrect order. • Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. RH Cylinder Head: 9 6 4 5 3 10 LH Cylinder Head: 8 2 Front 5 3 1 7 A 2 8 10 (4) Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts. (5) Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts. HINT: Arrange the bearing caps in the correct order. A 4 6 9 7 1 A072703E01 A002871 (b) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench. NOTICE: • Be careful not to damage the contact surfaces of the cylinder head and cylinder block. • The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly. HINT: If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–115 29. REMOVE WATER PUMP ASSEMBLY (a) Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. A134374 SST A072704E01 30. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove the 17 bolts and 2 nuts. (b) Insert the blade of SST between the oil pan and No. 2 oil pan, and cut off applied sealer. Remove the No. 2 oil pan. SST 09032-00100 NOTICE: • Be careful not to damage the contact surface of the oil pan and the No. 2 oil pan. • Be careful not to damage the No. 2 oil pan flange. 31. REMOVE OIL PAN BAFFLE PLATE (a) Remove the 2 bolts, 2 nuts and baffle plate. A072705 32. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 18 bolts and 2 nuts. A072706 EM EM–116 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the order shown in the illustration. NOTICE: • Be careful not to damage the contact surfaces of the cylinder block or oil pan. Pry EM A072707E01 33. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the 2 bolts, 2 nuts, oil strainer and gasket. A072708 34. REMOVE OIL PUMP ASSEMBLY (a) Remove the 7 bolts and stud bolt. HINT: Use a 6 mm hexagon wrench to tighten the hexagon head bolt. 6 mm Hexagon Wrench B013038E03 (b) Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pump. (c) Remove the O-ring from the cylinder block. B002617 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–117 35. REMOVE ENGINE REAR OIL SEAL RETAINER (a) Remove the 7 bolts. (b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap. (c) Remove the O-ring. Pry A005086E01 Bend 36. REMOVE SPARK PLUG TUBE GASKET (a) Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more. (b) Using a screwdriver, pry out the gasket. NOTICE: Be careful not to damage the cylinder head cover. Tape the screwdriver tip. Pry EM Claw A004107E01 Do not remove A054961E02 37. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY (a) Mount the hexagonal portion of the camshaft in a vise. NOTICE: • Be careful not to damage the camshaft. • Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one. (b) Remove the screw plug and seal washer. (c) Using a 10 mm hexagon wrench, and remove the bolt. (d) Pull out the timing tube and drive gear assembly from the camshaft. 10 mm Hexagon Wrench A054962E02 (e) Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal. SST 09960-10010 (09962-01000, 09963-00500) NOTICE: Be careful not to damage the timing tube. 5 mm Hexagon Wrench SST A054965E03 EM–118 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 38. REMOVE CAMSHAFT SUB GEAR (a) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A054968 (b) Using SST, turn the sub gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Recommended service bolt: Turn Service Bolt SST Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) EM A054969E01 (c) Using snap ring pliers, remove the snap ring. (d) Remove the wave washer, sub gear and gear spring. HINT: Arrange the camshaft sub gears and gear spring (RH and LH sides). A054970 39. REMOVE OIL PUMP SEAL (a) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the oil pump body. Tape the screwdriver tip. A054145E01 40. REMOVE ENGINE REAR OIL SEAL (a) Using a screwdriver and hammer, tap out the oil seal. 41. REMOVE VALVE LIFTER (a) Remove the valve lifter and adjusting shim. HINT: Arrange the valve lifters and shims in the correct order. A054147 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–119 42. REMOVE INTAKE VALVE (a) Using SST, compress the valve spring and remove the 2 valve spring retainer locks. SST 09202-70020 (09202-01010) (b) Remove the spring retainer, valve spring, valve and spring seat. HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. SST A050250E02 43. REMOVE EXHAUST VALVE (a) Using SST, compress the valve spring and remove the 2 valve spring retainer locks. SST 09202-70020 (09202-00010) (b) Remove the spring retainer, valve spring, valve and spring seat. HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. SST A050249E02 44. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seal. A003192 A005100 45. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 to 0.290 mm (0.0063 to 0.0114 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. Connecting rod thickness (Reference): 22.880 to 22.920 mm (0.9008 to 0.9024 in.) EM EM–120 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 46. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. A005104 EM A005105 (c) Using the removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Plastigage Lay a strip of Plastigage across the crank pin. A005102E01 (g) Match the numbered connecting rod cap with the connecting rod. (h) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. A005106 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (i) LH Bank: Front EM–121 Check that the outside mark of the connecting rod cap is facing in the correct direction. HINT: • The connecting rod cap bolts are tightened in 2 progressive steps. • If any one of the connecting rod cap bolts is broken or deformed, replace it. Outside Mark (Protrusion) RH Bank: Front EM Outside Mark (Protrusion) A005174E02 (j) A005101 90° Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. (k) Install and alternately tighten the 2 connecting rod cap bolts in several steps. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) NOTICE: Do not turn the crankshaft. If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. (l) Mark the front of the connecting cap bolts with paint. (m) Retighten the cap bolts 90° as shown in the illustration. (n) Check that the painted mark is now at a 90° angle to the front. 90° Front Painted Mark A005099E02 (o) Remove the 2 bolts, connecting rod cap and lower bearing. A005101 EM–122 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (p) Measure the Plastigage at its widest point. Standard oil clearance: 0.021 to 0.047 mm (0.0008 to 0.0019 in.) Maximum oil clearance: 0.065 mm (0.0026 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the connecting rod cap and crankshaft, then select the bearing with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7". Number Mark Item No. 4 EM No. 1 No. 3 No. 2 Number Mark Number Mark Number Mark Connecting rod cap 1 1 2 1 2 3 2 3 4 3 4 4 Crankshaft 1 2 1 3 2 1 3 2 1 3 2 3 Use bearing 2 3 4 5 6 7 EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4") Connecting rod big end inside diameter: Mark "1" 55.000 to 55.006 mm (2.1654 to 2.1656 in.) Mark "2" 55.006 to 55.012 mm (2.1656 to 2.1658 in.) Mark "3" 55.012 to 55.018 mm (2.1658 to 2.1661 in.) Mark "4" 55.018 to 55.024 mm (2.1661 to 2.1663 in.) Crankshaft crank pin diameter: A139502E01 Mark "1" 51.994 to 52.000 mm (2.0470 to 2.0472 in.) Mark "2" 51.988 to 51.994 mm (2.0468 to 2.0470 in.) Mark "3" 51.982 to 51.988 mm (2.0465 to 2.0468 in.) Standard sized bearing center wall thickness: Mark "2" 1.487 to 1.490 mm (0.0585 to 0.0587 in.) Mark "3" 1.490 to 1.493 mm (0.0587 to 0.0588 in.) Mark "4" 1.493 to 1.496 mm (0.0588 to 0.0589 in.) Mark "5" 1.496 to 1.499 mm (0.0589 to 0.0590 in.) Mark "6" 1.499 to 1.502 mm (0.0590 to 0.0591 in.) Mark "7" 1.502 to 1.505 mm (0.0591 to 0.0593 in.) (q) Completely remove the Plastigage. Ridge Reamer A054348E02 47. REMOVE PISTON AND CONNECTING ROD (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: • Keep the bearings, connecting rod and cap together. • Arrange the piston and connecting rod assemblies in the correct order. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–123 48. REMOVE PISTON (a) Check the fitting condition between the piston and piston pin. (1) Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. A004862 (b) Using a piston ring expander, remove the 2 piston rings. (c) Remove the oil ring (2 side rails and expander) by hand. HINT: Arrange the piston rings in the correct order. EM A004873 (d) Using a screwdriver, pry out the 2 snap rings. A004860 (e) Gradually heat the piston to approx. 60°C (140°F). A004887 (f) A004888 Using a plastic hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: • The piston and pin are a matched set. • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. EM–124 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT A005096 7 9 STD 2.440 to 2.490 mm (0.0961 to 0.0980 in.) O/S 0.125 2.503 to 2.553 mm (0.0985 to 0.1005 in.) 50. INSPECT CRANKSHAFT OIL CLEARANCE (a) Uniformly loosen and remove the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration. 3 5 EM 49. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 to 0.220 mm (0.0008 to 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness 4 1 10 8 6 2 A005095E01 A005093 (b) Using 2 screwdrivers, pry out the crankshaft bearing cap, and remove the 5 crankshaft bearing caps, 5 lower bearings and 2 lower thrust washers (No. 3 crankshaft bearing cap only). NOTICE: Be careful not to damage the cylinder block. HINT: • Keep the lower bearing and crankshaft bearing cap together. • Arrange the crankshaft bearing caps and lower thrust washers in the correct order. (c) Lift out the crankshaft. (d) Remove the 2 upper thrust washers. HINT: • Arrange the upper thrust washers in the correct order. • Keep the upper bearings together with the cylinder block. (e) Clean each crankshaft journal and bearing. (f) Check each crankshaft journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–125 (g) Place the crankshaft on the cylinder block. (h) Lay a strip of Plastigage across each journal. Plastigage A005097E01 (i) Install the 5 crankshaft bearing caps in their proper locations. HINT: • The crankshaft bearing cap bolts are tightened in 2 progressive steps (Procedures "A" and "B"). • If any one of the main bearing cap bolts is broken or deformed, replace it. EM A005091 (j) 4 2 8 6 7 10 3 1 5 9 A005095E02 Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. (k) Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration (Procedure "A"). Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) NOTICE: Do not turn the crankshaft. If any one of the crankshaft bearing cap bolts does not meet the torque specification, replace the crankshaft bearing cap bolt. (l) Mark the front of the crankshaft bearing cap bolts with paint. (m) Retighten the crankshaft bearing cap bolts by 90° in the order shown (Procedure "B"). (n) Check that the painted mark is now at a 90° angle to the front. (o) Remove the crankshaft bearing caps. 90° 90° Front Painted Mark A005094E02 EM–126 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (p) Measure the Plastigage at its widest point. Standard clearance No. 1 and No. 5 Others 0.028 to 0.046 mm (0.0011 to 0.0018 in.) 0.040 to 0.058 mm (0.0016 to 0.0023 in.) Maximum clearance No. 3 No. 4 No. 5 Number Mark No. 2 No. 1 Number Mark EM No. 5 No. 2 No. 1 No. 1 and No. 5 Others 0.065 mm (0.0026 in.) 0.065 mm (0.0026 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, add together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For the other position bearings, use bearings marked "1", "2", "3", "4" and "5". No. 1 and No. 5: - No. 3 Use bearing 0 to 5 No. 4 Number Mark A139503E01 Cylinder block (A) + Crankshaft (B) 3 6 to 11 4 12 to 17 5 18 to 23 6 24 to 28 7 EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5") Others: - Use bearing 0 to 5 Cylinder block (A) + Crankshaft (B) 1 6 to 11 2 12 to 17 3 18 to 23 4 24 to 28 5 EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3") Cylinder block crankshaft journal bore diameter (A): Mark "00" 72.000 mm (2.8347 in.) Mark "01" 72.001 mm (2.8347 in.) Mark "02" 72.002 mm (2.8347 in.) Mark "03" 72.003 mm (2.8348 in.) Mark "04" 72.004 mm (2.8348 in.) Mark "05" 72.005 mm (2.8348 in.) Mark "06" 72.006 mm (2.8349 in.) EM–127 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT Mark "07" 72.007 mm (2.8349 in.) Mark "08" 72.008 mm (2.8350 in.) Mark "09" 72.009 mm (2.8350 in.) Mark "10" 72.010 mm (2.8350 in.) Mark "11" 72.011 mm (2.8351 in.) Mark "12" 72.012 mm (2.8351 in.) Mark "13" 72.013 mm (2.8352 in.) Mark "14" 72.014 mm (2.8352 in.) Mark "15" 72.015 mm (2.8352 in.) Mark "16" 72.016 mm (2.8353 in.) Crankshaft journal diameter (B): Mark "00" 67.000 mm (2.6378 in.) Mark "01" 66.999 mm (2.6378 in.) Mark "02" 66.998 mm (2.6377 in.) Mark "03" 66.997 mm (2.6377 in.) Mark "04" 66.996 mm (2.6376 in.) Mark "05" 66.995 mm (2.6376 in.) Mark "06" 66.994 mm (2.6376 in.) Mark "07" 66.993 mm (2.6375 in.) Mark "08" 66.992 mm (2.6375 in.) Mark "09" 66.991 mm (2.6374 in.) Mark "10" 66.990 mm (2.6374 in.) Mark "11" 66.989 mm (2.6374 in.) Mark "12" 66.988 mm (2.6373 in.) Standard bearing center wall thickness No. 1 and No. 5: Mark "3" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark "4" 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark "5" 2.493 to 2.496 mm (0.0982 to 0.0983 in.) Mark "6" 2.496 to 2.499 mm (0.0983 to 0.0984 in.) Mark "7" 2.499 to 2.502 mm (0.0984 to 0.0985 in.) Others: Mark "1" 2.481 to 2.484 mm (0.0977 to 0.0978 in.) Mark "2" 2.484 to 2.487 mm (0.0978 to 0.0979 in.) Mark "3" 2.487 to 2.490 mm (0.0979 to 0.0980 in.) Mark "4" 2.490 to 2.493 mm (0.0980 to 0.0982 in.) Mark "5" 2.493 to 2.496 mm (0.0982 to 0.0983 in.) (q) Completely remove the Plastigage. 51. REMOVE CRANKSHAFT (a) Lift up the crankshaft. (b) Remove the 5 upper crankshaft bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the crankshaft bearing caps, bearings and thrust washers in the correct order. 52. REMOVE CRANKSHAFT PULLEY SET CRANKSHAFT KEY EM EM–128 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT INSPECTION HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets, O-rings and oil seals with new ones. 1. INSPECT TIMING BELT NOTICE: • Do not bend, twist or turn the timing belt inside out. • Do not allow the timing belt to come into contact with oil, water or steam. • Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects as shown in the illustration, check the following points: (a) If premature parting occurs, check the following: • Check for proper installation. • Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, inspect the camshaft. (c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump. (d) If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check for damage on the timing belt or foreign objects on the pulley teeth. Check if the gasket is installed correctly. If necessary, replace the timing belt. 2. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY (a) Visually check the seal portion of the tensioner for oil leakage. HINT: If there is a faint trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. EM A054954 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–129 (b) Hold the tensioner by hands and push the push rod strongly as shown in the illustration to check that it does not move. If the push rod moves, replace the tensioner. NOTICE: Do not face the tensioner push rod downward. A054955 (c) Measure the protrusion of the push rod from the housing end. Protrusion: 11.2 to 12.2 mm (0.440 to 0.480 in.) If the protrusion is not as specified, replace the tensioner. Protrusion EM A054956E01 3. INSPECT TIMING BELT IDLER (a) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. (b) Check that the idler pulley turns smoothly. If necessary, replace the idler. 4. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810 to 9.960 mm (0.3862 to 0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) 5. INSPECT CAMSHAFTS (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than maximum, replace the camshaft. A054957 Measuring Point 75 to 85 mm (2.95 to 3.35 in.) A002827E01 A005912 EM–130 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake: 41.94 to 42.04 mm (1.6512 to 1.6551 in.) Exhaust: 41.96 to 42.06 mm (1.6520 to 1.6559 in.) Minimum cam lobe height: Intake: 41.79 mm (1.6453 in.) Exhaust: 41.81 mm (1.6461 in.) If the cam lobe height is less than the minimum, replace the camshaft. EM02011 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Journal diameter: 26.954 to 26.970 mm (1.0612 to 1.0618 in.) If the journal diameter is not as specified, check the oil clearance. EM A134375 6. A134376 INSPECT CAMSHAFT TIMING TUBE ASSEMBLY (a) Using a micrometer, measure the journal diameter. Journal diameter: 39.955 to 39.964 mm (1.5730 to 1.5734 in.) If the journal diameter is not as specified, check the oil clearance. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–131 (b) Install the timing tube to the intake camshaft, and check that the timing tube turns smoothly. If necessary, replace the timing tube and intake camshaft. Turn A134377E01 7. 18.2 to 18.8 mm INSPECT CAMSHAFT GEAR SPRING (a) Using vernier calipers, measure the gap distance of the gear spring. Gap distance: 18.2 to 18.8 mm (0.717 to 0.740 in.) If the gap distance is not as specified, replace the gear spring. EM A053870E01 8. INSPECT CYLINDER HEAD SUB-ASSEMBLY (a) Clean the cylinder head. (1) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A053862 (2) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. A053863 (3) Using a valve guide bushing brush and solvent, clean all the guide bushes. P021861 EM–132 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (4) Using a soft brush and solvent, thoroughly clean the cylinder head. EM06325 (b) Inspect for warpage. (1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and the manifolds. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than the maximum, replace the cylinder head. EM A005592 (c) Inspect for cracks. (1) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. EM06327 9. EM00580 INSPECT VALVE (a) Clean the valves. (1) Using a gasket scraper, chip off any carbon from the valve head. (2) Using a wire brush, thoroughly clean the valve. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–133 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) Exhaust: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Z000052E01 (c) Check the valve face angle. (1) Grind the valve enough to remove pits and carbon. (2) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° 44.5° EM Z000054E01 Margin Thickness EM00181E02 Overall Length EM02534E01 (d) Check the valve head margin thickness. Standard margin thickness: Intake: 1.25 mm (0.049 in.) Exhaust: 1.4 mm (0.055 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. (e) Check the valve overall length. Standard overall length: Intake: 95.05 mm (3.7421 in.) Exhaust: 95.10 mm (3.7441 in.) Minimum overall length: Intake: 94.55 mm (3.7224 in.) Exhaust: 94.60 mm (3.7244 in.) If the overall length is less than the minimum, replace the valve. EM–134 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (f) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than the minimum. A053828E01 10. INSPECT VALVE SPRING (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the valve spring. EM EM00988E01 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 54.1 mm (2.130 in.) If the free length is not as specified, replace the valve spring. EM00801 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 210 to 226 N (21.4 to 23.0 kgf, 47.2 to 50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring. EM00281 P021862 11. INSPECT VALVE GUIDE BUSH (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: Intake: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust: 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–135 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: Intake: 0.08 mm (0.0031 in.) Exhaust: 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush. 12. REMOVE VALVE GUIDE BUSH (a) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F). 80 to 100°C A003195E01 (b) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100) SST A005708E01 13. INSTALL VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. A003197 Intake (b) Select a new guide bush (STD or O/S 0.05). Exhaust 34.5 mm (1.358 in.) 40.5 mm (1.594 in.) P021844E01 Bush bore diameter Bush size 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Use STD 10.335 to 10.356 mm (0.4069 to 0.4077 in.) Use O/S 0.05 If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore so that the dimension is between 10.335 and 10.356 mm (0.4069 and 0.4077 in.). If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. EM EM–136 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT HINT: Different bushes are used for the intake and exhaust. SST A005709E01 (c) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F). (d) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Protrusion height: Intake: 9.2 to 9.8 mm (0.362 to 0.386 in.) Exhaust: 8.2 to 8.8 mm (0.323 to 0.346 in.) SST 09201-01055, 09950-70010 (09951-07100) (e) Using a sharp 5.5mm reamer, ream the guide bush to obtain the specified clearance between the guide bush and valve stem. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100) Sharp 5.5 mm Reamer EM A003200E01 45° Carbide Cutter 14. INSPECT VALVE SEAT (a) Using a 45° carbide cutter, resurface the valve seats. Clean metal filings from the valve seats. EM06330E01 Width Z000055E01 (b) Check the valve seating position. (1) Apply a light coat of prussian blue (or white lead) to the valve face. (2) Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following: (1) If prussian blue appears around the entire face, the valve is centered. If not, replace the valve. (2) If prussian blue appears around the entire valve seat, the guide and face are centered. If not, resurface the seat. (3) Check that the seat contacts in the middle of the valve face with the following width: Width: 1.0 to 1.4 mm (0.039 to 0.055 in.) 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 45° 30° EM–137 15. REPAIR VALVE SEAT (a) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. 1.0 to 1.4 mm A066652E01 60° (b) If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat. 45° EM 1.0 to 1.4 mm Z003989E01 (c) Handrub the valve and valve seat with an abrasive compound. (d) After handrubbing, clean the valve and valve seat. EM06331 16. INSPECT VALVE LIFTER (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 to 31.016 mm (1.2205 to 1.2211 in.) A003209 12.3 to 12.7 mm A053835E02 (b) Using a micrometer, measure the lifter diameter where the distance from the top surface is 12.3 to 12.7 mm (0.484 to 0.500 in.). Lifter diameter: 30.968 to 30.976 mm (1.2192 to 1.2195 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 to 0.050 mm (0.0009 to 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) EM–138 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. Plastigage A134380E01 17. INSPECT CAMSHAFT OIL CLEARANCE (a) Install the camshaft timing tube to the camshaft (See page EM-160). (b) Clean the bearing caps and camshaft journals. (c) Check the bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. (d) Place the camshafts on the cylinder head. (e) Lay a strip of Plastigage across each of the camshaft journals. (f) EM Install the bearing caps (See page EM-168). Torque: For bolt A 7.5 N*m (76 kgf*cm, 66 ft.*lbf) For others 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTICE: Do not turn the camshaft. (g) Remove the bearing caps. A A A134381E01 (h) Measure the Plastigage at its widest point. Standard oil clearance Camshaft journal Camshaft timing tube journal 0.030 to 0.071 mm (0.0012 to 0.0028 in.) 0.036 to 0.057 mm (0.0014 to 0.0022 in.) Maximum oil clearance Camshaft journal Camshaft timing tube journal 0.100 mm (0.0039 in.) 0.075 mm (0.0030 in.) A134382 (i) (j) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts. Completely remove the Plastigage. 18. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshaft (See page EM-168). (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance A134383 Intake Exhaust 0 to 0.040 mm (0 to 0.0016 in.) 0.030 to 0.070 mm (0.0012 to 0.0028 in.) Maximum thrust clearance Intake Exhaust 0.12 mm (0.0047 in.) 0.10 mm (0.0039 in.) 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–139 If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts. (d) Remove the camshaft timing tube from the intake camshaft. A134384 19. INSPECT CAMSHAFT GEAR BACKLASH (a) Install the drive gear to the camshaft timing tube (See page EM-160). (b) Install the camshaft timing tube to the intake camshaft (See page EM-160). (c) Install the camshafts without installing the exhaust camshaft sub-gear No. 3 and front bearing cap (See page EM-160). (d) Using a dial indicator, measure the backlash. Standard backlash: 0.020 to 0.200 mm (0.0008 to 0.0079 in.) Maximum backlash: 0.30 mm (0.0118 in.) If the backlash is greater than the maximum, replace the intake camshaft drive gear and exhaust camshaft. (e) Remove the camshafts. (f) Remove the camshaft timing tube from the intake camshaft. (g) Remove the drive gear from the camshaft timing tube. 20. CLEAN CYLINDER BLOCK SUB-ASSEMBLY (a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. (b) Using a soft brush and solvent, thoroughly clean the cylinder block. A004849 EM EM–140 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 21. INSPECT CYLINDER BLOCK SUB-ASSEMBLY (a) Inspect for warpage. (1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and crankshaft bearing cap. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than the maximum, replace the cylinder block sub-assembly. Cylinder Head Side EM Crankshaft Bearing Cap Side A074955E02 (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block. A004853 (c) Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block. No. 2 No. 4 No. 6 No. 8 Front No. 1 No .3 No. 5 No. 7 Mark 1, 2 or 3 A074956E01 EM–141 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT Thrust Direction Front (1) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter Axial Direction A B 10 mm (0.39 in) STD Mark "1" Mark "2" Mark "3" 94.002 to 94.010 mm (3.7009 to 3.7012 in.) 94.010 to 94.023 mm (3.7012 to 3.7017 in.) 94.023 to 94.031 mm (3.7017 to 3.7020 in.) Maximum diameter: 94.230 mm (3.5917 in.) If the diameter is greater than the maximum, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block. Center STD 94.231 mm (3.7099 in.) O/S 0.50 94.731 mm (3.7296 in.) EM A005181E02 (d) Remove the cylinder ridge. If the wear is less than 0.2mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. Ridge Reamer A004852E01 22. INSPECT PISTON (a) Clean the piston. (1) Using a gasket scraper, remove the carbon from the piston top. A004877 (2) Using a groove cleaning tool or broken ring, clean the piston ring grooves. A004878 EM–142 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (3) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. A004879 Mark 2 LH Piston 30.75 mm EM (b) Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" or "3" accordingly. The mark is stamped on the piston top. (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Piston diameter O/S 0.50 RH Piston 94.402 to 94.430 mm (3.7168 to 3.7177 in.) Mark 2 A134386E01 STD Mark "1" Mark "2" Mark "3" 93.902 to 93.912 mm (3.6969 to 3.6973 in.) 93.912 to 93.920 mm (3.6973 to 3.6976 in.) 93.920 to 93.930 mm (3.6976 to 3.6980 in.) 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (2) Measure the cylinder bore diameter in the thrust directions. (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.090 to 0.111 mm (0.0035 to 0.0044 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 8 pistons and rebore all the 8 cylinders. If necessary, replace the cylinder block. HINT: Use a new cylinder block: • Use a piston with the same number mark as the cylinder diameter marked on the cylinder block. • The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2". No. 2 No. 4 No. 6 No. 8 Front No. 1 No .3 No. 5 No. 7 LH Piston EM–143 Mark 2 Mark 2 RH Piston Mark 2 A134387E01 (c) Inspect the piston pin fit. (1) Heat the piston to approx. 60° C (140° F), and push the piston pin into the piston pin hole with your thumb. 60°C A004048E03 (d) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) EM00227 EM EM–144 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 23. INSPECT PISTON RING SET (a) Inspect the piston ring groove clearance. (1) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Ring groove clearance No. 1 No. 2 0.030 to 0.080 mm (0.0012 to 0.0032 in.) 0.020 to 0.060 mm (0.0008 to 0.0024 in.) A004880 If the clearance is not as specified, replace the piston. (b) Inspect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. EM 105 mm A004872E02 (3) Using a feeler gauge, measure the end gap. Standard end gap No. 1 No. 2 Oil (Side rail) 0.300 to 0.400 mm (0.0118 to 0.0158 in.) 0.400 to 0.550 mm (0.0158 to 0.0217 in.) 0.130 to 0.380 mm (0.0051 to 0.0150 in.) Maximum end gap No. 1 No. 2 Oil (Side rail) 1.10 mm (0.0433 in.) 1.30 mm (0.0512 in.) 0.90 mm (0.0354 in.) EM07639 If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 8 cylinders or replace the cylinder block sub-assembly. 24. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than the maximum, replace the connecting rod sub-assembly. 100 mm Z014454E01 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–145 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than the maximum, replace the connecting rod sub-assembly. 100 mm Z014455E01 (b) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) EM EM06525 EM00227 (2) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) (3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the connecting rod subassembly. If necessary, replace the piston and piston pin as a set. 25. REMOVE CONNECTING ROD SMALL END BUSH (a) Using SST and a press, press out the bushing. SST 09222-30010 EM06363E01 EM–146 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 26. INSTALL CONNECTING ROD SMALL END BUSH (a) Align the oil holes of a new bushing and the connecting rod. A051812E01 (b) Using SST and a press, press in the bushing. SST 09222-30010 EM EM06363E01 (c) Using a pin hole grinder, hone the bushing to obtain the specified clearance between the bushing and piston pin. EM06535 (d) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. P000326 Tension Portion A004223E01 27. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion diameter of the connecting rod bolt. Standard diameter: 7.200 to 7.300 mm (0.2835 to 0.2874 in.) Minimum diameter: 7.00 mm (0.2756 in.) If the diameter is less than the minimum, replace the bolt. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–147 28. INSPECT CRANKSHAFT BEARING CAP BOLT (a) Using vernier calipers, measure the thread outside diameter of the crankshaft bearing cap bolt. Standard diameter: 10.760 to 10.970 mm (0.4236 to 0.4319 in.) Minimum diameter: 10.40 mm (0.4094 in.) If the diameter is less than the minimum, replace the cap bolt. 50 to 64 mm (1.97 to 2.52 in.) A066653E01 29. INSPECT CRANKSHAFT (a) Inspect for circle runout. (1) Place the crankshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than the maximum, replace the crankshaft. A005121 (b) Inspect the crankshaft journals and crank pins. (1) Using a micrometer, measure the diameter of each crankshaft journal and crank pin. Crankshaft journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 in.) Crank pin diameter: 51.982 to 52.000 mm (2.0465 to 2.0472 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. (2) Check each crankshaft journal and crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. A005169E01 EM EM–94 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE UNIT 2UZ-FE ENGINE MECHANICAL ENGINE COMPONENTS AIR PUMP ASSEMBLY WITH BRACKET EM 16 (163, 12) STARTER ASSEMBLY 18 (185, 13) 9.8 (100, 7.2) NO. 2 ENGINE WIRE O-RING WATER BY-PASS PIPE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119821E02 EM–95 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT KNOCK SENSOR 20 (204, 15) VVT SENSOR 7.5 (80, 66 in.*lbf) VENTILATION VALVE COVER EM 39 (400, 29) VENTILATION VALVE SUB-ASSEMBLY 7.5 (80, 66 in.*lbf) REAR TIMING BELT PLATE RH 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) REAR TIMING BELT PLATE LH IGNITION COIL ASSEMBLY NO. 2 REAR TIMING BELT PLATE LH 7.5 (80, 66 in.*lbf) CAMSHAFT POSITION SENSOR NO. 2 REAR TIMING BELT PLATE RH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A119927E02 EM–96 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT V-RIBBED BELT TENSIONER ASSEMBLY 16 (160, 12) 16 (160, 12) 16 (160, 12) EM FAN BRACKET SUB-ASSEMBLY 32 (326, 24) NO. 1 TIMING BELT COVER NO. 2 TIMING BELT COVER SUB-ASSEMBLY 245 (2,498, 181) COVER PLATE 7.5 (80, 66 in.*lbf) CRANKSHAFT DAMPER SUB-ASSEMBLY 39 (398, 24) DUST BOOT NO. 2 IDLER PULLEY SUB-ASSEMBLY NO. 1 CHAIN TENSIONER ASSEMBLY 26 (270, 19) N*m (kgf*cm, ft.*lbf) : Specified torque A119822E09 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–97 NO. 1 TIMING BELT IDLER SUB-ASSEMBLY PLATE WASHER 35 (352, 25) CAMSHAFT TIMING PULLEYS EM 8.1 (83, 72 in.*lbf) 8.1 (83, 72 in.*lbf) TIMING BELT CRANKSHAFT TIMING PULLEY NO. 1 CRANKSHAFT POSITION SENSOR PLATE 35 (352, 25) NO. 2 TIMING BELT IDLER SUB-ASSEMBLY TIMING GEAR COVER SPACER N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 TIMING CHAIN COVER GASKET Precoated part A119928E02 EM–98 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT CYLINDER HEAD COVER SUB-ASSEMBLY 6.0 (60, 53 in.*lbf) x9 GASKET EM OIL FEED PIPE 16 (163, 12) FRONT BEARING CAP CAMSHAFT BEARING CAP 7.5 (76, 66 in.*lbf) CAMSHAFT DRIVE GEAR CAMSHAFT CAMSHAFT TIMING TUBE ASSEMBLY 7.5 (76, 66 in.*lbf) 15 (152, 11) SCREW PLUG CAMSHAFT SETTING OIL SEAL 78 (795, 58) SEAL WASHER NO. 2 CAMSHAFT NO. 3 CAMSHAFT SUB GEAR CAMSHAFT GEAR SPRING CAMSHAFT SUB GEAR SHAFT SNAP RING CAMSHAFT SUB GEAR WAVE WASHER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119823E05 EM–99 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT *1 1st: 40 (408, 30) 2nd: Turn 90° 3rd: Turn 90° OIL CONTROL VALVE FILTER x10 SEMICIRCULAR PLUG NO. 1 ENGINE HANGER EM 37 (380, 27) CAMSHAFT HOUSING PLUG CYLINDER HEAD SUB-ASSEMBLY CYLINDER HEAD GASKET *1: See paragraph REASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119929E01 EM–100 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT OIL FILTER CAP 7.5 (76, 66 in.*lbf) 18 (178, 13) SPARK PLUG EM OIL FILLER CAP HOUSING GASKET 6.0 (60, 53 in.*lbf) CYLINDER HEAD COVER SUB-ASSEMBLY LH x9 GASKET SPARK PLUG TUBE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119824E01 EM–101 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 7.5 (76, 66 in.*lbf) FRONT BEARING CAP 16 (163, 12) NO. 3 CAMSHAFT SUB-ASSEMBLY CAMSHAFT SETTING OIL SEAL CAMSHAFT TIMING TUBE ASSEMBLY 16 (160, 12) 78 (795, 58) 7.5 (76, 66 in.*lbf) SEAL WASHER 15 (152, 11) CAMSHAFT OIL FEED PIPE SUB-ASSEMBLY SCREW PLUG BEARING CAP CAMSHAFT DRIVE GEAR CAMSHAFT SUB GEAR WAVE WASHER NO. 4 CAMSHAFT SUB-ASSEMBLY CAMSHAFT SUB GEAR SHAFT SNAP RING CAMSHAFT HOUSING PLUG CAMSHAFT GEAR SPRING 37 (380, 27) x10 NO. 3 CAMSHAFT SUB GEAR NO. 1 ENGINE HANGER 1st: 40 (408, 30) *1 OIL CONTROL VALVE FILTER 2nd: Turn 90° 3rd: Turn 90° SEMICIRCULAR PLUG CYLINDER HEAD LH NO. 2 CYLINDER HEAD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part *1: See paragraph REASSEMBLY A130722E04 EM EM–102 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT ENGINE REAR OIL SEAL 49 (500, 36) CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY ENGINE REAR OIL SEAL RETAINER 16 (160, 11) O-RING 31 (311, 23) EM x7 8.0 (82, 71 in.*lbf) O-RING 49 (500, 36) 16 (160, 11) OIL PUMP ASSEMBLY OIL PUMP SEAL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY CRANKSHAFT TIMING PULLEY 18 (184, 13) 21 (214, 15) GASKET x5 18 (184, 13) WATER PUMP ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part A119825E02 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–103 GASKET OIL STRAINER SUB-ASSEMBLY 7.5 (76, 66 in.*lbf) EM OIL PAN SUB-ASSEMBLY (NO. 1) 7.5 (76, 66 in.*lbf) 28 (290, 31) OIL PAN BAFFLE PLATE 7.5 (76, 66 in.*lbf) NO. 2 OIL PAN SUB-ASSEMBLY GASKET x17 N*m (kgf*cm, ft.*lbf) : Specified torque 39 (398, 29) OIL PAN DRAIN PLUG 7.5 (76, 66 in.*lbf) Non-reusable part A119930E01 EM–104 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT CYLINDER HEAD RH VALVE LIFTER VALVE ADJUST SHIM VALVE SPRING RETAINER LOCK EM VALVE SPRING RETAINER VALVE SPRING VALVE SPRING SEAT OIL SEAL VALVE GUIDE BUSH VALVE RING PIN 9.0 (90, 80 in.*lbf) STUD BOLT CYLINDER HEAD LH TIGHT PLUG RING PIN N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 15 (150, 11) Precoated part A119826E04 EM–105 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT SIDE RAIL OIL RING NO. 1 PISTON RING EXPANDER SIDE RAIL NO. 2 PISTON RING SNAP RING PISTON SNAP RING PISTON PIN CONNECTING ROD SMALL END BUSH CONNECTING ROD *1 1st: 25 (250, 18) CONNECTING ROD BEARING 2nd: Turn 90° CONNECTING ROD BEARING CAP *1: See paragraph REASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119827E04 EM EM–106 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT TIGHT PLUG 20 (200, 14) STUD BOLT CYLINDER BLOCK RING PIN RING PIN EM TIGHT PLUG 12 (120, 9) STUD BOLT 20 (200, 14) STUD BOLT UPPER CRANKSHAFT THRUST WASHER 14 (145, 10) STUD BOLT UPPER CRANKSHAFT BEARING CRANKSHAFT CRANKSHAFT PULLEY SET CRANKSHAFT KEY LOWER CRANKSHAFT THRUST WASHER LOWER CRANKSHAFT BEARING *1 1st: 27 (275, 20) CRANKSHAFT BEARING CAP 2nd: Turn 90° *1: See paragraph REASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part A119931E01 EM–148 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT REASSEMBLY HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets, O-rings and oil seals with new ones. 1. INSTALL TIGHT PLUG (a) Install the tight plug. EM A072720E01 (1) Apply adhesive to the tight plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (2) Using SST and a hammer, tap in a new tight plug as shown in the illustration. SST 09950-60010 (09951-00350), 0995070010 (09951-07100) SST A072721E01 EM–149 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 2. INSTALL STUD BOLT (a) Install the stud bolt. D E A C B B E D 15 mm (0.59 in.) EM 16 mm (0.63 in.) 120 mm (4.72 in.) 116 mm (4.57 in.) 12 mm (0.47 in.) 35 mm (1.38 in.) 15 mm (0.59 in.) A (Thread diameter: 8 mm) 37 mm (1.46 in.) 20 mm (0.79 in.) B (Thread diameter: 10 mm) 15 mm (0.59 in.) 14 mm (0.55 in.) 12 mm (0.47 in.) 32 mm (1.26 in.) C (Thread diameter: 8 mm) D (Thread diameter: 8 mm) 7.5 mm (0.30 in.) 24 mm (0.94 in.) E (Thread diameter: 8 mm) G039840E01 Torque: For A 8.0 N*m (80 kgf*cm, 71 in.*lbf) For B 20 N*m (200 kgf*cm, 14 ft.*lbf) For C 12 N*m (120 kgf*cm, 9 ft.*lbf) For D 14 N*m (145 kgf*cm, 10 ft.*lbf) For E 8.0 N*m (80 kgf*cm, 71 ft.*lbf) EM–150 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 3. INSTALL STRAIGHT PIN (a) Install the straight pin. Until pin stops 10 mm (0.39 in.) 6 mm (0.24 in.) B B A 22 mm (0.87 in.) 14 mm (0.55 in.) A A B A053947E02 EM 4. INSTALL RING PIN (a) Install the ring pin. A A C B C C C B A Until pin stops 13 mm (0.51 in.) 11 mm (0.43 in.) 20 mm (0.79 in.) 12 mm (0.47 in.) 8 mm (0.31 in.) A 16 mm (0.63 in.) B C A134388E01 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 5. EM–151 INSTALL PISTON (a) Using a screwdriver, install a new snap ring on one side of the piston pin hole. A004861 (b) Gradually heat the piston to about 60°C (140°F). 60°C EM A004876E02 (c) Coat the piston pin with engine oil. (d) Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration. NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2". (e) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb. LH Piston Front Mark (1 Cavity) Outside Mark RH Piston Front Mark (2 Cavities) Outside Mark A134389E01 (f) 6. A004860 Using a screwdriver, install a new snap ring on the other side of the piston pin hole. INSTALL PISTON RING SET (a) Install the oil ring expander and 2 side rails by hand. EM–152 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using a piston ring expander, install the 2 piston rings with the code mark facing upward. Code mark: No. 1 No. 1 None No. 2 2R No. 2 Code Mark 2R A134390E01 LH Piston (c) Position the piston rings so that the ring ends are as shown in the illustration. NOTICE: Do not align the ring ends. No. 2 Piston Ring Lower Side Rail 45° 60° Expander EM Front Mark (1 Cavity) 45° 60° RH Piston Lower Side Rail 60° Upper Side Rail No. 1 Piston Ring No. 2 Piston Ring 45° Expander Front Mark (2 Cavities) 60° Upper Side Rail 45° No. 1 Piston Ring A054735E01 EM06484 7. INSTALL CONNECTING ROD BEARING (a) Align the bearing claw with the groove of the connecting rod or connecting cap. (b) Install the bearings in the connecting rod and connecting rod cap. 8. INSTALL CRANKSHAFT BEARING HINT: • Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions. • Upper bearings have an oil groove and oil holes; lower bearings do not. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–153 (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. A004216 (b) Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each bearing cap to indicate the installation position. Mark 1, 2, 3, 4, or 5 EM A004214E02 9. INSTALL CRANKSHAFT THRUST WASHER SET (a) Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. A066654 (b) Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward. 10. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY A004217 11. INSTALL CRANKSHAFT (a) Place the crankshaft on the cylinder block. (b) Install the 5 crankshaft bearing caps in their proper locations. HINT: Place the bearing caps level and let them return to their original positions by their own weight. NOTICE: Do not install the bearing cap by tapping it. A005091 EM–154 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 4 2 8 6 7 10 3 1 5 9 A005095E02 EM (c) Install the crankshaft bearing cap bolts. HINT: • The bearing cap bolts are tightened in 2 progressive steps. • If any one of the bearing cap bolts is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads and under the heads of the crankshaft bearing cap bolts. (2) Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 in.*lbf) If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt. (3) Mark the front of the crankshaft bearing cap bolts with paint. (4) Retighten the crankshaft bearing cap bolts by 90° in the order shown. (5) Check that the painted mark is now at a 90° angle to the front. (6) Check that the crankshaft turns smoothly. 90° 90° Front Painted Mark A005094E02 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–155 12. INSTALL PISTON AND CONNECTING ROD (a) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2". Front LH Piston Front Mark (1 Cavity) EM Front Front Mark (2 Cavities) RH Piston A134391E01 (b) Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with the connecting rod. (2) Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. A005106 EM–156 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (3) Check that the outside mark of the connecting rod cap is facing in the correct direction. LH Bank: Front Outside Mark (Protrusion) RH Bank: Front EM Outside Mark (Protrusion) A005174E02 A005101 90° (c) Install the connecting rod cap bolts. HINT: • The connecting rod cap bolts are tightened in 2 progressive steps. • If any one of the connecting rod cap bolts is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. (2) Install and alternately tighten the 2 connecting rod cap bolts in several steps. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. (3) Mark the front of the connecting cap bolt with paint. (4) Retighten the cap bolts 90° as shown in the illustration. (5) Check that the painted mark is now at a 90° angle to the front. (d) Check that the crankshaft turns smoothly. 90° Front Painted Mark A005099E02 EM–157 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 13. INSTALL NO. 1 TIGHT PLUG (a) Apply adhesive to the tight plug. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (b) Using SST and a hammer, tap in a new tight plug as shown in the illustration. SST 09950-60010 (09951-00300), 09950-70010 (09951-07100) Front Side 14. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (a) Install the camshaft bearing cap setting ring pin. EM Rear Side SST A134385E01 Cylinder Head Cover Side A A A A Front Side of LH Bank A A A Front Side of RH Bank C C A B A A A A B A A A 10 mm (0.39 in.) A 3 mm (0.12 in.) 8 mm (0.31 in.) 7 mm (0.28 in.) A: Ring Pin B 4 mm (0.16 in.) 0.5 mm (0.020 in.) 8 mm (0.31 in.) B: Ring Pin C: Ball A053859E01 EM–158 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 15. INSTALL STUD BOLT (a) Install the stud bolt. Intake Manifold Side A A C C C C Exhaust Manifold Side B B B B B EM A: Stud Bolt (Thread diameter: 8 mm) B: Stud Bolt (Thread diameter: 10 mm) 24.5 mm (0.965 in.) 26 mm (1.02 in.) 14 mm (0.55 in.) 12 mm (0.47 in.) B C: Stud Bolt (Thread diameter: 8 mm) 12 mm (0.47 in.) 28 mm (1.10 in.) B B 12 mm (0.47 in.) 28 mm (1.10 in.) 12 mm (0.47 in.) A053860E01 Torque: For A and C 9.0 N*m (90 kgf*cm, 80 in.*lbf) For B 15. N*m (150 kgf*cm, 11 ft.*lbf) Exhaust Black Gray Intake Gray Brown A053861E03 16. INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to a new oil seal. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later. HINT: The intake valve oil seal is gray/brown and the exhaust valve oil seal is black/gray. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–159 (b) Using SST, push in a new oil seal. SST 09201-41020 NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated. SST A053857E02 17. INSTALL VALVE (a) Install the following parts: (1) Valve (1) (2) Spring seat (2) (3) Valve spring (3) (4) Spring retainer (4) (4) (3) (2) (1) EM A005711E01 (b) Using SST, compress the valve spring and place the 2 spring retainer locks around the valve stem. SST 09202-70020 (09202-00010) SST A005712E01 (c) Using a plastic hammer and the valve stem (not in use) tip wrapped with vinyl tape, lightly tap the valve stem tip to assure proper fit. NOTICE: Be careful not do damage the valve stem tip. 18. INSTALL VALVE LIFTER (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. Vinyl tape A054352E02 SST Return Claw SST Downward A004108E01 19. INSTALL SPARK PLUG TUBE GASKET (a) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950-60010 (09951-00240, 09951-00440, 09952-06010), 09950-70010 (09951-07100) NOTICE: Be careful of the installation direction. (b) Apply a light coat of MP grease to the gasket lip. (c) Return the 4 ventilation case claws to the original positions. EM–160 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 20. INSTALL CAMSHAFT SETTING OIL SEAL (a) Insert a new oil seal into the camshaft timing tube until it reaches the stopper. NOTICE: • Be careful of the installation direction. • Do not turn over the oil seal lip. Front A054966E01 5 mm Hexagon Wrench SST EM A054965E03 21. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY (a) Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts. (b) Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps. SST 09960-10010 (09962-01000, 09963-00500) Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Be careful not to damage the timing tube. (c) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A054967 (d) Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom. (e) Using a 10 mm hexagon wrench, install the bolt. Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) (f) Install the seal washer and screw plug. Torque: 15 N*m (152 kgf*cm, 11 ft.*lbf) 10 mm Hexagon Wrench A054962E02 [1] [2] Pin [3] Pin A054971E01 22. INSTALL CAMSHAFT SUB GEAR (a) Install the gear spring [1], sub gear [2] and wave washer [3]. HINT: Attach the pins on the gears to the gear spring ends. EM–161 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (b) Using snap ring pliers, install the snap ring. A054970 (c) Mount the hexagonal portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. EM A054968 Sub Gear SST Main Gear Service Bolt Turn A054972E01 (d) Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) (e) Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm (0.63 to 0.79 in.) 23. INSTALL OIL PUMP SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09316-60011 (09316-00011) (b) Apply MP grease to the oil seal lip. SST A054146E02 24. INSTALL ENGINE REAR OIL SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 (b) Apply MP grease to the oil seal lip. SST A054148E02 EM–162 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 25. INSTALL ENGINE REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block. (1) Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves. (2) Thoroughly clean all components to remove all the loose material. (3) Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent (1) Use a nozzle that has been cut to a 3 to 4 mm (0.12 to 0.16 in.) opening. (2) Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. (3) Immediately remove the nozzle from the tube and reinstall the cap. A B EM Seal Width 3 to 4 mm A B A004848E02 (c) Install a new O-ring to the cylinder block. (d) Install the oil seal retainer with the 7 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) New O-Ring A004855E02 EM–163 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT A B A Seal Width 2 to 3 mm B B000960E03 26. INSTALL OIL PUMP ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. (1) Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. (2) Thoroughly clean all components to remove all the loose material. (3) Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Avoid applying an excessive amount to the surface, especially around the oil passage. (1) Use a nozzle that has been cut to a 2 to 3 mm (0.08 to 0.12 in.) opening. (2) Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. (3) Immediately remove the nozzle from the tube and reinstall the cap. (c) Install a new O-ring to the cylinder block. (d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. New O-Ring Engage P021388E01 (e) Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts diagonally. HINT: • Use a 6mm hexagon wrench to tighten the hexagon head bolt. • The following chart is the reference of the oil pump bolt length. C C C 6 mm Hexagon Wrench B E D C Bolt A B013038E04 Size of Bolt Head Length A 12 mm 50 mm (1.97 in.) B 14 mm Stud Bolt 102.8 mm (4.047 in.) C 12 mm 35 mm (1.38 in.) D 14 mm 44 mm (1.73 in.) E 6 mm Hexagon 28 mm (1.10 in.) Torque: For bolts A, B, C and E 16 N*m (160 kgf*cm, 11 ft.*lbf) EM EM–164 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT For bolt D 31 N*m (311 kgf*cm, 23 ft.*lbf) 27. INSTALL OIL STRAINER SUB-ASSEMBLY (a) Install a new gasket and the oil strainer with the 2 bolts and 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) HINT: Use bolts 12 mm (0.47 in.) in length. 28. INSTALL STUD BOLT (a) Install the stud bolt. A072708 8.5 mm (0.335 in.) EM 24.5 mm (0.965 in.) 8.5 mm (0.335 in.) Stud Bolt (Thread diameter: 6mm) A072716E01 Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) B A A Seal Width 3 to 5 mm B A072709E01 29. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylinder block, oil pump and rear oil seal retainer. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. • Thoroughly clean all components to remove all the loose material. • Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the No. 1 oil pan as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent • Use a nozzle that has been cut to a 3 to 5 mm (0.12 to 0.20 in.) opening. • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. • Immediately remove the nozzle from the tube and reinstall the cap. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (c) Temporarily install the oil pan with the 18 bolts and 2 nuts. HINT: The following chart is the reference for the oil pump bolt length. 0.2 mm B B B B C C A A D A D A B B B B EM–165 C C A072710E01 Bolt Size of Bolt Head Length A 10 mm 20 mm (0.79 in.) B 12 mm 25 mm (0.98 in.) C 12 mm 60 mm (2.36 in.) D 10 mm 35 mm (1.38 in.) (d) Set the oil pan as shown in the illustration. NOTICE: Make sure that the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the clearance is more than 0.2 mm (0.008 in.), the oil pan will be stretched. (e) Uniformly tighten the bolts and nuts diagonally. Torque: For bolts A and D 7.5 N*m (76 kgf*cm, 66 in.*lbf) For bolts B, C and nut 28 N*m (286 kgf*cm, 21 ft.*lbf) 30. INSTALL OIL PAN BAFFLE PLATE (a) Install the baffle plate with the 2 bolts and 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) HINT: Use bolts 12 mm (0.47 in.) in length. A072705 EM EM–166 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT A B A EM Seal Width 3 to 5 mm B A072711E01 A054358 31. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 and No. 2 oil pans. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. • Thoroughly clean all components to remove all the loose material. • Using a non-residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. (b) Apply seal packing to the No. 2 oil pan as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent • Use a nozzle that has been cut to a 3 to 5 mm (0.12 to 0.20 in.) opening. • Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. • Immediately remove the nozzle from the tube and reinstall the cap. (c) Install the No. 2 oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) HINT: Use bolts 14 mm (0.55 in.) in length. 32. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several steps. Torque: Bolt 21 N*m (214 kgf*cm, 15 ft.*lbf) Stud bolt and nut 18 N*m (184 kgf*cm, 13 ft.*lbf) HINT: Use bolts 35 mm (1.38 in.) in length. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–167 33. INSTALL CYLINDER HEAD SUB-ASSEMBLY (a) Place 2 new cylinder head gaskets in position on the cylinder block. HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank. NOTICE: Be careful of the installation direction. (b) Place the 2 cylinder heads in position on the cylinder head gaskets. RH Cylinder Head LH Cylinder Head EM A134378E01 RH Cylinder Head 10 4 2 5 7 1 3 9 Front 1 6 8 A 6 8 LH Cylinder Head 9 3 A 7 5 2 4 10 A072703E02 (c) Install the cylinder head bolts. HINT: • The cylinder head bolts are tightened in 2 progressive steps (Procedures "A" and "B"). • If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several steps in the order shown in the illustration, then do the other side in the same way (Procedure "A"). Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan. EM–168 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (4) Mark the front of the cylinder head bolt head with paint. (5) Retighten the cylinder head bolts by 90° in the numerical order shown (Procedure "B"). (6) Retighten the cylinder head bolts by an additional 90°. (7) Check that the painted mark is now at a 180° angle to front. 90° 180° Painted Mark A011159E01 EM Dot Set Key Turn A054460E01 34. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Set the crankshaft position. (1) Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body. CAUTION: Having the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when installing the camshaft, causing damage. So always set the crankshaft at the correct angle. (b) Install the camshafts of the RH bank. (1) Apply engine oil to the thrust portions of the intake and exhaust camshafts. (2) Align the timing marks (1-dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts. (3) Set the timing marks (1-dot mark) of the camshaft drive and driven main gears at approx. 10° angle. Apporx. 10° A054974E01 Seal Packing RH Bank A054975E02 (4) Apply seal packing to the camshaft housing plug. • Remove the old packing (FIPG) material. • Apply seal packing to the housing plug. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–169 (5) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration. NOTICE: Be careful of the installation direction. A054976 Seal Width 1.5 to 2.0 mm Seal Packing Groove A072712E01 (6) Apply seal packing to the front bearing cap. • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. • Apply seal packing to the bearing cap as shown in the illustration. Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall the cap. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Do not apply seal packing to the front bearing cap grooves. (7) Install the front bearing cap. HINT: The thrust position of the camshaft will be determined after installing the front bearing cap. (8) Install the other bearing caps in the order shown with the arrow mark facing forward. A054977 EM EM–170 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (9) Push in the camshaft setting oil seal. Push A054978E01 C E D E A B EM E E D C A004469E01 RH Bank 21 8 5 9 17 10 18 3 4 11 15 7 13 1 12 6 14 2 19 20 22 16 (10) Install new seal washers to the bearing cap bolts (A and B). (11) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E). NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C). HINT: Each bolt length is as follows: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E (12) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. (13) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration. Torque: For bolt C 7.5 N*m (76 kgf*cm, 66 in.*lbf) For others 16 N*m (163 kgf*cm, 12 ft.*lbf) A054151E05 (14) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench. (15) Remove the service bolt. Service Bolt A054149E01 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–171 (c) Install the camshafts of the LH bank. (1) Apply MP grease to the thrust portion of the camshafts. (2) Align the timing marks (2-dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts. A054979 Seal Packing LH Bank (3) Apply seal packing to the camshaft housing plug. • Remove the old packing (FIPG) material. • Apply seal packing to the housing plug. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent EM A054975E03 (4) Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration. CAUTION: Be careful of the installation direction. B002649 Seal Packing Seal Width 1.5 to 2.0 mm Groove A072713E01 (5) Apply seal packing to the front bearing cap. • Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. • Apply seal packing to the bearing cap as shown in the illustration. Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube and reinstall the cap. EM–172 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Do not apply seal packing to the front bearing cap grooves. (6) Install the front bearing cap. HINT: The thrust position of the camshaft will be determined after installing the front bearing cap. (7) Install the other bearing cap in the order shown with the arrow mark facing forward. A054981 (8) Push in the camshaft setting oil seal. EM Push A054982E01 A C A E B B C D E E E E E E E E E E E D E E A054154E03 (9) Install a new seal washer to the bearing cap bolts (A and B). (10) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E). NOTICE: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C). HINT: Each bolt length is as follows: 94 mm (3.70 in.) for A with seal washer 72 mm (2.83 in.) for B with seal washer 25 mm (0.98 in.) for C 55 mm (2.17 in.) for D 40 mm (1.57 in.) for E (11) Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration. 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 1 21 LH Bank 2 10 3 4 6 14 9 5 17 13 7 22 12 19 18 8 20 11 15 16 EM–173 (12) Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration. Torque: For bolt C 7.5 N*m (76 kgf*cm, 66 in.*lbf) For others 16 N*m (163 kgf*cm, 12 ft.*lbf) A054154E05 (13) Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench. (14) Remove the service bolt. 35. INSTALL REAR TIMING BELT PLATE RH (a) Install the rear timing belt plate with the bolt and stud bolt. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) Service Bolt A054152E01 36. INSTALL NO. 2 REAR TIMING BELT PLATE RH (a) Install the rear timing belt plate with the 2 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 37. INSTALL REAR TIMING BELT PLATE LH (a) Install the rear timing belt plate with the bolt. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 38. INSTALL NO. 2 REAR TIMING BELT PLATE LH (a) Install the rear timing belt plate with the 2 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) Inward SST 39. INSTALL CRANKSHAFT TIMING PULLEY (a) Fit the timing pulley set key to the key groove of the pulley. (b) Using SST and a hammer, tap in the timing pulley with the flange side facing inward. SST 09223-46011 A004446E01 40. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY (a) Install the idler with the bolt. Torque: 35 N*m (352 kgf*cm, 25 ft.*lbf) (b) Check that the idler moves smoothly. A072699 EM EM–174 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT Adhesive Plate Washer 10 mm Hexagon Wrench 41. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY (a) Apply adhesive to 2 or 3 threads of the pivot bolt. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (b) Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt. Torque: 35 N*m (352 kgf*cm, 25 ft.*lbf) (c) Check that the idler bracket moves smoothly. A054472E02 42. INSTALL CAMSHAFT TIMING PULLEYS (a) Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley. (b) Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" and "L" marks forward. (c) Hold the hexagonal portion of the camshaft. (d) Using a 5 mm hexagon wrench, install the 8 bolts. Torque: 8.1 N*m (83 kgf*cm, 72 in.*lbf) RH Bank: EM 43. INSTALL TIMING BELT NOTICE: The engine should be cold. LH Bank: A134379E01 1 Tooth 1/2 Teeth A139504E01 (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates. HINT: By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy: 1/2 teeth turn for the left bank camshaft timing pulley 1 tooth turn for the right bank camshaft timing pulley 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–175 (2) Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body. Turn A054465E01 A054463 1.27 mm Hexagon Wrench A054983E02 (b) Install the timing belt. (1) Remove any oil or water on each pulley. Keep them clean after removal. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (2) Face the front mark (arrow) on the timing belt forward. (3) Connect the timing belt to the crankshaft timing pulley. • Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (4) Connect the No. 2 timing belt to the idler. (5) Connect the timing belt to the camshaft timing pulley LH. • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. (6) Connect the timing belt to the water pump pulley. (7) Connect the timing belt to the camshaft timing pulley (RH bank). • Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. (8) Connect the No. 1 timing belt to the idler. (c) Set the belt tensioner. (1) Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure. (2) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (3) Release the press. (4) Install the dust boot to the belt tensioner. EM EM–176 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT (d) Install the belt tensioner. (1) Temporarily install the belt tensioner with the 2 bolts. (2) Alternately tighten the 2 bolts. Torque: 26 N*m (270 kgf*cm, 19 ft.*lbf) (3) Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner. 1.27 mm Hexagon Wrench A054462E02 (e) Check the valve timing. (1) Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise. EM Turn A054456E01 (2) Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it. A054458 44. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE (a) Install the sensor plate as shown in the illustration. NOTICE: Take care not to install it in a wrong direction. Front A053994E01 45. INSTALL TIMING GEAR COVER SPACER (a) Install the gasket to the cover spacer. (b) Install the cover spacer. A072695E01 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–177 46. INSTALL NO. 1 TIMING BELT COVER (a) Install the timing belt cover with the 4 bolts. Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) A072694 47. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY (a) Align the pulley set key with the key groove of the crankshaft damper. (b) Using SST and a hammer, tap in the crankshaft damper. SST 09223-46011 SST EM A054471E02 (c) Using SST, install the damper bolt. SST 09213-70011 (90105-08076), 09330-00021 Torque: 245 N*m (2,498 kgf*cm, 181 ft.*lbf) 48. INSPECT VALVE CLEARANCE (See page EM-8) 49. ADJUST VALVE CLEARANCE (See page EM-8) SST A054469E02 [A] [B] [A] A134365E04 50. INSTALL FAN BRACKET SUB-ASSEMBLY (a) Install the idler pulley with the 2 bolts and 2 nuts. Torque: For 12 mm head 16 N*m (160 kgf*cm, 12 ft.*lbf) For 14 mm head 32 N*m (326 kgf*cm, 24 ft.*lbf) HINT: Each bolt length is as follows: 106 mm (4.17 in.) for 12 mm head [A] 114 mm (4.49 in.) for 14 mm head [B] 51. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Install the belt tensioner with the bolt and 2 nuts. Torque: 16 N*m (160 kgf*cm, 11 ft.*lbf) HINT: Use a bolt 106 mm (4.17 in.) in length. A072692 EM–178 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 52. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY (a) Install the timing belt cover and fit the claws and pins into each part. (b) Install the timing belt cover with the 2 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) HINT: Use bolts 106 mm (4.17 in.) in length. A054467 53. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the idler pulley and cover plate with the bolt. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) EM A072691 54. INSTALL SEMICIRCULAR PLUG (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the semicircular plug grooves. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing A054984E02 (c) Install the 4 semicircular plugs to the cylinder heads as shown in the illustration. RH Bank: LH Bank: A054985E02 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT EM–179 55. INSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent (c) Install the gasket to the cylinder head cover. (d) Install the seal washer to the bolt. (e) Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps. Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) RH Bank: LH Bank: EM Seal Packing : A054067E02 56. INSTALL OIL FILLER CAP HOUSING (a) Install a new gasket and the oil filler cap housing with the 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 57. INSTALL OIL FILLER CAP SUB-ASSEMBLY 58. INSTALL SPARK PLUG Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) A072688 59. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Apply seal packing to 2 or 3 threads. Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent Seal Packing P012477E01 (b) Install the 2 drain cocks. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) HINT: After tightening to the specified torque, rotate the drain union clockwise until its drain port is facing forward. A004856 EM–180 2UZ-FE ENGINE MECHANICAL – ENGINE UNIT 60. INSTALL ENGINE HANGERS (a) Install the 2 engine hangers with the 4 bolts. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) A072687 EM FU–10 2UZ-FE FUEL – FUEL INJECTOR REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See page FU-1) 2. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 cap nuts and throttle body cover subassembly. 3. REMOVE AIR CLEANER HOSE ASSEMBLY (a) Disconnect the vacuum hoses (for the P/S idle-up and fuel pressure regulator) and ventilation hose. (b) Remove the air cleaner hose assembly. 4. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (a) Remove the 2 union bolts and 4 gaskets. (b) Remove the bolts and fuel pipe sub-assembly. 5. SEPARATE NO. 3 FUEL PIPE SUB-ASSEMBLY (a) Remove the No. 2 fuel pipe clamp. (b) Remove the 3 bolts and disconnect the fuel return pipe sub-assembly from the fuel pressure regulator. HINT: Move it aside to secure more work space. 6. DISCONNECT FUEL HOSE (a) Remove the pulsation damper and 2 gaskets. (b) Disconnect the No. 1 fuel hose. 7. SEPARATE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (a) Remove the bolts and separate the vacuum switching valve assembly from the intake manifold. 8. DISCONNECT ENGINE WIRE (a) Disconnect the 8 fuel injector connectors. (b) Remove the 3 bolts and disconnect the engine wire. 9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Remove the 2 nuts, and then the fuel delivery pipe by holding both ends and pulling it straight upward. FU A133776 A066659 10. REMOVE NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY (a) Remove the 2 nuts, and then the No.2 fuel delivery pipe by holding both ends and pulling it straight upward. 11. REMOVE FUEL INJECTOR ASSEMBLY (a) Remove the injector from the delivery pipe. NOTICE: Do not apply any force to the injector in the horizontal direction because the O-ring might be stuck. 2UZ-FE FUEL – FUEL INJECTOR FU–11 (b) Remove the O-ring, grommet and insulator from the injector. FU FU–12 2UZ-FE FUEL – FUEL INJECTOR INSPECTION 1. Pressure Regulator SST INSPECT FUEL INJECTOR ASSEMBLY (a) Inspect the injector resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 13.4 to 14.2 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (b) Inspect the injector. CAUTION: Avoid any sparks or flame during the test. Fuel Tube Connector SST Injector SST A067125E01 FU (1) Obtain a new fuel main hose (part No. 2327150190) and take the fuel tube connector out of the hose. Fuel Tube Connector A050710E14 Fuel Tube Connector Fuel Pipe SST (Hose) B012947E09 Pressure Regulator SST (Hose) SST (Union) O-Ring Fuel Return Hose A133773E01 (2) Install the fuel tube connector to SST (hose), then connect the tube connector and fuel pipe. SST 09268-31011 (95336-08070) CAUTION: Observe the precautions when connecting the fuel tube connector (quick type). (3) Remove the pressure regulator from the delivery pipe. (4) Install the O-ring to the fuel inlet of the pressure regulator. (5) Connect the SST (hose) to the fuel inlet of the pressure regulator with another SST (union) and the 2 bolts. SST 09268-31011 (95336-08070, 0926841091) Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) (6) Connect the fuel return hose to the fuel outlet of the pressure regulator. 2UZ-FE FUEL – FUEL INJECTOR (7) Install the O-ring to the injector. (8) Connect SSTs (union and hose) to the injector, and hold the injector and union with another SST (clamp). SST 09268-31011 (09268-41110, 0926841300, 95336-08070) (9) Put the injector into a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. (10) Operate the fuel pump (See page FU-5). SST (Hose) SST (Union) O-Ring SST (Clamp) Vinyl Tube FU–13 B000884E02 (11) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 to 69 cm3 (3.4 to 4.2 cu in.) per 15 seconds Difference between each injector: 13 cm3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. SST (Wire) Connect B000883E01 (c) Check for leakage. (1) In the condition above, disconnect the tester probes of the SST (wire) from the battery and check for fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes A001293 INSTALLATION New Insulator 1. INSTALL FUEL INJECTOR ASSEMBLY (a) Install a new grommet and insulator to the injector. (b) Check that there is no foreign object or damage to the groove of the O-ring of the injector. Apply gasoline to a new O-ring, and install it to the injector. (c) Install the injector to the delivery pipe while turning the injector in both ways. (d) Check that the injector can turn smoothly. NOTICE: When the injector cannot turn smoothly, the Oring might be caught in something. In that case, replace the O-ring with a new one. 2. INSTALL NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY (a) Install the injector with the delivery pipe to the intake manifold. (b) Turn the injector in both ways by approximately 45 degrees. New Grommet New O-Ring A066663E01 FU FU–14 2UZ-FE FUEL – FUEL INJECTOR (c) Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) New Gasket FU 3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Install the injector with the delivery pipe to the intake manifold. (b) Turn the injector in both ways by approximately 45 degrees. (c) Inserting a spacer between the delivery pipe and the intake manifold, install the delivery pipe with the injector with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 4. INSTALL FUEL HOSE (a) Using 2 new gaskets, install the fuel main hose with the fuel pressure pulsation damper. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 5. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 6. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) 7. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (a) Install the fuel pipe sub-assembly with the bolts. (b) Using 4 new gaskets, install the No. 1 fuel pipe subassembly with the 2 union bolts. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 8. INSTALL AIR CLEANER HOSE ASSEMBLY 9. CHECK FOR FUEL LEAKAGE (See page FU-5) A066659E02 10. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 ft.*lbf) 2UZ-FE FUEL – FUEL PUMP FU–17 (d) Remove the O-ring from the fuel pump. A133793 5. REMOVE NO. 2 FUEL SUCTION PLATE (a) Using a screwdriver, remove the 2 E-rings from the No. 2 suction plate. (b) Remove the No. 2 suction plate and 2 springs from the No. 1 fuel suction plate. A133794 Ohmmeter INSPECTION 1. A133774E01 2 1 Battery A133775E01 INSPECT FUEL PUMP (a) Inspect the fuel pump resistance. (1) Using an ohmmeter, measure the resistance between terminals 1 and 2. Standard resistance:: 0.2 to 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. (b) Inspect fuel pump operation. (1) Connect the lead wire to the fuel pump. (2) Connect the positive (+) lead from the battery to terminal 1 of the connector, and the negative (-) lead to terminal 2. Check that the fuel pump operates. NOTICE: • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. • Keep the fuel pump as far away from the battery as possible. • Always switch on the battery side. If the fuel pump dose not operate, replace the fuel pump and/or lead wire. (3) Disconnect the lead wire from the fuel pump. FU FU–18 2UZ-FE FUEL – FUEL PUMP REASSEMBLY 1. INSTALL NO. 2 FUEL SUCTION PLATE (a) Install the 2 springs and No. 2 suction plate to the No. 1 suction plate. (b) Using needle-nose pliers, install 2 new E-rings to the No. 2 suction plate. 2. INSTALL FUEL PUMP (a) Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the fuel pump. A133794 A133793 FU (b) Connect the fuel pump harness connector to the fuel pump. A133792 (c) Install the suction filter to the fuel pump. (d) Install the fuel pump with the suction filter to the fuel filter. A133791 3. A133795 INSTALL FUEL PUMP ASSEMBLY WITH FILTER (a) Install the fuel filter to the fuel sub-tank. 2UZ-FE FUEL – FUEL PUMP 4. FU–19 INSTALL FUEL SUB-TANK (a) Engage the 3 claws to install the No. 2 fuel suction plate the fuel sub-tank. A133789 (b) Connect the 2 tubes to the tube clamps. A133788 (c) Connect the suction filter hose to the fuel sub-tank. A133787 (d) Connect the fuel pump harness connector to the No. 1 fuel suction plate. A133786 5. Slide A133796E01 INSTALL FUEL SENDER GAGE ASSEMBLY (a) Install the fuel sender gage to the fuel suction support. FU FU–20 2UZ-FE FUEL – FUEL PUMP (b) Connect the sender gage connector to the No. 1 fuel suction plate. A133784 FU 2UZ-FE FUEL – FUEL SYSTEM FU–1 FUEL SYSTEM PRECAUTION 1. 2. C/OPN Relay A067118E01 3. PRECAUTION (a) Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. (b) Do not smoke or work near fire when working on the fuel system. (c) Keep gasoline away from rubber or leather parts. WORK FOR PREVENT GASOLINE FROM SPILLING OUT CAUTION: • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure. • Even after discharging the fuel pressure, place a shop rag or piece of cloth over fittings to prevent fuel splashing on yourself or in the engine compartment when separating the fittings. (a) Remove the circuit opening relay from the engine room relay block. (b) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system too lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and let the air out of the fuel tank. (e) Disconnect the negative (-) terminal cable from the battery. (f) Reinstall the circuit opening relay. FUEL SYSTEM (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Disconnect the fuel pump tube (See page FU23). (2) Drain the fuel remained inside the fuel pump tube. (3) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. (4) Place a container under the connection. B000679 FU FU–2 2UZ-FE FUEL – FUEL SYSTEM (b) When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe the following procedures: (1) Always use new gaskets. (2) Tighten the union bolt by hand. New Gasket A133772E01 Fulcrum Length: 30 cm SST (3) Using SST, tighten the union bolt to the specified torque. SST 09612-24014 (09617-24011) Torque: for use with SST 33 N*m (340 kgf*cm, 24 ft.*lbf) 39 N*m (400 kgf*cm, 29 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). A067124E01 FU (c) Observe the following precautions when removing and installing the injectors: (1) Never reuse the O-ring. (2) When placing a new O-ring on the injector, do not damage the O-ring. (3) Coat the new O-ring with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake fluid. CORRECT O-Ring WRONG Delivery Pipe B002714E04 O-Ring Delivery Pipe Grommet Injector Lower Intake Manifold (d) Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration. NOTICE: Before installing the injector, apply spindle oil or gasoline where the delivery pipe or intake manifold contacts the O-ring of the injector. Insulator B004939E02 (e) Observe the following precautions when disconnecting the fuel tube connector (Quick type A): (1) Remove the fuel pipe clamp No. 1. (2) Check that there is no dirt on the pipe and around the connector before disconnecting them. Clean them if necessary. (3) Disconnect them by hand. Quick Type A Fuel Pipe Clamp No. 1 A060083E19 2UZ-FE FUEL – FUEL SYSTEM (4) When the connector and the pipe are stuck, pinch the fuel pipe with your fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out of the pipe. (5) Check that there is no dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. (6) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. Quick Type A Push Push Pull B016533E03 (f) Quick Type A Push FU–3 Observe the following precautions when connecting the fuel tube connector (Quick Type A): (1) Check that there is no damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe. B016534E03 (3) After finishing the connection, check if the pipe and the connector are securely connected by pulling them. (4) Check for fuel leaks. Quick Type A Pull B016535E03 Quick Type B Pull Push B002045E01 (g) Observe the following precautions when disconnecting the fuel tube connector (Quick type B): (1) Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. (2) Disconnect them by hand. (3) When the connector and the pipe are stuck, push and pull the connector. Disconnect and pull it out. Do not use any tool at this time. (4) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. (5) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. FU FU–4 2UZ-FE FUEL – FUEL SYSTEM (h) Observe the following precautions when connecting the fuel tube connector (Quick type B): (1) Match the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of new engine oil to the tip of the pipe. Quick Type B Push B002046E01 (2) After finishing the connection, check if the pipe and the connector are securely connected by pulling them. (3) Check for fuel leaks. Quick Type B Pull B002077E01 FU (i) Quick Type C Fuel Hose Connector Cover Observe the following precautions when disconnecting the fuel tube connector (Quick type C): (1) Pull the fuel hose connector cover up to release the lock. (2) Check that there is no dirt in the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. (3) Be sure to disconnect them by hand. G038120E01 (4) When the connector and the pipe are stuck, pinch the fuel pipe between the hands, and push and pull the connector. Disconnect and pull it out. Do not use any tool at this time. (5) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe. Clean it away if necessary. (6) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag. Quick Type C Push Push Pull B016533E05 (j) Quick Type C Push B016534E05 Observe the following precautions when connecting the fuel tube connector (Quick Type C): (1) Check that there is no damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe. 2UZ-FE FUEL – FUEL SYSTEM FU–5 (3) After finishing the connection, check if the pipe and the connector are securely connected by pulling them. Quick Type C Pull B016535E05 Quick Type C Fuel Hose Connector Cover G038121E01 4. (4) Lock the fuel hose connector cover. HINT: If the fuel tube is not completely connected, the half connection prevention connector prevents the fuel hose connector cover from being locked. (5) Check for fuel leaks. (k) Observe the following precautions when handling a nylon tube: CAUTION: • Do not twist the connection part of the nylon tube and the quick connector by force when connecting them. • Do not twist the nylon tube. • Do not remove the EPDM protector on the outside of the nylon tube. • Do not close the piping with the nylon tube by bending it. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks anywhere on the fuel system after doing maintenance (See page FU5). FU FU–6 2UZ-FE FUEL – FUEL SYSTEM ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FUEL LEAK (a) When using the intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON and intelligent tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the intelligent tester. (4) Please refer to the intelligent tester operator's manual for further details. (b) When not using the intelligent tester (1) Remove the circuit opening relay. (2) Using a service wire, connect terminals FP and +B of the relay block. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. FU FP +B A067117E01 (d) Check that the pulsation damper screw rises up when the fuel pump operates. If operation is not as specified, check the following parts: • Fusible link • Fuses • EFI main relay • Fuel pump • ECM • Wiring connections (e) Turn the ignition switch OFF. (f) Disconnect the intelligent tester from the DLC3. Screw UP Pulsation Damper A067121E01 2. CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the front fuel pipe from the LH delivery pipe (See page FU-10). 2UZ-FE FUEL – FUEL SYSTEM SST (Adaptor) SST (Union) SST (Gauge) Gasket Front Fuel Pipe A067122E01 FU–7 (d) Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and another SST (adaptor). SST 09268-45014 (09268-41200, 09268-41190, 90405-06167, 09268-41210, 90467-11009) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (e) Wipe off any splattered gasoline. (f) Reconnect the negative (-) terminal cable to the battery. (g) Connect the intelligent tester to the DLC3 (See step 1 in check fuel pump operation). (h) Measure the fuel pressure. Fuel pressure: 265 to 304 kPa (2.7 to 3.1 kgf/cm2, 38 to 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts: • Fuel hoses and connections • Fuel pump • Fuel filter • Fuel pressure regulator (i) Disconnect the intelligent tester from the DLC3. (j) Start the engine. (k) Measure the fuel pressure at idle. Fuel pressure: 265 to 304 kPa (2.7 to 3.1 kgf/cm2, 38 to 44 psi) (l) Stop the engine. (m) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (n) After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45014 (09268-41200, 09268-41190, 90405-06167, 09268-41210, 90467-11009) (o) Reinstall the front fuel pipe to the LH delivery pipe (See page FU-13). (p) Reconnect the negative (-) terminal cable to the battery. (q) Check for fuel leaks (See step 1 in check fuel pump operation). FU 2UZ-FE FUEL – FUEL PUMP FU–21 INSTALLATION 1. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY (See page FU-27) FU FU–8 2UZ-FE FUEL – FUEL INJECTOR FUEL INJECTOR 2UZ-FE FUEL ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY 8.2 (84, 73 in.*lbf) VSV FOR AIR INJECTION SYSTEM NO. 3 FUEL PIPE SUB-ASSEMBLY FU FUEL PRESSURE REGULATOR ASSEMBLY 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) O-RING FUEL DELIVERY PIPE SUB-ASSEMBLY 39 (400, 29) GASKET 39 (400, 29) NO. 2 FUEL PIPE CLAMP GASKET 7.5 (80, 66 in.*lbf) 21 (214, 16) GASKET NO. 1 FUEL PIPE SUB-ASSEMBLY O-RING INSULATOR NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY FUEL INJECTOR N*m (kgf*cm, ft.*lbf) : Specified torque DELIVERY PIPE NO. 1 SPACER GROMMET Non-reusable part A119782E01 FU–9 2UZ-FE FUEL – FUEL INJECTOR 18 (185, 13) NO. 1 VACUUM SWITCHING VALVE ASSEMBLY VACUUM HOSE VENTILATION HOSE IDLE UP NO. 2 HOSE ENGINE WIRE FU AIR CLEANER HOSE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A119948E01 FU–14 2UZ-FE FUEL – FUEL PUMP FUEL PUMP 2UZ-FE FUEL ENGINE COMPONENTS FUEL SUCTION SUPPORT NO. 1 FUEL SUCTION PLATE WITH FUEL FILTER FUEL PUMP HARNESS FUEL FILTER FU O-RING FUEL SENDER GAGE ASSEMBLY SPRING NO. 2 FUEL SUCTION PLATE E-RING E-RING SUCTION FILTER HOSE FUEL PUMP FUEL SUCTION FILTER FUEL SUB-TANK Non-reusable part A119785E01 2UZ-FE FUEL – FUEL PUMP FU–15 REMOVAL 1. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY (See page FU-25) DISASSEMBLY 1. REMOVE FUEL SENDER GAGE ASSEMBLY (a) Disconnect the sender gage connector from the No. 1 fuel suction plate. A133784 (b) Unlock the fuel sender gage and remove it. Unlock FU Slide A133785E01 2. REMOVE FUEL SUB-TANK (a) Disconnect the fuel pump harness connector from the No. 1 fuel suction plate. A133786 (b) Disconnect the suction filter hose from the fuel subtank. A133787 FU–16 2UZ-FE FUEL – FUEL PUMP (c) Disconnect the 2 tubes from the tube clamps. A133788 (d) Using a screwdriver with the tip wrapped in tape, disengage the 3 claws to separate the No. 2 fuel suction plate. NOTICE: Do not damage the No. 2 fuel suction plate or fuel sub-tank. (e) Disconnect the No. 1 fuel suction plate with the fuel filter assembly from the fuel sub-tank. A133789 FU 3. REMOVE FUEL PUMP ASSEMBLY WITH FILTER (a) Using a screwdriver with the tip wrapped in tape, disengage the 2 claws to separate the fuel suction support. NOTICE: Do not damage the fuel filter assembly or fuel suction support. (b) Remove the fuel filter assembly with the fuel pump from the fuel suction support. 4. REMOVE FUEL PUMP (a) Using a screwdriver with the tip wrapped in tape, disengage the 5 claws to separate the suction filter. NOTICE: Do not damage the fuel filter assembly or suction filter. (b) Remove the fuel suction filter with the fuel pump from the fuel filter. A133790 A133791 (c) Disconnect the fuel pump harness connector from the fuel pump. A133792 2UZ-FE FUEL – FUEL PUMP RESISTOR Ohmmeter FU–21 FUEL PUMP RESISTOR INSPECTION 1. A072544E01 INSPECT FUEL PUMP RESISTOR (a) Inspect the fuel pump resistor resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 0.70 to 0.76 Ω at 20°C (68°F) FU FU–22 2UZ-FE FUEL – FUEL TANK FUEL TANK 2UZ-FE FUEL ENGINE COMPONENTS REAR FLOOR SERVICE HOLE COVER Retainer FUEL TANK MAIN TUBE CLIP FUEL TANK RETURN TUBE FUEL TANK BREATHER TUBE SUB-ASSEMBLY GASKET FU FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY FUEL TANK TO FILLER PIPE HOSE FUEL TANK ASSEMBLY PIN PIN CLIP CLIP FUEL TANK BAND FUEL TANK BAND 40 (408, 30) 40 (408, 30) 20 (204, 15) 20 (204, 15) NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY FUEL HOSE PROTECTOR 20 (204, 15) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A151308E01 2UZ-FE FUEL – FUEL TANK FU–23 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: (See page FU-1) 2. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Hold the rear No. 1 seat assembly LH. (b) Hold the rear No. 1 seat assembly RH. (c) Remove the rear floor carpet assembly. (d) Remove the 3 screws and rear floor service hole cover. (e) Disconnect the connector. 3. DISCONNECT FUEL TANK TO FILLER PIPE HOSE (a) Disconnect the fuel tank to filler pipe hose from the fuel filler pipe. 4. DRAIN FUEL 5. REMOVE NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY (a) Set a transmission jack to the fuel tank protector. (b) Remove the 6 bolts and the fuel tank protector. 6. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Pinch and turn the projections of the retainers in the direction shown by the arrow to release the lock. Pull out the 2 fuel tank tubes. NOTICE: • Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary. • Do not use any tool in this work. • Do not bend or twist the nylon tube by force. • To protect the tube, cover it with a plastic bag after checking. • When the connector and the pipe are stuck, turn the retainer carefully to release. Disconnect the fuel tank tube. A133777 A067088 Nylon Tube Retainer O-ring Pipe A139367E01 FU FU–24 2UZ-FE FUEL – FUEL TANK Nylon Tube 7. DISCONNECT FUEL TANK BREATHER TUBE SUBASSEMBLY (a) Pinch and turn the projection of the retainer in the direction shown by the arrow to release the lock. Pull out the fuel tank breather tube. NOTICE: • Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary. • Do not use any tool in this work. • Do not bend or twist the nylon tube by force. • To protect the tube, cover it with a plastic bag after checking. • When the connector and the pipe are stuck, turn the retainer carefully to release. Disconnect the tube. 8. DISCONNECT FUEL TANK VENT HOSE (a) Disconnect the fuel tank breather tube from the fuel tank. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. 9. REMOVE FUEL TANK ASSEMBLY (a) Set a transmission jack to the fuel tank. (b) Remove the 2 bolts, 2 fuel tank bands and fuel tank. Retainer O-ring Pipe A139368E01 FU Push Pinch A Pinch A A067090E01 10. REMOVE FUEL TANK CUSHION 2UZ-FE FUEL – FUEL TANK Nylon Tube Fuel Tube Joint O-ring Tube Joint Clip Fuel Suction Plate FU–25 11. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Remove the 2 clips, and pull out the 2 fuel tank tubes. NOTICE: • Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary. • Do not use any tool in this work. • Do not bend or twist the nylon tube by force. • After disconnecting, cover the fuel tube joint with a plastic bag. • When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to release and disconnect it. Likewise, disconnect the fuel tank return tube. 12. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY NOTICE: Protect a connector and tube joint with masking tape or something in order to prevent sticking foreign objects onto them, and clean dirt and foreign objects from the fuel suction tube assembly before removing it. A139373E01 SST Rib A072554E01 (a) Using SST, loosen the retainer. SST 09808-14020 (09808-01410, 09808-01430) HINT: A rib on the retainer can be fitted into the tip of SST. (b) Remove the retainer. (c) Remove the fuel suction with pump & gage tube assembly. NOTICE: Be careful not to bend the arm of the sender gage. (d) Remove the gasket from the fuel tank. FU FU–26 2UZ-FE FUEL – FUEL TANK 13. REMOVE FUEL TANK BREATHER TUBE SUBASSEMBLY (a) Pinch and turn the projection of the retainer in the direction shown by the arrow to release the lock. Pull out the fuel tank breather tube. NOTICE: • Check that there is no dirt or mud around the quick connector before this work. Clean the connector if necessary. • Do not use any tool in this work. • Do not bend or twist the nylon tube by force. • To protect the tube, cover it with a plastic bag after checking. • When the connector and the pipe are stuck, turn the fuel tank breather tube carefully to release. Disconnect the tube. Nylon Tube Retainer 14. REMOVE FUEL TANK TO FILLER PIPE HOSE (a) Remove the fuel tank to filler pipe hose from the fuel tank. FU O-ring Pipe A139370E01 INSTALLATION 0 to 3 mm (0 to 0.12 in.) 1. CONNECT FUEL TANK TO FILLER PIPE HOSE (a) Connect a new fuel tank to filler pipe hose to the fuel tank. HINT: Make sure that the hose and tank are connected as shown in the illustration. 2. INSTALL FUEL TANK BREATHER TUBE SUBASSEMBLY (a) Push in the tube connector to the pipe until the connector makes a "click" sound. NOTICE: • Check if there is any damage or foreign objects on the connected part of the pipe. • After connecting, check if the pipe and the connector are securely connected by pulling them. Marking Location A067094E02 A067097 2UZ-FE FUEL – FUEL TANK 3. A133779 Mark Screw threads Starting Point FU–27 INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY (a) Install a new gasket onto the fuel tank. (b) Set the fuel suction with pump & gage tube assembly to the fuel tank. NOTICE: Be careful not to bend the arm of the fuel sender gage. (c) Fit the spline of the fuel suction with pump & gage tube assembly into the keyway of the fuel tank. (d) Install the retainer. (1) Using a new retainer, align the mark on the retainer with the screw-thread starting point of the fuel tank. (2) While holding the fuel suction with pump & gage tube assembly, tighten the retainer one complete turn by hand. A151298E01 SST Rib A Mark A151299E01 (e) Using SST, tighten the retainer one more complete turn, and position the mark on the retainer into range A of the fuel tank. SST 09808-14020 (09808-01410, 09808-01430) HINT: • Turn the retainer two complete turns and position the mark within range A to install the retainer. • A rib on the retainer can be fitted into the tip of SST. FU FU–28 2UZ-FE FUEL – FUEL TANK 4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Connect the 2 fuel tank tubes with the 2 clips. NOTICE: • Check that there is no scratch or foreign objects on the connecting parts. • Check that the connector is fully inserted. • Check that the tube joint clip is on the collar of the connector. • After installing the tube joint clip, check if the tubes are securely connected by puling then. 5. INSTALL FUEL TANK CUSHION (a) Install 3 new fuel tank cushions to the fuel tank. 6. INSTALL FUEL TANK ASSEMBLY (a) Set a transmission jack to the fuel tank. (b) Install the fuel tank and 2 fuel tank bands with the 2 bolts. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 7. CONNECT FUEL TANK BREATHER TUBE SUBASSEMBLY (a) Push in the tube connector to the pipe until the connector makes a "click" sound. NOTICE: • Check that there is no damage or foreign objects on the connected part of the pipe. • After connecting, check if the pipe and the connector are securely connected by pulling them. 8. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Push in the tube connector to the pipe until the connector makes a "click" sound. NOTICE: • Check that there is no damage or foreign objects on the connected part of the pipe. • After connecting, check if the pipe and the connector are securely connected by pulling them. A133782 FU A133783 A067103 A067104 2UZ-FE FUEL – FUEL TANK 9. 0 to 3 mm (0 to 0.12 in.) FU–29 INSTALL NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY (a) Set a transmission jack to the fuel tank protector. (b) Install the fuel tank protector with the 6 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 10. INSTALL FUEL TANK TO FILLER PIPE HOSE (a) Install the fuel tank to filler pipe hose to the fuel filler pipe. HINT: Make sure that the hose and pipe are connected as shown in the illustration. 11. CHECK FOR FUEL LEAKAGE (See page FU-5) Location Marking A067096E02 12. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Connect the connector. (b) Install the 3 screws and rear floor service hole cover. (c) Install the rear floor carpet assembly. FU EC–10 2UZ-FE EMISSION CONTROL – AIR PUMP ON-VEHICLE INSPECTION E4-28 (E2) E4-32 (AIP) 1. INSPECT PRESSURE SENSOR (a) Turn the ignition switch to the ON position. (b) Measure the voltage between terminals E4-32 (AIP) and E4-28 (E2) of the ECM connector. Voltage: 1.0 to 2.2 V If the voltage is not as specified, replace the pressure sensor, wire harness or ECM. 2. INSPECT VSV FOR AIR INJECTION SYSTEM (a) Disconnect the connector from the VSV (Procedure "A"). (b) Disconnect the 2 vacuum hoses from the VSV (Procedure "B"). A133797E01 A133798 (c) Using an ohmmeter, measure the resistance between the terminals (Procedure "C"). Resistance 1 EC 2 A133799E01 Tester Connection Specified Condition 1-2 33 to 39 Ω at 20°C (68°F) 1 - Body ground 10 MΩ or higher 2 - Body ground 10 MΩ or higher If the resistance is not as specified, replace the VSV. (d) Check that air does not flow from the port as shown in the illustration (Procedure "D"). If the result is not as specified, replace the VSV. Air A133800E01 (e) Apply positive battery between the terminals, and check that air flows from the port (Procedure "E"). If the result is not as specified, replace the VSV. (f) Connect the 2 vacuum hoses to the VSV (Procedure "F"). NOTICE: Be sure to connect the vacuum hoses correctly. (g) Connect the connector to the VSV (Procedure "G"). (h) Perform procedures "A" to "G" for the other VSV. Air A133801E01 2UZ-FE EMISSION CONTROL – AIR PUMP EC–11 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. DRAIN ENGINE COOLANT (See page CO-3) 3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (See page ES-495) 4. REMOVE AIR CLEANER HOSE ASSEMBLY (See page ES-495) 5. DISCONNECT FUEL HOSE (See page FU-10) 6. DISCONNECT FUEL NO. 2 HOSE 7. DISCONNECT CONNECTORS FROM INTAKE MANIFOLD (See page ES-500) 8. DISCONNECT HOSES FROM INTAKE MANIFOLD (See page ES-500) 9. REMOVE INTAKE MANIFOLD ASSEMBLY (See page ES-501) 10. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (See page EM-45) 11. REMOVE AIR PUMP ASSEMBLY WITH BRACKET (a) Disconnect the No.2 air hose from the air switching valve. (b) Disconnect the air switching valve connector. (c) Disconnect the pressure sensor connector for the air injection system. (d) Remove the 4 bolts and air pump with bracket assembly. A133809 12. REMOVE AIR PUMP ASSEMBLY (a) Remove the 3 bolts and air pump assembly. (b) Remove the 3 insulators from the air pump assembly. A133810 1 2 INSPECTION 1. A133804E01 INSPECT AIR PUMP ASSEMBLY (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that air flows. If operation is not as specified, replace the air pump. EC EC–12 2UZ-FE EMISSION CONTROL – AIR PUMP INSTALLATION 1. INSTALL AIR PUMP ASSEMBLY (a) Install the 3 insulators to the air pump assembly. (b) Install the air pump assembly with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 2. INSTALL AIR PUMP ASSEMBLY WITH BRACKET (a) Install the air pump assembly with the 4 bolts. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) (b) Connect the pressure sensor connector for the air injection system. (c) Connect the air switching valve connector. (d) Connect the No. 2 air hose to the air switching valve. 3. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See page EM-53) 4. INSTALL INTAKE MANIFOLD ASSEMBLY (See page ES-503) 5. CONNECT HOSES FROM INTAKE MANIFOLD (See page ES-504) 6. CONNECT CONNECTORS FROM INTAKE MANIFOLD (See page ES-504) 7. INSTALL FUEL NO. 2 HOSE 8. INSTALL FUEL HOSE (See page FU-13) 9. INSTALL AIR CLEANER HOSE ASSEMBLY A133810 A133809 EC 10. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (See page ES-496) 11. ADD ENGINE COOLANT (See page CO-3) 12. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 13. CHECK FOR FUEL LEAKS (See page FU-5) 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE EC–17 ON-VEHICLE INSPECTION 1. A133802 INSPECT NO. 2 AIR SWITCHING VALVE (a) Disconnect the vacuum hose from the VSV for the air injection system (Procedure "A"). (b) Apply vacuum (30 kPa (306 gf/cm2, 4.35 psi)) to the vacuum hose, and check that the vacuum does not decrease (Procedure "B"). If operation is not as specified, replace the No. 2 air switching valve. (c) Release the vacuum, and check that an operation sound is emitted from the No. 2 air switching valve (Procedure "C"). If operation is not as specified, replace the No. 2 air switching valve. (d) Perform procedures "A" to "C" for the other No. 2 air switching valve. A133803 EC EC–18 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. DRAIN ENGINE COOLANT (See page CO-3) 3. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (See page ES-495) 4. REMOVE AIR CLEANER HOSE ASSEMBLY (See page ES-495) 5. DISCONNECT FUEL HOSE (See page FU-10) 6. DISCONNECT FUEL NO. 2 HOSE 7. DISCONNECT CONNECTORS FROM INTAKE MANIFOLD (See page ES-500) 8. DISCONNECT HOSES FROM INTAKE MANIFOLD (See page ES-500) 9. REMOVE INTAKE MANIFOLD ASSEMBLY (See page ES-501) 10. REMOVE AIR NO. 2 TUBE (a) Remove the 4 nuts and 2 gaskets, and disconnect the air No. 2 tube. 11. REMOVE AIR NO. 3 TUBE (a) Remove the 4 nuts and 2 gaskets, and disconnect the air No. 3 tube. EC 12. REMOVE WATER BY-PASS JOINT RR (See page EM45) 13. REMOVE NO. 2 AIR SWITCHING VALVE (a) Remove the 2 vacuum hoses from the No. 2 air switching valves. (b) Remove the 4 bolts, 2 gaskets and the 2 No. 2 air switching valves from the water by-pass joint rear. 14. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (See page EM-45) A134352 15. REMOVE AIR PUMP ASSEMBLY WITH BRACKET (See page EC-11) 16. REMOVE PRESSURE SENSOR (a) Remove the vacuum hose from the pressure sensor and air switching valve. (b) Remove the 2 bolts and pressure sensor from the air switching valve. A134350 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE EC–19 17. REMOVE AIR SWITCHING VALVE (a) Remove the 2 bolts and air switching valve from the air pump bracket. (b) Remove the No. 1 air hose from the air switching valve and air pump. A134351 INSPECTION Air 1. INSPECT AIR SWITCHING VALVE (a) Blow air into port A and check that air is not discharged from port B. Port A Port B A133805E01 (b) Apply positive battery between the terminals. (c) Blow air into port A and check that air is discharged from port B. If operation is not as specified, replace the air switching valve. Port B Air Battery Port A A133806E01 2. Port A INSPECT NO. 2 AIR SWITCHING VALVE (a) Blow air into port B and check that air is not discharged from port C. Port C Air Port B A133807E01 Port A Port C Air Port B A133808E01 (b) Apply vacuum (30 kPa (306 gf/cm2, 4.35 psi)) to port A, blow air into port B and check that air is discharged from port C. If operation is not as specified, replace the No. 2 air switching valve. EC EC–20 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE INSTALLATION 1. INSTALL AIR SWITCHING VALVE (a) Install the No. 1 air hose to the air switching valve and air pump. (b) Install the air switching valve with the 2 bolts to the air pump bracket. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 2. INSTALL PRESSURE SENSOR (a) Install the pressure sensor with the 2 bolts to the air switching valve. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Install the vacuum hose to the pressure sensor and air switching valve. 3. INSTALL AIR PUMP ASSEMBLY WITH BRACKET (See page EC-12) 4. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See page EM-53) 5. INSTALL NO. 2 AIR SWITCHING VALVE (a) Install 2 new gaskets and the 2 No. 2 air switching valves with the 4 bolts to the water by-pass joint rear. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (b) Connect the 2 vacuum hoses to the No. 2 air switching valves. 6. INSTALL WATER BY-PASS JOINT RR 7. INSTALL NO. 3 AIR TUBE (a) Install the 4 nuts and 2 new gaskets, and connect the No. 3 air tube. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 8. INSTALL NO. 2 AIR TUBE (a) Install the 4 nuts and 2 new gaskets, and connect the No. 2 air tube. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 9. INSTALL INTAKE MANIFOLD ASSEMBLY (See page ES-503) A134351 A134350 EC A134352 10. CONNECT HOSES FROM INTAKE MANIFOLD (See page ES-504) 11. CONNECT CONNECTORS FROM INTAKE MANIFOLD (See page ES-504) 12. INSTALL FUEL NO. 2 HOSE 13. INSTALL FUEL HOSE (See page FU-13) 14. INSTALL AIR CLEANER HOSE ASSEMBLY 15. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (See page ES-496) 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE EC–21 16. ADD ENGINE COOLANT (See page CO-3) 17. CHECK FOR ENGINE COOLANT LEAKS (See page CO-4) 18. CHECK FOR FUEL LEAKS (See page FU-5) EC 2UZ-FE EMISSION CONTROL – CANISTER EC–23 REMOVAL A 1. REMOVE SPARE TIRE 2. REMOVE CHARCOAL CANISTER NO. 2 FILTER (a) Disconnect the canister outlet hose No. 2 from the charcoal canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (b) Disconnect the canister outlet hose from the fuel tank filler pipe. A Push A067130E02 (c) Remove a bolt and the charcoal canister filter. EC A067131 Connector Fuel Tank Vent Hose Canister Outlet Hose No. 2 Purge Hose A A Push A151297E01 3. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the fuel tank vent hose from the charcoal canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (b) Disconnect the canister outlet hose No. 2 from the charcoal canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (c) Disconnect the connector from the pump module. (d) Disconnect the purge line hose from the charcoal canister. (e) Remove the 3 bolts, and the charcoal canister from the body. EC–24 2UZ-FE EMISSION CONTROL – CANISTER INSPECTION 1. INSPECT CHARCOAL CANISTER ASSEMBLY (a) Visually check the charcoal canister for cracks and damage. If there is any cracks or damage, replace the charcoal canister assembly. A150754 Purge Port (b) Check the charcoal canister operation. (1) While holding the purge port closed, blow air at 1.67 kPa (17.0 gf/cm2, 0.24 psi) into the vent port, and check that the air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assembly Air Inlet Port Air Vent Port A150755E01 Purge Port Vacuum EC Vent Port (2) While holding the vent port closed, apply a vacuum of 1.10 kPa (8.3 mmHg, 0.32 in.Hg) into the purge port, and check that the air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assembly Air Inlet Port A150756E01 (c) Check for air leakage. (1) Remove the air hose between ports A and B. A150757 2UZ-FE EMISSION CONTROL – CANISTER Port B Purge Port Port A Air Inlet Port Vent Port EC–25 (2) Connect the pressure gauge to the vent port of the charcoal canister. (3) While holding port B, the purge port and air inlet port closed with your fingers, leave port A open and apply pressurized air at 19.6 kPa (0.2 kgf/cm2, 2.81 psi) into the vent port. Check that the pressure is retained. If the result is not as specified, replace the charcoal canister assembly Pressure Gauge A150758E01 (d) Check the leak detection pump. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the pump module. C A Air B EC A092453E01 Valve Battery Closed A092454E02 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the pump module. 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1 EMISSION CONTROL SYSTEM 2UZ-FE EMISSION CONTROL ENGINE PARTS LOCATION VACUUM SWITCHING VALVE (Purge VSV) VACUUM SURGE TANK CHARCOAL CANISTER CHARCOAL CANISTER NO. 2 FILTER VENTILATION VALVE PUMP MODULE FUEL TANK CAP FUEL TANK A150760E05 EC EC–2 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) VSV FOR AIR INJECTION CONTROL (BANK 1) VSV FOR AIR INJECTION CONTROL (BANK 2) EC HEATED OXYGEN SENSOR A/F SENSOR (BANK 1 SENSOR 2) (BANK 2 SENSOR 1) A/F SENSOR (BANK 1 SENSOR 1) A119840E06 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–3 NO. 2 AIR SWITCHING VALVE (NO. 2 ASV) (BANK 2) NO. 2 AIR SWITCHING VALVE (NO. 2 ASV) (BANK 1) AIR PUMP EC AIR SWITCHING VALVE (ASV) A119841E05 EC–4 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM Evaporative Emission (EVAP) Control System Refueling Valve To Inteke Manifold Canister Purge VSV Vent Line Purge Line Fuel Tank Vent Valve Air Inlet line Air Filter M Pump Motor ECM P Pressure Sensor Pump Module Secondary Air Injection System EC TWC Pressure Sensor P Air Pump Air Switching Valve VSVs M Air Switching Valve No.2 ECM Air Injection Control Driver A151293E02 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–5 ON-VEHICLE INSPECTION 1. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS (a) Check for cracks, leaks or damage. HINT: Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause an engine failure or engine malfunctions. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause an engine failure or engine malfunctions. 2. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank (See page FU-24). (b) Apply pressure to the fuel tank and make the internal pressure of the air pressure 4 kPa (41 gf/ cm2, 0.58 psi). (c) Check that the internal pressure of the fuel tank is maintained for 1 minute. (d) Check the connections for each hose and pipe. (e) Check the installed parts on the fuel tank. If there is no abnormality, replace the fuel tank and filler pipe. (f) Reconnect the vent line hose to the fuel tank. 3. INSPECT FUEL CUT-OFF VALVE AND FILL CHECK VALVE (a) Disconnect the vent line hose from the fuel tank (See page FU-24). (b) Apply 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: In the condition that the fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume). (c) Remove the fuel tank cap, and check that the pressure inside the tank drops. If pressure does not drop, replace the fuel tank assembly. (d) Reconnect the vent line hose to the fuel tank. A074799 Vent Line Hose A067134E02 Vent Line Hose Fuel Tank Cap A067135E02 EC EC–6 2UZ-FE EMISSION CONTROL – EMISSION CONTROL SYSTEM 4. Air Inlet Line Hose Air A150753E01 EC CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister. (b) Check that there is ventilation in the air inlet line. (c) Reconnect the air inlet line hose to the charcoal canister. EC–26 2UZ-FE EMISSION CONTROL – CANISTER INSTALLATION A067131 EC 1. INSTALL CHARCOAL CANISTER ASSEMBLY (a) Install the charcoal canister with the 3 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the purge line hose to the charcoal canister. (c) Connect the connector to the pump module. (d) Connect the canister outlet hose No. 2 to the charcoal canister. (e) Connect the fuel tank hose to the charcoal canister. 2. INSTALL CHARCOAL CANISTER NO. 2 FILTER (a) Install the charcoal canister with a bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the canister outlet hose to the fuel tank filler pipe. (c) Connect the canister outlet hose No. 2 to the charcoal canister. 3. INSTALL SPARE TIRE 2UZ-FE EMISSION CONTROL – AIR PUMP EC–7 AIR PUMP 2UZ-FE EMISSION CONTROL ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY IDLE UP NO. 2 HOSE VACUUM HOSE VENTILATION HOSE AIR CLEANER HOSE ASSEMBLY EC N*m (kgf*cm, ft.*lbf) : Specified torque A130710E01 EC–8 2UZ-FE EMISSION CONTROL – AIR PUMP ENGINE WIRE 7.5 (76, 66 in.*lbf) 18 (185, 13) VSV FOR AIR INJECTION SYSTEM ENGINE WIRE 18 (185, 13) 18 (185, 13) INJECTION CONNECTOR WATER BY-PASS HOSE FUEL NO. 2 HOSE WATER BY-PASS NO. 7 HOSE FUEL HOSE FUEL PIPE NO. 2 CLAMP 7.5 (76, 66 in.*lbf) EC FUEL PIPE NO. 1 CLAMP GASKET VACUUM HOSE GASKET VSV CONNECTOR FOR EVAP WIRE BRACKET WATER BY-PASS PIPE SUB-ASSEMBLY 16 (163, 12) 16 (163, 12) 18 (185, 13) AIR PUMP ASSEMBLY WITH BRACKET O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134407E02 EC–9 2UZ-FE EMISSION CONTROL – AIR PUMP 16 (163, 12) AIR SWITCHING VALVE PRESSURE SENSOR 5.0 (51, 44 in.*lbf) VACUUM HOSE AIR PUMP ASSEMBLY EC 10 (102, 7) NO. 1 AIR HOSE x3 INSULATOR BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A134408E01 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE EC–13 AIR SWITCHING VALVE 2UZ-FE EMISSION CONTROL ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY IDLE UP NO. 2 HOSE VACUUM HOSE VENTILATION HOSE AIR CLEANER HOSE ASSEMBLY EC N*m (kgf*cm, ft.*lbf) : Specified torque A119860E02 EC–14 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE ENGINE WIRE 7.5 (76, 66 in.*lbf) ENGINE WIRE VSV FOR AIR INJECTION SYSTEM 18 (185, 13) 18 (185, 13) 18 (185, 13) WATER BY-PASS HOSE INJECTION CONNECTOR EC FUEL NO. 2 HOSE WATER BY-PASS NO. 7 HOSE INTAKE MANIFOLD ASSEMBLY FUEL HOSE FUEL PIPE CLAMP NO. 2 FUEL PIPE CLAMP NO. 1 VSV CONNECTOR FOR EVAP GASKET VACUUM HOSE 7.5 (76, 66 in.*lbf) WIRE BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE WIRE Non-reusable part A119820E09 EC–15 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE NO. 2 AIR SWITCHING VALVE 10 (102, 7) GASKET 10 (102, 7) 10 (102, 7) AIR NO. 2 TUBE GASKET GASKET GASKET NO. 2 AIR SWITCHING VALVE 18 (185, 13) WATER BY-PASS PIPE SUB-ASSEMBLY AIR NO. 3 TUBE GASKET EC 10 (102, 7) O-RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A130720E02 EC–16 2UZ-FE EMISSION CONTROL – AIR SWITCHING VALVE AIR SWITCHING VALVE 16 (163, 12) PRESSURE SENSOR 5.0 (51, 44 in.*lbf) VACUUM HOSE AIR PUMP EC 10 (102, 7) NO. 1 AIR HOSE x3 INSULATOR BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A134408E03 2UZ-FE EMISSION CONTROL – CANISTER EC–21 CANISTER 2UZ-FE EMISSION CONTROL ENGINE COMPONENTS EC SPARE TIRE C131379E02 EC–22 EC 2UZ-FE EMISSION CONTROL – CANISTER CHARCOAL CANISTER ASSEMBLY CHARCOAL CANISTER NO. 2 FILTER A150760E04 EC–26 2UZ-FE EMISSION CONTROL – VACUUM SWITCHING VALVE Ohmmeter VACUUM SWITCHING VALVE INSPECTION 1. Continuity B016402E01 Ohmmeter INSPECT PURGE VSV (a) Inspect the VSV for open circuit. (1) Using an ohmmeter, check resistance between the terminals. Resistance: 26 to 30 Ω at 20°C (68°F) If the resistance is not as specified, replace the VSV. (b) Inspect the VSV for ground. (1) Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity B016403E01 (c) Inspect the VSV operation. (1) Check that air does not flow from ports. EC Air B016404E01 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from ports. If operation is not as specified, replace the VSV. Air Battery B016405E01 2UZ-FE EMISSION CONTROL – VENTILATION VALVE EC–27 VENTILATION VALVE Clean Hose Air Cylinder Head Side B016486E01 1. INSPECT VENTILATION VALVE SUB-ASSEMBLY (a) Install a clean hose to the ventilation valve. (b) Inspect the ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through smoothly. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. (2) Blow air into the intake manifold side, and check that air does not passes through smoothly. If operation is not as specified, replace the ventilation valve. (c) Remove the clean hose from the ventilation valve. Air Intake Manifold Side INSPECTION Clean Hose B016487E01 EC EC–28 2UZ-FE EMISSION CONTROL – AIR FUEL RATIO SENSOR +B AIR FUEL RATIO SENSOR HT INSPECTION 1. E1 A061830E01 INSPECT AIR FUEL RATIO SENSOR (for Sensor 1) (a) Using an ohmmeter, measure resistance between the terminals. Resistance Terminal No. Resistance 1 (HT) ←→ 2 (+B) 11 to 16 Ω at 20°C (68°F) 1 (HT) ←→ 4 (E1) 10 kΩ or higher If the resistance is not as specified, replace the sensor. EC EC–29 2UZ-FE EMISSION CONTROL – HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR +B HT 2 1 4 3 INSPECTION 1. E1 A062378E43 INSPECT HEATED OXYGEN SENSOR (for Sensor 2) (a) Using an ohmmeter, measure resistance between the terminals. Resistance Terminal No. Resistance 1 (HT) ←→ 2 (+B) 11 to 16 Ω at 20°C (68°F) 1 (HT) ←→ 4 (E1) 10 kΩ or higher If the resistance is not as specified, replace the sensor. EC EC–30 2UZ-FE EMISSION CONTROL – FUEL TANK CAP FUEL TANK CAP INSPECTION 1. Gasket A076682E05 EC INSPECT FUEL TANK CAP ASSEMBLY (a) Visually check if the cap and/or gasket are deformed or damaged. IT–1 2UZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM INTAKE AIR CONTROL SYSTEM 2UZ-FE INTAKE ENGINE PARTS LOCATION INTAKE MANIFOLD ASSEMBLY VACUUM SWITCHING VALVE ASSEMBLY (for ACIS) INTAKE MANIFOLD ASSEMBLY: INTAKE AIR CONTROL VALVE A137561E01 ON-VEHICLE INSPECTION 1. A134353 INSPECT INTAKE AIR CONTROL VALVE OPERATION (a) Start the engine. (b) While the engine is idling, check that the actuator rod moves. IT IT–2 2UZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM (c) Disconnect the VSV connector, and check that the actuator rod returns. If operation is not as specified, inspect the intake air control valve, VSV and ECM. Disconnect A134354E01 INSPECTION 1. INSPECT INTAKE AIR CONTROL VALVE (a) With 39.9 kPa (300 mmHg, 11.8 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves (procedure [A]). (b) One minute after applying the vacuum in procedure [A], check that the actuator rod does not return. If operation is not as specified, replace the intake manifold. 2. INSPECT VACUUM SWITCHING VALVE ASSEMBLY (a) Using an ohmmeter, check that there is continuity between each terminal. Resistance: 33 to 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. A134355 Continuity Ohmmeter IT S004525E06 (b) Using an ohmmeter, check that there is no continuity between each terminal and the body. Resistance: 10 kΩ or higher If there is continuity, replace the VSV. No continuity Ohmmeter S004524E05 (c) Check that air flows from port E to the filter. Air E Filter FI06393E09 2UZ-FE INTAKE – INTAKE AIR CONTROL SYSTEM IT–3 (d) Apply battery voltage across the terminals. (e) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. Air E F S004523E08 IT 2UZ-FE EXHAUST – EXHAUST PIPE EX–3 INSTALLATION 1. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N*m (633 kgf*cm, 46 ft.*lbf) 2. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install the 2 new gaskets and the front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 bolts and 2 nuts. Torque: Nut 62 N*m (633 kgf*cm, 46 ft.*lbf) Bolt 48 N*m (489 kgf*cm, 35 ft.*lbf) 3. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using vernier calipers, measure the free length to the compression spring. Minimum length: 40.5 mm (1.5945 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with 2 bolts and 2 springs. Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf) 4. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with 2 bolts. Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) 5. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 6. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 7. INSPECT EXHAUST GAS LEAK Gasket Front Pipe A072559E01 EX EX–1 2UZ-FE EXHAUST – EXHAUST PIPE EXHAUST PIPE 2UZ-FE EXHAUST ENGINE COMPONENTS EXHAUST PIPE ASSEMBLY TAIL 48 (489, 35) 48 (489, 35) GASKET EXHAUST PIPE ASSEMBLY CENTER 43 (440, 32) COMPRESSION SPRING HEATED OXYGEN SENSOR 43 (440, 32) GASKET NO. 2 EXHAUST FRONT PIPE ASSEMBLY EX GASKET 44 (450, 33) COMPRESSION SPRING 48 (489, 35) 62 (633, 46) GASKET GASKET 44 (450, 33) HEATED OXYGEN SENSOR EXHAUST PIPE ASSEMBLY FRONT 62 (633, 46) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119776E01 EX–2 2UZ-FE EXHAUST – EXHAUST PIPE REMOVAL 1. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 2. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 3. REMOVE EXHAUST PIPE ASSEMBLY TAIL (a) Remove the 2 bolts, exhaust pipe support and tail pipe. 4. REMOVE EXHAUST PIPE ASSEMBLY CENTER (a) Remove the 2 bolts and 2 compression springs. (b) Remove the 4 exhaust pipe supports and exhaust pipe center. 5. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and No. 2 exhaust front pipe assembly. 6. REMOVE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 nuts and exhaust pipe assembly front. A067109 A067110 EX CO–14 2UZ-FE COOLING – RADIATOR REMOVAL 1. DRAIN ENGINE COOLANT (See page CO-3) 2. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (a) Remove the 4 bolts and engine under cover. 3. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support upper. 4. REMOVE RADIATOR RESERVE TANK ASSEMBLY (a) Disconnect the reserve tank hose from the radiator. (b) Remove the 3 bolts and reserve tank. 5. SEPARATE FAN SHROUD (a) Disconnect the reserve tank hose from the radiator. (b) Disconnect the radiator hose No. 1 from the radiator. (c) Disconnect the oil cooler inlet hose from the radiator. (d) Disconnect the oil cooler outlet hose from the radiator. (e) Disconnect the radiator hose No. 2 from the radiator. A072532 A072577 (f) Remove the 2 bolts, and separate the fan shroud. HINT: Temporarily put the separated fan shroud at an appropriate location in the engine room. CO A072533 A067113 6. REMOVE RADIATOR ASSEMBLY (a) Remove the 4 bolts and radiator. 7. REMOVE RADIATOR SUPPORT NO.1 (a) Remove the 2 radiator support No. 1. 8. REMOVE RADIATOR SUPPORT NO.2 (a) Remove the 2 radiator support No. 2. 9. REMOVE RADIATOR SUPPORT NO.1 BUSH (a) Remove the 4 radiator support No. 1 bush. 2UZ-FE COOLING – RADIATOR CO–15 INSTALLATION 1. INSTALL RADIATOR ASSEMBLY (a) Insert the tabs of the radiator support through the radiator service holes. (b) Install the radiator assembly with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 2. INSTALL FAN SHROUD (a) Insert the tabs in the slots shown in the illustration, attach the fan shroud with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 3. INSTALL RADIATOR RESERVE TANK ASSEMBLY (a) Install the reserve tank with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the reserve tank hose to the radiator. 4. ADD ENGINE COOLANT (See page CO-3) 5. INSPECT ENGINE COOLANT LEAK (See page CO-4) A067114 A072540 CO 2UZ-FE COOLING – COOLING SYSTEM CO–1 COOLING SYSTEM ON-VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKAGE (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (b) Fill the radiator with coolant and attach a radiator cap tester. (c) Warm up the engine. (d) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and cylinder head. (e) Reinstall the radiator cap. A067116 2. INSPECT ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant should be between the LOW and FULL lines when the engine is cold. If low, check for leakage and add Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line. 3. INSPECT ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (b) Check for any excessive deposits of rust or scale around the radiator cap and radiator filler hole; the coolant should be free of oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. CO CO–2 2UZ-FE COOLING – COOLING SYSTEM INSPECTION 1. INSPECT FLUID COUPLING ASSEMBLY (a) Check the fluid coupling for damage or silicon oil leaks. If necessary, replace the fluid coupling. 2. INSPECT FAN BRACKET SUB-ASSEMBLY (a) Check that the fan pulley turns smoothly. If necessary, replace the pulley bracket. P021660 B007456 CO 2UZ-FE COOLING – COOLANT CO–3 COOLANT REPLACEMENT 1. DRAIN ENGINE COOLANT CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (a) Remove the radiator cap. (b) Remove the service hole cover from the engine under cover No. 1. (c) Install a vinyl hose onto the drain on the radiator side. (d) Fix the vinyl hose with tape. Vinyl Hose Tape A070279E01 (e) Loosen the 3 drain plugs on the engine and radiator, and drain the coolant. (f) Drain the coolant from the reservoir tank. (g) Tighten the 3 drain plugs. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) for the engine (h) Remove the vinyl hose from the radiator. Drain Plug 2. A070477E01 ADD ENGINE COOLANT (a) Slowly fill the system with engine coolant. Capacity: 12.3 liters (13.0 US qts, 10.8 lmp. qts) HINT: • Use of improper coolants may damage the engine cooling system. • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). • New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50 % and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended. • Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. CO CO–4 2UZ-FE COOLING – COOLANT (b) (c) (d) (e) 3. CO NOTICE: Do not substitute plain water for engine coolant. Install the radiator cap securely. Bleed the cooling system. (1) Open the heater water valve while warming up the engine. (2) Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine. Stop the engine and wait until the coolant cools down. Add coolant into the reservoir until the coolant level is FULL. INSPECT ENGINE COOLANT LEAK (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm2 17.1 psi), then check for leakage. 2UZ-FE COOLING – WATER PUMP CO–5 WATER PUMP 2UZ-FE COOLING ENGINE COMPONENTS WATER INLET HOUSING CO WATER PUMP ASSEMBLY TIMING BELT A137956E01 CO–6 2UZ-FE COOLING – WATER PUMP REMOVAL 1. REMOVE TIMING BELT (a) Remove the timing belt (See page EM-16). 2. REMOVE WATER INLET HOUSING (a) Disconnect the water bypass hose from the water inlet housing. (b) Remove the 2 bolts holding the water inlet housing to the water pump. (c) Disconnect the water inlet housing from the front water bypass joint, and remove the water inlet housing w/ water inlet. 3. REMOVE WATER PUMP ASSEMBLY (a) Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. (b) Remove the O-ring from the water bypass pipe. A074954 B004461 INSPECTION 1. Water Hole Air Hole B004067E01 CO New O-ring INSTALLATION 1. Connect B004463E01 INSPECT WATER PUMP ASSEMBLY (a) Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump assembly. (b) Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump assembly. INSTALL WATER PUMP ASSEMBLY (a) Install a new O-ring to the water bypass pipe end. (b) Apply soapy water to the O-ring. (c) Connect the water pump to the water bypass pipe end. (d) Install the water pump and new gasket with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes. Torque: Bolt 21 N*m (215 kgf*cm, 16 ft.*lbf) Stud bolt and nut 18 N*m (185 kgf*cm, 13 ft.*lbf) 2UZ-FE COOLING – WATER PUMP 2. CO–7 INSTALL WATER INLET HOUSING (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump. (1) Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. (2) Thoroughly clean all components to remove all the loose material. (3) Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the sealing groove of water inlet housing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent (1) Cut the opening of a nozzle for seal packing to a diameter of 2 to 3 mm (0.08 to 0.12 in.), and install it. (2) Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. (3) Immediately remove the nozzle from the tube and reinstall cap. (c) Install a new O-ring to the water inlet housing. (d) Apply soapy water to the O-ring. (e) Attach the water inlet housing end to the front water bypass joint hole. (f) Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) Seal Width 2 to 3 mm New O-ring A074953E01 3. INSTALL TIMING BELT (a) Install timing belt (See page EM-19). CO CO–8 2UZ-FE COOLING – THERMOSTAT THERMOSTAT 2UZ-FE COOLING ENGINE COMPONENTS WATER INLET HOUSING CO A130721E02 2UZ-FE COOLING – THERMOSTAT CO–9 REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT (See page CO-3) 2. SEPARATE WATER INLET HOUSING (a) Remove the 3 nuts, and separate the water inlet from the water inlet housing. 3. REMOVE THERMOSTAT (a) Remove the thermostat. (b) Remove the gasket from the thermostat. A066664 INSPECTION 1. INSPECT WATER INLET WITH THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. A075918E01 (a) Immerse the thermostat in water, then gradually heat the water. (b) Check the valve opening temperature of the thermostat. Valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. A075919E01 Valve Lift A075920E02 (c) Check the valve lift. Valve lift: 8.0 mm (0.31 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperature (below 40°C (104°F)). If not fully closed, replace the thermostat. CO CO–10 2UZ-FE COOLING – THERMOSTAT INSTALLATION Jiggle Valve 30° 30° A066665E01 CO 1. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. (b) Insert the thermostat into the water inlet housing with the jiggle valve facing straight upward. HINT: The jiggle valve may be set within 30° of either side of the prescribed position. 2. INSTALL WATER INLET HOUSING (a) Install the water inlet with the 3 nuts. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 3. FILL UP ENGINE COOLANT (See page CO-3) 2UZ-FE COOLING – RADIATOR CO–11 RADIATOR 2UZ-FE COOLING ENGINE COMPONENTS RADIATOR SUPPORT SEAL UPPER RADIATOR ASSEMBLY FAN SHROUD CO A119815E03 CO–12 2UZ-FE COOLING – RADIATOR ON-VEHICLE INSPECTION 1. INSPECT RADIATOR CAP SUB-ASSEMBLY NOTICE: • If the radiator cap is contaminated, rinse it with water. • Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. • When performing the following steps [A] and [B], keep the tester at an angle of 30° or more above the horizontal. (a) Using a radiator cap tester, slowly pump and check that air comes from the vacuum valve [A]. Pumping speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air does not come from the vacuum valve, replace the reservoir cap. (b) Pump the tester, then measure the relief valve opening pressure [B]. Pumping speed: 1 push every second NOTICE: The above pumping speed is for the first pumping only (in order to close the vacuum valve). After the first pumping, the pumping speed can be reduced. HINT: Use the tester's maximum reading as the opening pressure. Standard opening pressure: 93 to 123 kPa (0.95 to 1.25 kgf*cm2, 13.5 to 17.8 psi) Minimum opening pressure: 78 kPa (0.8 kgf*cm2, 11.4 psi) If the opening pressure is less than the minimum, replace the radiator cap. Radiator Cap Tester 30qQTOQTG Radiator Cap Z000570E04 CO ON-VEHICLE CLEANING 1. A073603E04 INSPECT FINS FOR BLOCKAGE (a) If the fins are clogged, wash them with water or a steam cleaner, then dry them with compressed air. NOTICE: • If the distance between the steam cleaner and core is too small, there is a possibility of damaging the fins, so keep to the following injection distances. Injection Pressure kPa (kg/cm2, psi) Injection Distance mm (in.) 2,942 to 4,903 (30 to 50, 427 to 711) 300 (11.811) 4,903 to 7,845 (50 to 80, 711 to 1,138) 500 (19.685) 2UZ-FE COOLING – RADIATOR CO–13 • If the fins are bent, straighten them with a screwdriver or pliers. • Be careful not to expose electronic components to water. CO 2UZ-FE LUBRICATION – OIL PUMP LU–11 REMOVAL 1. REMOVE ENGINE ASSEMBLY (a) Remove engine assembly (See page EM-80). 2. REMOVE TIMING BELT (a) Remove timing belt (See page EM-16). 3. REMOVE CRANKSHAFT TIMING PULLEY (See page EM-112) 4. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-492) 5. REMOVE OIL COOLER ASSEMBLY (See page LU-17) 6. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (See page EM-115) 7. REMOVE OIL STRAINER SUB-ASSEMBLY (See page EM-116) 8. REMOVE OIL PAN BAFFLE PLATE (See page EM115) 9. REMOVE OIL PAN SUB-ASSEMBLY (See page EM115) 10. REMOVE OIL PUMP ASSEMBLY (a) Remove the 8 bolts. HINT: Use a 6 mm hexagon wrench for the hexagon head bolt. B001044 (b) Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pump. (c) Remove the O-ring from the cylinder block. 11. REMOVE OIL PUMP SEAL (See page EM-118) B000951 DISASSEMBLY 1. A134402 REMOVE OIL PUMP RELIEF VALVE (a) Remove the plug, compression spring and relief valve. LU LU–12 2UZ-FE LUBRICATION – OIL PUMP 2. REMOVE OIL PUMP ROTOR SET (a) Remove the 10 screws, pump body cover and the drive and driven rotors. A134403 INSPECTION 1. INSPECT OIL PUMP RELIEF VALVE (a) Coat the valve with engine oil and check that it falls smoothly into the valve hole under its own weight. If it dose not, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT OIL PUMP ROTOR SET (a) Place the drive and driven rotors into the pump body with the marks facing the pump body cover side. B002609 B002612 (b) Inspect the rotors for tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum tip clearance: 0.18 mm (0.0071 in.) If the tip clearance is greater than the maximum, replace the rotors as a set. LU B002613 B002614 (c) Inspect the rotors for side clearance. (1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 to 0.090 mm (0.0012 to 0.0035 in.) Maximum side clearance: 0.09 mm (0.0035 in.) If the side clearance is greater than the maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. 2UZ-FE LUBRICATION – OIL PUMP LU–13 (d) Inspect the rotor for body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum body clearance: 0.325 mm (0.0128 in.) If the body clearance is greater than the maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. B002615 REASSEMBLY 1. INSTALL OIL PUMP ROTOR SET (a) Place the drive and driven rotors into the pump body with the marks facing the pump body cover side. B002612 (b) Install the oil pump body cover with the 10 screws. Torque: 10 N*m (105 kgf*cm, 7 ft.*lbf) A134403 2. INSTALL OIL PUMP RELIEF VALVE (a) Insert the relief valve and compression spring into the oil pump body hole. (b) Install the plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) LU A134402 LU–14 2UZ-FE LUBRICATION – OIL PUMP INSTALLATION 1. A B A Seal Width 2 to 3 mm B B000960E04 INSTALL OIL PUMP ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block. (1) Using a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. (2) Thoroughly clean all components to remove all the loose material. (3) Using a non-residue solvent, clean both sealing surfaces. (b) Install a new oil pump seal (See page EM-161). (c) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTICE: Avoid applying an excessive amount to the surface. Be particularly careful around the oil passages. (1) Use a nozzle that has been cut to a 2 to 3 mm (0.08 to 0.12 in.) opening. (2) Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. (3) Immediately remove the nozzle from the tube and reinstall the cap. (d) Install a new O-ring to the cylinder block. (e) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. New O-ring Engage LU P021388E02 A A (f) A E C D A B B000950E01 Install the new pump with the 8 bolts. Uniformly tighten the bolts in several steps. Torque: 14 mm 31 N*m (311 kgf*cm, 23 ft.*lbf) For others 16 N*m (160 kgf*cm, 11 ft.*lbf) 2. INSTALL OIL PAN SUB-ASSEMBLY (See page EM164) 3. INSTALL OIL PAN BAFFLE PLATE (See page EM-165) 4. INSTALL OIL STRAINER SUB-ASSEMBLY (See page EM-164) 2UZ-FE LUBRICATION – OIL PUMP LU–15 5. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (See page EM-166) 6. INSTALL OIL COOLER ASSEMBLY (See page LU-17) 7. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-492) 8. INSTALL CRANKSHAFT TIMING PULLEY (See page EM-173) 9. INSTALL TIMING BELT (a) Install timing belt (See page EM-19). 10. INSTALL ENGINE ASSEMBLY (a) Install engine assembly (See page EM-87). LU LU–18 2UZ-FE LUBRICATION – ENGINE OIL COOLER INSTALLATION LU 1. INSTALL OIL COOLER ASSEMBLY (a) Clean the oil cooler contact surface on the cooler mounting. (b) Install a new O-ring to the oil cooler. (c) Apply a light coat of engine oil on the threads and under the head of the union bolt. (d) Install the plate washer and union bolt. Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf) (e) Connect the 2 oil cooler hoses to the cooler. 2. INSTALL OIL FILTER ASSEMBLY (See page LU-4) 3. ADD ENGINE OIL (See page LU-5) 4. FILL UP ENGINE COOLANT (See page CO-3) 5. INSPECT ENGINE OIL LEAKS 6. INSPECT ENGINE COOLANT LEAK (See page CO-4) 7. INSTALL ENGINE UNDER COVER ASSEMBLY REAR 2UZ-FE LUBRICATION – LUBRICATION SYSTEM LU–1 LUBRICATION SYSTEM ON-VEHICLE INSPECTION 1. CHECK ENGINE OIL LEVEL (a) Warm up the engine, then stop the engine and wait for 5 minutes. (b) Check that the engine oil level is between the low level and full level marks on the level gauge. If low, check for leakage and top oil up to the full level mark. NOTICE: Do not fill with engine oil to above the full level mark. 2. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water intrusion, discoloration or thinning. If the quality is visibly poor, replace the oil. Oil grade: ILSAC multigrade engine oil. SAE 5W-30 is the best choice for good fuel economy and good starting in cold weather. If SAE 5W-30 is not available, use SAE 10W-30. However, it should be replaced with SAE 5W-30 at the next oil replacement. 3. INSPECT OIL PRESSURE (a) Remove the engine under cover. (b) Disconnect the oil pressure switch connector. Recommended Viscosity (SAE): PREFERRED TEMPERATUER RANGE ANTICIPATED BEFORE NEXT OIL CHANGE B000319E02 (c) Using a 24 mm deep socket wrench, remove the oil pressure switch. A067119E02 Oil Pressure Switch Oil Pressure Gauge A067120E02 (d) Install the oil pressure gauge. (e) Warm up the engine. (f) Inspect the oil pressure. Oil pressure When Idling 29 kPa (0.3 kgf*cm2, 4.2 psi) or more At 3,000 rpm 294 to 588 kPa (3.0 to 6.0kgf*cm2, 43 to 85 psi) LU LU–2 2UZ-FE LUBRICATION – LUBRICATION SYSTEM Adhesive P013638E07 LU (g) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent (h) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not start the engine within 1 hour of installation. (i) Connect the oil pressure switch connector. (j) Start the engine and check for engine oil leakage. LU–3 2UZ-FE LUBRICATION – OIL FILTER OIL FILTER 2UZ-FE LUBRICATION ENGINE COMPONENTS OIL FILTER ASSEMBLY LU A119819E04 LU–4 2UZ-FE LUBRICATION – OIL FILTER REMOVAL CAUTION: • Prolonged and repeated contact with engine oil will cause the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. • Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents. • For environmental protection, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the engine under cover seal No. 3. (b) Remove the oil pan drain plug and drain the engine oil. (c) Clean the oil pan drain plug and install a new gasket and it. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 2. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY 3. REMOVE OIL FILTER ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-07501 A072683 SST A072684E01 INSTALLATION LU 1. A072685 INSTALL OIL FILTER ASSEMBLY (a) Clean the oil filter contact surface on the oil filter mounting. (b) Lubricate the filter rubber gasket with clean engine oil. (c) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. LU–5 2UZ-FE LUBRICATION – OIL FILTER (d) Using SST, give it an additional 3/4 turn to set the filter. SST 09228-07501 3/4 Turn 2. SST ADD ENGINE OIL (a) Fill with fresh engine oil. Capacity Drain and refill with oil filter change 6.2 liters (6.5 US qts, 5.5 lmp. qts) Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) Dry fill 7.1 liters (7.5 US qts, 6.2 lmp. qts) A072686E01 (b) Reinstall the oil filler cap. 3. INSPECT ENGINE OIL LEAKS 4. INSPECT ENGINE OIL LEVEL 5. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY LU LU–6 2UZ-FE LUBRICATION – OIL PUMP OIL PUMP 2UZ-FE LUBRICATION ENGINE COMPONENTS TIMING BELT LU CRANKSHAFT TIMING PULLEY CRANKSHAFT POSITION SENSOR A119928E03 LU–7 2UZ-FE LUBRICATION – OIL PUMP OIL COOLER ASSEMBLY LU A119819E05 LU–8 2UZ-FE LUBRICATION – OIL PUMP CRANKSHAFT TIMING PULLEY OIL PUMP ASSEMBLY OIL PUMP SEAL LU A119825E03 LU–9 2UZ-FE LUBRICATION – OIL PUMP OIL STRAINER SUB-ASSEMBLY OIL PAN SUB-ASSEMBLY OIL PAN BAFFLE PLATE NO. 2 OIL PAN SUB-ASSEMBLY A119930E02 LU LU–10 2UZ-FE LUBRICATION – OIL PUMP DRIVEN ROTOR 10 (105, 8) OIL PUMP BODY x10 DRIVE ROTOR OIL PUMP BODY COVER OIL PUMP SEAL OIL PUMP RELIEF VALVE COMPRESSION SPRING LU PLUG 49 (500, 36) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A134406E01 LU–16 2UZ-FE LUBRICATION – ENGINE OIL COOLER ENGINE OIL COOLER 2UZ-FE LUBRICATION ENGINE COMPONENTS OIL COOLER ASSEMBLY LU OIL FILTER ASSEMBLY A119819E07 2UZ-FE LUBRICATION – ENGINE OIL COOLER LU–17 REMOVAL 1. REMOVE ENGINE UNDER COVER ASSEMBLY REAR 2. DRAIN ENGINE OIL (See page LU-4) 3. DRAIN ENGINE COOLANT (See page CO-3) 4. REMOVE OIL FILTER ASSEMBLY (See page LU-4) 5. REMOVE OIL COOLER ASSEMBLY (a) Disconnect the 2 oil cooler hoses from oil cooler. (b) Remove the union bolt, plate washer and the oil cooler. (c) Remove the O-ring from the oil cooler. LU 2UZ-FE IGNITION – IGNITION SYSTEM IG–1 IGNITION SYSTEM ON-VEHICLE INSPECTION 1. INSPECT IGNITION COIL ASSEMBLY AND SPARK TEST (a) Confirm DTCs (See page ES-35). NOTICE: If any DTCs are indicated, carry out troubleshooting in accordance with the procedures for those DTCs. (b) Check that a spark occurs. (1) Remove the ignition coils (See page EM-86). (2) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (3) Install the spark plugs to each ignition coil, and connect the ignition coil connectors. (4) Disconnect the 8 injector connectors. (5) Ground the spark plugs. (6) Check if a spark occurs while the engine is being cranked. NOTICE: • Be sure to ground the spark plugs when checking. • Replace the ignition coil if it is subjected to an impact. • Do not crank the engine for more than 2 seconds. (c) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (d) Install the ignition coils. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) IG IG–2 2UZ-FE IGNITION – IGNITION SYSTEM INSPECTION 1. Ohmmeter Ground IG00147E05 INSPECT SPARK PLUG NOTICE: • Never use a wire brush for cleaning. • Never attempt to adjust the electrode gap on a used spark plug. • The spark plug should be replaced every 200,000 km (120,000 miles). (a) Check the electrode. (1) Using an ohmmeter, measure the insulation resistance. Correct insulation resistance: 10 MΩ or more If the resistance is below the specified range, go to procedure "A". HINT: If an ohmmeter is not available, the following simple inspection provides fairly accurate results. (b) Simple Method: (1) Quickly race the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug. (4) If the electrode is dry... OK. (5) If the electrode is wet... Go to procedure "B". (6) Reinstall the spark plug. B001301 (c) Check the spark plug for thread or insulator damage (Procedure "B"). If damaged, replace the spark plug. Recommended spark plug: DENSO made NGK made SK20R11 IFR6A11 IG00316 (d) Measure the spark plug electrode gap (Procedure "A") Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) IG 1.1 mm (0.043 in.) B002101E09 2UZ-FE IGNITION – IGNITION SYSTEM IG–3 (e) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove them with gasoline before using a spark plug cleaner. B062019 2. INSPECT VVT SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold: 835 to 1,400 Ω Hot: 1,060 to 1,645 Ω NOTICE: "Cold" and "Hot" above mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 3. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold: 1,630 to 2,740 Ω Hot: 2,065 to 3,225 Ω NOTICE: "Cold" and "Hot" above mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). IG ST–10 2UZ-FE STARTING – STARTER REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-10) 2. DRAIN ENGINE COOLANT (See page CO-3) 3. DISCONNECT BATTERY NEGATIVE TERMINAL (a) Disconnect the battery negative terminal. 4. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY (a) Remove the 2 nuts and throttle body cover subassembly. 5. REMOVE AIR CLEANER HOSE ASSEMBLY (See page ES-495) 6. DISCONNECT FUEL HOSE (See page FU-10) 7. DISCONNECT NO. 2 FUEL HOSE (See page EM-82) 8. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY (a) Disconnect the fuel vapor feed hose assembly. 9. SEPARATE ENGINE WIRE (a) Disconnect the 8 fuel injector connectors. (b) Disconnect the throttle position sensor connector. (c) Disconnect the water temperature sensor connector. (d) Remove the 3 bolts and separate the engine wire harness. 10. DISCONNECT NO. 7 WATER BY-PASS HOSE (a) Disconnect the No. 7 water by-pass hose. 11. DISCONNECT WATER BY-PASS HOSE (a) Disconnect the water by-pass hose. 12. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Remove the 6 bolts and 4 nuts. (b) Remove the intake manifold and 2 gaskets. 13. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (a) Separate the No. 2 engine wire. (b) Remove the nut and water by-pass pipe subassembly. 14. REMOVE REAR WATER BY-PASS JOINT RH (a) Remove the 4 nuts, water by-pass joint and 2 gaskets. 15. REMOVE AIR PUMP ASSEMBLY (See page EC-11) ST 2UZ-FE STARTING – STARTER ST–11 16. REMOVE STARTER ASSEMBLY (a) Disconnect the starter connector. (b) Remove the nut and disconnect the starter cable. (c) Remove the bolt and disconnect the engine wire protector. (d) Remove the 2 bolts and starter. A066669 DISASSEMBLY 1. REMOVE STARTER YOKE ASSEMBLY (a) Remove the nut and disconnect the terminal C wire. (b) Remove the 2 through bolts. (c) Pull out the starter yoke assembly with the armature assembly. (d) Remove the O-ring from the starter yoke assembly. 2. REMOVE STARTER BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws with O-ring and end cover from the field frame. (b) Remove the O-ring from the field frame. A074961 B004654 (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. (d) Disconnect the 4 brushes, and remove the brush holder. 3. REMOVE STARTER ARMATURE ASSEMBLY (a) Remove the starter armature assembly from starter yoke assembly. 4. REMOVE STARTER CLUTCH SUB-ASSEMBLY (a) Remove the 2 screws and starter drive housing. P010568 ST A074962 ST–12 2UZ-FE STARTING – STARTER Starter Housing Idle Gear (b) Remove the return spring, idler gear, bearing and starter clutch sub-assembly from the starter housing. Bearing Return Spring Starter Clutch Sub-assembly B004552E01 (c) Using a magnetic finger, remove the steel ball from the clutch shaft hole. Magnetic Finger ST00948E02 ST 2UZ-FE STARTING – STARTER ST–13 INSPECTION 1. INSPECT STARTER ASSEMBLY NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. (a) Do pull-in test. (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. Terminal 50 Terminal C Battery A074957E01 (b) Do holding test. (1) With battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion hear remains out. Disconnect Battery Terminal C A074958E01 (c) Inspect clutch pinion gear return. (1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. Disconnect Battery A074959E01 Terminal 50 Terminal 30 Battery Ammeter A074960E01 (d) Perform the operation test without load. (1) Connect the field coil lead wire to terminal C. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) (2) Grip the starter in a vise. (3) Connect the battery and ammeter to the starter as shown. (4) Check that the ammeter reads the specified current. Specified current (for standard area): 90 A or less at 11.5 V Specified current (for cold area): 100 A or less at 11.5 V ST ST–14 2UZ-FE STARTING – STARTER 2. INSPECT STARTER ARMATURE ASSEMBLY (a) Inspect commutator for dirty and burnt surface. If the surface of the commutator is dirty or burned, polish the part with sandpaper (#400) or replace the armature. (b) Inspect commutator for open circuit. (1) Using an ohmmeter, check that there is continuity between the segments, replace the armature. If there is no continuity between any segments, replace the armature. Continuity Ohmmeter S000054E05 (c) Inspect commutator for ground. (1) Using an ohmmeter, check that there is no continuity between the commutator and armature core. If there is continuity, replace the armature assembly. No Continuity Ohmmeter S000055E05 (d) Inspect commutator circle runout. (1) Place the armature on the V-blocks. (2) Using a dial gauge, measure the circuit runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. S000056 (e) Using vernier calipers, measure the commutator diameter. Standard diameter: 35.0 mm (1.378 in.) Minimum diameter: 34.0 mm (1.339 in.) If the diameter is less than minimum, replace the armature assembly. ST S000057 2UZ-FE STARTING – STARTER ST–15 (f) Measure the undercut depth of commutator. Standard undercut depth: 0.7 mm (0.028 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than the minimum, correct it with a hacksaw blade. (g) Inspect the bearings. (1) Check that the bearing rotates smoothly. ST00040 3. Continuity INSPECT STARTER YOKE ASSEMBLY (a) Inspect field coil for open circuit. (1) Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the starter yoke assembly. P010588E01 (b) Inspect shunt coil for open circuit. (1) Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Standard resistance: 1.5 to 1.9 Ω at 20°C (68°F) If the resistance is not as specified, replace the starter yoke assembly. Ohmmeter (B) (A) 4. INSPECT BRUSH (a) Using vernier calipers, measure the brush length. Standard length: 15.0 mm (0.591 in.) Minimum length: 9.0 mm (0.354 in.) If the length is less than the minimum, replace the brush holder and starter yoke assembly. 5. INSPECT STARTER BRUSH HOLDER ASSEMBLY (a) Using an ohmmeter, check that there is no continuity between the positive and negative brush holders. If there is continuity, replace the brush holder. S002267E02 Ohmmeter No Continuity P021088E05 ST ST–16 2UZ-FE STARTING – STARTER (b) Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum spring installed load: 12.7 N (1.3 kgf, 2.9 lbf) If spring load is less than the minimum, replace the brush springs. ST00019 6. INSPECT STARTER CLUTCH SUB-ASSEMBLY (a) Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch sub-assembly. 7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY (a) Check the pull-in coil continuity. (1) Using an ohmmeter, check that there is continuity between terminal 50 and C. If there is no continuity, replace the starter magnetic switch assembly. Free Lock P010821E05 Ohmmeter Continuity Terminal 50 Terminal C B012319E02 (b) Check the holding coil continuity. (1) Using an ohmmeter, check that there is continuity between terminals 50 and switch body. If there is no continuity, replace the magnet starter switch assembly. Ohmmeter Continuity Terminal 50 B012320E02 REASSEMBLY 1. ST Idle Gear Bearing Steel Ball Return Spring Starter Housing Starter Clutch Sub-assembly A072547E01 INSTALL STARTER CLUTCH SUB-ASSEMBLY (a) Apply grease to the steel ball, return spring, clutch rollers and starter idler pinions. (b) Install the steel ball. (c) Install a new O-ring to the starter housing. (d) Insert the return spring into the magnet starter switch hole. (e) Install the starter clutch sub-assembly, idler gear and bearing. 2UZ-FE STARTING – STARTER (f) ST–17 Install the starter housing to the magnet switch assembly with the 2 screws. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) A074962 2. P010568 INSTALL STARTER BRUSH HOLDER ASSEMBLY (a) Align the claw of the brush holder with the claw groove of the starter yoke assembly. (b) Place the brush holder on the starter yoke assembly. (c) Using a screwdriver, hold the brush spring back. (d) Connect the brush into the brush holder. (e) Connect the 4 brushes. NOTICE: Check that the positive (+) lead wires are not grounded. (f) Install an O-ring to the groove of the starter yoke. (g) Install 2 new O-rings and the end cover with the 2 screws. Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf) B004654 3. INSTALL STARTER YOKE ASSEMBLY (a) Install a new O-ring to the groove of the starter yoke assembly. (b) Align the protrusion of the starter yoke assembly with the groove of the magnetic switch. B012328 ST ST–18 2UZ-FE STARTING – STARTER (c) Install the starter yoke assembly with the 2 through bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) (d) Connect the terminal C wire with the nut. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) A074961 ST 2UZ-FE STARTING – STARTER ST–19 INSTALLATION 1. INSTALL STARTER ASSEMBLY (a) Install the starter assembly with the 2 bolts. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (b) Connect the engine wire protector with the bolt. (c) Connect the starter cable with the nut. Torque: 9.8 N*m (100 kgf*cm, 86 in.*lbf) (d) Connect the starter connector. 2. INSTALL AIR PUMP ASSEMBLY (See page EC-12) 3. INSTALL REAR WATER BY-PASS JOINT RH (a) Install 2 new gaskets to the cylinder head. (b) Install the 4 nuts holding the water by-pass joint to the cylinder heads. Alternately tighten the nuts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 4. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (a) Install a new O-ring to the water by-pass pipe. (b) Apply soapy water to the O-ring. (c) Push the water by-pass pipe end into the pipe hole of the water pump. (d) Install the water by-pass pipe with the bolt. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) (e) Install the wire clamp to the bracket of the water bypass pipe. 5. INSTALL INTAKE MANIFOLD ASSEMBLY (a) Install 2 new gaskets to the cylinder head. (b) Install the intake manifold with the 6 bolts and 2 nuts. Torque: Bolt 18 N*m (185 kgf*cm, 13 ft.*lbf) Nut 18 N*m (185 kgf*cm, 13 ft.*lbf) 6. CONNECT WATER BY-PASS HOSE (a) Connect the water by-pass hose. 7. CONNECT NO. 7 WATER BY-PASS HOSE (a) Connect the No. 7 water by-pass hose. 8. INSTALL ENGINE WIRE (a) Install the engine wire with the 3 bolts. Torque: 8.2 N*m (83 kgf*cm, 72 in.*lbf) (b) Connect the water temperature sensor connector, (c) Connect the throttle position sensor connector. (d) Connect the 8 fuel injector connectors. 9. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY (a) Connect the fuel vapor feed hose assembly. 10. CONNECT NO. 2 FUEL HOSE (a) Connect the No. 2 fuel hose. 11. CONNECT FUEL HOSE (See page FU-13) 12. INSTALL AIR CLEANER HOSE ASSEMBLY (a) Install the air cleaner hose assembly. ST ST–20 2UZ-FE STARTING – STARTER 13. ADD ENGINE COOLANT (See page CO-3) 14. CHECK FOR ENGINE COOLANT LEAK (See page CO-4) 15. CHECK FOR FUEL LEAK (See page FU-5) 16. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf) 17. CONNECT BATTERY NEGATIVE TERMINAL (a) Connect the battery negative terminal. ST 2UZ-FE STARTING – STARTING SYSTEM ST–1 STARTING SYSTEM 2UZ-FE STARTING ENGINE PARTS LOCATION ENGINE ROOM R/B - ACC CUT RELAY - STARTER RELAY ST A119840E07 ST–2 2UZ-FE STARTING – STARTING SYSTEM STARTER ST A119821E03 2UZ-FE STARTING – STARTING SYSTEM ST–3 IGNITION SWITCH ST C131333E05 ST–23 2UZ-FE STARTING – IGNITION SWITCH REMOVAL 1. REMOVE STEERING COLUMN LOWER COVER (See page SR-9) 2. REMOVE STEERING COLUMN UPPER COVER (a) Remove the steering column upper cover. 3. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY (a) Disconnect the ignition switch connector and unlock warning switch connector. (b) Remove the clamp. (c) Remove the 2 screws and ignition switch. B062162 INSPECTION ACC LOCK 1. ON START 4 8 3 7 2 6 1 INSPECT IGNITION OR STARTER SWITCH ASSEMBLY (a) Inspect the switch continuity. Standard Terminal No. Switch Position Specified Condition Between all terminals LOCK No continuity No Pin B052423E09 2-3 ACC Continuity 2-3-4 6-7 ON Continuity 1-2-4 6-7-8 START Continuity If the result is not as specified, replace the switch assembly. INSTALLATION B062162 1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY (a) Install the ignition switch with the 2 screws. (b) Install the clamp. (c) Connect the un-lock warning switch connector. 2. INSTALL STEERING COLUMN UPPER COVER (a) Install the steering column upper cover. 3. INSTALL STEERING COLUMN LOWER COVER (See page SR-21) ST ST–4 2UZ-FE STARTING – STARTER STARTER 2UZ-FE STARTING ENGINE COMPONENTS 7.5 (80, 66 in.*lbf) THROTTLE BODY COVER SUB-ASSEMBLY AIR CLEANER HOSE ASSEMBLY ST N*m (kgf*cm, ft.*lbf) : Specified torque A119814E03 ST–5 2UZ-FE STARTING – STARTER 18 (185, 13) 8.2 (83, 72 in.*lbf) ENGINE WIRE GASKET 18 (185, 13) 18 (185, 13) 18 (185, 13) 18 (185, 13) 8.2 (83, 72 in.*lbf) GASKET REAR WATER BY-PASS JOINT RH NO. 7 WATER BY-PASS HOSE NO. 2 FUEL HOSE FUEL HOSE INTAKE MANIFOLD ASSEMBLY GASKET N*m (kgf*cm, ft.*lbf) : Specified torque ST Non-reusable part A139365E01 ST–6 2UZ-FE STARTING – STARTER FUEL VAPOR FEED HOSE ASSEMBLY ST A119779E01 ST–7 2UZ-FE STARTING – STARTER 16 (163, 12) STARTER ASSEMBLY AIR PUMP ASSEMBLY 18 (185, 13) 9.8 (100, 7.2) WATER BY-PASS PIPE SUB-ASSEMBLY O-RING N*m (kgf*cm, ft.*lbf) : Specified torque ST Non-reusable part A119821E04 ST–8 2UZ-FE STARTING – STARTER 39 (400, 29) ST N*m (kgf*cm, ft.*lbf) : Specified torque A119927E03 ST–9 2UZ-FE STARTING – STARTER 9.3 (95, 82 in.*lbf) IDLER GEAR BEARING O-RING MAGNETIC SWITCH ASSEMBLY STARTER HOUSING ASSEMBLY STARTER CLUTCH SUB-ASSEMBLY STEEL BALL RETURN SPRING STARTER ARMATURE ASSEMBLY O-RING STARTER BRUSH HOLDER ASSEMBLY O-RING STARTER YOKE ASSEMBLY 9.3 (95, 82 in.*lbf) END COVER 3.8 (39, 34 in.*lbf) 9.3 (95, 82 in.*lbf) ST N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119850E01 ST–19 2UZ-FE STARTING – STARTER RELAY STARTER RELAY INSPECTION 1. A060553 INSPECT STARTER RELAY ASSEMBLY (a) Continuity inspection. (1) Using an ohmmeter, check that there is continuity between each terminal. Specified condition Between Terminals Specified Condition 1-2 Continuity 3-5 No continuity (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity ST ST–20 2UZ-FE STARTING – ACC CUT RELAY ACC CUT RELAY INSPECTION 1. A030519 INSPECT ACC CUT RELAY (a) Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition Between Terminals Specified Condition 1-2 Continuity 3-5 No continuity (2) Using an ohmmeter, check for continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity ST 2UZ-FE STARTING – IGNITION SWITCH ST–21 IGNITION SWITCH 2UZ-FE STARTING ENGINE COMPONENTS STEERING COLUMN UPPER COVER STEERING COLUMN LOWER COVER ST C131331E08 ST–22 2UZ-FE STARTING – IGNITION SWITCH IGNITION OR STARTER SWITCH ASSEMBLY ST C131333E03 2UZ-FE CHARGING – CHARGING SYSTEM CH–3 ON-VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell. (1) If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. 2. CHECK BATTERY VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. (b) Turn the ignition switch OFF and turn off the electrical systems. (c) Measure the battery voltage between the negative () and positive (+) terminals of the battery. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) HINT: If the voltage is less than the specification, charge the battery. A001260 (d) Check the indicator as shown in the illustration. HINT: • Blue: OK • White: Charging Necessary • Red: Insufficient Water Z011580E03 3. CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. 4. CHECK FUSIBLE LINK AND FUSES (a) Check the fusible link, H-fuses and fuses for continuity. 5. INSPECT FAN AND GENERATOR V BELT (a) Visually check the belt for excessive wear, frayed cords etc. HINT: • If any defect has been found, replace the fan and generator V belt. • Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. B000543 CH CH–4 2UZ-FE CHARGING – CHARGING SYSTEM (b) Check that it fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. 6. VISUALLY CHECK GENERATOR WIRING (a) Check that the wiring is in good condition. 7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. 8. INSPECT CHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch ON. Check that the charge warning light comes on. (b) Start the engine. Check that the light goes off. HINT: If the light does not operate as specified, troubleshoot the charge warning light circuit. 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD (a) If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer's instructions. B000540 Ammeter Battery Disconnected Wire from Terminal B Generator Voltmeter A073946E03 CH (b) If a tester is not available, connect a voltmeter to the charging circuit as follows: (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative (-) lead of the voltmeter. (c) Check the charging circuit. (1) With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.0 V HINT: • If the voltmeter reading is more than standard voltage, replace the voltage regulator. • If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator. 10. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "H". 2UZ-FE CHARGING – CHARGING SYSTEM CH–5 (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT: • If the ammeter reading is less than standard amperage, repair the generator. • If the battery is fully charged, the indication will sometimes be less than standard amperage. CH CH–10 2UZ-FE CHARGING – GENERATOR REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE RADIATOR UPPER SUPPORT SEAL (a) Remove the 11 clips and radiator upper support seal. 3. REMOVE FAN AND GENERATOR V BELT (See page EM-6) 4. REMOVE FAN AND FLUID COUPLING (a) Separate the 2 oil cooler hoses from fan shroud. (b) Remove the 3 bolts and separate the fan shroud from radiator. (c) Remove the 4 nuts and separate the fan w/ fluid coupling from engine. (d) Remove the fan shroud and fan w/ fluid coupling from the vehicle at the same time. 5. REMOVE VANE PUMP ASSEMBLY (a) Disconnect the vacuum hose. (b) Remove the nut, 2 bolts and vane pump assembly. HINT: Hand up the hoses instead of detaching. 6. REMOVE GENERATOR ASSEMBLY (a) Disconnect the generator connector. (b) Remove the terminal cap and nut, and disconnect the generator wire. (c) Disconnect the alternator wire clamp from the cord clip on the generator. (d) Remove the bolt, 2 nuts and generator. A066671 DISASSEMBLY 1. REMOVE GENERATOR REAR END COVER (a) Remove the 3 nuts and end cover. (b) Remove the terminal insulator. 2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Remove the rear seal plate from the brush holder. (b) Remove the 2 screws and brush holder. (c) Remove the front seal plate from the coil assembly. B016513 CH B016362 2UZ-FE CHARGING – GENERATOR 3. SST (A) Turn CH–11 REMOVE GENERATOR PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (b) Check that SST (A) is secured to the rotor shaft. SST (B) B016520E02 (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (B) Insert SST (C) B016524E02 (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. (f) Remove the generator from SST (C). SST (C) SST (A) Turn B016373E02 (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. Turn SST (A) SST (B) B016519E02 4. REMOVE GENERATOR COIL ASSEMBLY (a) Remove the 4 bolts. CH B016364 CH–12 2UZ-FE CHARGING – GENERATOR (b) Using SST, remove the coil assembly. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) (c) Remove the generator washer. SST 5. REMOVE GENERATOR ROTOR ASSEMBLY B016366E02 INSPECTION Ohmmeter 1. Continuity Continuity INSPECT GENERATOR ROTOR ASSEMBLY (a) Check the rotor for open circuit. (1) Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.3 to 2.7 Ω at 20°C (68°F) If there is no continuity, replace the rotor. B012264E09 (b) Check the rotor for ground. (1) Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. (c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. Ohmmeter No Continuity No Continuity B012265E08 (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than minimum, replace the rotor. B012266 2. Length CH B016374E08 INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (.413 in.) Minimum exposed length: 4.5 mm (0.177 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly. 2UZ-FE CHARGING – GENERATOR CH–13 3. INSPECT GENERATOR ROTOR BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. 4. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. 5. REMOVE GENERATOR ROTOR BEARING (a) Remove the 4 screws, bearing retainer and bearing. B016375 (b) Using SST and a hammer, tap out the bearing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) SST B016518E02 6. INSTALL GENERATOR ROTOR BEARING (a) Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) (b) Install the bearing retainer with the 4 screws. Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) 7. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST B016515E02 SST B012270E01 CH CH–14 2UZ-FE CHARGING – GENERATOR (c) Place the bearing cover (inside) on the rotor. B012271 8. SST INSTALL GENERATOR DRIVE END FRAME BEARING (a) Using SST and a press, press in a new bearing. SST 09820-00031 B012272E01 (b) Using SST, push in the bearing cover (outside). SST 09285-76010 SST B012273E01 REASSEMBLY Pulley 1. INSTALL GENERATOR ROTOR ASSEMBLY (a) Place the drive end frame on the pulley. (b) Install the rotor to the drive end frame. 2. INSTALL GENERATOR COIL ASSEMBLY (a) Place the generator washer on the rotor. B016368E01 CH B016521 2UZ-FE CHARGING – GENERATOR CH–15 (b) Using SST and a press, slowly press in the coil assembly. SST 09285-76010 SST B016512E03 (c) Install the coil assembly with the 4 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) B016364 3. SST (A) Turn INSTALL GENERATOR PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (c) Check that SST (A) is secured to the pulley shaft. SST (B) B016520E02 (d) Mount SST (C) in a vise. (e) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (B) Insert SST (C) B016524E02 (f) SST (C) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf) (g) Remove the generator from SST (C). SST (A) Turn CH B016523E02 CH–16 2UZ-FE CHARGING – GENERATOR (h) Turn SST (B), and remove SST (A and B). Turn SST (A) SST (B) B016519E02 4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY (a) Place the front seal plate on the coil assembly. B016363 (b) Place the brush holder on the coil assembly with the pin facing upward. NOTICE: Be careful of the holder installation direction. (c) Install the 2 screws. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) Upward Pin B016361E01 (d) Align the pins of the brush holder with the holes of the rear seal plate, and install the rear seal plate. B016360 5. CH B016359 INSTALL GENERATOR REAR END COVER (a) Install the terminal insulator. NOTICE: Be careful of the terminal insulator installation direction. 2UZ-FE CHARGING – GENERATOR CH–17 (b) Install the end cover with the 3 nuts. Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) B016513 CH CH–18 2UZ-FE CHARGING – GENERATOR INSTALLATION CH 1. INSTALL GENERATOR ASSEMBLY (a) Install the generator with the bolt and 2 nuts. Torque: Bolt 39 N*m (400 kgf*cm, 29 ft.*lbf) Nut (M10) 39 N*m (40 kgf*cm, 29 ft.*lbf) Nut (M8) 16 N*m (158 kgf*cm, 11 ft.*lbf) (b) Connect the generator connector. (c) Connect the generator wire with the nut and rubber cap. Torque: 9.8 N*m (100 kgf*cm, 86 in.*lbf) (d) Install the generator wire clamp to the cord clip on the generator. 2. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump assembly with the nut and 2 bolts. Torque: Nut 43 N*m (438 kgf*cm, 32 ft.*lbf) Bolt 43 N*m (438 kgf*cm, 32 ft.*lbf) (b) Connect the vacuum hose. 3. INSTALL FAN WITH FLUID COUPLING (a) Put the fan w/ fluid coupling and fan shroud into the engine room at the same time. (b) Install the fan shroud with 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (c) Install the fan w/ fluid coupling with 4 nuts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 4. INSTALL FAN AND GENERATOR V BELT (See page EM-6) 5. INSTALL RADIATOR UPPER SUPPORT SEAL 6. CONNECT BATTERY NEGATIVE TERMINAL 2UZ-FE CHARGING – CHARGING SYSTEM CH–1 CHARGING SYSTEM PRECAUTION 1. PRECAUTION (a) Check that the battery cables are connected to the correct terminals. (b) Disconnect the battery cables when the battery is given a quick charge. (c) Do not perform tests with a high voltage insulation resistance tester. (d) Never disconnect the battery while the engine is running. (e) Check that the charging cable is tightened on terminal B of the alternator and the fuse box. (f) Do not perform inspection of the alternator generators in which terminal F is connected to the other terminal. CH CH–2 2UZ-FE CHARGING – CHARGING SYSTEM PARTS LOCATION GENERATOR CH A119851E01 CH–6 2UZ-FE CHARGING – GENERATOR GENERATOR 2UZ-FE CHARGING ENGINE COMPONENTS RADIATOR UPPER SUPPORT SEAL FAN AND FLUID COUPLING 29 (296, 21) FAN AND GENERATOR V BELT CH N*m (kgf*cm, ft.*lbf) : Specified torque A119815E02 2UZ-FE CHARGING – GENERATOR CH–7 VANE PUMP ASSEMBLY 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque A119817E02 CH CH–8 2UZ-FE CHARGING – GENERATOR 9.8 (100, 86 in.*lbf) GENERATOR ASSEMBLY 39 (400, 29) 16 (158, 11) 39 (400, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A119818E02 CH CH–9 2UZ-FE CHARGING – GENERATOR GENERATOR WASHER REAR BEARING GENERATOR ROTOR ASSEMBLY BEARING RETAINER BEARING COVER 2.6 (27, 23 in.*lbf) FRONT BEARING DRIVE END FRAME (STATOR) 111 (1,125, 81) GENERATOR PULLEY GENERATOR REAR END COVER TERMINAL INSULATOR 4.6 (47, 41 in.*lbf) 1.8 (18, 16 in.*lbf) SEAL PLATE SEAL PLATE GENERATOR BRUSH HOLDER ASSEMBLY 5.8 (59, 51 in.*lbf) RECTIFIER END FRAME N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A119851E02 CH VF4AM TRANSFER – TRANSFER ASSEMBLY TF–17 REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY (See page EM-6) 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR (See page AT-346) 4. REMOVE EXHAUST PIPE ASSEMBLY (See page AT346) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-14) 6. REMOVE PROPELLER SHAFT ASSEMBLY (See page PR-3) 7. DRAIN AUTOMATIC TRANSMISSION FLUID (See page AT-347) 8. DRAIN TRANSFER OIL 9. REMOVE FRONT SUSPENSION MEMBER BRACKET (See page AT-347) 10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (See page AT-347) 11. REMOVE TRANSMISSION OIL FILTER TUBE SUBASSEMBLY 12. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (See page AT-347) 13. REMOVE NO. 1 OIL COOLER INLET TUBE (See page AT-347) 14. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page AT-348) 15. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (See page AT-350) 16. REMOVE TRANSFER CASE LOWER PROTECTOR (a) Remove the 4 bolts and transfer case lower protector. 17. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER (See page AT-348) 18. REMOVE NO. 3 CROSSMEMBER SUB-ASSEMBLY (See page AT-348) 19. DISCONNECT CONNECTOR F043499 20. DISCONNECT WIRE HARNESS 21. REMOVE STARTER ASSEMBLY (See page AT-349) 22. REMOVE MANIFOLD STAY (See page EM-79) 23. REMOVE NO. 2 MANIFOLD STAY (See page EM-79) 24. SEPARATE FRONT DIFFERENTIAL ASSEMBLY 25. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER (See page AT-350) TF TF–18 VF4AM TRANSFER – TRANSFER ASSEMBLY 26. REMOVE TRANSFER ASSEMBLY (a) Remove the 8 bolts and 2 clamps. (b) Remove the transfer from the automatic transmission. TF F043500 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–19 DISASSEMBLY 1. REMOVE HOSE 2. TEST TRANSFER RH BEARING RETAINER SUBASSEMBLY (a) Remove the 5 bolts and front bearing retainer subassembly. HINT: If necessary, tap the front bearing retainer subassembly with a plastic hammer to remove it. 3. REMOVE TRANSFER COVER TYPE T OIL SEAL (a) Using a screwdriver and hammer, remove the oil seal from the front bearing retainer sub-assembly. 4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY (a) Remove the 4 bolts and the case cover subassembly. 5. REMOVE BREATHER OIL DEFLECTOR SUBASSEMBLY 6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut. (b) Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut. SST 09330-00021 F043427 F043428 SST F043429E01 (c) Using SST, remove the output shaft companion flange sub-assembly. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 7. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly. 8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly. SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) SST F043430E01 TF TF–20 VF4AM TRANSFER – TRANSFER ASSEMBLY 9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly. 10. REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY (a) Remove the 5 bolts and extension housing subassembly. HINT: If necessary, tap the extension housing subassembly with a plastic hammer to remove it. TF F043431 11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using a screwdriver and hammer, remove the extension housing type T oil seal. 12. REMOVE TRANSFER OUTPUT WASHER 13. REMOVE COLLAR F043432 14. REMOVE TRANSFER REAR CASE (a) Remove the 12 bolts and clamp. (b) Remove the transfer rear case. HINT: If necessary, tap the transfer rear case with a plastic hammer to remove it. F043433 15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE (a) Remove the bolt, gear shift fork No. 2 and high and low clutch sleeve. F043434 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–21 16. REMOVE TRANSFER SHIFT SHAFT STOPPER (a) Remove the bolt and shift shaft stopper. 17. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT (a) Turn the front drive shift fork shaft, and remove it from the rear case aligning the cut out position and the inter-lock pin position. TF F044750 18. REMOVE OR ROLLER SHIFT INTER-LOCK PIN (a) Using a magnetic finger, remove the 2 shift interlock pin. 19. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT F043437 20. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY, NO. 1 GEAR SHIFT FORK, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET (a) Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring. F043438 (b) Using 2 screwdrivers and a hammer, tap out the snap ring. F043439 (c) Using a snap ring expander, remove the output shaft snap ring. F043440 TF–22 VF4AM TRANSFER – TRANSFER ASSEMBLY (d) Mount the transfer case rear in a vise. (e) Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft subassembly together with gear shift fork No. 1, front drive clutch sleeve, front drive chain and driven sprocket sub-assembly. TF F043441 (f) Remove the rear output shaft sub-assembly, gear shift fork No. 1, front drive chain and driven sprocket sub-assembly. F043442 21. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT (a) Remove No. 2 stopper transfer shift shaft. F043443 22. REMOVE TRANSFER DRIVEN SPROCKET BEARING (a) Using a press, remove the driven sprocket bearing. F043523 Steel Bar SST F043524E02 23. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING (a) Using SST, a press and steel bar, remove the transfer input gear radial ball bearing. SST 09555-55010 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–23 24. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY (a) Using 2 screwdrivers and a hammer, tap out the snap ring. TF F043444 (b) Remove the 3 bolts and transfer shift actuator assembly. 25. REMOVE TRANSFER CASE NO.1 PLUG (a) Remove the transfer case No. 1 plug (filler plug) and gasket. 26. REMOVE TRANSFER CASE NO.1 PLUG (a) Remove the transfer case No. 1 plug (drain plug) and gasket. F043445 27. REMOVE TRANSFER OIL SEPARATOR SUBASSEMBLY (a) Remove the 3 bolts and oil separator sub-assembly. 28. REMOVE TRANSFER CASE MAGNET F043446 29. REMOVE TRANSFER OIL PUMP BODY SUBASSEMBLY (a) Remove the 3 bolts and oil pump body subassembly. F043447 30. REMOVE TRANSFER OIL PUMP BODY O-RING (a) Using a screwdriver, remove the oil pump body Oring. F043462 TF–24 VF4AM TRANSFER – TRANSFER ASSEMBLY 31. REMOVE TRANSFER OIL PUMP GEAR (a) Remove the transfer oil pump gear. TF F043448 32. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY (a) Using a snap ring expander, remove the snap ring. F043449 (b) Remove the low planetary gear assembly with input shaft assembly. Q007221 33. REMOVE TRANSFER OUTPUT SHAFT SPACER (a) Remove the transfer output shaft spacer. 34. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 35. REMOVE TRANSFER CASE OIL SEAL (a) Using a screwdriver and hammer, remove the transfer case oil seal. F043451 36. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING (a) Using a snap ring expander, remove the input gear stopper shaft snap ring. F043452 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–25 37. REMOVE TRANSFER INPUT GEAR STOPPER (a) Remove the transfer input gear stopper. 38. REMOVE TRANSFER INPUT GEAR STOPPER BALL 39. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER TF F043453 40. REMOVE TRANSFER INPUT SHAFT (a) Remove the transfer input shaft. 41. REMOVE TRANSFER NO. 1 THRUST BEARING RACE Front 42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING F043454E01 43. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING (a) Remove the 2 seal rings. F043525E01 44. INSPECT TRANSFER INPUT SHAFT (a) Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum diameter: 47.59 mm (1.8736 in.) If the outer diameter is less than the minimum, replace the input shaft. F043458 (b) Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum diameter: 48.14 mm (1.8953 in.) If the inside diameter exceeds the maximum, replace the input shaft. F043459 TF–26 VF4AM TRANSFER – TRANSFER ASSEMBLY F043465 45. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear. Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. F043466 46. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard clearance: 0.009 to 0.038 mm (0.0004 to 0.0015 in.) Maximum clearance: 0.038 mm (0.0015 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. TF 47. REMOVE TRANSFER INPUT SHAFT BEARING (a) Using a snap ring expander, remove the input bearing shaft snap ring. (b) Using SST and a press, remove the input shaft bearing. SST 09554-30011, 09555-55010 SST F043467E02 48. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE (a) Using a screwdriver, remove the snap ring. (b) Remove the low planetary gear spline piece. F043507 49. REMOVE TRANSFER LOW PLANETARY GEAR BEARING (a) Using SST, remove the low planetary gear bearing. SST 09612-65014 (09612-01030, 09612-01050) NOTICE: Hang SST securely to the clearance between the bearing and the low planetary gear. SST F043526E02 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–27 50. INSPECT DRIVE SPROCKET THRUST CLEARANCE (a) Using a feeler gauge, measure the drive sprocket thrust clearance. Standard clearance: 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Maximum clearance: 0.24 mm (0.0094 in.) If the clearance exceeds the maximum, replace the drive sprocket. F044049 F044050 51. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the drive sprocket. Standard clearance: 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Maximum clearance: 0.06 mm (0.0024 in.) If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing. 52. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING (a) Using a snap ring expander, remove the snap ring. 53. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER 54. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL 55. REMOVE CENTER DIFFERENTIAL CASE F044051 56. REMOVE TRANSFER CLUTCH HUB (a) Remove the transfer clutch hub. 57. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 58. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER F043472 59. REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING (a) Using a screwdriver, remove the 2 shifting key springs. 60. REMOVE SYNCHROMESH SHIFTING KEY TRANSFER DRIVE (a) Remove the 3 shifting keys. 61. REMOVE FRONT DRIVE CLUTCH SLEEVE F043473 TF TF–28 VF4AM TRANSFER – TRANSFER ASSEMBLY 62. REMOVE TRANSFER SYNCHRONIZER RING SET (a) Remove the transfer synchronizer ring. TF F043474 63. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING (a) Using SST and a press, remove the output shaft rear radial ball bearing. SST 09555-55010 SST F043475E01 64. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER (a) Remove the transfer output shaft spacer. 65. REMOVE TRANSFER DRIVE SPROCKET SUBASSEMBLY 66. REMOVE TRANSFER DRIVE SPROCKET BEARING 67. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER F043476 D C B A F043511E01 68. INSPECT TRANSFER OUTPUT SHAFT REAR (a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface. Standard diameter: Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Minimum diameter: Part A: 27.98 mm (1.1016 in.) Part B: 31.98 mm (1.2591 in.) Part C: 34.98 mm (1.3772 in.) Part D: 36.98 mm (1.4559 in.) VF4AM TRANSFER – TRANSFER ASSEMBLY TF–29 If the outer diameter is less than the minimum, replace the output shaft rear. F043481 F043483 69. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE (a) Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the high and low clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2. 70. INSPECT FRONT DRIVE CLUTCH SLEEVE AND NO. 1 GEAR SHIFT FORK (a) Using vernier calipers, measure the thickness of the No. 1 gear shift fork claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the front drive clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the front drive clutch sleeve and No.1 gear shift fork. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the front drive clutch sleeve or No.1 gear shift fork. 71. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F043493 TF TF–30 VF4AM TRANSFER – TRANSFER ASSEMBLY 72. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. TF F044398 73. REMOVE TRANSFER CASE PLUG (a) Remove the transfer case plug. 74. REMOVE COMPRESSION SPRING 75. REMOVE WITH HEAD PIN F043455 76. REMOVE TRANSFER LOW PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring. F043456 (b) Remove the low planetary ring gear from the front case. Front F043457E01 INSPECTION 1. Q007292 INSPECT TRANSFER INPUT SHAFT (a) Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum diameter: 47.59 mm (1.8736 in.) If the outer diameter is less than the minimum, replace the input shaft. VF4AM TRANSFER – TRANSFER ASSEMBLY TF–31 (b) Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum diameter: 48.14 mm (1.8593 in.) If the inside diameter exceeds the maximum, replace the input shaft. TF Q007293 2. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear. Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. 3. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard clearance: 0.009 to 0.038 mm (0.0004 to 00015 in.) Maximum clearance: 0.038 mm (0.0015 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. 4. INSPECT DRIVE SPROCKET THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the drive sprocket. Standard clearance: 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Maximum clearance: 0.24 mm (0.0094 in.) If the clearance exceeds the maximum, replace the drive sprocket. 5. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the drive sprocket. Standard clearance: 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Maximum clearance: 0.06 mm (0.0024 in.) If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing. F043465 F043466 F044049 F044050 TF–32 VF4AM TRANSFER – TRANSFER ASSEMBLY D C B 6. INSPECT TRANSFER OUTPUT SHAFT REAR (a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface. Standard diameter: Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Minimum diameter: Part A: 27.98 mm (1.1016 in.) Part B: 31.98 mm (1.2591 in.) Part C: 34.98 mm (1.3772 in.) Part D: 36.98 mm (1.4559 in.) If the outer diameter is less than the minimum, replace the output shaft rear. 7. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE (a) Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the high and low clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2. 8. INSPECT FRONT DRIVE CLUTCH SLEEVE AND GEAR SHIFT FORK (a) Using vernier calipers, measure the thickness of the No. 1 gear shift fork claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the front drive clutch sleeve. Distance: 10.5 mm (0.4134 in.) A TF F043511E01 F043481 F043483 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–33 (c) Calculate a clearance between the front drive clutch sleeve and No.1 gear shift fork. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the front drive clutch sleeve or No.1 gear shift fork. 9. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F043493 10. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F044398 TF VF4AM TRANSFER – TRANSFER SYSTEM TF–1 TRANSFER SYSTEM PRECAUTION • Before disassembly, clean the transfer assembly and remove any deposited sand and mud to prevent it from entering the transfer during disassembly and assembly. • When removing any light alloy parts such as the transfer covers, do not pry them off with a tool like a screwdriver, but tap them out with a plastic hammer. • Always organize the removed parts properly and protect them from dust. • After cleaning and drying the transfer completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts or ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean rubber parts such as oil seals. • Apply sufficient hypoid gear oil to all sliding surfaces and rotating parts. • Do not directly hold any parts in a vise. Be sure to put an aluminum sheet between them. • Replace any damaged or deformed snap rings with new ones. • If the mating surface of the case is scratched, it could cause oil leakage. Therefore, handle with care to prevent such damage. • Using a razor blade and gasket scraper, remove old FIPG from the seal surface. • Clean all the components to remove the redundant FIPG completely. • Clean the sealing surface with solvent so that no residue remains on the seal surface. • Apply a line of FIPG approximately 1.2 mm (0.047 in.) diameter of bead state along the sealing surface. • Be sure to assemble parts within 10 minutes of application. Otherwise, the FIPG must be removed and reapplied. • Do not pour in oil immediately after installing sealed parts. Leave it for at least an hour. • Scratches on the contact surface with an oil seal or gasket could cause oil leakage. Handle with care to prevent such damage. • When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged. • When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing Repair Manual diagnostic procedures may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator. TF TF–2 VF4AM TRANSFER – TRANSFER SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. Replace the applicable parts as necessary. TRANSFER SYSTEM TF Symptom Noise Oil leakage Tight corner braking Shift from 4WD (H4) to 4WD (L4) impossible Shift from 4WD (L4) to 4WD (H4) impossible Shift from 2WD (H2) to 4WD (H4) impossible Shift from 4WD (H4) to 2WD (H2) impossible Shift from 2WD (H2) to 4WD (L4) impossible Shift from 4WD (L4) to 2WD (H2) impossible Suspected area See page 1. Oil (Level low) TF-3 2. Oil (Wrong) TF-3 3. Transfer faulty TF-8 1. Oil (Level too high) TF-3 2. Gasket (Damaged) TF-8 3. Oil seal (Worn or damaged) TF-8 4. O-ring (Worn or damaged) TF-8 1. Transfer faulty TF-8 1. Four wheel drive control switch TF-46 2. Differential lock switch TF-50 3. Wire harness TF-51 4. Four wheel drive control ECU TF-52 1. Four wheel drive control switch TF-46 2. Differential lock switch TF-50 3. Wire harness TF-51 4. Four wheel drive control ECU TF-52 1. Four wheel drive control switch TF-46 2. Wire harness TF-51 3. Four wheel drive control ECU TF-52 1. Four wheel drive control switch TF-46 2. Wire harness TF-51 3. Four wheel drive control ECU TF-52 1. Four wheel drive control switch TF-46 2. Differential lock switch TF-50 3. Wire harness TF-51 4. Four wheel drive control ECU TF-52 1. Four wheel drive control switch TF-46 2. Differential lock switch TF-50 3. Wire harness TF-51 4. Four wheel drive control ECU TF-52 TF–34 VF4AM TRANSFER – TRANSFER ASSEMBLY REASSEMBLY 1. INSTALL TRANSFER LOW PLANETARY RING GEAR (a) Install the low planetary ring gear to the front case. (b) Using a screwdriver, install the snap ring. TF F043456 2. INSTALL WITH HEAD PIN (a) Install w/ head pin. 3. INSTALL COMPRESSION SPRING 4. INSTALL TRANSFER CASE PLUG Torque: 18.6 N*m (190 kgf*cm, 14 ft.*lbf) 5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER (a) Install the transfer output shaft plate washer. 6. INSTALL TRANSFER DRIVE SPROCKET BEARING 7. INSTALL TRANSFER DRIVE SPROCKET SUBASSEMBLY 8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER 9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING (a) Using SST and a press, install a new output shaft rear radial ball bearing. SST 09316-60011 (09316-00011, 09316-00071) NOTICE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear. F043455 F043476 SST Rear F044046E01 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–35 10. INSTALL TRANSFER SYNCHRONIZER RING SET (a) Install the synchronizer ring. TF F043474 11. INSTALL FRONT DRIVE CLUTCH SLEEVE (a) Install front drive clutch sleeve. F044754 12. INSTALL SYNCHROMESH SHIFTING KEY TRANSFER DRIVE (a) Install the3 shifting keys to the clutch hub. 13. INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING (a) Install the 2 shifting key springs to the clutch hub. NOTICE: Position the shifting key springs so that their end gaps are not aligned. F044410 14. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER (a) Install the transfer output shaft plate washer. 15. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 16. INSTALL TRANSFER CLUTCH HUB F043472 17. INSTALL CENTER DIFFERENTIAL CASE (a) Install the center differential case. 18. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 19. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2 20. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING (a) Using a snap ring expender, install the snap ring. F044051 21. INSTALL DRIVE SPROCKET RADIAL CLEARANCE TF–36 VF4AM TRANSFER – TRANSFER ASSEMBLY 22. INSPECT DRIVE SPROCKET THRUST CLEARANCE 23. INSTALL TRANSFER INPUT SHAFT BEARING (a) Using SST and a press, install a new bearing with the groove facing forward. SST 09223-15020, 09515-30010, 09950-70010 (09951-07100) SST TF SST F043513E01 24. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE (a) Using a screwdriver, install the spline piece and low planetary gear with the snap ring. F043507 25. INSTALL TRANSFER LOW PLANETARY GEAR BEARING (a) Using SST and a press, tap in a new low planetary gear bearing. SST 09950-60010 (09951-00570), 09950-70010 (09951-07100) Press in depth: 7.7 to 8.3 mm (0.303 to 0.327 in.) 7.7 to 8.3mm (0.303 to 0.327 in.) SST Q007440E01 26. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING (a) Select a snap ring that allows the minimum axial play. F043468 Mark Thickness mm (in.) 1 1.45 to 1.50 (0.0571 to 0.0591) 2 1.50 to 1.55 (0.0591 to 0.0610) 3 1.55 to 1.60 (0.0610 to 0.0630) 4 1.60 to 1.65 (0.0630 to 0.0650) 5 1.65 to 1.70 (0.0650 to 0.0669) (b) Using a snap ring expander, install a new snap ring. TF–37 VF4AM TRANSFER – TRANSFER ASSEMBLY 27. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING (a) Apply gear oil to the oil seal ring. (b) Engage securely to eliminate clearance as shown in the illustration. TF F043460 28. INSTALL TRANSFER LOW PLANETARY GEAR BEARING (a) Install the transfer low planetary gear bearing. Front 29. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 30. INSTALL TRANSFER INPUT SHAFT F043454E01 31. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER (a) Install the manual transfer planetary carrier washer. 32. INSTALL TRANSFER INPUT GEAR STOPPER BALL 33. INSTALL TRANSFER INPUT GEAR STOPPER F043453 34. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING (a) Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play. F043514 Mark Thickness mm (in.) A 2.10 to 2.15 (0.0827 to 0.0846) B 2.15 to 2.20 (0.0846 to 0.0866) C 2.20 to 2.25 (0.0866 to 0.0886) D 2.25 to 2.30 (0.0886 to 0.0906) E 2.30 to 2.35 (0.0906 to 0.0925) F 2.35 to 2.40 (0.0925 to 0.0945) G 2.40 to 2.45 (0.0945 to 0.0965) H 2.45 to 2.50 (0.0965 to 0.0984) J 2.50 to 2.55 (0.0984 to 0.1004) K 2.55 to 2.60 (0.1004 to 0.1024) L 2.60 to 2.65 (0.1024 to 0.1043) M 2.65 to 2.70 (0.1043 to 0.1063) N 2.70 to 2.75 (0.1063 to 0.1083) P 2.75 to 2.80 (0.1083 to 0.1102) TF–38 VF4AM TRANSFER – TRANSFER ASSEMBLY Mark Thickness mm (in.) Q 2.80 to 2.85 (0.1102 to 0.1122) R 2.85 to 2.90 (0.1122 to 0.1142) S 2.90 to 2.95 (0.1142 to 0.1161) T 2.95 to 3.00 (0.1161 to 0.1181) U 3.00 to 3.05 (0.1181 to 0.1201) (b) Using a snap ring expander, install the new input gear stopper shaft snap ring. TF Q007289 35. INSTALL TRANSFER CASE OIL SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface. SST 09316-60011 (09316-00011) (b) Coat the lip of the oil seal with MP grease. SST F043515E01 36. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY (a) Install the low planetary gear assembly with input shaft sub-assembly. F043450 (b) Using a snap ring expander, install the shaft snap ring. F043449 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–39 37. INSTALL TRANSFER OIL PUMP GEAR (a) Install transfer oil pump gear. TF F043448 38. INSTALL TRANSFER OIL PUMP BODY O-RING (a) Coat a new O-ring with gear oil and install it to the oil pump body. F043463E01 39. INSTALL TRANSFER OIL PUMP BODY SUBASSEMBLY (a) Install the oil pump body sub-assembly with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 40. INSTALL TRANSFER CASE MAGNET F043447 41. INSTALL TRANSFER OIL SEPARATOR SUBASSEMBLY (a) Install the oil separator sub-assembly with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 42. INSTALL TRANSFER CASE PLUG (a) Install the case plug No. 1 (filler plug) and a new gasket. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) F043446 43. INSTALL TRANSFER CASE PLUG (a) Install the case plug (drain plug) and a new gasket. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) TF–40 VF4AM TRANSFER – TRANSFER ASSEMBLY 44. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY (a) Install the shift actuator assembly with the 3 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) (b) Using a screwdriver and hammer, drive in the snap ring. TF F043445 45. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING (a) Using SST and a press, install a new input gear radial ball bearing. SST 09316-60011 (09316-00031) SST F043464E02 46. INSTALL TRANSFER DRIVEN SPROCKET BEARING (a) Using a press, install a new driven sprocket bearing. F044041 47. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT (a) Install No. 2 stopper transfer shift shaft. F043443 48. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, NO. 1 GEAR SHIFT FORK, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET (a) Install the rear output shaft sub-assembly, gear shift fork No. 1 and drive sprocket to the front drive chain. F043442 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–41 (b) Install the rear output shaft sub-assembly, gear shift fork No. 1, front drive clutch sleeve, front drive chain and driven sprocket sub-assembly to the case rear. HINT: Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly. TF F043441 (c) Using a snap ring expander, install the snap ring. F043440 (d) Using a screwdriver and hammer, drive in the snap ring. F044399 (e) Using a screwdriver and hammer, drive in the snap ring. F044400 49. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT (a) Install No. 2 stopper transfer shift shaft. 50. INSTALL OR ROLLER SHIFT INTER-LOCK PIN F043437 TF–42 VF4AM TRANSFER – TRANSFER ASSEMBLY 51. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT (a) Turn the front drive shift fork shaft, and install it on the rear case aligning the cut out position and the inter-lock pin position. 52. INSTALL TRANSFER SHIFT SHAFT STOPPER (a) Install the shift shaft stopper with the bolt. Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) TF F043436 53. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE (a) Install the gear shift fork No. 2 and high and low clutch sleeve. (b) Install the bolt. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) Front 54. INSTALL TRANSFER OUTPUT SHAFT SPACER F044401E01 FIPG 55. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 56. INSTALL TRANSFER CASE REAR (a) Apply FIPG to the case rear, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent F043488E01 (b) Install the clamp and case rear with the 12 bolts. Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf) F043433 57. INSTALL COLLAR (a) Install collar. 58. INSTALL TRANSFER OUTPUT WASHER F043432 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–43 59. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface. SST 09223-46011, 09631-32020 (b) Coat the lip of the oil seal with MP grease. SST TF F043516E02 FIPG F043489E01 60. INSTALL TRANSFER EXTENSION HOUSING SUBASSEMBLY FRONT (a) Apply FIPG to the extension housing sub-assembly, as shown in the illustration. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent (b) Apply sealant to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Install the extension housing sub-assembly with the 5 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) F043431 61. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using SST and a hammer, drive in a new oil seal (front side). SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) (b) Coat the lip of the oil seal with MP grease. SST F043517E02 62. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Drive in a new output shaft companion flange oil seal using the same procedure as for the oil seal. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) TF–44 VF4AM TRANSFER – TRANSFER ASSEMBLY Front: 63. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly. (b) Using SST to hold the companion flange, install a new companion flange lock nut. SST 09330-00021 Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) (c) Using a chisel and hammer, stake the companion flange lock nut. Rear: TF 64. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, install the companion flange subassembly using the same procedure as for the companion flange sub-assembly (rear side). Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) SST 09330-00021 SST 65. INSTALL BREATHER OIL DEFLECTOR F044048E02 66. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY (a) Install the case cover sub-assembly with the 4 bolts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) F043428 67. INSTALL TRANSFER COVER TYPE T OIL SEAL (a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface. (b) Coat the lip of the oil seal with MP grease. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) SST F043518E02 FIPG F043490E01 68. INSTALL TRANSFER RH BEARING RETAINER SUBASSEMBLY (a) Apply FIPG to the front bearing retainer subassembly, as shown in the illustration. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent (b) Apply sealant to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent VF4AM TRANSFER – TRANSFER ASSEMBLY TF–45 (c) Install the front bearing retainer sub-assembly with the 5 bolts. Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 69. INSTALL HOSES TF F043427 INSTALLATION 1. INSTALL TRANSFER ASSEMBLY (a) Install the transfer assembly with the 8 bolts. Torque: 24 N*m (240 kgf*cm, 17 ft.*lbf) NOTICE: Take care not to damage the adaptor rear oil seal with the transfer input gear spline. 2. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER (See page AT-352) 3. CONFIRM FRONT DIFFERENTIAL ASSEMBLY 4. INSTALL MANIFOLD STAY NO.2 (See page EM-92) 5. INSTALL MANIFOLD STAY (See page EM-92) 6. INSTALL STARTER ASSEMBLY (See page AT-353) 7. CONNECT WIRE HARNESS 8. CONNECT CONNECTOR 9. INSTALL NO. 3 FRAME CROSSMEMBER SUBASSEMBLY (See page AT-354) F043500 10. INSTALL TRANSFER CASE LOWER PROTECTOR (a) Install the transfer case lower protector with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 11. INSTALL NO. 1 TRANSFER CONTROL CABLE BRACKET (See page AT-352) 12. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page AT-354) F043499 13. INSTALL NO. 1 OIL COOLER INLET TUBE (See page AT-354) 14. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See page AT-354) 15. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY 16. INSTALL FRONT SUSPENSION MEMBER BRACKET LH (See page AT-355) 17. INSTALL FRONT SUSPENSION MEMBER BRACKET (See page AT-355) 18. ADD TRANSFER OIL TF–46 VF4AM TRANSFER – TRANSFER ASSEMBLY 19. ADD AUTOMATIC TRANSMISSION FLUID (See page AT-355) 20. INSPECT AUTOMATIC TRANSMISSION FLUID (See page AT-355) 21. INSTALL PROPELLER SHAFT ASSEMBLY (See page PR-6) TF 22. INSTALL PROPELLER SHAFT ASSEMBLY FRONT (See page PR-19) 23. INSTALL EXHAUST PIPE ASSEMBLY (See page AT355) 24. CONNECT OXYGEN SENSOR (See page AT-355) 25. INSTALL ENGINE UNDER COVER ASSEMBLY REAR (See page AT-355) 26. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY (See page AT-355) 27. INSPECT AUTOMATIC TRANSMISSION FLUID (See page AT-355) 28. INSPECT SHIFT LEVER POSITION (See page AT-355) 29. CHECK FOR EXHAUST GAS LEAKAGE 30. WARM UP 31. DRIVE TEST VF4AM TRANSFER – TRANSFER OIL 0 to 5 mm (0 to 0.20 in.) TF–3 TRANSFER OIL ADJUSTMENT 1. C083746E02 2. INSPECT TRANSFER OIL (a) Remove the filler plug and gasket. (b) Check that the oil level is within 5 mm (0.20 in.) of the bottom of the filler plug hole. NOTICE: • When replacing the oil, recheck the oil level after driving. • Excessively large or small quantities of oil may cause troubles. (c) When the oil level is too low, check for oil leakage. (d) Tighten the filler plug with a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) ADJUST TRANSFER OIL (a) Remove the filler plug and gasket then supply oil. NOTICE: • When supplying oil, pour slowly. • Pour the oil in several stages allowing several minutes between each step. HINT: The oil level should be within 5 mm (0.20 in.) of the bottom of the oil filler plug hole. (b) After leaving it alone for 5 minutes, check the oil level again. (c) Tighten the filler plug with a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) TF TF–4 VF4AM TRANSFER – TRANSFER CASE OIL SEAL TRANSFER CASE OIL SEAL DRIVE LINE VF4AM TRANSFER COMPONENTS TF 18 (185, 13) 18.6 (190, 14) CASE PLUG CASE COVER SUB-ASSEMBLY LOW PLANETARY RING GEAR COMPRESSION SPRING BREATHER OIL DEFLECTOR HEAD PIN SNAP RING * 11.5 (117, 8) x5 SNAP RING OIL SEAL FRONT BEARING RETAINER SUB-ASSEMBLY TRANSFER FRONT CASE OIL SEAL TRANSFER CASE OIL SEAL 118 (1,200, 87) N*m (kgf*cm, ft.*lbf) : Specified torque OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Non-reusable part * Precoated part C131342E03 VF4AM TRANSFER – TRANSFER CASE OIL SEAL TF–5 REMOVAL 1. DRAIN TRANSFER OIL 2. REMOVE TRANSFER CASE LOWER PROTECTOR (See page TF-17) 3. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-346) 4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-18) 5. REMOVE TRANSFER CASE OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the case. SST F043485E02 INSTALLATION 1. INSTALL TRANSFER CASE OIL SEAL (a) Coat the lip of a new oil seal with MP grease. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the case upper surface. SST 09316-60011 (09316-00011) 2. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-43) 3. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-351) 4. INSTALL TRANSFER CASE LOWER PROTECTOR (See page TF-44) 5. ADD TRANSFER OIL (See page TF-3) 6. ADD AUTOMATIC TRANSMISSION FLUID (See page AT-355) 7. INSPECT AUTOMATIC TRANSMISSION FLUID (See page AT-355) 8. WARMING UP 9. DRIVE TEST SST F043487E02 TF TF–6 VF4AM TRANSFER – EXTENSION HOUSING OIL SEAL EXTENSION HOUSING OIL SEAL DRIVE LINE VF4AM TRANSFER COMPONENTS TF OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY TRANSFER EXTENSION HOUSING TYPE T OIL SEAL C139738E02 VF4AM TRANSFER – EXTENSION HOUSING OIL SEAL TF–7 REMOVAL SST 1. DRAIN TRANSFER OIL 2. REMOVE TRANSFER CASE LOWER PROTECTOR (See page TF-17) 3. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER (See page TF-5) 4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-18) 5. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the extension housing sub-assembly rear. F043484E02 INSTALLATION SST 1. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Coat the lip of a new oil seal with MP grease. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the housing upper surface. SST 09223-46011, 09631-32020 2. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-43) 3. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER (See page TF-5) 4. INSTALL TRANSFER CASE LOWER PROTECTOR (See page TF-44) 5. ADD TRANSFER OIL (See page TF-3) 6. ADD AUTOMATIC TRANSMISSION FLUID (See page AT-355) 7. INSPECT AUTOMATIC TRANSMISSION FLUID (See page AT-355) 8. WARMING UP 9. DRIVE TEST F043486E02 TF TF–8 VF4AM TRANSFER – TRANSFER ASSEMBLY TRANSFER ASSEMBLY DRIVE LINE VF4AM TRANSFER COMPONENTS TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY TF PROPELLER SHAFT ASSEMBLY ATF LEVEL GAUGE 88 (900, 65) 88 (900, 65) 12 (120, 9) O-RING 5 (50, 43 in.*lbf) OIL COOLER INLET TUBE NO. 1 AND OIL COOLER OUTLET TUBE NO. 1 24 (240, 17) x5 34 (346, 25) TRANSFER ASSEMBLY AUTOMATIC TRANSMISSION 18 (184, 13) 24 (240, 17) 48 (490, 35) TRANSFER CASE LOWER PROTECTOR 25 (255, 18) x6 x3 TRANSMISSION CONTROL CABLE ASSEMBLY 71 (720, 53) 12 (120, 9) TRANSMISSION CONTROL CABLE BRACKET NO. 1 88 (900, 65) PROPELLER SHAFT ASSEMBLY FRONT N*m (kgf*cm, ft.*lbf) : Specified torque 88 (900, 65) Non-reusable part C131340E02 TF–9 VF4AM TRANSFER – TRANSFER ASSEMBLY MANIFOLD STAY GASKET EXHAUST PIPE ASSEMBLY STARTER ASSEMBLY 40 (408, 30) 40 (490, 35) GASKET GASKET 62 (630, 46) MANIFOLD STAY NO.2 40 (408, 30) EXHAUST PIPE ASSEMBLY GASKET 62 (630, 46) NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY ENGINE MOUNTING INSULATOR REAR NO. 1 65 (663, 48) FRONT SUSPENSION MEMBER BRACKET 72 (734, 53) 18 (184, 13) 33 (336, 24) 33 (336, 24) REAR ENGINE UNDER COVER ASSEMBLY FRONT SUSPENSION MEMBER BRACKET LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131341E02 TF TF–10 VF4AM TRANSFER – TRANSFER ASSEMBLY 18 (185, 13) 18.6 (190, 14) TF CASE PLUG CASE COVER SUB-ASSEMBLY SNAP RING COMPRESSION SPRING BREATHER OIL DEFLECTOR WITH HEAD PIN SNAP RING * LOW PLANETARY RING GEAR 11.5 (117, 8) x5 TRANSFER FRONT CASE OIL SEAL FRONT BEARING RETAINER SUB-ASSEMBLY TRANSFER CASE OIL SEAL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 118 (1,200, 87) OIL SEAL N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * Precoated part C131342E04 TF–11 VF4AM TRANSFER – TRANSFER ASSEMBLY SPACER INPUT SHAFT SUB-ASSEMBLY BALL LOW PLANTARY GEAR ASSEMBLY OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING PLANETARU CARR WASHER THRUST BEARING RACE NO. 1 LOW PLANETARY GEAR BEARING INPUT GEAR STOPPER 7.8 (80, 66 in.*lbf) SNAP RING O-RING 7.5 (80, 66 in.*lbf) OIL SEPARATOR SUB-ASSEMBLY TRANSFER CASE MAGNET OIL PUMP GEAR 7.8 (80, 66 in.*lbf) OIL PUMP BODY SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131343E02 TF TF–12 VF4AM TRANSFER – TRANSFER ASSEMBLY ACTUATOR ASSEMBLY 20 (200, 14) SNAP RING GEAR SHIFT FORK NO. 1 TF GEAR SHIFT FORK NO. 2 SNAP RING x12 REAR OUTPUT SHAFT SUB-ASSEMBLY 24 (245, 18) 28 (285, 21) NO. 2 STOPPER SHIFT SHAFT CLAMP GASKET 37 (380, 27) NO. 1 PLUG (DRAIN PLUG) 37 (380, 27) NO. 1 PLUG (DRAIN PLUG) HIGH AND LOW CLUTCH SLEEVE ROLLER SHIFT INTER-LOCK PIN GASKET FRONT DRIVE CHAIN TRANSFER CASE REAR DRIVEN SPROCKET SUB-ASSEMBLY NO. 2 STOPPER SHIFT SHAFT FRONT DRIVE SHIFT FORK SHAFT SHIFT SHAFT STOPPER 19 (195, 14) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131344E02 TF–13 VF4AM TRANSFER – TRANSFER ASSEMBLY TF 118 (1,200, 87) * 12 (120, 9) x5 EXTENSION HOUSING SUB-ASSEMBLY REAR OIL SEAL SNAP RING OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY TRANSFER EXTENSION HOUSING TYPE T OIL SEAL COLLAR OUTPUT WASHER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * Precoated part C131345E02 TF–14 VF4AM TRANSFER – TRANSFER ASSEMBLY INPUT SHAFT SUB-ASSEMBLY: SEAL RING NO. 1 TF TRANSFER INPUT SHAFT Non-reusable part C131346E02 DRIVEN SPROCKET SUB-ASSEMBLY: TRANSFER DRIVEN SPROCKET BEARING TRANSFER INPUT GEAR RADIAL BALL BEARING TRANSFER DRIVEN SPROCKET Non-reusable part C131347E02 VF4AM TRANSFER – TRANSFER ASSEMBLY TF–15 LOW PLANETARY GEAR SUB-ASSEMBLY: TRANSFER INPUT SHAFT BEARING SNAP RING TF LOW PLANETARY GEAR TRANSFER LOW PLANETARY GEAR SPLINE PIECE SNAP RING TRANSFER LOW PLANETARY GEAR BEARING Non-reusable part C131348E02 TF–16 VF4AM TRANSFER – TRANSFER ASSEMBLY REAR OUTPUT SHAFT SUB-ASSEMBLY: TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING TRANSFER OUTPUT SHAFT SPACER DRIVE SPROCKET SUB-ASSEMBLY TRANSFER DRIVE SPROCKET BEARING TF OUTPUT SHAFT PLATE WASHER TRANSFER OUTPUT SHAFT REAR OUTPUT SHAFT PLATE WASHER TRANSFER SYNCHRONIZER RING SET FRONT DRIVE CLUTCH SLEEVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING SYNCHROMESH SHIFTING KEY CLUTCH HUB CENTER DIFFERENTIAL CASE TRANSFER OUTPUT SHAFT SPACER BALL SNAP RING TRANSFER OUTPUT SHAFT SPACER NO.2 Non-reusable part C131349E03 TF–46 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM DRIVE LINE VF4AM TRANSFER PARTS LOCATION TF FOUR WHEEL DRIVE CONTROL SWITCH FOUR WHEEL DRIVE CONTROL ECU DIFFERENTIAL LOCK SWITCH TRANSFER SHIFT ACTUATOR ASSEMBLY C131359E03 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM TF–47 INSPECTION NOTICE: • H4 to L4: Stop the vehicle and apply brake, then shift the transmission shift lever into "N" position first. • Do not operate the four wheel drive control switch and the differential lock switch at the same time. • Do not change from 2WD to 4WD when the vehicle speed is 100 km/h or more. 1. INSPECT H2 (2WD) TO H4 (4WD AND DIFFERENTIAL LOCK "FREE") SHIFT (a) Start the engine, and the differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch from the "H2" position to the "H4" position. (c) Check that the 4WD indicator light comes on after it is blinking. (The center diff. lock indicator blinks while shifting.) (d) Turn the four wheel drive control switch from the "H4" position to the "H2" position. (The center diff. lock indicator blinks while shifting.) (e) Check that the 4WD indicator light goes off after it is blinking. 2. INSPECT H4 (4WD AND DIFFERENTIAL LOCK "LOCK") TO H2 (2WD) SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. (c) Turn the four wheel drive control switch from the "H4" position to the "H2" position. (d) Check that the 4WD indicator light and center diff. lock indicator light goes off after those are blinking. F044403 F044404 TF TF–48 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM 3. INSPECT H4 (4WD AND DIFFERENTIAL LOCK "FREE") TO H4 (4WD AND DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and the differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch to "H4" position while pressing it. (c) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. Check that the center diff. lock indicator light goes off after pressing the differential lock switch for 2 seconds. 4. INSPECT L4 (4WD AND DIFFERENTIAL LOCK "FREE") TO L4 (4WD AND DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch to "L4" position while pressing it. (c) Check that the 4LO indicator light comes on after it is blinking. (d) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. Check that the center diff. lock indicator light goes off after pressing the differential lock switch for 2 seconds. 5. INSPECT H4 (4WD AND DIFFERENTIAL LOCK "FREE") TO L4 (4WD AND DIFFERENTIAL LOCK "FREE") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch from the "H4" position to the "L4" position while pressing it. (c) Check that the 4LO indicator light comes on after it is blinking. (d) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (e) Check that the 4LO indicator light goes off after it is blinking. TF F044034 F044035 F044036 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM 6. F044037 TF–49 INSPECT H4 (4WD AND DIFFERENTIAL LOCK "LOCK") TO L4 (4WD AND DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. (c) Turn the four wheel drive control switch from the "H4" position to the "L4" position while pressing it. (d) Check that the 4LO indicator light comes on after it is blinking. (e) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (f) Check that the 4LO indicator light goes off after it is blinking. 7. INSPECT H2 (2WD) TO L4 (4WD AND DIFFERENTIAL LOCK "FREE") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch from the "H2" position to the "H4" position. (c) Check that the 4WD indicator light comes on after it is blinking. (The center diff. lock indicator blinks while shifting.) (d) Turn the four wheel drive control switch from the "H4" position to the "L4" position while pressing it. (e) Check that the 4LO indicator light comes on after it is blinking. 8. INSPECT L4 (4WD AND DIFFERENTIAL LOCK "FREE") TO H2 (2WD) SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (c) Check that the 4LO indicator light goes off after it is blinking. (d) Turn the four wheel drive control switch from the "H4" position to the "H2" position. (e) Check that the 4WD indicator light goes off after it is blinking. (The center diff. lock indicator blinks while shifting.) F044405 F044406 TF TF–50 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM 9. TF INSPECT L4 (4WD AND DIFFERENTIAL LOCK "LOCK") TO H2 (2WD) SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. (c) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (d) Check that the 4LO indicator light goes off after it is blinking. (e) Turn the four wheel drive control switch from the "H4" position to the "H2" position. (f) Check that the 4WD indicator light and center diff. lock indicator light goes off after those are blinking. F044407 10. INSPECT DIFFERENTIAL LOCK SWITCH (a) Remove the instrument panel finish lower panel sub-assembly. (b) Remove the differential lock switch from the instrument panel finish lower sub-assembly. (c) Inspect the continuity between the each terminal. OFF ON GND Tester connection Specified condition OFF +B (3) to GND (4) No continuity Hold ON +B (3) to GND (4) Continuity Illumination ILL+ (1) to ILL- (2) Continuity If continuity is not as specified, replace the differential lock switch or bulb. ILL- +B Switch position ILL+ F044040E01 TF–51 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM GND 2-4 11. INSPECT FOUR WHEEL DRIVE CONTROL SWITCH (a) Remove the center instrument cluster finish panel sub-assembly. (b) Remove the four wheel drive control switch from the center instrument cluster finish panel sub-assembly. (c) Inspect the continuity between the each terminals. LO ILL- Switch position Tester connection Specified condition H2 2-4 (5) to GND (4) Continuity 2-4 (5) to GND (4) Continuity 2-4 (5) to GND (4) No continuity ILL+ F044039E03 H4 LO (2) to GND (4) Continuity LO (2) to GND (4) No continuity L4 LO (2) to GND (4) Continuity Illumination ILL+ (1) to ILL- (3) Continuity If continuity is not as specified, replace the four wheel drive control switch or bulb. 12. INSPECT ACTUATOR NOTICE: Inspection for the actuator must be done with the actuator installed on the transfer assembly. (a) Turn the ignition switch to ON. (b) Check the operating sound produced by four wheel drive control switch operation and the differential lock switch operation. If the operating sound cannot be heard, check the four wheel control ECU and the wire harness in the next step. When the wire harness and four wheel drive control ECU is normal, replace the actuator. Four Wheel Drive Control ECU Connector F10 Transfer Shift Actuator Connector T3 F044038E01 13. INSPECT WIRE HARNESS (a) Disconnect the cable from the negative battery terminal or remove the 20A 4WD fuse. CAUTION: Failure to disconnect power for the 4WD ECU may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator. (b) Disconnect the actuator connector and four wheel drive control ECU connector. (c) Check continuity on the wire harness between four wheel drive control ECU and the actuator. Tester connection Specified condition TM1 (F10-2) - TM1 (T3-2) Continuity TM2 (F10-5) - TM2 (T3-1) Continuity TL2 (F10-24) - TL2 (T3-4) Continuity TL3 (F10-23) - TL3 (T3-5) Continuity HM2 (F10-4) - HM2 (T3-7) Continuity HM1 (F10-1) - HM1 (T3-8) Continuity P1 (F10-22) - CDL (T3-9) Continuity HL2 (F10-26) - HL2 (T3-11) Continuity HL1 (F10-17) - HL1 (T3-12) Continuity TF TF–52 VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM If continuity is not as specified, repair or replace the wire harness. 14. INSPECT FOUR WHEEL DRIVE CONTROL ECU (a) Connect the wire harness side connector to the four wheel drive control ECU. (b) Connect the cable to the negative battery terminal or install the 20A 4WD fuse. (c) Inspect the wire harness side connector from the back side, as shown below. TF F9 F10 C134067E01 STANDARD VALUE OF ECU TERMINAL Terminals (Symbols) Condition F10-1 (HM1) - F10-4 (HM2) • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position F10-4 (HM2) - F10-1 (HM1) • • Ignition switch ON Four wheel drive control switch "L4" position → Four wheel drive control switch "H4" position • • • Ignition switch ON Differential lock switch is in "OFF" position Four wheel drive control switch "H2" position → Four wheel drive control switch "H4" position • • Ignition switch ON Keep pressing the differential lock switch approx. 2 seconds to turn it ON Four wheel drive control switch "H4" position or "L4" position → Four wheel drive control switch "H2" position F10-2 (TM1) - F10-5 (TM2) F10-5 (TM2) - F10-2 (TM1) • STD Voltage (V) 10 - 14 to 2 or less or 0 (0.5 s) - 14 (50 ms) pulse generation 10 - 14 to 2 or less or 0 (0.5 s) - 14 (50 ms) pulse generation F10-3 (DM1) - F10-6 (DM2) • • Ignition switch ON A.D.D. FREE → A.D.D. LOCK F10-6 (DM2) - F10-3 (DM1) • • Ignition switch ON A.D.D. LOCK → A.D.D. FREE F10-4 (HM2) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position F9-1 (GND) - Body ground • Ignition switch OFF Continuity 10 - 14 10 - 14 to 2 or less or 0 (0.5 s) - 14 (50 ms) pulse generation 2 or less to 10 - 14 F9-6 (IG) - F9-1 (GND) • Ignition switch ON F10-12 (DL2) - F9-1 (GND) • • Ignition switch ON A.D.D. LOCK → A.D.D. FREE 2 or less to 10 - 14 F10-13 (DL1) - F9-1 (GND) • • Ignition switch ON A.D.D. FREE → A.D.D. LOCK 2 or less to 10 - 14 F10-17 (HL1) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 - 14 to 2 or less F9-8 (2-4) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "L4" position → Four wheel drive control switch "H22" position or "H4" position 10 - 14 to 2 or less F9-9 (SPD) - F9-1 (GND) • During driving Pulse generation VF4AM TRANSFER – TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM Terminals (Symbols) Condition TF–53 STD Voltage (V) F9-11 (IND3) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "L4" position 10 - 14 to 0 - 3.5 F9-15 (LO) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "L4" position 10 - 14 to 2 or less F9-16 (DL) - F9-1 (GND) • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 - 14 to 2 or less • • Ignition switch ON A.D.D. FREE → A.D.D. LOCK 10 - 14 to 2 or less • • Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "L4" position Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 2 or less to 10 - 14 Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "L4" position Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 - 14 to 2 or less Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "L4" position Differential lock switch is in "OFF" position → "ON" position 2 or less to 10 - 14 F10-18 (ADD) - F9-1 (GND) F10-23 (TL3) - F9-1 (GND) • • • F10-24 (TL2) - F9-1 (GND) • F10-25 (TL1) - F9-1 (GND) • • • F10-26 (HL2) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H4"position → Four wheel drive control switch "L4" position 2 or less to 10 - 14 F9-19 (IND1) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H2" position → Four wheel drive control switch "H4" position or "L4" position 10 - 14 to 2 or less F9-20 (IND2) - F9-1 (GND) • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 - 14 to 2 or less F9-22 (N) - F9-1 (GND) • • Ignition switch ON Transmission shift lever other position → Transmission shift lever N position 2 or less to 10 - 14 F9-24 (L4) - F9-1 (GND) • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 - 14 to 2 or less TF VF4BM TRANSFER – TRANSFER ASSEMBLY TF–17 REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY (See page CO-13) 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR (See page AT-359) 4. REMOVE EXHAUST PIPE ASSEMBLY (See page AT359) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-14) 6. REMOVE PROPELLER SHAFT ASSEMBLY (See page PR-3) 7. DRAIN AUTOMATIC TRANSMISSION FLUID (See page AT-359) 8. DRAIN TRANSFER OIL 9. REMOVE FRONT SUSPENSION MEMBER BRACKET (See page AT-347) 10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (See page AT-359) 11. REMOVE TRANSMISSION OIL FILTER TUBE SUBASSEMBLY 12. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (See page AT-359) 13. REMOVE NO. 1 OIL COOLER INLET TUBE (See page AT-359) 14. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page AT-360) 15. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (See page AT-360) 16. REMOVE TRANSFER CASE LOWER PROTECTOR (a) Remove the 4 bolts and transfer case lower protector. 17. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER (See page AT-360) 18. REMOVE NO. 3 CROSSMEMBER SUB-ASSEMBLY (See page AT-360) 19. DISCONNECT CONNECTOR F043499 20. DISCONNECT WIRE HARNESS 21. REMOVE FLYWHEEL HOUSING UNDER COVER (See page AT-360) 22. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER (See page AT-361) TF TF–18 VF4BM TRANSFER – TRANSFER ASSEMBLY 23. REMOVE TRANSFER ASSEMBLY (a) Remove the 8 bolts and 2 clamps. (b) Remove the transfer from the automatic transmission. TF F043500 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–19 DISASSEMBLY 1. REMOVE HOSE 2. TEST TRANSFER RH BEARING RETAINER SUBASSEMBLY (a) Remove the 5 bolts and front bearing retainer subassembly. HINT: If necessary, tap the front bearing retainer subassembly with a plastic hammer to remove it. 3. REMOVE TRANSFER COVER TYPE T OIL SEAL (a) Using a screwdriver and hammer, remove the oil seal from the front bearing retainer sub-assembly. 4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY (a) Remove the 4 bolts and the case cover subassembly. 5. REMOVE BREATHER OIL DEFLECTOR SUBASSEMBLY 6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut. (b) Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut. SST 09330-00021 F043427 F043428 SST F043429E01 (c) Using SST, remove the output shaft companion flange sub-assembly. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 7. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly. 8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly. SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) SST F043430E01 TF TF–20 VF4BM TRANSFER – TRANSFER ASSEMBLY 9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly. 10. REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY (a) Remove the 5 bolts and extension housing subassembly. HINT: If necessary, tap the extension housing subassembly with a plastic hammer to remove it. TF F043431 11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using a screwdriver and hammer, remove the extension housing type T oil seal. 12. REMOVE TRANSFER OUTPUT WASHER 13. REMOVE COLLAR F043432 14. REMOVE TRANSFER REAR CASE (a) Remove the 12 bolts and clamp. (b) Remove the transfer rear case. HINT: If necessary, tap the transfer rear case with a plastic hammer to remove it. F043433 15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE (a) Remove the bolt, gear shift fork No. 2 and high and low clutch sleeve. F043434 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–21 16. REMOVE CTR DIFFERENTIAL LOCK FORK SUBASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE (a) Using 2 screwdrivers and hammer, tap out the snap ring. TF F043502 (b) Remove the bolt, CTR differential lock fork subassembly and front drive clutch sleeve. F043503 17. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY (a) Mount the transfer case rear in a vise. (b) Using a plastic hammer, carefully tap the a transfer case rear, and remove the rear output shaft sub assembly together with front drive chain and driven sprocket sub-assembly. F043504 (c) Remove the rear output shaft sub-assembly, front drive chain and driven sprocket sub assembly. F043505 18. REMOVE TRANSFER DRIVEN SPROCKET BEARING (a) Using a press, remove the driven sprocket bearing. F043523 TF–22 VF4BM TRANSFER – TRANSFER ASSEMBLY 19. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING (a) Using SST, a press and steel bar, remove the transfer input gear radial ball bearing. SST 09555-55010 Steel Bar SST TF F043524E02 20. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY (a) Using 2 screwdrivers and a hammer, tap out the 2 snap rings. F043506 (b) Remove the 3 bolts and transfer shift actuator assembly. 21. REMOVE TRANSFER CASE NO.1 PLUG (a) Remove the transfer case No. 1 plug (filler plug) and gasket. 22. REMOVE TRANSFER CASE NO.1 PLUG (a) Remove the transfer case No. 1 plug (drain plug) and gasket. F043445 23. REMOVE TRANSFER OIL SEPARATOR SUBASSEMBLY (a) Remove the 3 bolts and oil separator sub-assembly. 24. REMOVE TRANSFER CASE MAGNET F043446 25. REMOVE TRANSFER OIL PUMP BODY SUBASSEMBLY (a) Remove the 3 bolts and oil pump body subassembly. F043447 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–23 26. REMOVE TRANSFER OIL PUMP BODY O-RING (a) Using a screwdriver, remove the oil pump body Oring. TF F043462 27. REMOVE TRANSFER OIL PUMP GEAR (a) Remove the transfer oil pump gear. F043448 28. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY (a) Using a snap ring expander, remove the snap ring. F043449 (b) Remove the low planetary gear assembly with input shaft assembly. Q007221 29. REMOVE TRANSFER OUTPUT SHAFT SPACER (a) Remove the transfer output shaft spacer. 30. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 31. REMOVE TRANSFER CASE OIL SEAL (a) Using a screwdriver and hammer, remove the transfer case oil seal. F043451 TF–24 VF4BM TRANSFER – TRANSFER ASSEMBLY 32. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING (a) Using a snap ring expander, remove the input gear stopper shaft snap ring. TF F043452 33. REMOVE TRANSFER INPUT GEAR STOPPER (a) Remove the transfer input gear stopper. 34. REMOVE TRANSFER INPUT GEAR STOPPER BALL 35. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER F043453 36. REMOVE TRANSFER INPUT SHAFT (a) Remove the transfer input shaft. 37. REMOVE TRANSFER NO. 1 THRUST BEARING RACE Front 38. REMOVE TRANSFER LOW PLANETARY GEAR BEARING F043454E01 39. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING (a) Remove the 2 seal rings. F043525E01 40. INSPECT TRANSFER INPUT SHAFT (a) Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum diameter: 47.59 mm (1.8736 in.) If the outer diameter is less than the minimum, replace the input shaft. F043458 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–25 (b) Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum diameter: 48.14 mm (1.8953 in.) If the inside diameter exceeds the maximum, replace the input shaft. TF F043459 F043465 41. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear. Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. F043466 42. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard clearance: 0.009 to 0.038 mm (0.0004 to 0.0015 in.) Maximum clearance: 0.038 mm (0.0015 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. 43. REMOVE TRANSFER INPUT SHAFT BEARING (a) Using a snap ring expander, remove the snap ring. (b) Using SST and a press, remove the input shaft bearing. SST 09554-30011, 09555-55010 SST F043467E02 44. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE (a) Using a screwdriver, remove the snap ring. (b) Remove the low planetary gear spline piece. F043507 TF–26 VF4BM TRANSFER – TRANSFER ASSEMBLY 45. REMOVE TRANSFER LOW PLANETARY GEAR BEARING (a) Using SST, remove the low planetary gear bearing. SST 09612-65014 (09612-01030, 09612-01050) NOTICE: Hang SST securely to the clearance between the bearing and the low planetary gear. SST TF F043526E02 46. INSPECT DRIVE SPROCKET THRUST CLEARANCE (a) Using a feeler gauge, measure the drive sprocket thrust clearance. Standard clearance: 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Maximum clearance: 0.24 mm (0.0094 in.) If the clearance exceeds the maximum, replace the drive sprocket. F044049 F044050 47. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the drive sprocket. Standard clearance: 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Maximum clearance: 0.06 mm (0.0024 in.) If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing. 48. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING (a) Using a snap ring expander, remove the snap ring. 49. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER 50. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL 51. REMOVE CENTER DIFFERENTIAL CASE F044051 52. REMOVE TRANSFER CLUTCH HUB (a) Remove the transfer clutch hub. 53. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 54. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER F043510 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–27 55. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING (a) Using SST and a press, remove the output shaft rear radial ball bearing. SST 09555-55010 SST TF F043475E01 56. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER (a) Remove the transfer output shaft spacer. 57. REMOVE TRANSFER DRIVE SPROCKET SUBASSEMBLY 58. REMOVE TRANSFER DRIVE SPROCKET BEARING 59. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER F043476 D C B A F043511E01 60. INSPECT TRANSFER OUTPUT SHAFT REAR (a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface. Standard diameter: Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Minimum diameter: Part A: 27.98 mm (1.1016 in.) Part B: 31.98 mm (1.2591 in.) Part C: 34.98 mm (1.3772 in.) Part D: 36.98 mm (1.4559 in.) If the outer diameter is less than the minimum, replace the output shaft rear. TF–28 TF VF4BM TRANSFER – TRANSFER ASSEMBLY F043481 F043483 61. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE (a) Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the high and low clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2. 62. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE (a) Using vernier calipers, measure the thickness of the CTR differential lock fork clow. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the front drive clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the front drive clutch sleeve and CTR differential lock fork. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the front drive clutch sleeve or CTR differential lock fork. 63. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F043493 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–29 64. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. TF F044398 65. REMOVE TRANSFER CASE PLUG (a) Remove the transfer case plug. 66. REMOVE COMPRESSION SPRING 67. REMOVE WITH HEAD PIN F043455 68. REMOVE TRANSFER LOW PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring. F043456 (b) Remove the low planetary ring gear from the front case. Front F043457E01 INSPECTION 1. F043458 INSPECT TRANSFER INPUT SHAFT (a) Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum diameter: 47.59 mm (1.8736 in.) If the outer diameter is less than the minimum, replace the input shaft. TF–30 VF4BM TRANSFER – TRANSFER ASSEMBLY (b) Using a dial indicator, measure the inside diameter of the input shaft bushing. Maximum diameter: 48.14 mm (1.8593 in.) If the inside diameter exceeds the maximum, replace the input shaft. TF Q007293 2. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear. Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. 3. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard clearance: 0.009 to 0.038 mm (0.0004 to 00015 in.) Maximum clearance: 0.038 mm (0.0015 in.) If the clearance exceeds the maximum, replace the planetary gear assembly. 4. INSPECT DRIVE SPROCKET THRUST CLEARANCE (a) Using a feeler gauge, measure the thrust clearance of the drive sprocket. Standard clearance: 0.15 to 0.24 mm (0.0059 to 0.0094 in.) Maximum clearance: 0.24 mm (0.0094 in.) If the clearance exceeds the maximum, replace the drive sprocket. 5. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (a) Using a dial indicator, measure the radial clearance of the drive sprocket. Standard clearance: 0.01 to 0.06 mm (0.0004 to 0.0024 in.) Maximum clearance: 0.06 mm (0.0024 in.) If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing. F043465 F043466 F044049 F044050 VF4BM TRANSFER – TRANSFER ASSEMBLY 6. D C B A F043511E01 INSPECT TRANSFER OUTPUT SHAFT REAR (a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface. Standard diameter: Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.) Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.) Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.) Minimum diameter: Part A: 27.98 mm (1.1016 in.) Part B: 31.98 mm (1.2591 in.) Part C: 34.98 mm (1.3772 in.) Part D: 36.98 mm (1.4559 in.) If the outer diameter is less than the minimum, replace the output shaft rear. 7. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE (a) Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the high and low clutch sleeve. Distance: 10.5 mm (0.4134 in.) (c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2. 8. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE (a) Using vernier calipers, measure the thickness of the CTR differential lock fork clow. Thickness: 10 mm (0.3937 in.) (b) Using vernier calipers, measure the groove of the front drive clutch sleeve. Distance: 10.5 mm (0.4134 in.) F043481 F043483 TF–31 TF TF–32 VF4BM TRANSFER – TRANSFER ASSEMBLY (c) Calculate a clearance between the front drive clutch sleeve and CTR differential lock fork. Standard clearance: 0.26 to 0.84 mm (0.0102 to 0.0331 in.) Maximum clearance: 0.84 mm (0.0331 in.) If the clearance exceeds the maximum, replace the front drive clutch sleeve or CTR differential lock fork. 9. TF INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F043493 10. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE (a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn. (b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly. F044398 VF4BM TRANSFER – TRANSFER SYSTEM TF–1 TRANSFER SYSTEM PRECAUTION • Before disassembly, clean the transfer assembly and remove any deposited sand and mud to prevent it from entering the transfer during disassembly and assembly. • When removing any light alloy parts such as the transfer covers, do not pry them off with a tool like a screwdriver, but tap them out with a plastic hammer. • Always organize the removed parts properly and protect them from dust. • After cleaning and drying the transfer completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts or ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean rubber parts such as oil seals. • Apply sufficient hypoid gear oil to all sliding surfaces and rotating parts. • Do not directly hold any parts in a vise. Be sure to put an aluminum sheet between them. • Replace any damaged or deformed snap rings with new ones. • If the mating surface of the case is scratched, it could cause oil leakage. Therefore, handle with care to prevent such damage. • Using a razor blade and gasket scraper, remove old FIPG from the seal surface. • Clean all the components to remove the redundant FIPG completely. • Clean the sealing surface with solvent so that no residue remains on the seal surface. • Apply a line of FIPG approximately 1.2 mm (0.047 in.) diameter of bead state along the sealing surface. • Be sure to assemble parts within 10 minutes of application. Otherwise, the FIPG must be removed and reapplied. • Do not pour in oil immediately after installing sealed parts. Leave it for at least an hour. • Scratches on the contact surface with an oil seal or gasket could cause oil leakage. Handle with care to prevent such damage. • When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged. • When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing Repair Manual diagnostic procedures may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator. TF TF–2 VF4BM TRANSFER – TRANSFER SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. Replace the applicable parts as necessary. TRANSFER SYSTEM Symptom TF Noise Oil leakage Tight corner braking Shift from 4WD (H4) to 4WD (L4) impossible Shift from 4WD (L4) to 4WD (H4) impossible Suspected area See page 1. Oil (Level low) TF-3 2. Oil (Wrong) TF-3 3. Transfer faulty TF-8 1. Oil (Level too high) TF-3 2. Gasket (Damaged) TF-8 3. Oil seal (Worn or damaged) TF-8 4. O-ring (Worn or damaged) TF-8 1. Center differential or transfer faulty TF-43 1. Four wheel drive control switch TF-45 2. Wire harness TF-46 3. Four wheel drive control ECU TF-46 1. Four wheel drive control switch TF-45 2. Wire harness TF-46 3. Four wheel drive control ECU TF-46 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–33 REASSEMBLY 1. INSTALL TRANSFER LOW PLANETARY RING GEAR (a) Install the low planetary ring gear to the front case. (b) Using a screwdriver, install the snap ring. TF F043456 2. INSTALL WITH HEAD PIN (a) Install w/ head pin. 3. INSTALL COMPRESSION SPRING 4. INSTALL TRANSFER CASE PLUG Torque: 18.6 N*m (190 kgf*cm, 14 ft.*lbf) 5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER (a) Install the transfer output shaft plate washer. 6. INSTALL TRANSFER DRIVE SPROCKET BEARING 7. INSTALL TRANSFER DRIVE SPROCKET SUBASSEMBLY 8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER 9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING (a) Using SST and a press, install a new output shaft rear radial ball bearing. SST 09316-60011 (09316-00011, 09316-00071) NOTICE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear. F043455 F043476 SST Rear F044046E01 TF–34 VF4BM TRANSFER – TRANSFER ASSEMBLY 10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER (a) Install the transfer output shaft plate washer. 11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 12. INSTALL TRANSFER CLUTCH HUB TF F043510 13. INSTALL CENTER DIFFERENTIAL CASE (a) Install the center differential case. 14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 15. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2 16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING (a) Using a snap ring expender, install the snap ring. F044051 17. INSTALL DRIVE SPROCKET RADIAL CLEARANCE 18. INSPECT DRIVE SPROCKET THRUST CLEARANCE 19. INSTALL TRANSFER INPUT SHAFT BEARING (a) Using SST and a press, install a new bearing with the groove facing forward. SST 09223-15020, 09515-30010, 09950-70010 (09951-07100) SST SST F043513E01 20. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE (a) Using a screwdriver, install the spline piece and low planetary gear with the snap ring. F043507 TF–35 VF4BM TRANSFER – TRANSFER ASSEMBLY 21. INSTALL TRANSFER LOW PLANETARY GEAR BEARING (a) Using SST and a press, tap in a new low planetary gear bearing. SST 09950-60010 (09951-00570), 09950-70010 (09951-07100) Press in depth: 7.7 to 8.3 mm (0.303 to 0.327 in.) 7.7 to 8.3mm (0.303 to 0.327 in.) SST TF F043469E01 22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING (a) Select a snap ring that allows the minimum axial play. F043468 Mark Thickness mm (in.) 1 1.45 to 1.50 (0.0571 to 0.0591) 2 1.50 to 1.55 (0.0591 to 0.0610) 3 1.55 to 1.60 (0.0610 to 0.0630) 4 1.60 to 1.65 (0.0630 to 0.0650) 5 1.65 to 1.70 (0.0650 to 0.0669) (b) Using a snap ring expander, install a new snap ring. 23. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING (a) Apply gear oil to the oil seal ring. (b) Engage securely to eliminate clearance as shown in the illustration. F043460 24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING (a) Install the transfer low planetary gear bearing. Front 25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 26. INSTALL TRANSFER INPUT SHAFT F043454E01 TF–36 VF4BM TRANSFER – TRANSFER ASSEMBLY 27. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER (a) Install the manual transfer planetary carrier washer. 28. INSTALL TRANSFER INPUT GEAR STOPPER BALL 29. INSTALL TRANSFER INPUT GEAR STOPPER TF F043453 30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING (a) Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play. F043514 Mark Thickness mm (in.) A 2.10 to 2.15 (0.0827 to 0.0846) B 2.15 to 2.20 (0.0846 to 0.0866) C 2.20 to 2.25 (0.0866 to 0.0886) D 2.25 to 2.30 (0.0886 to 0.0906) E 2.30 to 2.35 (0.0906 to 0.0925) F 2.35 to 2.40 (0.0925 to 0.0945) G 2.40 to 2.45 (0.0945 to 0.0965) H 2.45 to 2.50 (0.0965 to 0.0984) J 2.50 to 2.55 (0.0984 to 0.1004) K 2.55 to 2.60 (0.1004 to 0.1024) L 2.60 to 2.65 (0.1024 to 0.1043) M 2.65 to 2.70 (0.1043 to 0.1063) N 2.70 to 2.75 (0.1063 to 0.1083) P 2.75 to 2.80 (0.1083 to 0.1102) Q 2.80 to 2.85 (0.1102 to 0.1122) R 2.85 to 2.90 (0.1122 to 0.1142) S 2.90 to 2.95 (0.1142 to 0.1161) T 2.95 to 3.00 (0.1161 to 0.1181) U 3.00 to 3.05 (0.1181 to 0.1201) (b) Using a snap ring expander, install the new input gear stopper shaft snap ring. Q007289 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–37 31. INSTALL TRANSFER CASE OIL SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface. SST 09316-60011 (09316-00011) (b) Coat the lip of the oil seal with MP grease. SST TF F043515E01 32. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY (a) Install the low planetary gear assembly with input shaft sub-assembly. F043450 (b) Using a snap ring expander, install the shaft snap ring. F043449 33. INSTALL TRANSFER OIL PUMP GEAR (a) Install transfer oil pump gear. F043448 34. INSTALL TRANSFER OIL PUMP BODY O-RING (a) Coat a new O-ring with gear oil and install it to the oil pump body. F043463E01 TF–38 VF4BM TRANSFER – TRANSFER ASSEMBLY 35. INSTALL TRANSFER OIL PUMP BODY SUBASSEMBLY (a) Install the oil pump body sub-assembly with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 36. INSTALL TRANSFER CASE MAGNET TF F043447 37. INSTALL TRANSFER OIL SEPARATOR SUBASSEMBLY (a) Install the oil separator sub-assembly with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 38. INSTALL TRANSFER CASE PLUG (a) Install the case plug No. 1 (filler plug) and a new gasket. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) F043446 39. INSTALL TRANSFER CASE PLUG (a) Install the case plug (drain plug) and a new gasket. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 40. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY (a) Install the shift actuator assembly with the 3 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) (b) Using a screwdriver and hammer, drive in the snap ring. F043445 41. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING (a) Using SST and a press, install a new input gear radial ball bearing. SST 09316-60011 (09316-00031) SST F043464E02 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–39 42. INSTALL TRANSFER DRIVEN SPROCKET BEARING (a) Using a press, install a new driven sprocket bearing. TF F044041 43. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY (a) Install the rear output shaft sub-assembly, and drive sprocket to the front drive chain. F043442 (b) Install the rear output shaft sub-assembly, front drive chain and driven sprocket sub-assembly to the rear case. HINT: Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly. F043441 44. INSTALL CTR DIFFERENTIAL LOCK FORK SUBASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE (a) Install the CTR differential lock fork sub-assembly and front drive clutch sleeve. (b) Install the bolt. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) (c) Using a screwdriver and hammer, drive in the snap ring. Front F043519E01 45. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE (a) Install the gear shift fork No. 2 and high and low clutch sleeve. (b) Install the bolt. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) Front 46. INSTALL TRANSFER OUTPUT SHAFT SPACER F044401E01 47. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING TF–40 VF4BM TRANSFER – TRANSFER ASSEMBLY FIPG TF 48. INSTALL TRANSFER CASE REAR (a) Apply FIPG to the case rear, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent F043488E01 (b) Install the clamp and case rear with the 12 bolts. Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf) F043433 49. INSTALL COLLAR (a) Install collar. 50. INSTALL TRANSFER OUTPUT WASHER F043432 51. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface. SST 09223-46011, 09631-32020 (b) Coat the lip of the oil seal with MP grease. SST F043516E02 FIPG F043489E01 52. INSTALL TRANSFER EXTENSION HOUSING SUBASSEMBLY REAR (a) Apply FIPG to the extension housing sub-assembly, as shown in the illustration. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent (b) Apply sealant to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent VF4BM TRANSFER – TRANSFER ASSEMBLY TF–41 (c) Install the extension housing sub-assembly with the 5 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) TF F043431 53. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Using SST and a hammer, drive in a new oil seal (front side). SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) (b) Coat the lip of the oil seal with MP grease. SST F043517E02 Front: 54. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (a) Drive in a new output shaft companion flange oil seal using the same procedure as for the oil seal. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 55. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly. (b) Using SST to hold the companion flange, install a new companion flange lock nut. SST 09330-00021 Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) (c) Using a chisel and hammer, stake the companion flange lock nut. Rear: SST 56. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (a) Using SST, install the companion flange subassembly using the same procedure as for the companion flange sub-assembly (rear side). Torque: 118 N*m (1200 kgf*cm, 87 ft.*lbf) SST 09330-00021 57. INSTALL BREATHER OIL DEFLECTOR F044048E02 TF–42 VF4BM TRANSFER – TRANSFER ASSEMBLY 58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY (a) Install the case cover sub-assembly with the 4 bolts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) TF F043428 59. INSTALL TRANSFER COVER TYPE T OIL SEAL (a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface. (b) Coat the lip of the oil seal with MP grease. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) SST F043518E02 FIPG F043490E01 60. INSTALL TRANSFER BEARING RETAINER SUBASSEMBLY (a) Apply FIPG to the front bearing retainer subassembly, as shown in the illustration. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent (b) Apply sealant to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Install the front bearing retainer sub-assembly with the 5 bolts. Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 61. INSTALL HOSES F043427 INSTALLATION F043500 1. INSTALL TRANSFER ASSEMBLY (a) Install the transfer assembly with the 8 bolts. Torque: 24 N*m (240 kgf*cm, 17 ft.*lbf) NOTICE: Take care not to damage the adaptor rear oil seal with the transfer input gear spline. 2. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER (See page EM-67) VF4BM TRANSFER – TRANSFER ASSEMBLY F043499 TF–43 3. INSTALL FLYWHEEL HOUSING UNDER COVER (See page AT-362) 4. CONNECT WIRE HARNESS 5. CONNECT CONNECTOR 6. INSTALL NO. 3 FRAME CROSSMEMBER SUBASSEMBLY (See page AT-362) 7. INSTALL TRANSFER CASE LOWER PROTECTOR (a) Install the transfer case lower protector with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 8. INSTALL NO. 1 TRANSFER CONTROL CABLE BRACKET (See page AT-362) 9. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See page AT-362) 10. INSTALL NO. 1 OIL COOLER INLET TUBE (See page AT-363) 11. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See page AT-363) 12. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY (See page AT-363) 13. INSTALL FRONT SUSPENSION MEMBER BRACKET LH (See page AT-351) 14. INSTALL FRONT SUSPENSION MEMBER BRACKET (See page AT-363) 15. ADD TRANSFER OIL HINT: (See page TF-3) 16. ADD AUTOMATIC TRANSMISSION FLUID (See page AT-364) 17. INSPECT AUTOMATIC TRANSMISSION FLUID 18. INSTALL PROPELLER SHAFT ASSEMBLY (See page PR-12) 19. INSTALL PROPELLER SHAFT ASSEMBLY FRONT (See page PR-19) 20. INSTALL EXHAUST PIPE ASSEMBLY (See page AT363) 21. CONNECT OXYGEN SENSOR (See page AT-364) 22. INSTALL ENGINE UNDER COVER ASSEMBLY REAR 23. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY 24. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: (See page AT-316) 25. INSPECT SHIFT LEVER POSITION (See page AT-364) TF TF–44 VF4BM TRANSFER – TRANSFER ASSEMBLY 26. CHECK FOR EXHAUST GAS LEAKAGE 27. WARM UP 28. DRIVE TEST TF VF4BM TRANSFER – TRANSFER OIL 0 to 5 mm (0 to 0.20 in.) TF–3 TRANSFER OIL ADJUSTMENT 1. C083746E02 2. INSPECT TRANSFER OIL (a) Remove the filler plug and gasket. (b) Check that the oil level is within 5 mm (0.20 in.) of the bottom of the filler plug hole. NOTICE: • When replacing the oil, recheck the oil level after driving. • Excessively large or small quantities of oil may cause troubles. (c) When the oil level is too low, check for oil leakage. (d) Tighten the filler plug with a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) ADJUST TRANSFER OIL (a) Remove the filler plug and gasket then supply oil. NOTICE: • When supplying oil, pour slowly. • Pour the oil in several stages allowing several minutes between each step. HINT: The oil level should be within 5 mm (0.20 in.) of the bottom of the oil filler plug hole. (b) After leaving it alone for 5 minutes, check the oil level again. (c) Tighten the filler plug with a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) TF TF–4 VF4BM TRANSFER – TRANSFER CASE OIL SEAL TRANSFER CASE OIL SEAL DRIVE LINE VF4BM TRANSFER COMPONENTS 18 (185, 13) TF 18.6 (190, 14) CASE PLUG CASE COVER SUB-ASSEMBLY LOW PLANETARY RING GEAR COMPRESSION SPRING BREATHER OIL DEFLECTOR HEAD PIN SNAP RING * 11.5 (117, 8) x5 SNAP RING OIL SEAL FRONT BEARING RETAINER SUB-ASSEMBLY TRANSFER FRONT CASE OIL SEAL TRANSFER CASE OIL SEAL 118 (1,200, 87) N*m (kgf*cm, ft.*lbf) : Specified torque OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Non-reusable part * Precoated part C131342E03 VF4BM TRANSFER – TRANSFER CASE OIL SEAL TF–5 REMOVAL 1. DRAIN TRANSFER OIL 2. REMOVE TRANSFER CASE LOWER PROTECTOR (See page TF-17) 3. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-358) 4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-18) 5. REMOVE TRANSFER CASE OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the case. SST F043485E02 INSTALLATION 1. INSTALL TRANSFER CASE OIL SEAL (a) Coat the lip of a new oil seal with MP grease. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the case upper surface. SST 09316-60011 (09316-00011) 2. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-40) 3. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-361) 4. INSTALL TRANSFER CASE LOWER PROTECTOR (See page TF-41) 5. ADD TRANSFER OIL 6. ADD AUTOMATIC TRANSMISSION FLUID 7. INSPECT AUTOMATIC TRANSMISSION FLUID 8. WARMING UP 9. DRIVE TEST SST F043487E02 TF TF–6 VF4BM TRANSFER – EXTENSION HOUSING OIL SEAL EXTENSION HOUSING OIL SEAL DRIVE LINE VF4BM TRANSFER COMPONENTS OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY TF TRANSFER EXTENSION HOUSING TYPE T OIL SEAL C139738E02 VF4BM TRANSFER – EXTENSION HOUSING OIL SEAL TF–7 REMOVAL SST 1. DRAIN TRANSFER OIL 2. REMOVE TRANSFER CASE LOWER PROTECTOR (See page TF-17) 3. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-358) 4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-18) 5. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the extension housing sub-assembly rear. F043484E02 INSTALLATION SST 1. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Coat the lip of a new oil seal with MP grease. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the housing upper surface. SST 09223-46011, 09631-32020 2. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (See page TF-40) 3. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER HINT: (See page AT-361) 4. INSTALL TRANSFER CASE LOWER PROTECTOR (See page TF-41) 5. ADD TRANSFER OIL 6. ADD AUTOMATIC TRANSMISSION FLUID 7. INSPECT AUTOMATIC TRANSMISSION FLUID 8. WARMING UP 9. DRIVE TEST F043486E02 TF TF–8 VF4BM TRANSFER – TRANSFER ASSEMBLY TRANSFER ASSEMBLY DRIVE LINE VF4BM TRANSFER COMPONENTS TF 88 (900, 65) ATF LEVEL GAUGE PROPELLER SHAFT ASSEMBLY 12 (122, 9) 88 (900, 65) O-RING TRANSMISSION OIL FILTER TUBE SUB-ASSEMBLY TRANSFER ASSEMBLY 34 (346, 25) 5 (50, 43 in.*lbf) x5 24 (240, 17) OIL COOLER INLET TUBE NO. 1 AND OIL COOLER OUTLET TUBE NO. 1 18 (184, 13) 48 (490, 35) TRANSFER CASE LOWER PROTECTOR x6 24 (240, 17) x3 FLYWHEEL HOUSING UNDER COVER TRANSMISSION CONTROL CABLE 71 (720, 53) AUTOMATIC TRANSMISSION ASSEMBLY 18 (184, 13) 88 (900, 65) PROPELLER SHAFT ASSEMBLY FRONT N*m (kgf*cm, ft.*lbf) : Specified torque 88 (900, 65) Non-reusable part C131350E02 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–9 48 (490, 35) GASKET TF EXHAUST PIPE ENGINE MOUNTING INSULATOR REAR NO. 1 GASKET 62 (630, 46) 62 (630, 46) GASKET ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 65 (663, 48) FRONT CROSSMEMBER SUB-ASSEMBLY NO. 3 72 (734, 53) 72 (734, 53) 33 (336, 24) ENGINE UNDER COVER ASSEMBLY REAR 33 (336, 24) FRONT SUSPENSION MEMBER BRACKET LH FRONT SUSPENSION MEMBER BRACKET Non-reusable part C131351E01 TF–10 VF4BM TRANSFER – TRANSFER ASSEMBLY 18 (185, 13) TF CASE PLUG 18.6 (190, 14) CASE COVER SUB-ASSEMBLY BREATHER OIL DEFLECTOR COMPRESSION SPRING HEAD PIN FRONT BEARING RETAINER SUBASSEMBLY SNAP RING LOW PLANETARY RING GEAR 11.5 (119, 8) x5 SNAP RING OIL SEAL TRANSFER FRONT CASE OIL SEAL 118 (1,200, 87) N*m (kgf*cm, ft.*lbf) : Specified torque OIL SEAL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Non-reusable part Precoated part C131342E06 TF–11 VF4BM TRANSFER – TRANSFER ASSEMBLY TF BALL SPACER TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING TRANSFER INPUT SHAFT THRUST BEARING RACE NO. 1 TRANSFER LOW PLANETARY GEAR BEARING LOW PLANETARY GEAR ASSEMBLY PLANETARY CARR WASHER INPUT GEAR STOPPER 7.5 (80, 66 in.*lbf) 7.5 (80, 66 in.*lbf) SNAP RING MAGNET TRANSFER OIL PUMP GEAR TRANSFER OIL PUMP BODY SUB-ASSEMBLY O-RING TRANSFER OIL SEPARATOR SUB-ASSEMBLY 7.5 (80, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131343E03 TF–12 VF4BM TRANSFER – TRANSFER ASSEMBLY 20 (200, 15) CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY TF 20 (200, 15) SNAP RING 24 (245, 18) GEAR SHIFT FORK NO. 2 SNAP RING TRANSFER SHIFT ACTUATOR ASSEMBLY CLAMP x12 24 (245, 18) 28 (285, 21) GASKET REAR OUTPUT SHAFT SUB-ASSEMBLY 37 (380, 27) NO. 1 PLUG (FILLER PLUG) 37 (380, 27) GASKET NO. 1 PLUG (DRAIN PLUG) TRANSFER CASE REAR FRONT DRIVE CLUTCH SLEEVE FRONT DRIVE CHAIN HIGH AND LOW CLUTCH SLEEVE DRIVEN SPROCKET SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131353E01 TF–13 VF4BM TRANSFER – TRANSFER ASSEMBLY TF 12 (120, 9) 118 (1,200, 87) x5 OIL SEAL OIL SEAL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY TRANSFER EXTENSION HOUSING SUB-ASSEMBLY REAR COLLAR OUTPUT WASHER SNAP RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part C131568E01 TF–14 VF4BM TRANSFER – TRANSFER ASSEMBLY INPUT SHAFT: TRANSFER NO. 1 INPUT SHAFT SEAL RING TF TRANSFER INPUT SHAFT Non-reusable part C131346E03 DRIVEN SPROCKET SUB-ASSEMBLY: DRIVEN SPROCKET TRANSFER INPUT GEAR RADIAL BALL BEARING Non-reusable part TRANSFER DRIVEN SPROCKET BEARING C131347E03 TF–15 VF4BM TRANSFER – TRANSFER ASSEMBLY LOW PLANETARY GEAR SUB-ASSEMBLY: SNAP RING TF LOW PLANETARY GEAR LOW PLANETARY GEAR BEARING TRANSFER LOW PLANETARY GEAR SPLINE PIECE TRANSFER INPUT SHAFT BEARING SNAP RING Non-reusable part C131348E04 TF–16 VF4BM TRANSFER – TRANSFER ASSEMBLY REAR OUTPUT SHAFT SUB-ASSEMBLY: TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING NO. 1 TRANSFER OUTPUT SHAFT SPACER DRIVE SPROCKET SUB-ASSEMBLY TF DRIVE SPROCKET BEARING OUTPUT SHAFT PLATE WASHER TRANSFER OUTPUT SHAFT REAR OUTPUT SHAFT PLATE WASHER TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING BALL CLUTCH HUB CENTER DIFFERENTIAL CASE SNAP RING NO. 2 TRANSFER OUTPUT SHAFT SPACER Non-reusable part C131357E01 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM TF–43 CENTER DIFFERENTIAL LOCK SYSTEM DRIVE LINE VF4BM TRANSFER PARTS LOCATION TF DIFFERENTIAL LOCK SWITCH FOUR WHEEL DRIVE CONTROL ECU FOUR WHEEL DRIVE CONTROL SWITCH TRANSFER SHIFT ACTUATOR ASSEMBLY C131358E02 TF–44 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM INSPECTION NOTICE: • Switch the four wheel drive control switch under the condition that A/T shift lever is in "N" position and the vehicle speed is 5 km/h or less. • Do not operate the four wheel drive control switch and the differential lock switch at the same time. 1. INSPECT H4 (DIFFERENTIAL LOCK "FREE") TO H4 (DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and the differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch to "H4" position while pressing it. (c) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. Check that the center diff. lock indicator light goes off after pressing the differential lock switch for 2 seconds. 2. INSPECT L4 (DIFFERENTIAL LOCK "FREE" TO H4 (DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch to "L4" position while pressing it. (c) Check that the 4LO indicator light comes on after it is blinking. (d) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. Check that the center diff. lock indicator light goes off after pressing the differential lock switch for 2seconds. 3. INSPECT H4 (DIFFERENTIAL LOCK "FREE") TO L4 (DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Turn the four wheel drive control switch from the "H4" position to the "L4" position while pressing it. (c) Check that the 4LO indicator light comes on after it is blinking. (d) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (e) Check that the 4LO indicator light goes off after it is blinking. TF F044042 F044043 F044044 TF–45 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM 4. INSPECT H4 (DIFFERENTIAL LOCK "LOCK") TO L4 (DIFFERENTIAL LOCK "LOCK") SHIFT (a) Start the engine, and differential lock switch is in "OFF" position. (b) Check that the center diff. lock indicator light comes on after pressing the differential lock switch for 2 seconds. (c) Turn the four wheel drive control switch from the "H4" position to the "L4" position while pressing it. (d) Check that the 4LO indicator light comes on after it is blinking. (e) Turn the four wheel drive control switch from the "L4" position to the "H4" position while pressing it. (f) Check that the 4LO indicator light goes off after it is blinking. F044045 5. INSPECT DIFFERENTIAL LOCK SWITCH CONTINUITY (a) Remove the instrument panel finish lower panel sub- assembly. (b) Remove the differential lock switch from the instrument panel finish lower sub-assembly. (c) Inspect the continuity between the each terminal. Switch position OFF ON ILL- GND +B Tester connection Specified condition OFF +B (3) - GND (4) No continuity Hold ON +B (3) - GND (4) Continuity Illumination ILL+ (1) - ILL- (2) Continuity If continuity is not as specified, replace the differential lock switch or bulb. ILL+ F044040E02 6. GND ILL- LO ILL+ INSPECT FOUR WHEEL DRIVE CONTROL SWITCH (a) (a) Remove the center instrument cluster finish panel sub- assembly. (b) Remove the four wheel drive control switch from the center instrument cluster finish panel sub-assembly. (c) Inspect the continuity between the each terminals. Switch position Tester connection Specified condition H4 LO (2) - GND (4) No continuity L4 LO (2) - GND (4) Continuity Illumination ILL+ (1) - ILL- (3) Continuity F044039E04 If continuity is not as specified, replace the four wheel drive control switch or bulb. TF TF–46 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM 7. INSPECT ACTUATOR NOTICE: Inspection for the actuator must be done with the actuator installed on the transfer assembly. (a) Turn the ignition switch to ON. (b) Check the operating sound produced by four wheel drive control switch operation and the differential lock switch operation. If the operating sound cannot be heard, check the four wheel control ECU and the wire harness in the next step. When the wire harness and four wheel drive control ECU is normal, replace the actuator. 8. INSPECT WIRE HARNESS (a) Disconnect the cable from the negative battery terminal or remove the 20A 4WD fuse. CAUTION: Failure to disconnect power for the 4WD ECU may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator. (b) Disconnect the actuator connector and four wheel drive control ECU connector. (c) Check continuity on the wire harness between four wheel drive control ECU and the actuator. TF Four Wheel Drive Control ECU Connector F10 Transfer Shift Actuator Connector T3 F044038E02 Tester connection Specified condition TM1 (F10-2) - TM1 (T3-2) Continuity TM2 (F10-5) - TM2 (T3-1) Continuity TL2 (F10-24) - TL2 (T3-4) Continuity TL3 (F10-23) - TL3 (T3-5) Continuity HM2 (F10-4) - HM2 (T3-7) Continuity HM1 (F10-1) - HM1 (T3-8) Continuity P1 (F10-22) - CDL (T3-9) Continuity HL2 (F10-26) - HL2 (T3-11) Continuity HL1 (F10-17) - HL1 (T3-12) Continuity If continuity is not as specified, repair or replace the wire harness. 9. INSPECT FOUR WHEEL DRIVE CONTROL ECU (a) Connect the wire harness side connector to the four wheel drive control ECU. (b) Connect the cable to the negative battery terminal or install the 20A 4WD fuse. TF–47 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM (c) Inspect the wire harness side connector from the back side, as shown below. F9 F10 TF C134067E02 STANDARD VALUE OF ECU TERMINAL Terminals (Symbols) Condition STD Voltage (V) F9-9 (SPD) - F9-1 (GND) During driving Pulse generation F9-22 (N) - F9-1 (GND) F9-16 (DL) - F9-1 (GND) F10-23 (TL3) - F9-1 (GND) • • Ignition switch ON Transmission shift lever other position → Transmission shift lever N position 10 to 14 → 2 or less • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 to 14 → 2 or less • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 2 or less → 10 to 14 F9-6 (IG) - F9-1 (GND) F10-2 (TM1) - F10- 5 (TM2) F9-15 (LO) - F9-1 (GND) F9-20 (IND2) - F9-1 (GND) F9-11 (IND3) - F9-1 (GND) F10-24 (TL2) - F9-1 (GND) Ignition switch ON • • Ignition switch ON Differential lock switch is in "OFF" position • • Ignition switch ON Keep pressing the differential lock switch approx. 2 seconds to turn it ON • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 to 14 → 2 or less • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 to 14 → 1.5 to 3.5 • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 to 14 → 1.5 to 3.5 • • Ignition switch ON Differential lock switch is in "OFF" position → Keep pressing the differential lock switch approx. 2 seconds to turn it ON 10 to 14 → 2 or less F9-1 (GND) - Body ground F9-24 (L4) - F9-1 (GND) F10-1 (HM1) - F9-1 (GND) 10 to 14 Ignition switch OFF 10 to 14 (for about 5 seconds) then less than 0.5 Continuity • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 to 14 → 2 or less • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 to 14 → 2 or less TF–48 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM Terminals (Symbols) F10-4 (HM2) - F9-1 (GND) 14 F10-17 (HL1) - F9-1 (GND) TF F10-26 (HL2) - F9-1 (GND) Condition STD Voltage (V) • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 2 or less → 10 to 14 • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 10 to 14 → 2 or less • • Ignition switch ON Four wheel drive control switch "H4" position → Four wheel drive control switch "L4" position 2 or less → 10 to 14 PR–6 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 2WD) (f) 2. PR • Must use retainer rings of the same thickness as possible on both ends. Using a hammer, tap the yoke until there is no clearance between the spider bearing outer race and snap ring. HINT: Install a new spider bearing on the sleeve side in the procedure described above. INSPECT REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING INSTALLATION SST 1. INSTALL PROPELLER SHAFT ASSEMBLY (a) Remove the SST from the extension housing. SST 09325-40010 (b) Install the propeller shaft assembly in the extension housing. C098710E03 (c) Align the matchmarks on the propeller shaft flange and differential flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) Matchmarks C098711E02 PR–10 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) INSPECTION C061260 1. INSPECT PROPELLER SHAFT ASSEMBLY (a) Using a dial indicator, check the propeller shaft runout. Maximum runout: 0.3 mm (0.012 in.) If the shaft runout is greater than maximum, replace the shaft. 2. INSPECT REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear or damage. (b) Check the spider bearing axial play by turning the yoke with holding the shaft tightly. Maximum bearing axial play: 0 mm(0 in.) If necessary, replace the spider bearing. PR REASSEMBLY 1. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Apply MP grease No. 2 to a new spider and bearings. (b) Fit the spider into the flange yoke. C060598 (c) Using SST, install the bearings on the spider. SST 09332-25010 (d) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in width. SST 09332-25010 SST C063061E04 (e) Install new 4 snap rings of equal thickness which will allow no axial play. HINT: Do not reuse the snap rings. Thickness of snap ring (Both ends thin type) G020755 Parts No. Thickness mm (in.) Mark 90520-25039 2.28 to 2.30 1 90520-25040 2.30 to 2.32 2 90520-25041 2.32 to 2.34 - 90520-25042 2.34 to 2.36 Brown 90520-25043 2.36 to 2.38 Blue 90520-25044 2.38 to 2.40 6 90520-25045 2.40 to 2.42 7 90520-25046 2.42 to 2.44 8 PR–11 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) Parts No. Thickness mm (in.) 90520-25047 2.44 to 2.46 90520-25048 2.46 to 2.48 10 90520-25049 2.48 to 2.50 A 90520-25050 2.50 to 2.52 B 90520-25051 2.52 to 2.54 C 90520-25052 2.54 to 2.56 D 90520-25053 2.56 to 2.58 E 90520-25054 2.18 to 2.20 J 90520-25055 2.20 to 2.22 K 90520-25056 2.22 to 2.24 F 90520-25057 2.24 to 2.26 G 90520-25058 2.26 to 2.28 H (f) SST Mark NOTICE: • Must use a new retainer ring. • Must use retainer rings of the same thickness as possible on both ends. Using a hammer, tap the yoke until there is no clearance between the spider bearing outer race and snap ring. HINT: Install a new spider bearing on the sleeve side in the procedure described above. 2. INSTALL REAR PROPELLER SHAFT SLIDING SHAFT DUST COVER SUB-ASSEMBLY (a) Using SST and press, press in a new dust cover. NOTICE: Place the universal joint straight when pressing in the dust cover. Apply MP grease to the "A" part. 3. INSTALL RR PROPELLER SHAFT UNIVERSAL JOINT SLEEVE YOKE SUB-ASSEMBLY (a) Install the grease fitting to the universal joint sleeve yoke. (b) Apply MP grease to the propeller shaft spline and sleeve yoke sliding surface. (c) Align the matchmarks on the sleeve yoke propeller shaft. (d) Install the propeller shaft into the sleeve yoke. 4. INSPECT REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (A) D003049E01 Matchmarks G022296E02 PR PR–12 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) 5. INSPECT PROPELLER SHAFT ASSEMBLY HINT: When replacing the spider bearing, be sure that the grease fitting assembly hole is facing to the direction shown in the illustration. SPIDER GREASE FITTING ASSEMBLY DIRECTION FOR PROPELLER SHAFT ASSEMBLY Rear Side PR G022300E02 INSTALLATION 1. INSTALL PROPELLER SHAFT ASSEMBLY (a) Align the matchmarks on the propeller shaft flange and differential flange. (b) Install the propeller shaft assembly with the 4 bolts, 4 nuts and 4 washers. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) Matchmarks C098700E04 (c) Align the matchmarks on the propeller shaft flange and transfer flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) Matchmarks C098699E04 PR–16 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY INSPECTION C029928 1. INSPECT FRONT PROPELLER SHAFT ASSEMBLY (a) Using a dial indicator, check the propeller shaft runout. Maximum runout: 0.3 mm (0.012 in.) If the shaft runout is greater than maximum, replace the propeller shaft. 2. INSPECT FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear or damage. (b) Check the spider bearing axial play by turning the yoke with holding the shaft tightly. Maximum bearing axial play: 0 mm (0 in.) If necessary, replace the spider bearing. PR REASSEMBLY 1. INSTALL FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Apply MP grease No. 2 to a new spider and spider bearing. (b) Fit the spider into the flange yoke. Z004248 (c) Using SST, install the spider bearings on the spider. SST 09332-25010 (d) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in width. SST 09332-25010 SST C063061E06 (e) Install 4 new snap rings of equal thickness which will allow no axial play. HINT: Do not reuse the snap rings. Thickness of snap ring G020755 Parts No. Thickness mm (in.) Mark 90520-25039 2.28 to 2.30 1 90520-25040 2.30 to 2.32 2 90520-25041 2.32 to 2.34 - 90520-25042 2.34 to 2.36 Brown 90520-25043 2.36 to 2.38 Blue 90520-25044 2.38 to 2.40 6 90520-25045 2.40 to 2.42 7 90520-25046 2.42 to 2.44 8 PR–17 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY Parts No. Thickness mm (in.) Mark 90520-25047 2.44 to 2.46 90520-25048 2.46 to 2.48 10 90520-25049 2.48 to 2.50 A 90520-25050 2.50 to 2.52 B 90520-25051 2.52 to 2.54 C 90520-25052 2.54 to 2.56 D 90520-25053 2.56 to 2.58 E 90520-25054 2.18 to 2.20 J 90520-25055 2.20 to 2.22 K 90520-25056 2.22 to 2.24 F 90520-25057 2.24 to 2.26 G 90520-25058 2.26 to 2.28 H NOTICE: • Must use a new retainer ring. • Must use retainer rings of the same thickness as possible on both ends. (f) Using a hammer, tap the yoke until there is no clearance between the spider bearing outer race and snap ring. HINT: Install a new spider bearing on the sleeve side in the procedure described above. (g) Align the matchmarks on the flange yoke and the sleeve yoke. Hammering Point G022297E04 SST F044258E03 (h) Using SST, install the spider bearings on the spider. SST 09332-25010 (i) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in width. SST 09332-25010 (j) Install new 4 snap rings of equal thickness which will allow no axial play. HINT: Do not reuse the snap rings. Thickness of snap ring Parts No. Thickness mm (in.) Mark 90520-25039 2.28 to 2.30 1 90520-25040 2.30 to 2.32 2 90520-25041 2.32 to 2.34 - 90520-25042 2.34 to 2.36 Brown 90520-25043 2.36 to 2.38 Blue 90520-25044 2.38 to 2.40 6 90520-25045 2.40 to 2.42 7 90520-25046 2.42 to 2.44 8 PR PR–18 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY PR Parts No. Thickness mm (in.) Mark 90520-25047 2.44 to 2.46 90520-25048 2.46 to 2.48 10 90520-25049 2.48 to 2.50 A 90520-25050 2.50 to 2.52 B 90520-25051 2.52 to 2.54 C 90520-25052 2.54 to 2.56 D 90520-25053 2.56 to 2.58 E 90520-25054 2.18 to 2.20 J 90520-25055 2.20 to 2.22 K 90520-25056 2.22 to 2.24 F 90520-25057 2.24 to 2.26 G 90520-25058 2.26 to 2.28 H NOTICE: • Must use a new retainer ring. • Must use retainer rings of the same thickness as possible on both ends. (k) Using a plastic hammer, tap the yoke until there is no clearance between the spider bearing outer race and snap ring. HINT: Install a new spider bearing on the sleeve side in the procedure described above. Hammering Point SST G022298E02 2. INSTALL FRONT PROPELLER SHAFT SLIDING SHAFT DUST COVER SUB-ASSEMBLY (a) Using SST and press, press in a new dust cover. SST 09636-20010 NOTICE: Place the universal joint straight when pressing in the dust cover. Apply MP grease to the "A" part. 3. INSTALL FR PROPELLER SHAFT UNIVERSAL JOINT SLEEVE YOKE SUB-ASSEMBLY (a) Install the grease fitting to the universal joint sleeve yoke. (b) Apply MP grease to the propeller shaft spline and sleeve yoke sliding surface. (c) Align the matchmarks on the sleeve yoke propeller shaft. (d) Install the propeller shaft into the sleeve yoke. 4. INSPECT FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING A D003049E02 Matchmarks G022296E05 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY 5. PR–19 INSPECT PROPELLER SHAFT ASSEMBLY HINT: When replacing the spider bearing, be sure that the grease fitting assembly hole is facing to the direction shown in the illustration. SPIDER GREASE FITTING ASSEMBLY DIRECTION FOR PROPELLER SHAFT ASSEMBLY FRONT Rear Side PR C098696E03 INSTALLATION 1. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (a) Align the matchmarks on the yoke and differential flange. (b) Install the propeller shaft assembly with the 4 bolts, 4 nuts and 4 washers. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) Matchmarks C098708E06 Matchmarks C098709E05 (c) Align the matchmarks on the yoke and transfer flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) PR–1 PROPELLER SHAFT – PROPELLER SHAFT SYSTEM PROPELLER SHAFT SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. PROPELLER SHAFT Symptom Noise Vibration Suspected area See page 1. Spider bearing (Worn or stuck) (2WD) PR-4 2. Spider bearing (Worn or stuck) (4WD) PR-10 1. Propeller shaft (Runout) (2WD) PR-4 2. Propeller shaft (Runout) (4WD) PR-10 3. Propeller shaft (Imbalance) - PR PR–2 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 2WD) PROPELLER SHAFT ASSEMBLY (for 2WD) DRIVE LINE SHAFT PROPELLER COMPONENTS PR 88 (897, 65) SPIDER BEARING SNAP RING x4 x4 x4 x4 SPIDER BEARING x4 SNAP RING SPIDER x4 UNIVERSAL JOINT FLANGE YOKE PROPELLER SHAFT ASSEMBLY SPIDER UNIVERSAL JOINT SLEEVE YOKE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part MP grease No. 2 C131367E01 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 2WD) PR–3 REMOVAL 1. REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange. (b) Remove the 4 nuts and 4 washers. Matchmarks C098711E01 (c) Remove the propeller shaft. (d) Insert SST in the transmission to prevent oil leakage. SST 09325-40010 SST C098710E02 DISASSEMBLY Matchmarks 1. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Place matchmarks on the flange yoke and sleeve yoke. F015023E06 (b) Using a brass bar and a hammer, slightly tap in the spider bearing outer races. (c) Using 2 screwdrivers, remove the 4 snap rings from the grooves. C061264 (d) Using SST, push out the spider bearing from the propeller shaft. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the spider bearing. SST (A) F015025E06 PR PR–4 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 2WD) (e) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the spider bearing on opposite side in the same procedure. NOTICE: Do not tap the shaft. Hammering Point F044192E03 (f) Install the 2 removed spider bearing outer races to the spider. (g) Using SST, push out the bearing from the yoke. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the bearing. PR (A) SST F015030E05 (h) Clamp the outer bearing race in a vise and tap off the yoke with a hammer. (i) Remove the spider. Hammering Point F044193E04 INSPECTION C061260 1. INSPECT PROPELLER SHAFT ASSEMBLY (a) Using a dial indicator, check the propeller shaft runout. Maximum runout: 0.3 mm (0.012 in.) If the shaft runout is greater than maximum, replace the shaft. 2. INSPECT REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Check the spider bearings for wear or damage. (b) Check the spider bearing axial play by turning the yoke with holding the shaft tightly. Maximum bearing axial play: 0 mm (0 in.) If necessary, replace the spider bearing. PR–5 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 2WD) REASSEMBLY 1. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Apply MP grease No. 2 to a new spider and bearings. (b) Fit the spider into the flange yoke. C060598 (c) Using SST, install the bearings on the spider. SST 09332-25010 (d) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in width. SST 09332-25010 SST C063061E03 (e) Install new 4 snap rings of equal thickness which will allow no axial play. HINT: Do not reuse the snap rings. Thickness of snap ring (Both ends thin type) G020755 Parts No. Thickness mm (in.) Mark 90520-25039 2.28 to 2.30 1 90520-25040 2.30 to 2.32 2 90520-25041 2.32 to 2.34 - 90520-25042 2.34 to 2.36 Brown 90520-25043 2.36 to 2.38 Blue 90520-25044 2.38 to 2.40 6 90520-25045 2.40 to 2.42 7 90520-25046 2.42 to 2.44 8 90520-25047 2.44 to 2.46 90520-25048 2.46 to 2.48 10 90520-25049 2.48 to 2.50 A 90520-25050 2.50 to 2.52 B 90520-25051 2.52 to 2.54 C 90520-25052 2.54 to 2.56 D 90520-25053 2.56 to 2.58 E 90520-25054 2.18 to 2.20 J 90520-25055 2.20 to 2.22 K 90520-25056 2.22 to 2.24 F 90520-25057 2.24 to 2.26 G 90520-25058 2.26 to 2.28 H NOTICE: • Must use a new retainer ring. PR PR–7 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) PROPELLER SHAFT ASSEMBLY (for 4WD) DRIVE LINE SHAFT PROPELLER COMPONENTS PR 88 (897, 65) SPIDER BEARING x4 x4 x4 x4 SNAP RING x4 88 (897, 65) SPIDER BEARING x4 x4 SNAP RING SPIDER x4 x4 PROPELLER SHAFT ASSEMBLY DUST COVER SPIDER UNIVERSAL JOINT SLEEVE YOKE GREASE FITTING UNIVERSAL JOINT FLANGE YOKE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part MP grease MP grease No. 2 C131577E01 PR–8 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) REMOVAL 1. REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and transfer flange. (b) Remove the 4 nuts, 4 washers and propeller shaft assembly. Matchmarks C098699E03 (c) Place matchmarks on the propeller shaft flange and differential flange. (d) Remove the 4 nuts, 4 bolts and 4 washers. PR Matchmarks C098700E03 DISASSEMBLY Matchmarks 1. REMOVE RR PROPELLER SHAFT UNIVERSAL JOINT SLEEVE YOKE SUB-ASSEMBLY (a) Place matchmarks on the propeller shaft and sleeve yoke. (b) Remove the sleeve yoke from the propeller shaft. (c) Remove the grease fitting from the universal joint sleeve yoke. 2. REMOVE REAR PROPELLER SHAFT SLIDING SHAFT DUST COVER SUB-ASSEMBLY (a) Cut the dust cover spirally at the pressing-in part with a saw and pry it off with a chisel. NOTICE: Do not damage the propeller shaft. If damage, replace the shaft with a new one. 3. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (a) Place matchmarks on the flange yoke and sleeve yoke. G022296E01 1.2 mm (0.047 in.) 19.5 mm (0.768 in.) D003048E02 Matchmarks F015023E08 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY (for 4WD) PR–9 (b) Using a brass bar and a hammer, slightly tap in the spider bearing outer races. (c) Using 2 screwdrivers, remove the 4 snap rings from the grooves. C061264 (d) Using SST, push out the spider bearing from the propeller shaft. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the spider bearing. SST (A) F015025E07 Hammering Point (e) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the spider bearing on opposite side in the same procedure. NOTICE: Do not tap the shaft. F044192E04 (f) Install the 2 removed spider bearing outer races to the spider. (g) Using SST, push out the bearing from the yoke. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the bearing. (A) SST F015030E06 (h) Clamp the outer bearing race in a vise and tap off the yoke with a hammer. (i) Remove the spider. Hammering Point F044193E05 PR PR–13 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY FRONT PROPELLER SHAFT ASSEMBLY DRIVE LINE SHAFT PROPELLER COMPONENTS PR UNIVERSAL JOINT FLANGE YOKE 88 (897, 65) SPIDER BEARING SNAP RING 88 (897, 65) UNIVERSAL SLEEVE FLANGE YOKE x4 x4 x4 x4 SPIDER BEARING x4 x4 x4 SPIDER SNAP RING x4 x4 DUST COVER GREASE FITTING FRONT PROPELLER SHAFT ASSEMBLY SPIDER UNIVERSAL JOINT FLANGE YOKE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part MP grease MP grease No. 2 C131366E01 PR–14 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY REMOVAL 1. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential. (b) Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly. Matchmarks C098708E05 (c) Place matchmarks on the propeller shaft flange and transfer flange. (d) Remove the 4 nuts, 4 washers and front propeller shaft assembly. PR Matchmarks C098709E04 DISASSEMBLY Matchmarks 1. REMOVE FR PROPELLER SHAFT UNIVERSAL JOINT SLEEVE SUB-ASSEMBLY (a) Place matchmarks on the propeller shaft and sleeve yoke. (b) Remove the sleeve yoke from the propeller shaft. (c) Remove the grease fitting from the universal joint sleeve yoke. 2. REMOVE FRONT PROPELLER SHAFT SLIDING SHAFT DUST COVER SUB-ASSEMBLY (a) Cut the dust cover spirally at the pressing-in part with a saw and pry it off with a chisel and a hammer. NOTICE: Do not damage the propeller shaft. If damage, replace the shaft with a new one. 3. REMOVE FRONT UNIVERSAL JOINT SPIDER BEARING (a) Place matchmarks on the flange yoke and sleeve yoke. G022296E04 1.2 mm (0.047 in.) 19.5 mm (0.768 in.) D003048E03 Matchmarks F015023E09 PROPELLER SHAFT – FRONT PROPELLER SHAFT ASSEMBLY PR–15 (b) Using a brass bar and a hammer, slightly tap in the spider bearing outer races. (c) Using 2 screwdrivers, remove the 4 snap rings from the grooves. C061264 (d) Using SST, push out the spider bearing from the propeller shaft. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the spider bearing. SST (A) F015025E08 Hammering Point (e) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the bearing on opposite side in the same procedure. NOTICE: Do not tap the shaft. F044192E05 (f) Install the 2 removed spider bearing outer races to the spider. (g) Using SST, push out the bearing from the yoke. SST 09332-25010 HINT: Sufficiently raise the part indicated by (A) so that it does not come into contact with the bearing. (A) SST F015030E07 (h) Clamp the outer bearing race in a vise and tap off the flange yoke with a hammer. (i) Remove the spider. Hammering Point F044193E06 PR DS–4 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY REMOVAL DS 1. REMOVE FRONT WHEEL 2. DRAIN DIFFERENTIAL OIL (See page DF-3) 3. REMOVE FRONT AXLE HUB LH NUT (a) Remove the cotter pin and a adjusting cap. (b) Remove the front axle hub LH nut. 4. SEPARATE FRONT SPEED SENSOR (a) Using a hexagon wrench, separate the front speed sensor. (b) Disengage the 2 clamps. (c) Remove the bolt and separate the speed sensor wire harness from the steering knuckle. 5. SEPARATE TIE ROD END SUB-ASSEMBLY LH (a) Remove the cotter pin and nut. F042732 F042730 (b) Using SST, separate the tie rod end from the steering knuckle. SST 09628-62011 F042735 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–5 6. SEPARATE NO. 1 FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY (a) Remove the 2 bolts and separate the No. 1 front suspension lower arm sub-assembly from the steering knuckle. 7. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Using SST, remove the front drive shaft. SST 09520-01010, 09520-24010 (09520-32040) NOTICE: Be careful not to damage the oil seal. F042737 SST 8. F042739E01 REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT: Remove the RH side by the same procedure with LH side. SST 09520-01010, 09520-24010 (09520-32040) DISASSEMBLY 1. REMOVE FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Using a screwdriver, disclamp the inboard joint boot clamp. (b) Using the same manner to the inboard joint small boot clamp. 2. SEPARATE INBOARD JOINT BOOT 3. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Place matchmarks on the tripod, inboard and outboard joint shafts. NOTICE: Do not punch the marks. (b) Remove the inboard joint from the outboard joint shaft. F043637 Matchmarks FA01615E03 (c) Using a snap ring expander, remove the snap ring. G022501 DS DS–6 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (d) Place matchmarks on the outboard joint shaft and tripod. NOTICE: Do not punch the marks. (e) Using a brass bar and hammer, remove the tripod from the drive shaft. NOTICE: Do not tap the roller. Matchmarks N000194E02 4. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Using a screwdriver, disclamp the inboard joint boot clamps. HINT: If the outboard joint boot clamps that have been replaced are installed to the drive shaft, use a side cutter to remove them. (b) Using the same manner to the outboard joint small boot clamp. 5. REMOVE OUTBOARD JOINT BOOT 6. REMOVE FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING (a) Using a screwdriver, remove the snap ring. 7. REMOVE FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, remove the dust cover. SST 09950-00020 DS C063445 C057543 SST F040647E01 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY 8. DS–7 REMOVE STEERING KNUCKLE LH OIL SEAL (a) Using a screwdriver and a hammer, remove the oil seal. C034791 INSPECTION 1. F052122 INSPECT FRONT DRIVE SHAFT ASSEMBLY (a) Check whether there is no remarkable play in the outboard joint. (b) Check whether the inboard joint slides smoothly in the thrust direction. (c) Check whether there is no remarkable play in the radial direction of the inboard joint. (d) Check the boots for damage. NOTICE: Move the drive shaft while keeping it level. REASSEMBLY 1. INSTALL STEERING KNUCKLE OIL SEAL (a) Using a screwdriver and a hammer, install a new oil seal. NOTICE: Do not damage the oil seal. 2. INSTALL FRONT DRIVE SHAFT DUST COVER (a) Using SST and a press, install a new dust cover. SST 09527-10011 3. INSTALL FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING (a) Install a new snap ring. 4. INSTALL OUTBOARD JOINT BOOT HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged. (a) Temporary install a new outboard joint boot with 2 new clamps onto the outboard joint shaft. C034792 SST F041033E01 Vinyl Tape W001994E07 DS DS–8 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (b) Pack the outboard joint assembly and boot with grease in the boot kit. Grease capacity: 260 to 270 g (9.2 to 9.5 oz.) 5. SST DS INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (a) Mount drive shaft in a soft vice. (b) Sure the outboard joint boot clamps onto the boot. (c) Place SST onto the outboard joint large boot clamp. SST 09521-24010 (d) Tighten the SST so that the large clamp is pinched. NOTICE: Do not overtighten the SST. F052126E01 (e) Using SST, adjust the clearance of the large clamp. SST 09240-00020 Clearance: 0.8 mm (0.031 in.) or less (f) Employ the same manner to the outboard joint small boot clamp. SST 6. INSTALL INBOARD JOINT BOOT (a) Provisionally install a new inboard joint boot the outboard joint shaft. 7. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (a) Place the beveled side of the tripod axle spline toward the inboard joint. (b) Align the matchmarks and install the tripod into the inboard joint. (c) Using a brass bar and hammer, tap the tripod into the drive shaft. NOTICE: Do not tap the roller. (d) Pack the inboard joint assembly and boot with grease in the boot kit. Grease capacity: 231 to 241 g (8.1 to 8.5 oz.) F052127E01 Beveled Matchmarks C067417E02 (e) Using a snap ring expander, install a new snap ring. G022501 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY DS–9 8. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP (a) Bend the band and lock a new inboard joint large boot clamp with a screwdriver. (b) Using the same manner to the inboard joint small boot clamp. 9. INSPECT FRONT DRIVE SHAFT ASSEMBLY (a) Check whether there is no remarkable play in the outboard joint. (b) Check whether the inboard joint slides smoothly in the thrust direction. (c) Check whether there is no remarkable play in the radial direction of the inboard joint. (d) Check the boots for damage. NOTICE: Move the drive shaft while keeping it level. C083397 F052122 INSTALLATION 1. F042771 INSTALL FRONT DRIVE SHAFT ASSEMBLY (a) Coat the spline of the inboard joint shaft assembly with ATF. (b) Align the shaft splines and install the drive shaft with a brass bar and hammer. NOTICE: • Set the snap ring with the opening side facing downward. • Be careful not to damage the oil seal. HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be confirmed from the sound or feeling when driving it. DS DS–10 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY 2. INSTALL FRONT SPEED SENSOR (a) Install the speed sensor wire harness to the steering knuckle with a bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the 2 clips. (c) Using a hexagon wrench, install the speed sensor with the bolt. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 3. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY (a) Install the No. 1 front suspension lower ball joint attachment with the 2 bolts. Torque: 160 N*m (1,631 kgf*cm, 118 ft.*lbf) 4. INSTALL TIE ROD END SUB-ASSEMBLY (a) Install the tie rod end onto the steering knuckle. (b) Install the nut. Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf) (c) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, tighten the nut further to 60°. 5. INSTALL FRONT AXLE HUB LH NUT (a) Install the hub nut. Torque: 294 N*m (3,000 kgf*cm, 217 ft.*lbf) (b) Install a new cotter pin and adjusting cap. 6. FILL UP DIFFERENTIAL OIL (See page DF-3) 7. INSPECT DIFFERENTIAL OIL (See page DF-3) 8. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) DS F042730 F042737 F043604 F042732 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY 9. DS–11 CHECK VSC SENSOR SIGNAL HINT: (See page BC-23) DS DS–1 DRIVE SHAFT – DRIVE SHAFT SYSTEM DRIVE SHAFT SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Front wheel shimmy Suspected area Front drive shaft (worn) See page DS-6 DS DS–2 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY DRIVE SHAFT LINE COMPONENTS DS FRONT DRIVE SHAFT ASSEMBLY 8.3 (85, 73 in.*lbf) 13 (133, 10) SPEED SENSOR FRONT LH FRONT AXLE HUB LH NUT COTTER PIN 294 (3,000, 217) 91 (928, 67) ADJUSTING CAP TIE ROD END SUB-ASSEMBLY COTTER PIN 160 (1, 630, 118) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131368E01 DS–3 DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY SUPPLY PARTS: FRONT DRIVE INNER SHAFT OUTER SHAFT SNAP RING FRONT DRIVE SHAFT DUST COVER FRONT AXLE OUTBOARD JOINT BOOT CLAMP FRONT DRIVE INBOARD JOINT ASSEMBLY DS SNAP RING FRONT AXLE OUTBOARD JOINT BOOT CLAMP TRIPOD INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP OUTBOARD JOINT BOOT FRONT DRIVE OUTBOARD JOINT ASSEMBLY STEERING KNUCKLE LH OIL SEAL Non-reusable part C131567E01 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL DF–7 INSTALLATION 1. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new rear differential drive pinion bearing spacer. 2. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using a brass bar and a hammer, install a new oil storage ring. (b) Using SST and a hammer, install the front bearing outer race. (c) Install the front bearing. SST 09316-60011 (09316-00011, 09316-00021) 3. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 4. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST 09554-30011 Oil seal drive in depth: 0.7 to 1.3 mm (0.0276 to 0.0512 in.) (b) Coat oil seal lip with MP grease. 5. INSTALL REAR DRIVE COMPANION FLANGE SUBASSEMBLY REAR (a) Using SST, install the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) (b) Coat the threads of a new nut with hypoid gear oil LSD. SST F040719E02 SST F040716E02 SST C088916E02 (c) Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) Torque: 215 N*m (2,190 kgf*cm, 159 ft.*lbf) DF DF–8 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL 6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring rear. New bearing: 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) Reused bearing: 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) If necessary, disassemble and inspect the differential assembly. 7. INSTALL REAR DRIVE PINION NUT (a) Using a chisel and a hammer, stake the nut. 8. INSTALL PROPELLER SHAFT ASSEMBLY (a) Align the matchmarks on the propeller shaft differential flange. (b) 2WD Drive Type: Install the propeller shaft with the 4 washers and 4 nuts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) (c) 4WD Drive Type: Install the propeller shaft with the 4 bolts, 4 washers and 4 nuts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 9. FILL UP DIFFERENTIAL OIL (See page DF-3) C089308 DF C089310 Matchmarks C060588E02 10. INSPECT DIFFERENTIAL OIL (See page DF-3) DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–15 REMOVAL 1. REMOVE FRONT WHEELS 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY (a) Remove the 6 bolts and engine under cover assembly. 3. REMOVE NO.1 ENGINE UNDER COVER SUBASSEMBLY (a) Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See page DF-3) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-14) 6. REMOVE FRONT AXLE HUB LH NUT (See page AH14) 7. REMOVE FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side. 8. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page SP-28) 9. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure as for the LH side. 10. SEPARATE FRONT SPEED SENSOR LH (See page BC-211) 11. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 12. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See page PS-20) 13. SEPARATE TIE ROD END SUB-ASSEMBLY RH (See page PS-20) 14. REMOVE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page SP-22) 15. REMOVE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER RH HINT: Use the same procedure as for the LH side. 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-5) 17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-5) DF DF–16 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) C097020E05 18. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the bolt and separate the front differential breather tube bracket. (b) Support the front differential with a jack. (c) Remove the front differential mount nut No. 1. (d) Remove the 2 front mounting bolts and 2 nuts. (e) Disconnect the actuator hose and connector. (f) Lower the jack and remove the front differential assembly. (g) Remove the 2 bolts and No. 3 front differential support. (h) Remove the 5 bolts and 2 front differential supports. DISASSEMBLY DF 1. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Remove the 4 bolts. (b) Using a hammer, handle, remove the actuator assembly. 2. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove the 4 bolts. (b) Using a plastic hammer, remove the differential tube. 3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 G023135 G023134 SST R013209E01 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–17 4. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (a) Using SST, remove the side gear inter shaft. SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011) (b) Remove the snap ring from the side gear inter shaft. 5. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST and a hammer, remove the nut. SST 09930-00010 SST G023136E02 SST F044234E01 (b) Using SST to hold the companion flange, remove the nut. SST 09330-00021 (09330-00030) SST SA02349E05 (c) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) SST F052175E01 6. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal from the differential carrier assembly. SST 09308-10010 7. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER SST SA02348E03 DF DF–18 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 8. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 (b) Remove the bearing spacer. 9. REMOVE DIFFERENTIAL SIDE BEARING RETAINER (a) Using a screwdriver, remove the union. (b) Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer. SST Z000641E04 10. REMOVE DIFFERENTIAL CASE ASSEMBLY 11. REMOVE DIFFERENTIAL DRIVE PINION 12. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and a press, remove the front bearing and washer from the drive pinion. SST 09950-00020 HINT: If the drive gear or ring gear is damaged, replace them as a set. DF SST R002482E02 13. REMOVE FRONT BEARING OUTER RACE (a) Using a brass bar and a hammer, remove the front bearing outer race. R013226 14. REMOVE REAR BEARING OUTER RACE (a) Using SST, remove the rear bearing outer race. SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) (b) Using a brass bar and a hammer, remove the oil storage ring. SST F044257E01 15. REMOVE SIDE BEARING OUTER RACE HINT: • Measure the plate washer and note its thickness. • Tag the bearing outer races to show the location for reassembly. DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–19 (a) Using SST and a press, remove the outer race and plate washer from the bearing retainer. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) SST R013211E01 (b) Using SST and a press, remove the outer race and plate washer from the differential carrier assembly. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) SST R013213E01 SST SST R011392E02 RA00997 16. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case assembly. (b) Remove the 10 bolts. (c) Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly. 17. REMOVE FRONT DIFFERENTIAL CASE BEARING (a) Using SST, remove the 2 differential case bearings from the differential case assembly. SST 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) HINT: Fix the claws of SST into the notch in the differential case assembly. 18. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and a hammer, remove the straight pin. (b) Remove these parts from the differential case assembly. (1) 2 Differential side gears (2) 2 Differential side gear thrust washers (3) Differential pinion shaft (4) 2 Differential pinion gears (5) 2 Differential pinion gear thrust washers 19. INSPECT DIFFERENTIAL GEAR KIT (a) Check that there is no damage to the pinion gear and side gear. If the pinion gear and/or side gear is damaged, replace the differential gear kit. 20. INSPECT FRONT DIFFERENTIAL CASE (a) Check that the differential case assembly is not damaged. If the differential case assembly is damaged, replace it. DF DF–20 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 21. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING (a) Using a brass bar and hammer, remove the 2 bearings. SA00353 22. REMOVE DIFFERENTIAL CLUTCH HUB (a) Using a snap ring expander, remove the snap ring. (b) Remove the differential clutch hub. DF G023137 23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, remove the oil seal from the differential tube. SST 09308-00010 SST R013199E01 24. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUBASSEMBLY RH (a) Using a snap ring expander, remove the snap ring. (b) Remove the side gear shaft from the differential tube. C097022 25. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using a snap ring expander, remove the snap ring. (b) Using SST, a brass bar and a press, remove the bearing. SST 09950-00020 NOTICE: Do not damage the bearing. SST R013420E02 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–21 26. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR (a) Using SST, a socket wrench and a press, remove the dust deflector. SST 09950-00020 SST R004465E01 27. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB (a) Check for wear and damage to the clutch hub and clutch sleeve. If necessary, replace them. (b) Check that the clutch sleeve slides smoothly on the clutch hub. G023141 28. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT (a) Check for wear and damage to the clutch hub and side gear inter shaft. (b) Check that the clutch sleeve slides smoothly on the side gear inter shaft. G023144 29. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE (a) Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve. Maximum clearance: 0.35 mm (0.0138 in.) If the clearance exceeds the maximum, replace the fork or clutch sleeve. G023142 INSPECTION 1. SST R012683E03 INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.11 to 0.18 mm (0.0043 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. DF DF–22 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 2. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Torque: 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If necessary, disassemble and inspect the differential assembly. 3. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.20 to 0.63 N*m (2.0 to 6.4 kgf*cm, 1.8 to 5.6 in.*lbf) If necessary, disassemble and inspect the differential. FA01158 DF REASSEMBLY 1. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR (a) Using a steel plate and a press, install a new dust deflector. NOTICE: Do not damage the dust deflector. 2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using SST and a press, install the bearing. SST 09223-00010 (b) Using a snap ring expander, install the snap ring. 3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUBASSEMBLY RH (a) Install the side gear shaft into the differential tube. (b) Using snap ring pliers, install the snap ring. Steel Plate G022166E01 SST R013421E02 C097022 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–23 4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic hammer, install a new oil seal. SST 09608-32010 Oil seal drive in depth: 4.8 to 5.8 mm (0.1890 to 0.2284 in.) (b) Coat the oil seal lip with MP grease. 5. INSTALL DIFFERENTIAL CLUTCH HUB (a) Install the clutch hub onto the side gear inter shaft. (b) Using snap ring pliers, install the snap ring. NOTICE: Be sure to install the differential clutch hub in the correct direction. SST R013419E01 G023138 6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING (a) Using SST and a press, install 2 new bearings. SST 09950-60010 (09951-00380) Bearing press in depth: 1.4 to 2.0 mm (0.055 to 0.079 in.) 7. INSTALL FRONT DIFFERENTIAL CASE (a) Install the 2 proper thrust washers onto the 2 side gears. HINT: Using the table below, select the thrust washer which will ensure that the backlash is within the specifications. Washer thickness SST SA00355E02 FA01121 Thickness mm (in.) Thickness mm (in.) 1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0681 to 0.0697) 1.53 to 1.57 (0.0602 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0717) 1.58 to 1.62 (0.0622 to 0.0638) 1.83 to 1.87 (0.0720 to 0.0736) 1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0740 to 0.0756) 1.68 to 1.72 (0.0661 to 0.0677) - (b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly. HINT: Align the holes of the differential case assembly and pinion shaft. DF DF–24 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (c) Measure the side gear backlash. (1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly. Backlash: 0 to 0.15 mm (0 to 0.0059 in.) If the backlash is not within the specification, install a side gear thrust washer with a different thickness. F043636 (d) Using a pin punch and hammer, install the straight pin through the differential case assembly and hole of the pinion shaft. (e) Stake the differential case assembly. DF FA01124 8. INSTALL DIFFERENTIAL RING GEAR (a) Clean the contact surfaces of the differential case assembly and ring gear. (b) Heat the ring gear to about 100°C (212°F) in boiling water. (c) Carefully take the ring gear out of the boiling water. (d) After any moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case assembly. HINT: Align the matchmarks on the ring gear and differential case assembly. (e) Temporarily install 10 bolts so that the bolt holes in the ring gear and differential case assembly are aligned. (f) After the ring gear has cooled sufficiently, tighten the ring gear set bolts to which thread lock has been applied. Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf) Thread lock: Part No. 08833-00100, THREE BOND 1360k or equivalent 9. INSTALL FRONT DIFFERENTIAL CASE BEARING (a) Using SST and a press, install the 2 differential case bearings into the differential case assembly. SST 09226-10010 Boiling Water SA02160E02 SST R013784E01 10. INSTALL SIDE BEARING OUTER RACE HINT: When replacing the 2 differential case bearings, fit 2 of the thinnest new washers to each bearing and when reusing the bearings, fit washers of the same thickness as those removed. DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–25 (a) Install a new plate washer to the side bearing retainer. (b) Using SST and a press, install the bearing outer race onto the differential case bearing retainer assembly. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) (c) Install a new plate washer onto the differential carrier assembly. SST R013375E02 (d) Using SST and a press, install the bearing outer race onto the differential carrier assembly. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) SST R013376E02 11. INSTALL FRONT BEARING OUTER RACE (a) Using SST, install the outer race. SST 09950-00020 (09951-00680, 09951-00890) SST Front: 12. INSTALL REAR BEARING OUTER RACE (a) Install the oil storage ring. (b) Using SST, install the outer race. SST 09950-00020 (09951-00680, 09951-00890) 13. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Install the washer onto the drive pinion. HINT: First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary. Rear: R013281E02 DF DF–26 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (b) Using SST and a press, install the front bearing onto the drive pinion. SST 09506-30012 SST 14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Install the drive pinion. HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern. R001197E01 (b) Using SST, install the rear bearing, oil slinger and companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) (c) Coat the threads of the nut with hypoid gear oil. SST DF SST R011163E05 (d) Adjust the drive pinion preload by tightening the companion flange nut. (e) Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. SST SA02347E03 (f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) Bearing Standard New 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) Reused 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If necessary, disassemble and inspect the differential assembly. SA02352 15. INSTALL DIFFERENTIAL CASE ASSEMBLY 16. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Install the side bearing retainer with the 10 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) SST R012683E03 DF–27 (b) Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.11 to 0.18 mm (0.0043 to 0.0071 in.) (c) If it is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount. HINT: There should be no clearance between the plate washer and differential case. Make sure that there is ring gear backlash. Washer thickness Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.59 to 1.61 (0.0626 to 0.0634) 1.89 to 1.91 (0.0744 to 0.0752) 2.19 to 2.21 (0.0862 to 0.0870) 1.62 to 1.64 (0.0638 to 0.0646) 1.92 to 1.94 (0.0756 to 0.0764) 2.22 to 2.24 (0.0874 to 0.0882) 1.65 to 1.67 (0.0650 to 0.0657) 1.95 to 1.97 (0.0768 to 0.0776) 2.25 to 2.27 (0.0886 to 0.0894) 1.68 to 1.70 (0.0661 to 0.0669) 1.98 to 2.00 (0.0780 to 0.0787) 2.28 to 2.30 (0.0898 to 0.0906) 1.71 to 1.73 (0.0673 to 0.0681) 2.01 to 2.03 (0.0791 to 0.0800) 2.31 to 2.33 (0.0909 to 0.0917) 1.74 to 1.76 (0.0685 to 0.0693) 2.04 to 2.06 (0.0803 to 0.0811) 2.34 to 2.36 (0.0921 to 0.0929) 1.77 to 1.79 (0.0697 to 0.0705) 2.07 to 2.09 (0.0815 to 0.0823) 2.37 to 2.39 (0.0933 to 0.0941) 1.80 to 1.82 (0.0709 to 0.0717) 2.10 to 2.12 (0.0827 to 0.0835) 2.40 to 2.42 (0.0945 to 0.0953) 1.83 to 1.85 (0.0720 to 0.0728) 2.13 to 2.15 (0.0839 to 0.0846) 2.43 to 2.45 (0.0957 to 0.0965) 1.86 to 1.88 (0.0732 to 0.0740) 2.16 to 2.18 (0.0850 to 0.0858) 2.46 to 2.48 (0.0969 to 0.0976) 17. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.20 to 0.63 N*m (2.0 to 6.4 kgf*cm, 1.8 to 5.6 in.*lbf) If necessary, disassemble and inspect the differential. SA02352 18. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Remove the side bearing retainer and differential case assembly. (b) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. (c) Install the differential case assembly and side bearing retainer. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (d) Hold the companion flange firmly and rotate the ring gear in both directions. (e) Remove the differential case, side bearing retainer and differential case assembly. R013220 DF DF–28 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (f) Inspect the tooth contact pattern. Washer FA02008E01 DF Heel Contact Face Contact Select an adjusting washer that will bring the drive pinion closer to the ring gear. Proper Contact Toe Contact Flank Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. Z000699E01 If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction. Washer thickness Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.69 to 1.71 (0.0665 to 0.0673) 1.93 to 1.95 (0.0760 to 0.0768) 2.17 to 2.19 (0.0854 to 0.0862) 1.72 to 1.74 (0.0677 to 0.0685) 1.96 to 1.98 (0.0772 to 0.0780) 2.20 to 2.22 (0.0866 to 0.0874) 1.75 to 1.77 (0.0689 to 0.0697) 1.99 to 2.01 (0.0783 to 0.0791) 2.23 to 2.25 (0.0878 to 0.0886) 1.78 to 1.80 (0.0701 to 0.0709) 2.02 to 2.04 (0.0795 to 0.0803) 2.26 to 2.28 (0.0890 to 0.0898) 1.81 to 1.83 (0.0713 to 0.0720) 2.05 to 2.07 (0.0807 to 0.0815) 2.29 to 2.31 (0.0902 to 0.0909) 1.84 to 1.86 (0.0724 to 0.0732) 2.08 to 2.10 (0.0819 to 0.0827) 2.32 to 2.34 (0.0913 to 0.0921) 1.87 to 1.89 (0.0736 to 0.0744) 2.11 to 2.13 (0.0831 to 0.0839) - 1.90 to 1.92 (0.0748 to 0.0756) 2.14 to 2.16 (0.0843 to 0.0850) - (g) Using SST, remove the companion flange and oil slinger. SST 09330-00021 (09330-00030), 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) (h) Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–29 19. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer and oil storage ring. 20. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 21. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 22. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT (a) Place the companion flange on the drive pinion. (b) Coat the threads of a new nut with hypoid gear oil LSD. (c) Using SST and the companion flange, install the rear tapered roller bearing, then remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) SST SST R011163E06 23. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, install the oil seal. SST 09330-00021 (09330-00030), 09554-22010 Oil seal drive in depth: 3.9 to 4.8 mm (0.153 to 0.189 in.) (b) Coat the oil seal lip with MP grease. SST R013417E02 (c) Using SST to hold the flange, tighten the nut. Torque: 370 N*m (3,770 kgf*cm, 273 ft.*lbf) SST SA02351E05 DF DF–30 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) FIPG R013200E02 DF 24. INSTALL DIFFERENTIAL SIDE BEARING RETAINER (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer. (b) Clean the contact surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the side bearing retainer, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the side bearing retainer within 10 minutes of applying FIPG. (d) Install the side bearing retainer with the 10 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (e) Install the union. 25. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) SA02352 Bearing Standard New 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) Reused 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut to 13 N*m (130 kgf*cm, 9 ft*lbf) a little at a time until the specified preload is reached. Torque: 370 N*m (3,773 kgf*cm, 273 ft.*lbf) or less If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure. Do not loosen the nut to reduce the preload. 26. INSPECT TOTAL PRELOAD 27. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION SST 09564-32011 28. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT 29. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–31 30. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end. SST 09608-32010 (b) Coat the oil seal lip with MP grease. Oil seal driven in depth: -0.45 to 0.45 mm (-0.0177 to 0.0177 in.) SST F044255E01 31. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY (a) Install a new snap ring onto the side gear inter shaft. (b) Using a plastic hammer, install the side gear inter shaft onto the differential case. (c) Check that there are 2 to 3 mm (0.08 to 0.12 in.) of play in the axial direction. (d) Check that the side gear inter shaft will not come out by trying to pull it completely out by hand. G023139 32. INSTALL FRONT DIFFERENTIAL SIDE BEARING RETAINER DEFLECTOR (a) Using a brass bar and a hammer, install the side bearing retainer deflector. NOTICE: Be sure to install the side bearing retainer deflector in the correct direction. G023145 FIPG F044256E01 33. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case. (b) Clean the contact surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the differential, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the differential tube within 10 minutes of applying FIPG. (d) Install the differential tube into the differential carrier assembly. DF DF–32 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (e) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (g) Install the 4 bolts. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) or less G023134 DF G023140 34. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case. (b) Clean the contact surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the differential tube, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the actuator within 10 minutes of applying FIPG. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the actuator assembly onto the differential tube. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1281 or equivalent (g) Install the 4 bolts. Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf) G023143 INSTALLATION 1. C097020 INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Connect the actuator hose and connector. (b) Install the No. 1 mounting support with the 3 bolts. Torque: 186 N*m (1,900 kgf*cm, 137 ft.*lbf) (c) Install the No. 2 mounting support with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) (d) Install the No. 3 front differential support with the 2 bolts. Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf) (e) Support the front differential with a jack. (f) Install the 2 front mounting bolts and nuts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) (g) Install the No. 1 front differential mount nut. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–33 (h) Install the front differential breather tube bracket with the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (i) Lower the jack. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 4. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page AH-17) 5. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER RH HINT: Use the same procedure as for the LH side. 6. INSTALL TIE ROD END SUB-ASSEMBLY LH (See page PS-34) 7. INSTALL TIE ROD END SUB-ASSEMBLY RH (See page PS-34) 8. INSTALL FRONT SPEED SENSOR LH (See page BC211) 9. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 10. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page SP-29) 11. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 12. INSTALL FRONT AXLE HUB LH NUT (See page AH17) 13. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side. 14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See page PR-19) 15. FILL UP DIFFERENTIAL OIL (See page DF-3) 16. INSPECT DIFFERENTIAL OIL (See page DF-3) 17. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Install the No. 1 engine under cover sub-assembly with the 4 bolts. 18. INSTALL REAR ENGINE UNDER COVER ASSEMBLY (a) Install the engine under cover assembly rear with the 6 bolts. 19. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) DF DF–34 DIFFERENTIAL – 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 20. INSPECT CHECK ABS SENSOR SIGNAL HINT: (See page BC-23) DF DF–42 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 3. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.25 to 0.45 N*m (2.5 to 4.6 kgf*cm, 2.2 to 4.0 in.*lbf) If necessary, disassemble and inspect the differential. REASSEMBLY 1. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR (a) Using a steel plate and a press, install a new dust deflector. NOTICE: Do not damage the dust deflector. 2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using SST and a press, install the bearing. SST 09223-00010 (b) Using a snap ring expander, install the snap ring. 3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUBASSEMBLY RH (a) Install the side gear shaft into the differential tube. (b) Using snap ring pliers, install the snap ring. 4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic hammer, install a new oil seal. SST 09608-32010 Oil seal drive in depth: 4.8 to 5.8 mm (0.1890 to 0.2284 in.) (b) Coat the oil seal lip with MP grease. Steel Plate DF G022166E01 SST R013421E02 C097022 SST R013419E01 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 5. FA01121 DF–43 INSTALL FRONT DIFFERENTIAL CASE (a) Install the 2 proper thrust washers onto the 2 side gears. HINT: Using the table below, select the thrust washer which will ensure that the backlash is within the specifications. Washer thickness Thickness mm (in.) Thickness mm (in.) 1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0681 to 0.0697) 1.53 to 1.57 (0.0602 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0717) 1.58 to 1.62 (0.0622 to 0.0638) 1.83 to 1.87 (0.0720 to 0.0736) 1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0740 to 0.0756) 1.68 to 1.72 (0.0661 to 0.0677) - (b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly. HINT: Align the holes of the differential case assembly and pinion shaft. (c) Measure the side gear backlash. (1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly. Backlash: 0 to 0.15 mm (0 to 0.0059 in.) If the backlash is not within the specification, install a side gear thrust washer with a different thickness. F043636 (d) Using a pin punch and hammer, install the straight pin through the differential case assembly and hole of the pinion shaft. (e) Stake the differential case assembly. FA01124 6. Boiling Water SA02160E02 INSTALL DIFFERENTIAL RING GEAR (a) Clean the contact surfaces of the differential case assembly and ring gear. (b) Heat the ring gear to about 100°C (212°F) in boiling water. (c) Carefully take the ring gear out of the boiling water. DF DF–44 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (d) After any moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case assembly. HINT: Align the matchmarks on the ring gear and differential case assembly. (e) Temporarily install 5 new lock plates and 10 bolts so that the bolt holes in the ring gear and differential case assembly are aligned. (f) After the ring gear has cooled sufficiently, tighten the ring gear set bolts to which thread lock has been applied. Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf) 7. INSTALL FRONT DIFFERENTIAL CASE BEARING (a) Using SST and a press, install the 2 differential case bearings into the differential case assembly. SST 09226-10010 8. INSTALL SIDE BEARING OUTER RACE HINT: When replacing the 2 differential case bearings, fit 2 of the thinnest new washers to each bearing and when reusing the bearings, fit washers of the same thickness as those removed. (a) Install a new plate washer to the side bearing retainer. DF SST R013784E01 (b) Using SST and a press, install the bearing outer race onto the differential case bearing retainer assembly. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) (c) Install a new plate washer onto the differential carrier assembly. SST R013375E02 (d) Using SST and a press, install the bearing outer race onto the differential carrier assembly. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) SST R013376E02 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 9. SST Front: DF–45 INSTALL FRONT BEARING OUTER RACE (a) Using SST, install the outer race. SST 09950-00020 (09951-00680, 09951-00890) 10. INSTALL REAR BEARING OUTER RACE (a) Install the oil storage ring. (b) Using SST, install the outer race. SST 09950-00020 (09951-00680, 09951-00890) 11. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Install the washer onto the drive pinion. HINT: First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary. Rear: R013281E02 (b) Using SST and a press, install the front bearing onto the drive pinion. SST 09506-30012 SST 12. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Install the drive pinion. HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern. R001197E01 (b) Using SST, install the rear bearing, oil slinger and companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) (c) Coat the threads of the nut with hypoid gear oil. SST SST R011163E05 (d) Adjust the drive pinion preload by tightening the companion flange nut. (e) Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. SST SA02347E03 DF DF–46 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) Bearing Standard New 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) Reused 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If necessary, disassemble and inspect the differential assembly. SA02352 13. INSTALL DIFFERENTIAL CASE ASSEMBLY 14. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Install the side bearing retainer with the 10 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) DF SST R012683E03 (b) Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) (c) If it is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount. HINT: There should be no clearance between the plate washer and differential case. Make sure that there is ring gear backlash. Washer thickness Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.59 to 1.61 (0.0626 to 0.0634) 1.89 to 1.91 (0.0744 to 0.0752) 2.19 to 2.21 (0.0862 to 0.0870) 1.62 to 1.64 (0.0638 to 0.0646) 1.92 to 1.94 (0.0756 to 0.0764) 2.22 to 2.24 (0.0874 to 0.0882) 1.65 to 1.67 (0.0650 to 0.0657) 1.95 to 1.97 (0.0768 to 0.0776) 2.25 to 2.27 (0.0886 to 0.0894) 1.68 to 1.70 (0.0661 to 0.0669) 1.98 to 2.00 (0.0780 to 0.0787) 2.28 to 2.30 (0.0898 to 0.0906) 1.71 to 1.73 (0.0673 to 0.0681) 2.01 to 2.03 (0.0791 to 0.0800) 2.31 to 2.33 (0.0909 to 0.0917) 1.74 to 1.76 (0.0685 to 0.0693) 2.04 to 2.06 (0.0803 to 0.0811) 2.34 to 2.36 (0.0921 to 0.0929) 1.77 to 1.79 (0.0697 to 0.0705) 2.07 to 2.09 (0.0815 to 0.0823) 2.37 to 2.39 (0.0933 to 0.0941) 1.80 to 1.82 (0.0709 to 0.0717) 2.10 to 2.12 (0.0827 to 0.0835) 2.40 to 2.42 (0.0945 to 0.0953) 1.83 to 1.85 (0.0720 to 0.0728) 2.13 to 2.15 (0.0839 to 0.0846) 2.43 to 2.45 (0.0957 to 0.0965) 1.86 to 1.88 (0.0732 to 0.0740) 2.16 to 2.18 (0.0850 to 0.0858) 2.46 to 2.48 (0.0969 to 0.0976) 15. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.25 to 0.45 N*m (2.5 to 4.6 kgf*cm, 2.2 to 4.0 in.*lbf) If necessary, disassemble and inspect the differential. SA02352 16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Remove the side bearing retainer and differential case assembly. DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–47 (b) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. (c) Install the differential case assembly and side bearing retainer. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (d) Hold the companion flange firmly and rotate the ring gear in both directions. (e) Remove the differential case, side bearing retainer and differential case assembly. R013220 (f) Inspect the tooth contact pattern. DF Washer FA02008E01 Heel Contact Face Contact Select an adjusting washer that will bring the drive pinion closer to the ring gear. Proper Contact Toe Contact Flank Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. Z000699E01 If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction. Washer thickness Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.69 to 1.71 (0.0665 to 0.0673) 1.93 to 1.95 (0.0760 to 0.0768) 2.17 to 2.19 (0.0854 to 0.0862) 1.72 to 1.74 (0.0677 to 0.0685) 1.96 to 1.98 (0.0772 to 0.0780) 2.20 to 2.22 (0.0866 to 0.0874) 1.75 to 1.77 (0.0689 to 0.0697) 1.99 to 2.01 (0.0783 to 0.0791) 2.23 to 2.25 (0.0878 to 0.0886) 1.78 to 1.80 (0.0701 to 0.0709) 2.02 to 2.04 (0.0795 to 0.0803) 2.26 to 2.28 (0.0890 to 0.0898) 1.81 to 1.83 (0.0713 to 0.0720) 2.05 to 2.07 (0.0807 to 0.0815) 2.29 to 2.31 (0.0902 to 0.0909) 1.84 to 1.86 (0.0724 to 0.0732) 2.08 to 2.10 (0.0819 to 0.0827) 2.32 to 2.34 (0.0913 to 0.0921) DF–48 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.87 to 1.89 (0.0736 to 0.0744) 2.11 to 2.13 (0.0831 to 0.0839) - 1.90 to 1.92 (0.0748 to 0.0756) 2.14 to 2.16 (0.0843 to 0.0850) - (g) Using SST, remove the companion flange and oil slinger. SST 09330-00021 (09330-00030), 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) (h) Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 17. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer and oil storage ring. DF 18. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 19. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 20. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT (a) Place the companion flange on the drive pinion. (b) Coat the threads of a new nut with hypoid gear oil LSD. (c) Using SST and the companion flange, install the rear tapered roller bearing, then remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) SST SST R011163E06 21. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, install the oil seal. SST 09330-00021 (09330-00030), 09554-22010 Oil seal drive in depth: 3.9 to 4.8 mm (0.153 to 0.189 in.) (b) Coat the oil seal lip with MP grease. SST R013417E02 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–49 (c) Using SST to hold the flange, tighten the nut. Torque: 370 N*m (3,770 kgf*cm, 273 ft.*lbf) SST SA02351E05 FIPG R013200E02 22. INSTALL DIFFERENTIAL SIDE BEARING RETAINER (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer. (b) Clean the contact surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the side bearing retainer, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the side bearing retainer within 10 minutes of applying FIPG. (d) Install the side bearing retainer with the 10 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (e) Install the union. 23. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) SA02352 Bearing Standard New 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) Reused 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut to 13 N*m (130 kgf*cm, 9 ft*lbf) a little at a time until the specified preload is reached. Torque: 370 N*m (3,773 kgf*cm, 273 ft.*lbf) or less If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repair the preload procedure. Do not loosen the nut to reduce the preload. 24. INSPECT TOTAL PRELOAD 25. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION SST 09564-32011 26. INSPECT FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT DF DF–50 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 27. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT NUT 28. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a plastic hammer, install a new oil seal until its surface is flush with the differential carrier end. SST 09608-32010 (b) Coat the oil seal lip with MP grease. Oil seal driven in depth: -0.45 to 0.45 mm (-0.0177 to 0.0177 in.) SST F044255E01 DF FIPG F044256E01 29. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential and clutch case. (b) Clean the contact surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the differential, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the differential tube within 10 minutes of applying FIPG. (d) Install the differential tube into the differential carrier assembly. (e) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (f) Apply adhesive to 2 to 3 threads of each bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (g) Install the 4 bolts. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) or less G023134 INSTALLATION 1. C097020 INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Install the No. 1 mounting support with the 3 bolts. Torque: 186 N*m (1,900 kgf*cm, 137 ft.*lbf) (b) Install the No. 2 mounting support with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) (c) Install the No. 3 front differential support with the 2 bolts. Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf) (d) Support the front differential with a jack. (e) Install the 2 front mounting bolts and nuts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) (f) Install the No. 1 front differential mount nut. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–51 (g) Install the front differential breather tube bracket with the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (h) Lower the jack. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedure as for the LH side. 4. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page SP-26) 5. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER RH 6. INSTALL TIE ROD END SUB-ASSEMBLY LH (See page PS-34) 7. INSTALL TIE ROD END SUB-ASSEMBLY RH (See page PS-34) 8. INSTALL FRONT SPEED SENSOR LH (See page BC211) 9. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 10. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page SP-29) 11. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure as for the LH side. 12. INSTALL FRONT AXLE HUB LH NUT (See page AH17) 13. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side. 14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See page PR-19) 15. FILL UP DIFFERENTIAL OIL (See page DF-3) 16. INSPECT DIFFERENTIAL OIL (See page DF-3) 17. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Install the No. 1 engine under cover sub-assembly with the 4 bolts. 18. INSTALL REAR ENGINE UNDER COVER ASSEMBLY (a) Install the engine under cover assembly rear with the 6 bolts. 19. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) DF DF–52 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 20. INSPECT CHECK ABS SENSOR SIGNAL HINT: (See page BC-23) DF DIFFERENTIAL – DIFFERENTIAL SYSTEM DF–1 DIFFERENTIAL SYSTEM PRECAUTION 1. Before disassembly, clean the outside of the front and rear differential assembly and remove any sand and mud to prevent it from entering the assembly during disassembly and installation. 2. When removing connected parts made of a light alloy, such as front and rear differential carrier covers, tap them off with a plastic hammer. Do not attempt to pry them off with a screwdriver. 3. Always arrange disassembled parts in order and protect them from dust. 4. Before installation, thoroughly clean and dry each part and then apply hypoid gear oil LSD to it. Do not use alkaline cleaner for aluminum or rubber parts and ring gear set bolts. Also, do not clean rubber parts such as O-rings or oil seals with white gasoline. 5. Coat all sliding surfaces and rotating parts with hypoid gear oil LSD. 6. When holding components in a vice, be sure to place an aluminum sheet under the M part. Do not put them directly in the vice. 7. Be careful not to damage the contact surfaces of the case. Such damage could cause oil leakage. 8. Before applying sealant, remove any deposited oil sealant and clean the part to be sealed using white gasoline. 9. Do not supply oil immediately after installing sealed parts. Leave them for at least an hour. 10. Damage to the surfaces in direct contact with oil seals, O-rings or gaskets could cause oil leakage. Special attention should be paid. 11. When press-fitting an oil seal, be careful not to damage the oil seal lip and outside periphery. 12. When replacing a bearing, replace the inner and outer races as a set. DF DF–2 DIFFERENTIAL – DIFFERENTIAL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. If necessary, replace these parts. DIFFERENTIAL SYSTEM Symptom Oil leakage from front differential DF Oil leakage from rear differential Oil leak from front drive pinion shaft Oil leak from rear drive pinion shaft Suspected area See page 1. Oil level (Too high or wrong grade) DF-3 2. Front differential rear oil seal (Worn or damaged) DF-6 3. Companion flange (Loose or damaged) (1GR-FE) DF-29 4. Companion flange (Loose or damaged) (2UZ-FE) DF-48 1. Oil level (Too high or wrong grade) DF-3 2. Rear differential front oil seal (Worn or damaged) DF-5 3. Companion flange (Loose or damaged) DF-57 1. Oil level (Too high or wrong grade) DF-3 2. Front differential rear oil seal (Worn or damaged) DF-6 3. Companion flange (Loose or damaged) (1GR-FE) DF-29 4. Companion flange (Loose or damaged) (2UZ-FE) DF-48 1. Oil level (Too high or wrong grade) DF-3 2. Rear differential front oil seal (Worn or damaged) DF-6 3. Companion flange (Loose or damaged) DF-71 DF–56 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY REMOVAL 1. REMOVE REAR WHEEL 2. SEPARATE PROPELLER SHAFT ASSEMBLY See procedure Vehicle Type Proceed to 2WD PR-3 4WD PR-8 3. DRAIN DIFFERENTIAL OIL (See page DF-3) 4. SEPARATE REAR SPEED SENSOR LH (See page BC213) 5. SEPARATE REAR SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 6. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Remove the 2 bolts and separate the rear disc brake caliper assembly LH. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly LH. 7. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY RH (a) Remove the 2 bolts and separate the rear disc brake caliper assembly RH. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly RH. 8. REMOVE REAR DISC (See page BR-46) 9. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-14) DF 10. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (See page PB-14) 11. REMOVE PARKING BRAKE SHOE STRUT LH 12. REMOVE PARKING BRAKE SHOE 13. REMOVE REAR AXLE SHAFT WITH BACKING PLATE (See page AH-24) 14. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the 10 nuts, 10 washers and differential carrier assembly. NOTICE: Be careful not to damage the contact surfaces of the differential carrier and rear axle housing. C030284 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–57 DISASSEMBLY 30 mm (1.18 in.) 1. REMOVE REAR DIFFERENTIAL CARRIER GASKET 2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY 3. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout: Vertical runout: 0.10 mm (0.0039 in.) Lateral runout: 0.10 mm (0.0039 in.) If the runouts are not with the specifications, replace the companion flange. 4. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR (a) Using a dial indicator, check the runout of the ring gear. Maximum runout: 0.07 mm (0.0028 in.) If the runout is greater than the maximum, replace the ring gear with a new one. 5. INSPECT DIFFERENTIAL RING GEAR BACKLASH (a) Using a dial indicator, check the backlash of the ring gear. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. 6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting): 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) If necessary, disassemble and inspect the differential assembly. HINT: Before measurement, rotate the ring gear 5 times or more. F001237E03 C014075 C028211 C003092 DF DF–58 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 7. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf) If necessary, disassemble and inspect the differential. 8. REMOVE REAR DRIVE PINION NUT (a) 2WD drive type: Using a "Torx" socket (E10), remove the 4 stud bolts. (b) Using SST and a hammer, unstake nut. SST 09930-00010 C003092 DF SST F044346E02 (c) Using SST to hold the drive pinion companion flange, remove the nut. SST 09330-00021 (09330-00030) SST SA02349E06 9. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using SST, remove the drive pinion companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) SST F052175E02 10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal from the differential carrier. SST 09308-10010 SST 11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER SA02348E03 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–59 12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the front bearing from the drive pinion. SST 09556-22010 SST Z000641E04 13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK (a) Remove the 2 bolts and 2 rear differential bearing adjusting nut locks. C030538 14. REMOVE DIFFERENTIAL CASE ASSEMBLY (a) Place matchmarks on the bearing cap and differential carrier. (b) Remove the 4 bolts and 2 differential bearing caps. (c) Remove the 2 adjusting nuts. Matchmarks C030539E03 (d) Remove the rear differential case assembly and 2 bearing outer races from the differential carrier assembly. HINT: Tag the 2 bearings outer races to show the locations for reassembly. C028220 15. REMOVE DIFFERENTIAL DRIVE PINION (a) Remove the differential drive pinion and bearing spacer from the differential carrier assembly. C030540 DF DF–60 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY SST R010668E02 16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST and a press, remove the rear bearing from the drive pinion. SST 09950-00020 HINT: If either the drive pinion or ring gear is damaged, replace them as a set. 17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER (a) Remove the plate washer from the drive pinion. 18. REMOVE FRONT BEARING OUTER RACE (a) Using a brass bar an a hammer, remove the front bearing outer race from the differential carrier assembly. DF 19. REMOVE DIFFERENTIAL OIL STORAGE RING (a) Using a brass bar and a hammer, remove the oil storage ring. C091046 20. REMOVE REAR BEARING OUTER RACE (a) Using a brass bar and a hammer, remove the rear tapered roller bearing from the carrier. C091047 21. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case assembly. (b) Using a screwdriver and a hammer, unstake the 5 lock plates. (c) Remove the 10 ring gear set bolts and 5 lock plates. (d) Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly. Matchmarks W001777E01 22. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT HINT: It will be done only when it exceeds the limit at the ring gear runout check. DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY C015154 SST W002838E01 DF–61 (a) Install the differential case assembly to the differential carrier assembly. (b) Align the matchmarks, install the 2 bearing caps with the 4 bolts to the differential carrier assembly. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) (c) Inspect the differential case runout. Maximum runout: 0.07 mm (0.0028 in.) (d) Remove the 4 bolts and bearing caps from the differential carrier assembly. (e) Remove the differential case assembly from the differential carrier assembly. 23. REMOVE REAR DIFFERENTIAL CASE BEARING (a) Using SST, remove the 2 rear differential case bearings from the differential case assembly. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480), 09950-60020 (09951-00730) HINT: Fix the claws of SST to the notches in the differential case assembly. 24. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR (a) Using SST and a press, remove the dust deflector. SST 09950-60010 (09951-00380), 09950-70010 (09951-07150), 09950-00020 SST F040564E10 25. DISASSEMBLE DIFFERENTIAL CASE (a) Place matchmarks on the LH and RH cases. (b) Remove the 8 bolts uniformly, a little at a time. (c) Using a plastic hammer, separate the LH and RH cases. Matchmarks R014029E01 DF DF–62 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (d) Remove these parts from the differential case. B A C E D D E A B DF C090324E02 A (2 pieces) Side gear B (2 pieces) Side gear thrust washer C Spider D (4 pieces) Pinion gear E (4 pieces) Pinion gear thrust washer 26. INSPECT DIFFERENTIAL PINION AND SIDE GEAR (a) Check that there is no damage to the differential pinion and differential side gear. If the differential pinion and/or differential side gear is damaged, replace the differential. DIFFERENTIAL – DIFFERENTIAL OIL DF–3 DIFFERENTIAL OIL ADJUSTMENT 1. 0 to 5 mm (0 to 0.20 in.) D025304E03 INSPECT DIFFERENTIAL OIL (a) Stop the vehicle on a level place. (b) Remove the differential filler plug and gasket. (c) Check that the oil level is within 5mm (0 to 0.20 in.) of the bottom of the filler plug opening. NOTICE: • Excessively large or small quantities of oil may cause problems. • After replacing the oil, drive the vehicle and check the oil level again. HINT: If necessary, fill the rear differential carrier assembly with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: Front differential carrier assembly: 1.35 to 1.45 litters (1.43 to 1.53 US qts, 1.19 to 1.27 lmp. qts) Rear differential carrier assembly 3.00 to 3.10 litters (3.17 to 3.27 US qts, 2.64 to 2.72 lmp. qts) (d) Check for oil leakage if the oil level is low. (e) Install the differential filler plug and a new gasket. Torque: Front differential carrier assembly 39 N*m (398 kgf*cm, 29 ft.*lbf) Rear differential carrier assembly 49 N*m (500 kgf*cm, 36 ft.*lbf) DF DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–63 INSPECTION 1. INSPECT DIFFERENTIAL CASE (a) Check that the differential case assembly is not damaged. If the differential case assembly is damaged, replace the differential case assembly. REASSEMBLY Steel Plate 1. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR (a) Using SST, a press and a steel plate, install the dust deflector. SST 09636-20010 NOTICE: Be careful not to damage the dust deflector. SST DF B053734E03 2. INSTALL DIFFERENTIAL CASE ASSEMBLY (a) Install the rear differential side gear thrust washer onto the rear differential side gear. (b) Install the 4 rear differential pinion thrust washers and rear differential pinion gears onto the rear differential spider. (c) Fix the differential case RH. ZK01881 (d) Install the rear differential side gear and rear differential spider onto the differential case RH. ZK09096 (e) Using a dial indicator, measure the differential case RH side backlash while holding the pinion toward the case. Backlash: 0.05 to 0.20 mm (0.002 to 0.008 in.) (f) Remove the rear differential spider from the differential case RH. ZK09097 DF–64 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (g) Install the rear differential side gear and rear differential spider onto the differential case LH. (h) Using a dial indicator, measure the differential case LH side backlash while holding the pinion toward the case. HINT: Measure at all 4 locations. Backlash: 0.05 to 0.20 mm (0.002 to 0.008 in.) If the backlash is not within the specification, install 2 side gear thrust washers of a different thickness. Thrust washer thickness ZK09098 DF Thickness mm (in.) Thickness mm (in.) 0.9 (0.0354) 1.2 (0.0472) 1.0 (0.0394) 1.3 (0.0512) 1.1 (0.0433) - (i) Install the differential side gear thrust washer to the RH case. (j) Install the differential pinion gears and differential spider to the RH case. (k) Install the differential side gear and differential side gear thrust washer to the RH case. W001779 (l) Align the matchmarks and assemble the RH and LH cases. (m) Using a plastic hammer, install the RH and LH case. (n) Install the 8 bolts. Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) Matchmarks C089323E02 3. SST SST R015935E01 INSTALL REAR DIFFERENTIAL CASE BEARING (a) Using SST and a press, install the 2 differential case bearings onto the differential case assembly. SST 09223-15020, 09950-60010 (09951-00480, 09951-00550), 09950-60020 (09951-00730) DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 4. Boiling Water DF–65 INSTALL DIFFERENTIAL RING GEAR (a) Clean the contact surfaces of the differential case assembly and ring gear. (b) Heat the ring gear to approximately 100°C (212°F) in boiling water. (c) Carefully take the ring gear out of the boiling water. (d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case. SA01143E02 (e) Align the matchmarks on the ring gear and differential case assembly. (f) Temporarily install 5 new lock plates and 10 set bolts. (g) After the ring gear cools down sufficiently, torque the 8 bolts uniformly at a time. Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf) HINT: Tighten the bolts in diagonal order little by little in several steps. Matchmarks W001777E01 (h) Using a chisel and a hammer, stake the 5 lock plates. HINT: Stake one claw so that it is flush with the flat surface of the bolt. For the claw in contacting with the protruding portion of the bolt, stake only the half on the tightening side. W001781 5. SA02465 INSPECT DIFFERENTIAL RING GEAR RUNOUT (a) Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no play in the bearing. (b) Install the 2 bearing caps with the 4 bolts. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) (c) Install the 2 adjusting nut locks with the 2 bolts. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) (d) Using a dial indicator, measure the runout of the ring gear. Maximum runout: 0.07 mm (0.0028 in.) If it is not within the specification, replace the ring gear. (e) Remove the 2 bolts and adjusting nut locks. (f) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly. DF DF–66 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 6. INSTALL FRONT BEARING OUTER RACE (a) Using a brass bar and a hammer, install a new oil storage ring. (b) Using SST and a hammer, install the front bearing outer race to the differential carrier assembly. SST 09316-60011 (09316-00011, 09316-00021) 7. INSTALL REAR BEARING OUTER RACE (a) Using SST and a press, install the rear bearing outer race to the differential carrier case. SST 09316-60011 (09316-00011, 09316-00051) 8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING (a) Install the plate washer onto the drive pinion. (b) Using SST and a press, install the rear bearing onto the drive pinion. SST 09506-30012 9. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (a) Install the drive pinion, front bearing and oil slinger. HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern. SST F044251E01 SST DF F044252E01 SST SA03102E03 C028218 (b) Using SST, install the drive pinion companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) (c) Coat the threads of the nut with hypoid gear oil LSD. SST F052182E01 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–67 (d) Using SST to hold the drive pinion companion flange, tighten the nut. Torque: 215 N*m (2,190 kgf*cm, 159 ft.*lbf) SST 09330-00021 NOTICE: • As there is no spacer, tighten a little at a time, being careful not to overtighten it. • Apply hypoid gear oil LSD to the nut. SST C014066E02 (e) Using a torque wrench, measure the preload. Preload (at starting) C003092 C028220 Bearing Standard New 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) Reused 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth. 10. INSTALL REAR DIFFERENTIAL CASE SUBASSEMBLY (a) Place the 2 bearing outer races on their corresponding bearings. (b) Install the differential case assembly in the differential carrier assembly. HINT: • Make sure the right and left races are not interchanged. • Make sure that there is a backlash between the ring rear and drive pinion. 11. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT (a) Install the rear differential bearing adjusting nuts into the carrier, making sure the nuts are threaded properly. C028221 Matchmarks C030539E03 12. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Align the matchmarks on the bearing cap and differential carrier assembly. (b) Install the 2 bearing caps with the 4 bolts. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) HINT: If the bearing cap does not fit tightly on the differential carrier assembly, the adjusting nuts are not threaded properly. DF DF–68 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY Reinstall the adjusting nuts if necessary. (c) Tighten the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST. SST 09504-00011 SST F051389E01 (d) Using the SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.). SST 09504-00011 DF SST Z006953E01 (e) While turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings have settled, loosen the adjusting nut on the drive pinion side. (f) Using SST, torque the adjusting nut 1 to 1.5 notches from the 0 preload position. SST Z006917E03 (g) Using a dial indicator, adjust the ring gear backlash until it is within the specification. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) SST 09504-00011 HINT: The backlash is adjusted by turning the left and right adjusting nuts for an equal amounts. For example, loosen the nut on the right side by one notch. SST C013842E02 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–69 (h) Torque the bearing cap bolts. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) Matchmarks F052194E01 13. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf) If necessary, disassemble and inspect the differential. C003092 14. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer. (b) Hold the companion flange firmly and rotate the ring gear in both directions. C014071 DF DF–70 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (c) Inspect the tooth contact pattern. Plate washer ZK01912E04 Heel Contact DF Face Contact Proper Contact Select an adjusting washer that bring the drive pinion closer to the ring gear Toe Contact Flank Contact Select an adjusting washer that shift the drive pinion away from the ring gear SA01653E10 If the teeth are not engaged properly, use the following chart to select an appropriate washer for correction. Plate Washer thickness Thickness mm (in.) Thickness mm (in.) 1.70 (0.0669) 2.03 (0.0799) 1.73 (0.0681) 2.06 (0.0811) 1.76 (0.0693) 2.09 (0.0823) 1.79 (0.0705) 2.12 (0.0835) 1.82 (0.0717) 2.15 (0.0847) 1.85 (0.0728) 2.18 (0.0853) 1.88 (0.0740) 2.21 (0.0870) 1.91 (0.0752) 2.24 (0.0882) 1.94 (0.0764) 2.27 (0.0894) 1.97 (0.0776) 2.30 (0.0906) 2.00 (0.0787) 2.33 (0.0917) 15. REMOVE REAR DRIVE PINION NUT (a) Using SST to hold the drive pinion companion flange, remove the nut. SST 09330-00021 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–71 16. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using SST, remove the drive pinion companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) 17. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the drive pinion tapered roller bearing from the drive pinion. SST 09556-22010 19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER (a) Install a new bearing spacer onto the drive pinion. 20. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Install the drive pinion, rear drive pinion taper roller bearing and rear differential drive oil slinger. 21. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER SST 22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST and a hammer, install a new carrier oil seal. SST 09554-30011 Oil seal drive in depth: 0.55 to 1.45 mm (0.021 to 0.057 in.) (b) Coat the oil seal lip with the MP grease. F052183E01 23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using SST, install the drive pinion companion flange onto the drive pinion. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030), 09330-00021 (b) Coat the threads of a new nut with hypoid gear oil LSD. SST F052182E01 DF DF–72 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (c) Using SST to hold the flange, tighten the nut. Torque: 215 N*m (2,190 kgf*cm, 159 ft.*lbf) SST 09330-00021 SST ZK09978E01 24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) DF SA02352 Bearing Standard New 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) Reused 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut to 13 N*m (130 kgf*cm, 9 ft*lbf) of torque at a time until the specified preload is reached. Torque: 370 N*m (3,773 kgf*cm, 27 ft.*lbf) or less If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. Do not loosen the pinion nut to reduce the preload. 25. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf) If necessary, disassemble and inspect the differential. SA02352 26. INSPECT DIFFERENTIAL RING GEAR BACKLASH (a) Using a dial indicator, check the backlash of the ring gear. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. C028211 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 30 mm (1.18 in.) F001237E03 DF–73 27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using a dial indicator, measure the runout of the drive pinion companion flange vertically and horizontally. Maximum runout: Vertical runout: 0.10 mm (0.0039 in.) Lateral runout: 0.10 mm (0.0039 in.) If the runouts are not within the specifications, replace the companion flange. 28. INSTALL REAR DRIVE PINION NUT (a) Using a chisel and hammer, stake the drive pinion nut. (b) 2WD drive type: Using a "Torx" socket (E10), install the 4 stud bolts. Torque: 10 N*m (101 kgf*cm, 7.3 ft.*lbf) ZK07449 29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK (a) Install 2 new rear differential bearing adjusting locks onto the bearing caps. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) (b) After tightening the 2 bolts, bend the nut locks. C028226 INSTALLATION 1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY (a) Clean the contact surfaces of the rear differential carrier assembly and the rear axle housing assembly. (b) Install the new rear differential carrier gasket and the differential carrier assembly with the 10 nuts and 10 washers. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 2. INSTALL REAR AXLE SHAFT WITH BACKING PLATE (See page AH-27) 3. INSTALL PARKING BRAKE SHOE (See page PB-16) 4. INSTALL PARKING BRAKE SHOE STRUT LH 5. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 6. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-16) 7. INSTALL REAR DISC (See page BR-47) C030284 DF DF–74 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 8. CONNECT REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Install the rear disc brake caliper assembly LH with the 2 bolts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 9. CONNECT REAR DISC BRAKE CALIPER ASSEMBLY RH (a) Install the rear disc brake caliper assembly RH with the 2 bolts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 10. CONNECT REAR SPEED SENSOR LH (See page BC213) DF 11. CONNECT REAR SPEED SENSOR RH HINT: Install the RH side by following the same procedures as the LH side. 12. INSTALL PROPELLER SHAFT ASSEMBLY See procedure Vehicle Type Proceed to 2WD PR-6 4WD PR-12 13. FILL UP RESERVOIR WITH BRAKE FLUID 14. BLEED MASTER CYLINDER 15. BLEED BRAKE LINE 16. BLEED BRAKE FLUID LEVEL IN RESERVOIR 17. CHECK FOR BRAKE FLUID LEAKAGE 18. FILL UP DIFFERENTIAL OIL (See page DF-3) 19. INSPECT DIFFERENTIAL OIL (See page DF-3) 20. INSTALL REAR WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 in.*lbf) 21. INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL HINT: (See page PB-1) 22. INSPECT CHECK ABS SENSOR SIGNAL HINT: (See page BC-23) DF–4 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL REAR DIFFERENTIAL CARRIER OIL SEAL DRIVE LINE DIFFERENTIAL COMPONENTS 4WD DRIVE TYPE: 2WD DRIVE TYPE: COMPANION FLANGE STUD BOLT DF 10 (101, 7.3) 215 (2,190, 159) 13 (130, 9) DUST DEFLECTOR 85 (867, 63) BEARING SPACER REAR DRIVE PINION NUT OIL SLINGER 215 (2,190, 159) OIL STORAGE RING BEARING CAP 13 (130, 9) FRONT BEARING OUTER RACE FRONT BEARING REAR DIFFERENTIAL CARRIER OIL SEAL ADJUSTING NUT LOCK DIFFERENTIAL CARRIER COMPANION FLANGE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131570E01 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL DF–5 REMOVAL 1. DRAIN DIFFERENTIAL OIL (See page DF-3) 2. REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange. (b) 2WD Drive Type: Remove the 4 nuts and 4 washers. (c) 4WD Drive Type: Remove the 4 nuts, 4 bolts and 4 washers. (d) Suspend the propeller shaft assembly with wire or similar. 3. REMOVE REAR DRIVE PINION NUT (a) Using SST and a hammer, unstake the nut. SST 09930-00010 Matchmarks C060588E02 SST C089309E02 (b) Using SST to hold the companion flange, remove the nut. SST 09330-00021 SST C088916E01 4. SST F040720E02 REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (a) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) DF DF–6 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL 5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal. SST 09308-10010 6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST, remove the front bearing. SST 09556-22010 (b) Using SST, remove the front bearing outer race. SST 09308-00010 (c) Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER SST F040717E02 SST DF W001770E03 DF–76 DIFFERENTIAL – 1GR-FE DIFFERENTIAL VACUUM ACTUATOR (for 4WD) INSPECTION 1. DF 12 mm (0.472 in.) INSPECT DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Measure the resistance between the terminals 1 to 2. Standard resistance: 0.1 to 100 Ω (b) Measure the resistance between the terminals 1 or 2 and body ground. Standard resistance: 5 MΩ or more If the resistance value is not as specified, replace the differential vacuum actuator assembly. (c) Apply battery positive voltage between the terminal 1 to 2, and check the actuator operation by sound, actuator status and continuity between the terminal 3 to 4, 5 to 4 and 6 to 4. F043678E06 Battery voltage applied terminal 3 to 4 terminals continuity 5 to 4 terminals continuity 6 to 4 terminals continuity Actuator status 1 (+) - 2 (-) Continuity Continuity No continuity Connected 1 (-) - 2 (+) No continuity No continuity Continuity Disconnected INSTALLATION 1. G023140 F043679 INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Remove the any oil FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case. (b) Clean connecting surfaces of any residual FIPG material using gasoline or alcohol. (c) Apply FIPG to the differential tube, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the actuator within 10 minutes after applying FIPG. (d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. (e) Install the differential vacuum actuator assembly to the differential tube. (f) Apply adhesive to 2 to 3 threads of the bolts end. Adhesive: Part No. 08833-00070, THREE BOND 1281 or equivalent (g) Install the 4 bolts. Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf) DIFFERENTIAL – 1GR-FE DIFFERENTIAL VACUUM ACTUATOR (for 4WD) DF–77 (h) Connect the actuator hose and connector. (i) Install the No. 1 mounting support with the 3 bolts. Torque: 186 N*m (1,900 kgf*cm, 137 ft.*lbf) (j) Install the No. 2 mounting support with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) (k) Install the front differential support No. 3 with the 2 bolts. Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf) (l) Support the front differential with a jack. (m) Install the 2 front mounting bolts and nuts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) (n) Install the front differential mount nuts No. 1. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) (o) Install the front differential breather tube bracket with a bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (p) Lower the jack. C097020 2. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See page PR-19) 3. INSPECT DIFFERENTIAL OIL (See page DF-3) 4. INSPECT AND ADJUST DIFFERENTIAL OIL (See page DF-3) 5. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Install the engine under cover sub-assembly No. 1 with the 4 bolts. 6. INSTALL ENGINE UNDER COVER ASSEMBLY REAR (a) Install the engine under cover assembly rear with the 6 bolts. DF DIFFERENTIAL – DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD) DF–9 DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD) DRIVE LINE DIFFERENTIAL COMPONENTS DF DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL FRONT DIFFERENTIAL CARRIER ASSEMBLY C139559E01 DF–10 DIFFERENTIAL – DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD) REMOVAL DF 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER ASSEMBLY REAR (a) Remove the 6 bolts and engine under cover assembly rear. 3. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See page DF-3) 5. REMOVE FRONT AXLE HUB LH NUT (See page AH14) 6. SEPARATE FRONT SPEED SENSOR LH (See page BC-211) 7. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See page PS-20) 8. SEPARATE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page SP-22) 9. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-5) 10. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 SST C097017E02 INSTALLATION SST C097018E01 1. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST 09554-30011 (b) Coat the oil seal lip with MP grease. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-9) 3. CONNECT NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page SP-26) 4. CONNECT TIE ROD END SUB-ASSEMBLY LH (See page PS-34) 5. CONNECT FRONT SPEED SENSOR LH (See page BC-211) 6. INSTALL FRONT AXLE HUB LH NUT (See page AH17) DIFFERENTIAL – DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD) DF–11 7. FILL UP DIFFERENTIAL OIL (See page DF-3) 8. INSPECT DIFFERENTIAL OIL (See page DF-3) 9. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Install the No. 1 engine under cover sub-assembly with the 4 bolts. 10. INSTALL ENGINE UNDER COVER ASSEMBLY REAR (a) Install the engine under cover assembly with the 6 bolts. 11. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 12. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) DF DIFFERENTIAL: 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPO... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Axle/Differential Model Year: 2007 Model: 4Runner Doc ID: RM0000016GB004X Title: DIFFERENTIAL: 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION DIFFERENTIAL: 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPO... ILLUSTRATION DIFFERENTIAL: 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPO... DIFFERENTIAL: 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPO... ILLUSTRATION DF–35 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DRIVE LINE DIFFERENTIAL COMPONENTS 13 (133, 10) FRONT DIFFERENTIAL BREATHER HOSE FRONT DIFFERENTIAL BREATHER TUBE DF SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH 88 (897, 65) FRONT PROPELLER SHAFT ASSEMBLY FRONT DIFFERENTIAL CARRIER ASSEMBLY 88 (897, 65) FRONT DIFFERENTIAL SUPPORT NO. 3 FRONT DIFFERENTIAL MOUNT STOPPER UPR x2 FRONT DIFFERENTIAL MOUNT STOPPER UPR 108 (1,101, 80) 87 (887, 64) FRONT DIFFERENTIAL MOUNT NUT NO. 1 FRONT DIFFERENTIAL SUPPORT NO. 2 SNAP RING 160 (1,630, 118) FRONT DRIVE SHAFT ASSEMBLY LH 137 (1,397, 101) 186 (1,897, 137) FRONT DIFFERENTIAL MOUNT STOPPER LWR FRONT DIFFERENTIAL SUPPORT NO. 1 FRONT DIFFERENTIAL MOUNT STOPPER LWR 137 (1,397, 101) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131362E04 DF–36 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) REMOVAL DF 1. REMOVE FRONT WHEELS 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY (a) Remove the 6 bolts and engine under cover assembly. 3. REMOVE NO.1 ENGINE UNDER COVER SUBASSEMBLY (a) Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See page DF-3) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-14) 6. REMOVE FRONT AXLE HUB LH NUT (See page AH14) 7. REMOVE FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side. 8. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See page SP-28) 9. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure as for the LH side. 10. SEPARATE FRONT SPEED SENSOR LH (See page BC-211) 11. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 12. SEPARATE TIE ROD SUB-ASSEMBLY LH (See page PS-20) 13. SEPARATE TIE ROD SUB-ASSEMBLY RH (See page PS-20) 14. REMOVE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (See page SP-22) 15. REMOVE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER RH HINT: Use the same procedure as for the LH side. 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-5) 17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-5) DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) C097020E05 DF–37 18. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (a) Remove the bolt and separate the front differential breather tube bracket. (b) Support the front differential with a jack. (c) Remove the front differential mount nut No. 1. (d) Remove the 2 front mounting bolts and 2 nuts. (e) Lower the jack and remove the front differential assembly. (f) Remove the 2 bolts and No. 3 front differential support. (g) Remove the 5 bolts and 2 front differential supports. DISASSEMBLY 1. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY (a) Remove the 4 bolts. (b) Using a plastic hammer, remove the differential tube. C097021 2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, remove the oil seal. SST 09308-00010 3. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY (a) Using SST and a hammer, remove the nut. SST 09930-00010 SST R013209E01 SST F044234E01 DF DF–38 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (b) Using SST to hold the companion flange, remove the nut. SST 09330-00021 (09330-00030) SST SA02349E05 (c) Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) DF SST F052175E01 4. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL (a) Using SST, remove the oil seal from the differential carrier assembly. SST 09308-10010 5. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER 6. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING (a) Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 (b) Remove the bearing spacer. 7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER (a) Using a screwdriver, remove the union. (b) Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer. 8. REMOVE DIFFERENTIAL CASE ASSEMBLY 9. REMOVE DIFFERENTIAL DRIVE PINION SST SA02348E03 SST Z000641E04 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–39 10. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING (a) Using SST and a press, remove the front bearing and washer from the drive pinion. SST 09950-00020 HINT: If the drive gear or ring gear is damaged, replace them as a set. SST R002482E02 11. REMOVE FRONT BEARING OUTER RACE (a) Using a brass bar and a hammer, remove the front bearing outer race. DF R013226 12. REMOVE REAR BEARING OUTER RACE (a) Using SST, remove the rear bearing outer race. SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) (b) Using a brass bar and a hammer, remove the oil storage ring. SST F044257E01 13. REMOVE SIDE BEARING OUTER RACE HINT: • Measure the plate washer and note its thickness. • Tag the bearing outer races to show the location for reassembly. (a) Using SST and a press, remove the outer race and plate washer from the bearing retainer. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) SST R013211E01 DF–40 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (b) Using SST and a press, remove the outer race and plate washer from the differential carrier assembly. SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) SST R013213E01 SST DF SST R011392E02 RA00997 14. REMOVE DIFFERENTIAL RING GEAR (a) Place matchmarks on the ring gear and differential case assembly. (b) Remove the 10 bolts. (c) Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly. 15. REMOVE FRONT DIFFERENTIAL CASE BEARING (a) Using SST, remove the 2 differential case bearings from the differential case assembly. SST 09950-60010 (09951-00390), 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) HINT: Fix the claws of SST into the notch in the differential case assembly. 16. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and a hammer, remove the straight pin. (b) Remove these parts from the differential case assembly. (1) 2 Differential side gears (2) 2 Differential side gear thrust washers (3) Differential pinion shaft (4) 2 Differential pinion gears (5) 2 Differential pinion gear thrust washers 17. INSPECT DIFFERENTIAL GEAR KIT (a) Check that there is no damage to the pinion gear and side gear. If the pinion gear and/or side gear is damaged, replace the differential gear kit. 18. INSPECT FRONT DIFFERENTIAL CASE (a) Check that the differential case assembly is not damaged. If the differential case assembly is damaged, replace it. 19. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (a) Using SST, remove the oil seal from the differential tube. SST 09308-00010 SST R013199E01 DIFFERENTIAL – 2UZ-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) DF–41 20. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUBASSEMBLY RH (a) Using a snap ring expander, remove the snap ring. (b) Remove the side gear shaft from the differential tube. C097022 21. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING (a) Using a snap ring expander, remove the snap ring. (b) Using SST, a brass bar and a press, remove the bearing. SST 09950-00020 NOTICE: Do not damage the bearing. SST R013420E02 22. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR (a) Using SST, a socket wrench and a press, remove the dust deflector. SST 09950-00020 SST R004465E01 INSPECTION 1. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION (a) Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. 2. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Torque: 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If necessary, disassemble and inspect the differential assembly. SST R012683E03 FA01158 DF DF–53 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY REAR DIFFERENTIAL CARRIER ASSEMBLY DRIVE LINE DIFFERENTIAL COMPONENTS 4WD DRIVE TYPE: CLIP 66 (670, 48) O-RING 49 (500, 36) FILLER PLUG GASKET PARKING BRAKE CABLE ASSEMBLY NO. 2 DF 15 (155, 11) GASKET BRAKE LINE 49 (500, 36) DRAIN PLUG REAR AXLE SHAFT RH O-RING PARKING BRAKE CABLE ASSEMBLY NO. 3 20 (204, 15) 66 (670, 48) x10 88 (897, 65) REAR DIFFERENTIAL CARRIER GASKET REAR DIFFERENTIAL CARRIER ASSEMBLY PROPELLER SHAFT ASSEMBLY REAR AXLE SHAFT LH 2WD DRIVE TYPE: 88 (897, 65) REAR DIFFERENTIAL CARRIER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131363E02 DF–54 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY 4WD DRIVE TYPE: PINION GEAR SIDE GEAR DF THRUST WASHER ADJUSTING NUT SPIDER DIFFERENTIAL RING GEAR THRUST WASHER THRUST WASHER DIFFERENTIAL RH CASE REAR DIFFERENTIAL CASE BEARING DIFFERENTIAL LH CASE 47 (480, 35) REAR DIFFERENTIAL CASE BEARING x8 DIFFERENTIAL DRIVE PINION PLATE WASHER ADJUSTING NUT LOCK PLATE x5 x10 REAR BEARING 97 (985, 71) REAR BEARING OUTER RACE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131364E02 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY DF–55 4WD DRIVE TYPE: 2WD DRIVE TYPE: REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR STUD BOLT DF 10 (101, 7.3) 215 (2,190, 159) 13 (130, 9) REAR DIFFERENTIAL DUST DEFLECTOR 85 (867, 63) BEARING SPACER OIL SLINGER 215 (2,190, 159) OIL STORAGE RING BEARING CAP 13 (130, 9) FRONT BEARING OUTER RACE FRONT BEARING OIL SEAL ADJUSTING NUT LOCK DIFFERENTIAL CARRIER REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131570E02 DF–74 DIFFERENTIAL – 1GR-FE DIFFERENTIAL VACUUM ACTUATOR (for 4WD) 1GR-FE DIFFERENTIAL VACUUM ACTUATOR (for 4WD) DRIVE LINE DIFFERENTIAL COMPONENTS DF CONNECTOR DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY C131365E01 DIFFERENTIAL – 1GR-FE DIFFERENTIAL VACUUM ACTUATOR (for 4WD) DF–75 REMOVAL 1. REMOVE ENGINE UNDER COVER ASSEMBLY REAR (a) Remove the 6 bolts and engine under cover assembly rear. 2. REMOVE NO. 1 ENGINE UNDER COVER SUBASSEMBLY (a) Remove the 4 bolts and No. 1 engine under cover sub-assembly. 3. REMOVE FRONT DIFFERENTIAL DRAIN PLUG 4. DRAIN DIFFERENTIAL OIL (See page DF-3) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See page PR-14) 6. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY (a) Remove the bolt and separate the front differential breather tube bracket. (b) Support the front differential with a jack. (c) Remove the No. 1 front differential mount nut. (d) Remove the 2 front mounting bolts and 2 nuts. (e) Disconnect the actuator hose and connector. (f) Lower the jack. C097020 (g) Remove the 4 bolts and differential vacuum actuator assembly. F043679 DF AXLE – FRONT AXLE HUB (for 2WD) AH–9 REASSEMBLY 1. INSTALL FRONT AXLE HUB SPACER (a) Using a brass bar and a hammer, install the new front axle hub spacer. NOTICE: Do not damage the spacer. 2. INSTALL FRONT AXLE WITH ABS ROTOR BEARING ASSEMBLY (a) Using SST and a press, install a new bearing to the front axle hub. SST 09649-17010 F042762 SST AH C098702E01 3. INSTALL FRONT AXLE HUB (a) Apply the MP grease to a new O-ring. (b) Install the new O-ring to the axle hub. (c) Install the dust cover, axle hub to the steering knuckle with the 4 bolts. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 4. INSTALL FRONT WHEEL ADJUSTING NUT (a) Using SST, install a new adjusting nut. Torque: 275 N*m (2,804 kgf*cm, 203 ft.*lbf) SST 09318-12010 5. INSTALL KNUCKLE GREASE RETAINER CAP INNER (a) Using a brass bar and a hammer, install a new knuckle grease retainer cap inner. NOTICE: Do not damage the knuckle grease retainer cap inner. F042759 SST F042758E01 F042765 AH–10 AXLE – FRONT AXLE HUB (for 2WD) INSTALLATION 1. INSTALL FRONT AXLE HUB ASSEMBLY 2. INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY (a) Install the front suspension upper arm assembly with a new nut. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) (b) Install a new cotter pin. 3. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER (a) Install the No. 1 front suspension arm sub-assembly lower with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) 4. INSTALL TIE ROD END SUB-ASSEMBLY (a) Install the tie rod end sub-assembly with a nut. Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf) (b) Install a new cotter pin. 5. INSTALL FRONT STABILIZER LINK ASSEMBLY (a) Install the stabilizer link with a nut to the steering knuckle. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 6. INSTALL FRONT DISC F043605 AH F042737 F043604 C099158 AXLE – FRONT AXLE HUB (for 2WD) 7. AH–11 INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (a) Install the front disc brake caliper with the 2 bolts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) F043121 (b) Install the brake tube bracket to the steering knuckle with a bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) (c) Using SST, connect the brake tube to the disc brake caliper assembly. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) F042731 8. INSTALL FRONT SPEED SENSOR (a) Install the speed sensor wire harness to the steering knuckle with a bolt. Torque: 13 N*m (133 kgf*cm, 10 in.*lbf) (b) Connect the 2 clips. (c) Using a hexagon wrench, install the speed sensor with the bolt. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 9. BLEED BRAKE LINE 10. INSPECT FLUID LEVEL IN RESERVOIR 11. INSPECT BRAKE FLUID LEAKAGE 12. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) F042730 14. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) AH AH–16 AXLE – FRONT AXLE HUB (for 4WD) REASSEMBLY 1. INSTALL FRONT AXLE HUB SPACER (a) Using a brass bar and a hammer, install a new front axle hub spacer. NOTICE: Do not damage the spacer. 2. INSTALL FRONT AXLE WITH ABS ROTOR BEARING ASSEMBLY (a) Using SST and a press, install a new bearing to the front axle hub. SST 09649-17010 3. INSTALL FRONT AXLE HUB (a) Apply MP grease to a new O-ring. (b) Install the new O-ring to the axle hub. (c) Install the dust cover and axle hub to the steering knuckle with the 4 bolts. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 4. INSTALL STEERING KNUCKLE OIL SEAL (a) Using SST and a press, install a new steering knuckle oil seal. SST 09527-17011, 09950-70010 (09951-07100), 09951-01000 F042762 SST AH C098702E01 F042759 SST F042767E02 AXLE – FRONT AXLE HUB (for 4WD) AH–17 INSTALLATION 1. INSTALL FRONT AXLE HUB ASSEMBLY 2. INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY (a) Install the front suspension upper arm assembly with a nut. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) (b) Install a new cotter pin. 3. INSTALL NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER (a) Install the No. 1 front suspension arm sub-assembly lower with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) F043605 F042737 4. INSTALL TIE ROD END SUB-ASSEMBLY (a) Install the tie rod end sub-assembly with the nut. Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf) (b) Install a new cotter pin. 5. INSTALL FRONT STABILIZER LINK ASSEMBLY (a) Install the stabilizer link with a nut to the steering knuckle. Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F043604 C099158 AH AH–18 AXLE – FRONT AXLE HUB (for 4WD) 6. INSTALL FRONT AXLE HUB NUT (a) Install the hub nut. Torque: 235 N*m (2,396 kgf*cm, 173 ft.*lbf) (b) Install the adjusting cap and cotter pin. 7. INSTALL FRONT AXLE HUB GREASE CAP 8. INSTALL FRONT DISC 9. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (a) Install the front disc brake caliper assembly with the 2 bolts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) F042732 AH F043121 (b) Install the brake tube bracket to the steering knuckle with a bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) (c) Using SST, connect the brake tube to the disc brake caliper assembly. Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) F042731 10. INSTALL FRONT SPEED SENSOR (a) Install the speed sensor wire harness to the steering knuckle with a bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Connect the 2 clips. (c) Using a hexagon wrench, install the speed sensor with the bolt. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 11. BLEED BRAKE LINE 12. INSPECT FLUID LEVEL IN RESERVOIR 13. CHECK BRAKE FLUID LEAKAGE 14. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) F042730 16. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) AH–24 AXLE – REAR AXLE SHAFT REMOVAL AH 1. REMOVE REAR WHEEL 2. REMOVE REAR SPEED SENSOR (See page BC-213) 3. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page BR-45) 4. REMOVE REAR DISC 5. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-14) 6. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (See page PB-14) 7. REMOVE PARKING BRAKE SHOE STRUT 8. REMOVE PARKING BRAKE SHOE (See page PB-14) 9. REMOVE REAR AXLE SHAFT WITH BACKING PLATE (a) Remove the 4 nuts and rear axle shaft with backing plate. (b) Remove the O-ring. F042741 10. REMOVE REAR AXLE SHAFT OIL SEAL (a) Using SST, remove the rear axle shaft oil seal. SST 09308-00010 SST F042742E01 11. REMOVE REAR AXLE SHAFT SNAP RING (a) Using a snap ring expander, remove the snap ring. F042773 AXLE – REAR AXLE SHAFT AH–25 12. REMOVE REAR AXLE SHAFT (a) Using SST and press, remove the rear axle shaft. SST 09521-25011, 09521-25023 SST SST F042774E01 AH AH–1 AXLE – AXLE SYSTEM AXLE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. If necessary, replace these parts. AXLE SYSTEM Symptom Suspected area Wander/pulls Front wheel shimmy Rear wheel shimmy See page 1. Hub bearings (Loosen or worn) AH-1 1. Ball joints (Worn) SP-24 2. Hub bearings (Loosen or worn) AH-1 3. Steering linkage (Loosen or worn) - 4. Steering gear (Out of adjustment or broken) - 1. Hub bearings (Loosen or worn) AH-1 ON-VEHICLE INSPECTION 1. F042745 INSPECT FRONT AXLE HUB (a) Remove the front wheel. (b) Remove front disc brake caliper (See page BR-39). (c) Remove the front disc. (d) Inspect the axle hub backlash. (1) Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (e) Inspect the axle hub deviation. (1) Using a dial indicator, check the distortion at the surface of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the bearing. F042746 2. F042747 INSPECT REAR AXLE HUB & BEARING ASSEMBLY (a) Remove the rear wheel. (b) Remove the rear disc brake caliper (See page BR45). (c) Remove the rear disc. (d) Inspect the axle shaft backlash. (1) Using a dial indicator, check the backlash near the center of the axle shaft. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. AH AH–2 AXLE – AXLE SYSTEM (e) Inspect the axle shaft deviation. (1) Using a dial indicator, check the distortion at the surface of the axle shaft. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the bearing. F042748 AH AH–26 AXLE – REAR AXLE SHAFT DISASSEMBLY 1. REMOVE REAR AXLE BEARING RETAINER INNER (a) Remove the rear axle bearing retainer inner from the rear axle bearing assembly. 2. REMOVE REAR AXLE SHAFT WASHER (a) Remove the rear axle shaft washer from the rear axle bearing assembly. 3. REMOVE PARKING BRAKE PLATE TO REAR AXLE HOUSING BOLT (a) Attach the 4 nuts to the parking brake plate to rear axle housing bolts. (b) Using a hammer, remove the 4 parking brake plate to rear axle housing bolts and rear axle bearing assembly. NOTICE: Do not reuse the nuts previously removed from the vehicle. 4. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY 5. REMOVE REAR AXLE HUB BOLT (a) Using SST, remove the 6 hub bolts. SST 09650-17011 6. REMOVE BRAKE DRUM OIL DEFLECTOR 7. REMOVE BRAKE DRUM OIL DEFLECTOR GASKET 8. REMOVE REAR AXLE BEARING OIL SEAL (a) Grind the rear axle bearing inner race surface using a grinder, then chisel them out with a chisel. (b) Remove the rear axle shaft oil seal from the rear axle shaft. 9. INSPECT REAR AXLE SHAFT (See page AH-26) AH F042776 SST F042775E01 F042797 INSPECTION 1. R012254 INSPECT REAR AXLE SHAFT (a) Using a dial indicator, measure the runout of the shaft and flange. Maximum runout: Shaft runout: 1.5 mm (0.0591 in.) Flange runout: 0.05 mm (0.0020 in.) If the rear axle shaft or flange is damaged or worn, or the runout is greater than the maximum, replace the rear axle shaft. AXLE – REAR AXLE SHAFT AH–27 REASSEMBLY 1. INSTALL REAR AXLE HUB BOLT (a) Install a new deflector gasket and deflector to the rear axle shaft. HINT: Align the 2 notches. G020977 (b) Pass the 6 bolts through the axle hub. (c) Pass a washer plate, as shown in the illustration, through the hub bolt, and install the hub bolt as tightening the hub nut. 2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY G020973 3. INSTALL PARKING BRAKE PLATE TO REAR AXLE HOUSING BOLT (a) Position the backing plate on a rear axle bearing assembly, and install the 4 parking brake plate to rear axle housing bolts using 2 socket wrenches and a press. 4. INSTALL REAR AXLE SHAFT WASHER (a) Install the rear axle shaft plate washer onto the rear axle shaft. 5. INSTALL REAR AXLE BEARING RETAINER INNER (a) Install a new rear axle bearing retainer inner to the rear axle shaft. F042777 INSTALLATION 1. SST F042778E01 INSTALL REAR AXLE SHAFT (a) Using SST and a press, install the rear axle shaft to the rear axle bearing assembly. SST 09521-25011 AH AH–28 AXLE – REAR AXLE SHAFT 2. INSTALL REAR AXLE SHAFT SNAP RING (a) Using a snap ring expander, install a new rear axle shaft snap ring. 3. INSTALL REAR AXLE SHAFT OIL SEAL (a) Using SST and a hammer, install a new axle shaft oil seal. SST 09950-60020 (09951-00770), 09950-70010 (09951-07150) 4. INSTALL REAR AXLE SHAFT WITH BACKING PLATE (a) Install a new O-ring. (b) Install the rear axle shaft with backing plate with the 4 nuts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) 5. INSTALL PARKING BRAKE SHOE (See page PB-16) 6. INSTALL PARKING BRAKE SHOE STRUT 7. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 8. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-16) 9. INSTALL REAR DISC F042773 SST AH F042743E01 F042741 10. CONNECT REAR DISC BRAKE CALIPER ASSEMBLY (See page BR-49) 11. INSTALL REAR SPEED SENSOR (See page BC-213) 12. ADD RESERVOIR WITH BRAKE FLUID 13. BLEED MASTER CYLINDER 14. BLEED BRAKE LINE 15. INSPECT BRAKE FLUID LEVEL IN RESERVOIR 16. INSPECT BRAKE FLUID LEAKAGE 17. INSTALL REAR WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 18. INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL HINT: (See page PB-1) AXLE – REAR AXLE SHAFT AH–29 19. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) AH AH–3 AXLE – FRONT AXLE HUB BOLT FRONT AXLE HUB BOLT SUSPENSION & AXLE AXLE COMPONENTS SPEED SENSOR FRONT LH 123 (1,254, 91) 26 (296, 21) 13 (133, 10) 15 (155, 11) FRONT DRIVE SHAFT ASSEMBLY LH BRAKE TUBE CLIP 110 (1,122, 81) 70 (714, 52) FRONT DISC BRAKE CALIPER ASSEMBLY TIE ROD END SUB-ASSEMBLY LH 91 (928, 67) FRONT STABILIZER LINK ASSEMBLY LH FRONT DISC COTTER PIN 160 (1,630, 118) FRONT AXLE HUB BOLT 4WD DRIVE TYPE: LOCK CAP FRONT AXLE HUB GREASE CAP LH 235 (2,396, 173) N*m (kgf*cm, ft.*lbf) : Specified torque COTTER PIN Non-reusable part C131369E04 AH AH–4 AXLE – FRONT AXLE HUB BOLT REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY (a) Using SST, disconnect the brake tube from the disc brake caliper assembly. SST 09023-00101 (b) Remove the 2 bolts and disc brake caliper assembly. 3. REMOVE FRONT DISC 4. REMOVE FRONT AXLE HUB BOLT (a) Using SST and a screwdriver, remove the hub bolt. SST 09611-12010 F043121 AH SST F044194E02 INSTALLATION 1. INSTALL FRONT AXLE HUB BOLT (a) Install a new hub bolt through the axle hub. (b) Install the washer plate, as shown in the illustration, through the hub bolt, and install the hub bolt by tightening the hub nut. 2. INSTALL FRONT DISC 3. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY (a) Install the disc brake caliper assembly with the 2 bolts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) (b) Using SST, connect the brake tube to the disc brake caliper assembly. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 4. BLEED BRAKE LINE 5. CHECK FLUID LEVEL IN RESERVOIR 6. CHECK FOR BRAKE FLUID LEAKAGE 7. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) C098706 F043121 AH–5 AXLE – FRONT AXLE HUB (for 2WD) FRONT AXLE HUB (for 2WD) SUSPENSION & AXLE AXLE COMPONENTS KNUCKLE GREASE RETAINER CAP INNER AH STEERING KNUCKLE LH FRONT AXLE WITH ABS ROTOR BEARING ASSEMBLY O-RING 80 (816, 59) DUST COVER 275 (2,804, 203) FRONT WHEEL ADJUSTING NUT LH FRONT AXLE HUB SPACER FRONT AXLE HUB ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Mp Grease C139954E01 AH–6 AXLE – FRONT AXLE HUB (for 2WD) REMOVAL 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT SPEED SENSOR (a) Using a hexagon wrench, separate the front speed sensor. (b) Disconnect the 2 clamps. (c) Remove the bolt and separate the speed sensor wire harness from the steering knuckle. 3. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY (a) Remove the bolt and separate the brake tube bracket from the steering knuckle. (b) Using SST, disconnect the brake tube from the front disc brake caliper assembly. SST 09023-00101 AH F042730 F042731 (c) Remove the 2 bolts and front disc brake caliper assembly. 4. F043121 REMOVE FRONT DISC AXLE – FRONT AXLE HUB (for 2WD) AH–7 5. SEPARATE FRONT STABILIZER LINK ASSEMBLY (a) Remove the nut and separate the stabilizer link assembly from the steering knuckle. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 6. SEPARATE TIE ROD END SUB-ASSEMBLY (a) Remove the cotter pin and nut. C099158 (b) Using SST, separate the tie rod end sub-assembly from the steering knuckle. SST 09628-62011 AH SST F042735E02 7. SEPARATE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER (a) Remove the 2 bolts and separate the front lower ball joint attachment from the front axle. 8. SEPARATE FRONT SUSPENSION UPPER ARM ASSEMBLY (a) Remove the clip and nut. (b) Using SST, separate the steering knuckle from the front suspension upper arm assembly. SST 09628-62011 9. REMOVE FRONT AXLE HUB SUB-ASSEMBLY (a) 4WD Drive Type: Using a plastic hammer, separate the front axle hub from the front drive shaft. (b) Remove the front axle hub sub-assembly. F042737 SST F042736E01 DISASSEMBLY 1. F042756 REMOVE KNUCKLE GREASE RETAINER CAP INNER (a) Using a screwdriver and a hammer, remove the knuckle grease retainer cap inner. AH–8 AXLE – FRONT AXLE HUB (for 2WD) 2. REMOVE FRONT WHEEL ADJUSTING NUT (a) Using SST and a hammer, unstake the adjusting nut. SST 09930-00010 F042757 (b) Using SST, remove the adjusting nut. SST 09318-12010 SST AH F042758E01 3. REMOVE FRONT AXLE HUB (a) Remove the 4 bolts and axle hub from the steering knuckle. (b) Remove the O-ring from the axle hub. 4. REMOVE FRONT AXLE WITH ABS ROTOR LH BEARING ASSEMBLY (a) Fix the front axle hub soft in vise. (b) Using SST, remove the bearing. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011) 5. REMOVE FRONT AXLE HUB SPACER (a) Using a screwdriver, remove the front axle hub spacer. F042759 SST F042760E02 F042761 AH–12 AXLE – FRONT AXLE HUB (for 4WD) FRONT AXLE HUB (for 4WD) SUSPENSION & AXLE AXLE COMPONENTS FRONT SPEED SENSOR 123 (1,254, 91) 26 (296, 21) 13 (133, 10) AH 15 (155, 11) FRONT DRIVE SHAFT ASSEMBLY LH BRAKE TUBE CLIP 110 (1,122, 81) 70 (714, 52) FRONT DISC BRAKE CALIPER ASSEMBLY TIE ROD END SUB-ASSEMBLY 91 (928, 67) FRONT STABILIZER LINK ASSEMBLY FRONT DISC COTTER PIN 160 (1,630, 118) FRONT AXLE HUB BOLT LOCK CAP FRONT AXLE HUB GREASE CAP 235 (2,396, 173) N*m (kgf*cm, ft.*lbf) : Specified torque COTTER PIN Non-reusable part C139736E01 AXLE – FRONT AXLE HUB (for 4WD) AH–13 REMOVAL 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT SPEED SENSOR (a) Using a hexagon wrench, separate the speed sensor front. (b) Disengage the 2 clamps. (c) Remove the bolt and separate the speed sensor wire harness from the steering knuckle. AH F042730 3. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY (a) Remove the bolt and separate the brake tube bracket from the steering knuckle. (b) Using SST, disconnect the brake tube from the disc brake cylinder. SST 09023-00101 F042731 (c) Remove the 2 bolts and front disc brake caliper assembly. 4. F043121 REMOVE FRONT DISC AH–14 AXLE – FRONT AXLE HUB (for 4WD) 5. REMOVE FRONT AXLE HUB GREASE CAP (a) Using a screwdriver and a hammer, remove the front axle hub grease cap. NOTICE: Do not damage the axle hub. 6. REMOVE FRONT AXLE HUB NUT (a) Remove the cotter pin and a lock cap. (b) Remove the front axle hub nut. 7. SEPARATE FRONT STABILIZER LINK ASSEMBLY (a) Remove the nut and separate the stabilizer link assembly from the steering knuckle. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 8. SEPARATE TIE ROD END SUB-ASSEMBLY (a) Remove the cotter pin and nut. (b) Using SST, separate the tie rod end sub-assembly from the steering knuckle. SST 09628-62011 9. REMOVE NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER (a) Remove the 2 bolts and separate the No.1 front suspension arm sub-assembly lower from the front steering knuckle. F042729 AH F042732 C099158 SST F042735E01 F042737 AXLE – FRONT AXLE HUB (for 4WD) AH–15 10. SEPARATE FRONT SUSPENSION UPPER ARM ASSEMBLY (a) Remove the cotter pin and nut. (b) Using SST, separate the steering knuckle from the front suspension upper arm assembly LH. SST 09628-62011 SST F042736E01 11. REMOVE FRONT AXLE HUB ASSEMBLY (a) for 4WD: (1) Using a plastic hammer, separate the front axle hub from the front drive shaft. (b) Remove the front axle hub assembly. DISASSEMBLY 1. REMOVE STEERING KNUCKLE OIL SEAL (a) Using a screwdriver and hammer, remove the steering knuckle LH oil seal. AH F042766 2. REMOVE FRONT AXLE HUB (a) Remove the 4 bolts and axle hub from the steering knuckle. (b) Remove the O-ring from the axle hub. 3. REMOVE FRONT AXLE WITH ABS ROTOR BEARING ASSEMBLY (a) Fix the front axle hub soft in vise. (b) Using SST, remove the bearing. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011) 4. REMOVE FRONT AXLE HUB SPACER (a) Using a screwdriver, remove the front axle hub spacer. F042759 SST F042760E02 F042761 AXLE – REAR AXLE HUB BOLT AH–19 REAR AXLE HUB BOLT SUSPENSION & AXLE AXLE COMPONENTS 15 (155, 11) BRAKE TUBE REAR AXLE HUB BOLT 47 (480, 35) REAR DISC BRAKE CALIPER ASSEMBLY AH 123 (1,254, 91) REAR AXLE SHAFT WITH BACKING PLATE O-RING REAR AXLE SHAFT OIL SEAL 8.3 (85, 73 in.*lbf) 8.0 (82, 71 in.*lbf) PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE ASSEMBLY REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131371E03 AH–20 AXLE – REAR AXLE HUB BOLT REMOVAL AH 1. REMOVE REAR WHEEL 2. REMOVE REAR SPEED SENSOR (See page BC-213) 3. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY (See page BR-45) 4. REMOVE REAR DISC 5. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-14) 6. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (See page PB-14) 7. REMOVE PARKING BRAKE SHOE STRUT 8. REMOVE PARKING BRAKE SHOE (See page PB-14) 9. REMOVE REAR AXLE HUB BOLT (a) Using SST, remove the hub bolt. SST 09650-17011 SST G020975E01 INSTALLATION G020976 1. INSTALL REAR AXLE HUB BOLT (a) Pass a new hub bolt through the axle hub. (b) Pass a washer plate, as shown in the illustration, through the hub bolt, and install the hub bolt as tightening the hub nut. 2. INSTALL PARKING BRAKE SHOE (See page PB-16) 3. INSTALL PARKING BRAKE SHOE STRUT 4. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 5. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-16) 6. INSTALL REAR DISC 7. CONNECT REAR DISC BRAKE CALIPER ASSEMBLY (See page BR-49) 8. INSTALL REAR SPEED SENSOR (See page BC-213) 9. ADJUST RESERVOIR WITH BRAKE FLUID 10. BLEED BRAKE LINE 11. INSPECT BRAKE FLUID LEVEL IN RESERVOIR 12. INSPECT BRAKE FLUID LEAKAGE 13. INSTALL REAR WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) AXLE – REAR AXLE HUB BOLT AH–21 14. INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL HINT: (See page PB-1) 15. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) AH AH–22 AXLE – REAR AXLE SHAFT REAR AXLE SHAFT SUSPENSION & AXLE AXLE COMPONENTS 15 (155, 11) BRAKE TUBE REAR AXLE HUB BOLT 47 (480, 35) REAR DISC BRAKE CALIPER ASSEMBLY AH 123 (1,254, 91) REAR AXLE SHAFT WITH BACKING PLATE O-RING REAR AXLE SHAFT OIL SEAL 8.3 (85, 73 in.*lbf) 8.0 (82, 71 in.*lbf) PARKING BRAKE CABLE ASSEMBLY NO. 3 PARKING BRAKE ASSEMBLY REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131371E04 AH–23 AXLE – REAR AXLE SHAFT REAR AXLE SHAFT SNAP RING REAR AXLE SHAFT WASHER REAR AXLE BEARING ASSEMBLY PARKING BRAKE PLATE TO REAR AXLE HOUSING BOLT REAR AXLE BEARING RETAINER INNER AH BACKING PLATE x6 REAR AXLE HUB BOLT BRAKE DRUM OIL DEFLECTOR BRAKE DRUM OIL DEFLECTOR GASKET REAR AXLE SHAFT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131372E02 SC–4 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM ADJUSTMENT SC HIGH NORMAL LOW 1. ADJUST STANDARD VEHICLE HEIGHT (a) Release the parking brake and stabilize the suspensions by pushing up and down on the corners of the vehicle. (b) Place the shift lever into the "N" position and settle the tires by moving the vehicle back and forth. (c) Start the engine. (d) On the height control switch, first press "HIGH" to raise the vehicle height, and then change the switch to "LOW" to lower it. Perform this operation one more time. NOTICE: Make sure to release the parking brake and move the shift lever into the "N" position. 2. INSPECT TIRE (See page TW-1) 3. MEASURE VEHICLE HEIGHT (See page SP-4) 4. OPERATE HEIGHT CONTROL SWITCH AND CHECK VEHICLE HEIGHT CHANGE (a) Start the engine and change the height control switch from the NORMAL position to the HIGH and LOW positions. Check the time until the height adjustment is completed and the amount of change in vehicle height. Adjustment time: From operation of height control switch to start of compressor. Approx. 2 sec. From start of compressor to completion of height adjustment. 15 to 20 sec. (HIGH position) Amount of change in vehicle height: HIGH position: 40 mm (1.57 in.) LOW position: -20 mm (-0.79 in.) C099140E01 SC–5 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM (b) While adjusting vehicle height in the HIGH position, start the engine and change the height control switch from the HIGH and LOW position to the NORMAL position. Check the time until the height adjustment is completed and the amount of change in vehicle height. Adjustment time: HIGH NORMAL LOW From operation of height control switch to open of exhaust valve. Approx. 2 sec. From open of exhaust valve to completion of height adjustment. 10 to 15 sec. (HIGH position) Amount of change in vehicle height: HIGH position: 40 mm (1.57 in.) LOW position: -20 (-0.79 mm) 5. C099139E01 CHECK CONNECTIONS OF TUBES FOR AIR LEAKAGE (a) Set the height control switch in the HIGH position and raise the vehicle height. (b) Stop the engine. SC SC–6 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM (c) Apply soapy water to the connections of the tubes and check if there is any air leakage. Front SC C099141E01 6. D C C125412E01 ADJUST VEHICLE HEIGHT NOTICE: While adjusting vehicle height, do not put anyone or anything on or in the vehicle as it will affect vehicle height. (a) Suspend the vehicle height control by pressing the height control mode select switch. (b) Put the vehicle on a level surface. (c) Measure the vehicle height (C - D measurement) on the right side and left side. Standard vehicle height value: See page SP-4 Difference between the right side and left side: 10 mm (0.39 in.) or less (d) If the actual vehicle height differs from the vehicle height (C - D measurement), adjust it by jacking up the frame, etc. (Procedure "A"). (e) Using the intelligent tester (Procedure "B"). (1) Turn the ignition switch to ON or ACC. SC–7 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM (2) Using the intelligent tester, measure each vehicle height value of the right side and the left side sensors. Difference between the tester value and vehicle height (C - D measurement): 5 mm (0.20 in.) or less Difference between the right side and the left side: 5 mm (0.20 in.) or less (f) Low Normal High LH: (+) (+) (-) (-) RH: (+) Not using the intelligent tester (Procedure "C"). (1) Disconnect the connector of the height control sensor. (2) Connect three 1.5 V dry cell batteries in series. (3) Connect the battery positive (+) and negative () to the terminals as shown in the illustration. Standard voltage Position Voltage High 2.58 to 2.98 V Normal 2.11 to 2.51 V Low 1.76 to 2.16 V Difference between the right side and the left side: 0.2 V or less (+) (-) (-) F043224E01 C125314 Lock Nut C125303E01 (g) If the procedure "B" or "C" differs from the vehicle height (C - D measurement), adjust it by following the procedures below: (1) Loosen the nut. (2) Move the height control sensor link up and down along the slotted hole of the bracket. (3) Adjust the vehicle height to the vehicle height (C - D measurement) while checking the value on the intelligent tester or voltmeter. (4) Tighten the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (h) If the vehicle height cannot be adjusted by performing procedure "A" , adjust it again by following the procedures below: (1) Loosen the 2 lock nuts of the height control sensor link. (2) Adjust the vehicle height to the vehicle height (C - D measurement) by turning the link while checking the value on the intelligent tester or the voltmeter. (3) Tighten the 2 lock nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) SC SC–8 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM (i) A A C125304E01 SC Check that the lengths of the screw parts, "A" in the illustration, are within the standard values. Standard length: 6.5 to 15.0 mm (0.26 to 0.59 in.) (j) Change the vehicle height. (From the normal position to the high position, and from the high position to the normal position) (k) Measure the vehicle height (C - D measurement) on the right side and left side (Procedure "D"). (l) Check if the vehicle height (C - D measurement) is within the specified range. HINT: If the values are outside the standard, perform the procedures from procedure "A" to "D" again. SC–12 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: Step 3, 6, 9, 12: Diagnostic steps permitting use of the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT SC 3 CHECK AND CLEAR DTC (a) Check for a DTC (See page SC-23). NEXT 4 PROBLEM SYMPTOM CONFIRMATION Symptom Does Not Occur (Go to step 5) Symptom Occurs (Go to step 6) NEXT 5 SYMPTOM SIMULATION NEXT 6 CHECK DTC (a) Check for a DTC (See page SC-23). Normal System Code OUTPUT (Go to step 7) DTC OUTPUT (Go to step 8) 7 PROBLEM SYMPTOMS TABLE (a) Refer to the Problem Symptoms Table (See page SC18). NEXT SUSPENSION CONTROL – AIR SUSPENSION SYSTEM 8 SC–13 DTC CHART (a) Refer to the Diagnostic Trouble Code Chart (See page SC-26). NEXT 9 CIRCUIT INSPECTION (a) Inspect the circuit (See page SC-30 to SC-74). NEXT 10 IDENTIFICATION OF PROBLEM SC NEXT 11 REPAIR OR REPLACE NEXT 12 NEXT END CONFIRMATION TEST SC–14 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM TEST MODE PROCEDURE 1. SC (3) Using SST, connect terminals TS and CG of the DLC3. (4) Turn the ignition switch to the ON position. CG DLC3: INPUT SIGNAL CHECK (Using SST check wire) HINT: • This function checks if signals from the stop light switch assembly and the door courtesy light switch, etc. are being input normally to the ECU. • When entering test mode, the suspension control ECU sets all the test mode DTCs first. After completing the test mode for each check item, the test mode DTCs that are determined normal by the suspension control ECU will be erased. The test mode DTCs for other check items may not be erased when only a certain signal is inspected. • When the test mode returns back to normal mode, all the test mode DTCs will be erased. (a) Procedure for Input Signal Check Mode (Test Mode) using SST check wire. SST 09843-18040 (1) Make sure the ignition switch is OFF. (2) Set each of the check items to the condition shown as Operation (A) in the test mode table. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS F100115E29 F041675 (5) Check that the height control OFF indicator light is blinking. HINT: • The height control OFF indicator light comes on for 2 seconds, then blinks at 0.25 sec. intervals. • If the height control OFF indicator light does not blink, inspect the height control manual indicator light circuit (See page SC-74) and the TS terminal circuit (See page SC-80). (6) Set each of the check items to the condition shown as Operation (B) in the test mode table. HINT: When checking each item, the height control OFF indicator light should comes on for 1 second. Test mode table Check Item Operation (A) Operation (B) Stop light switch signal OFF (Brake pedal not depressed) ON (Brake pedal depressed) Door courtesy light switch signal ON (Each door opened) OFF (All doors closed) SC–15 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Check Item Operation (A) Height control switch signal Operation (B) Press the height control switch "UP" first and then press "DOWN" - Height control OFF switch signal OFF (Height control OFF switch not pushed in) ON to OFF (Height control OFF switch pushed in and released) Right front speed sensor signal Vehicle speed below 20 km/h (12 mph) Vehicle speed 20 km/h (12 mph) or higher Left front speed sensor signal Vehicle speed below 20 km/h (12 mph) Vehicle speed 20 km/h (12 mph) or higher Crankshaft position sensor signal Engine speed below 2,000 rpm Engine speed 2,000 rpm or higher (7) Using SST, connect the 3rd terminal of the SST check wire to terminal TC of the DLC3. SST 09843-18040 CG DLC3: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS TC SC F100115E28 (8) Read the number of blinks of the height control OFF indicator light. HINT: • As examples, the blinking patterns of a normal system code and code 82 are shown in the illustration. • If 2 or more malfunctions are indicated at the same time, the lowest numbered code is displayed first. • When a DTC is not output, check the TC terminal circuit (See page SC-78). (9) Check the malfunction using the test mode DTC chart. F041675 Code 82: Normal: 0.25 sec. 0.5 sec. ON ON OFF OFF 0.25 sec. 0.5 sec. 1.5 sec. 4.5 sec. Repeat C120690E01 (b) Ending the Input Signal Check Mode (Test Mode) using SST check wire. SST 09843-18040 (1) With the ignition switch OFF, disconnect the SST check wire from the terminals of the DLC3 and then turn the ignition switch to the ON position. (c) Procedure for Sensor Test Mode (Test Mode) using the intelligent tester. (1) Make sure the ignition switch is OFF. (2) Set each of the check items to the condition shown as Operation (A) in the test mode table. SC–16 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (3) Connect the intelligent tester to the DLC3. (4) Turn the ignition switch to the ON position. (5) Select SIGNAL CHECK mode on the intelligent tester. (6) Set each of the check items to the condition shown as Operation (B) in the test mode table (Procedure "A"). HINT: In procedure "A", all signals can be checked together. (7) Read the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operators manual for further details. (d) DTC of air suspension system test mode (input signal check) function: If a trouble code is displayed during the test mode DTC check, check the circuit listed for that code. For details of each code, refer to "See page" under the respective DTC No. in the chart. SC Test Mode DTC Chart DTC No. C1782/82 Detection Item Stop light switch circuit malfunction Trouble Area • • • Stop light switch assembly Stop light switch circuit Suspension control ECU • • • • • • Door courtesy light switch assembly Back door lock assembly (Back door courtesy light switch) Door courtesy light switch circuit Body ECU Back door ECU Suspension control ECU • • • Height control switch Height control switch circuit Suspension control ECU • • • Height control OFF switch (Suspension control switch) Height control OFF switch circuit Suspension control ECU C1783/83 Door courtesy switch circuit malfunction C1786/86 Height control switch circuit malfunction C1788/88 Height control OFF switch circuit malfunction C1794/94 Right front speed sensor circuit malfunction • • • • Right front speed sensor Right front speed sensor circuit Skid control ECU assembly Suspension control ECU C1795/95 Left front speed sensor circuit malfunction • • • • Left front speed sensor Left front speed sensor circuit Skid control ECU assembly Suspension control ECU C1797/97 Crankshaft position sensor circuit malfunction • • • • Crankshaft position sensor Crankshaft position sensor circuit ECM Suspension control ECU 2. INPUT SIGNAL CHECK (Using INTELLIGENT TESTER) HINT: • This function checks if signals from the stop light switch assembly and the door courtesy light switch, etc. are being input normally to the ECU. SC–17 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM • When entering test mode, the suspension control ECU sets all the test mode DTCs first. After completing the test mode for each check item, the test mode DTCs that are determined normal by the suspension control ECU will be erased. The test mode DTCs for other check items may not be erased when only a certain signal is inspected. • When the test mode returns back to normal mode, all the test mode DTCs will be erased. Intelligent Tester DLC3 A066288E03 (a) Procedure for Test Mode (Input signal check). (1) Make sure that the ignition switch is off. (2) Set each of the check items to the condition shown as Operation (A) in the test mode table. (3) Connect the intelligent tester to the DLC3. (4) Turn the ignition switch to the ON position. (5) Select TEST MODE mode on the intelligent tester. (6) Set each of the check items to the condition shown as Operation (B) in the test mode table (Procedure "C"). Test mode (input signal check) table Check Item Operation (A) Stop light switch signal OFF (Brake pedal not depressed) Door courtesy light switch signal ON (Each door opened) Height control switch signal Operation (B) ON (Brake pedal depressed) OFF (All doors closed) Press the height control switch "UP" first and then press "DOWN" - Height control OFF switch signal OFF (Height control OFF switch not pushed in) ON to OFF (Height control OFF switch pushed in and released) Right front speed sensor signal Vehicle speed below 20 km/h (12 mph) Vehicle speed 20 km/h (12 mph) or higher Left front speed sensor signal Vehicle speed below 20 km/h (12 mph) Vehicle speed 20 km/h (12 mph) or higher Crankshaft position sensor signal Engine speed below 2,000 rpm Engine speed 2,000 rpm or higher HINT: In procedure "C", all signals can be checked together. (7) Read the test mode DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (8) Check the malfunction using the code table below. After completing the test mode, disconnect the tester and turn the ignition switch off. SC SC–18 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (b) DTC of air suspension system test mode (input signal check) function: If a trouble code is displayed during the test mode DTC check, check the circuit listed for that code. For details of each code, refer to "See page" under the respective DTC No. in the chart. Test Mode DTC Chart DTC No. C1782/82 Detection Item Stop light switch assembly Stop light switch circuit Suspension control ECU • • • • • • Door courtesy light switch assembly Back door lock assembly (Back door courtesy light switch) Door courtesy light switch circuit Main Body ECU Back door ECU Suspension control ECU • • • Height control switch Height control switch circuit Suspension control ECU • • • Height control OFF switch (Suspension control switch) Height control OFF switch circuit Suspension control ECU Right front speed sensor circuit malfunction • • • • Right front speed sensor Right front speed sensor circuit Skid control ECU assembly Suspension control ECU Left front speed sensor circuit malfunction • • • • Left front speed sensor Left front speed sensor circuit Skid control ECU assembly Suspension control ECU Crankshaft position sensor circuit malfunction • • • • Crankshaft position sensor Crankshaft position sensor circuit ECM Suspension control ECU Stop light switch circuit malfunction C1783/83 Door courtesy switch circuit malfunction C1786/86 Height control switch circuit malfunction SC C1788/88 C1794/94 C1795/95 C1797/97 Trouble Area • • • Height control OFF switch circuit malfunction SC–52 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1751/51 Continuous Electric Current to Height Control Compressor DESCRIPTION DTC No. C1751/51*1 DTC Detecting Condition With the AIR SUS relay activated, the vehicle does not go up to the standard vehicle height after 90 sec. have elapsed. Trouble Area • • • • • • • • • Height control compressor assembly Height control compressor circuit Height control sensor circuit Height control sensor link sub-assembly Relief valve AIR SUS relay circuit Air leakage from the air tube or each valve Clogging in the air tube or each valve Suspension control ECU *1: SC The relief pressure of the compressed air is 980 kPa (10 kgf/cm2, 142 psi). If the vehicle height control is attempted on a steeply sloping road, when the vehicle is overloaded, or when the vehicle is jacked up with the engine running, the compressor motor operates continuously to raise vehicle height, and causes electric current to flow to the AIR SUS relay for 100 seconds or longer. Thus DTC C1751/51 may be output and vehicle height control may be suspended. (This is not electrically abnormal.) In this case, however, the vehicle height operation is resumed approx. 10 min. after the ignition switch is turned ON after the ECU detects the first error. If ECU detects another error, it takes 70 minutes until control is resumed. INSPECTION PROCEDURE 1 INSPECT HEIGHT CONTROL COMPRESSOR CIRCUIT (a) Inspect the height control compressor circuit (See page SC-44). NEXT 2 INSPECT AIR LEAKAGE (a) Check tube connections for air leakage (See page SC28). OK: No leaks NG REPAIR OR REPLACE AIR TUBE OK 3 INSPECT HEIGHT CONTROL VALVE (GATE SOLENOID, LEVELING SOLENOID, EXHAUST SOLENOID VALVE) (a) When using intelligent tester: (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON, and push the intelligent tester main switch ON. SC–53 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (3) Select the item "LEVEL SOL REAR", "GATE SOL REAR", "LOW PRS TNK SOL", "EXHAUST SOL" in the ACTIVE TEST, and operate it with the intelligent tester. (4) Check whether the solenoid makes a sound. (5) Check whether the height control solenoid valve has continuity (will vibrate). OK: The solenoid makes a sound, and the height control solenoid valve has continuity. (It will vibrate.) (b) When not using intelligent tester: (1) Disconnect the valve connectors. (2) Check the operating sound of the valves when battery positive voltage is applied to the terminals as shown below. Gate Solenoid Valve: Leveling Solenoid Valve: (+) 3 Solenoid valve 1 2 (-) Exhaust Solenoid Valve: 2 1 2 Leveling solenoid valve 3 2 Exhaust solenoid valve 1 2 Tank solenoid valve 2 1 OK: It makes an operating sound (click). HINT: • When a malfunction is found in the gate solenoid valve, the leveling valve or the tank solenoid valve, replace the height control reservoir assembly. • When a malfunction is found in the exhaust solenoid valve, replace the height control compressor assembly. (+) Tank Solenoid Valve: 2 1 (+) Battery negative Gate solenoid valve 1 (-) Battery positive (-) F044510E01 B REPLACE HEIGHT CONTROL RESERVOIR ASSEMBLY C REPLACE HEIGHT CONTROL COMPRESSOR ASSEMBLY A 4 INSPECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (a) Inspect and adjust the height control sensor link subassembly. NEXT 5 CONFIRM DTC (a) Clear the DTC and repeat the procedure to re-check it (See page SC-23). SC SC–54 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM HINT: If the DTC C1751/51 is still output, proceed to the next step. NEXT REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS SC SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC SC–55 C1761/61 ECU Malfunction DESCRIPTION DTC No. C1761/61 DTC Detecting Condition Trouble Area Suspension control ECU malfunction Suspension control ECU INSPECTION PROCEDURE HINT: • If DTC C1774/74 (power source circuit) is displayed, perform the inspection necessary for DTC C1774/ 74 first (See page SC-54). • If DTC C1713/13 (right rear height control sensor circuit), C1714/14 (left rear height control sensor circuit) and C1761/61 (ECU malfunction) are output at the same time, perform the inspection necessary for DTC C1761/61 first. 1 INSPECT HEIGHT CONTROL OFF INDICATOR LIGHT (a) Turn the ignition switch to ON, and check the height control OFF indicator light. Result: A: Height control OFF indicator light come on B: Height control OFF indicator light does not come on B REPLACE SUSPENSION CONTROL ECU A 2 INSPECT SUSPENSION CONTROL ECU (HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAR POWER SOURCE) S15 GND (-) S13 SBL2 (+) SBR2 (+) F043242E01 OK (a) Remove the suspension control ECU with connectors being connected. (b) Turn the ignition switch ON, and measure voltage between terminals S13-20 (SBR2) and S15-1 (GND) and between terminals S13-22 (SBL2) and S15-1 (GND) of the suspension control ECU connector. Standard voltage: 4.5 to 5.5 V NG CHECK HEIGHT CONTROL SENSOR SUBASSEMBLY CIRCUIT SC SC–56 3 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECT SUSPENSION CONTROL ECU (ECU POWER SOURCE) S15 GND (-) (a) Turn the ignition switch OFF, and measure voltage between terminals S14-6 (B) and S15-1 (GND) and between S14-6 (B) and S14-5 (GND2) of the suspension control ECU connector. Standard voltage: 10 to 14 V S14 B (+) NG GND2 (-) F043242E02 OK SC REPLACE SUSPENSION CONTROL ECU CHECK POWER SOURCE CIRCUIT SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM SC–1 SUSPENSION CONTROL SYSTEM PRECAUTION 1. 2. C099154 (a) Disconnect the height control tube. (1) Pinch "A" of the connector No. 1 and pull out from the housing. “A” Housing WHEN LIFTING UP VEHICLE (a) When jacking up or lifting up, stop operation of the air suspension control system by pressing the height control OFF switch. DISCONNECTION AND CONNECTION OF HEIGHT CONTROL TUBE NOTICE: • Disconnection and connection of the height control tube should be performed by hand to prevent foreign objects from entering. • Never damage the height control tube. Air Tube Connector No. 1 C125294E01 (2) Set the SST to the tube. SST 09730-00010 SST Air Tube C125295E01 Connector No. 2 Plate O-ring Air Tube SST C125296E01 (3) Insert SST into the housing to expand the claw of the connector No. 2 in the housing. (4) Pull out the tube with SST inserted. NOTICE: Do not pull on the tube with excessive force. (5) Insert a screwdriver into the circular hole on the housing, and remove the connector No. 2, the 2 O-rings and the plate from the housing. HINT: The O-rings, plate and connector No. 2 are nonreusable parts. SC SC–2 SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM (b) Install height control tube O-ring and the plate. NOTICE: When replacing the parts on which the tube to be installed with a new one, it is not necessary to perform the procedure for installation. (1) Apply MP grease to 2 new O-rings and plate and install them to the straight tube or an equivalent. NOTICE: Install the plate between the O-rings. Keep foreign matter from adhering to the Orings and the height control tube in order to prevent air leaks. O-ring Plate C125408E01 O-ring (2) Insert the tube on which the 2 O-rings and plate are installed into the housing, and then push it in lightly with a piece of rolled up cardboard. Cardboard SC Plate C125409E01 (3) Push the connector No. 2 into the housing to where a clicking sound is heard. Connector No. 2 C125410E01 Housing Port (Hole) Claw Connector No. 1 Air Tube C125297E01 3. (c) Install the height control tube. (1) Push the tube and connector No. 1 into the housing to where a clicking sound is heard. NOTICE: • The port (hole) of the housing should be set in the position 90° from the claws of connector No. 1. • Pull the tube lightly to make sure that it is securely connected. • Prevent foreign matter from being attached to the O-rings and height control tube. Failure to do so may cause air leakage. HANDLING PRECAUTIONS FOR CENTER UNIT AND SHOCK ABSORBER (a) Replacement of each unit is allowed if there is no oil leakage. But, in case of oil leakage from the system, replace both the absorber and the center unit as a set. SUSPENSION CONTROL – SUSPENSION CONTROL SYSTEM 4. (b) For replacement of the system, make it possible to replace a unit only at the first time and replace the system as a set of delivery at the second time or later. (c) When carrying each unit, be sure to hold the body of the unit and never hang the body by holding joint parts or hoses. Also, do not deform metal tubes. (d) Each unit should not be at a high temperature at the time of replacement. (e) Since the shock absorber could be damaged by a sudden temperature change as being disconnected from the center unit, be careful about its storage. (f) Do not loosen the union bolt except the time of the disposal of each unit. (g) Never loosen the absorber hoses and the flare nuts at the joint parts. REMOVAL AND INSTALLATION PRECAUTION FOR CENTER UNIT AND SHOCK ABSORBER (a) Conduct the operations as stretching all the shock absorbers out by jacking up the vehicle. (b) Never put a great compressive load to the shock absorbers, such as contacting the tires on the ground, before connecting them to the center unit to avoid the break down. (c) Avoid the contacting surfaces of the joint parts to get any foreign objects, and wipe them away so as not to damage the O-rings in case of the adhesion. (d) Be sure to fit the detentes attached to the bracket on the front absorber hose side, the rear absorber hose side and the middle unit joint part into a hole on the frame side. (e) Never loosen the absorber hoses and the flare nuts at the joint parts. (f) G020407 SC–3 For the joint that is connecting the supplied parts, tighten the joint as checking the gap spacing shown in the illustration. Dimension of gap: 1 mm (0.04 in.) Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) SC SC–57 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1774/74 Power Source Circuit DESCRIPTION When turning the ignition switch to the ON position, the battery positive voltage is input to terminal B and IG of the suspension control ECU. By turning the ignition switch to OFF, the supply of the battery positive voltage to terminal B and IG terminals stops, and the power is turned OFF. DTC No. DTC Detecting Condition Trouble Area • • • The terminal B or IG voltage is detected being below or above a constant voltage for 0.5 seconds. C1774/74 Battery Power source circuit Suspension control ECU WIRING DIAGRAM Driver Side J/B I18 Ignition SW 2 AM1 ECU-IG 2 1C L-Y IG1 4 Suspension Control ECU 12 1E J4 J/C B-R B-R F F SC 10 S15 IG Engine Room R/B L-Y AIR SUS No. 2 2 AIR SUS 1 6 S14 B GR 2 2 2 2 W-L 1 ALT 2 2 2 B AM1 1 2 2 B 1 J/C 2 W-B A J2 A J3 A J3 W-B W-B 1 S15 GND 5 S14 GND2 Battery EB F045204E01 INSPECTION PROCEDURE 1 INSPECT SOURCE VOLTAGE (a) Check the battery voltage. SC–58 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Standard voltage: 11 to 14 V HINT: Start the inspection from step 2 when using the intelligent tester, and start from step 3 when not using the intelligent tester. NG REPLACE BATTERY OK 2 INSPECT FUSE (AIR SUS NO.2) (a) Remove the AIR SUS No. 2 fuse from the engine room R/B. (b) Measure the resistance of the AIR SUS No. 2 fuse. Standard resistance: Below 1 Ω Engine Room R/B: SC NG REPLACE FUSE AIR SUS No. 2 Fuse F043247E05 OK 3 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the driver side J/B. (b) Measure the resistance of the ECU-IG fuse. Standard resistance: Below 1 Ω Driver Side J/B: NG ECU-IG Fuse F043250E02 OK REPLACE FUSE SUSPENSION CONTROL – AIR SUSPENSION SYSTEM 4 SC–59 INSPECT SUSPENSION CONTROL ECU S15 GND (-) (a) Remove the suspension control ECU with connectors still connected. (b) Turn the ignition switch ON, and measure voltage between terminal S14-6 (B) and S15-1 (GND) and between terminal S14-6 (B) and S14-5 (GND2) of the suspension control ECU connector. Standard voltage: 10 to 14 V S14 B (+) GND2 (-) F043242E02 IG (+) (c) Turn the ignition switch ON, measure voltage between terminals S15-10 (IG) and S15-1 (GND) and between terminals S15-10 (IG) and S14-5 (GND2) of the suspension control ECU connector. Standard voltage: 10 to 14 V S15 S14 GND (-) OK REPLACE SUSPENSION CONTROL ECU GND2 (-) F043242E03 NG 5 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - BODY GROUND) GND2 S15 GND S14 F043248E01 (a) Disconnect the suspension control ECU connectors. (b) Turn the ignition switch ON and measure the resistance between terminal S15-1 (GND) and body ground and between terminal S14-5 (GND2) and body ground. Standard resistance: Below 1 Ω HINT: • OK: Repair or replace the harness or the connector between the AIR SUS fuse and the suspension control ECU and/or the ECU-IG fuse and the suspension control ECU. • NG: Repair or replace the harness or the connector between the suspension control ECU and body ground. NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC SC–60 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1776/76 Speed Sensor Circuit DTC C1794/94 Front Speed Sensor RH Circuit Malfunction DTC C1795/95 Front Speed Sensor LH Circuit Malfunction DESCRIPTION The speed sensor detects the wheel speed and transmits the appropriate vehicle speed signal to the suspension control ECU through the skid control ECU. DTC No. C1776/76 SC DTC Detection Condition Trouble Area • • • • Speed sensor circuit malfunction. Speed sensor Speed sensor circuit Skid control ECU Suspension control ECU HINT: When DTC C1794/94 and C1795/95 are output, follow the same procedure as DTC1776/76. WIRING DIAGRAM Skid Control ECU Suspension Control ECU 38 FLO S28 L-O 8 S15 FLO 37 FRO S28 L-R 9 S15 FRO F050633E01 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the intelligent tester, and start from step 2 when not using the intelligent tester. 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to DLC3. (b) Turn the ignition switch ON, and push the intelligent tester main switch ON. SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–61 (c) Select the item "VEHICLE SPEED" in the DATA LIST, and read its value displayed on the intelligent tester. (d) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: There is almost no difference in the displayed speed values. HINT: There is tolerance of +-10% in the speedometer indication. OK REPLACE SUSPENSION CONTROL ECU NG 2 CHECK DTC (VSC SYSTEM) (a) Check if the normal code is output by VSC (See page BC-48). NG REPAIR CIRCUIT INDICATED BY OUTPUT DTC OK 3 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - SKID CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and the skid control ECU (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT SUSPENSION CONTROL ECU (FLO SIGNAL, FRO SIGNAL) (a) Remove the suspension control ECU with connector still connected. (b) Turn the ignition switch ON. (c) Connect an oscilloscope to between terminals S15-8 (FLO) and S15-1 (GND) and between terminals S15-9 (FRO) and S15-1 (GND) of the suspension control ECU harness side connector. S15 GND FRO FLO F043242E04 SC SC–62 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Normal Signal Waveform GND 5 V/Division 5 ms/Division F044951E02 OK REPLACE SKID CONTROL ECU SC (d) Drive the vehicle with about 20 km/h (12 mph), and check the signal waveform. OK: Signal waveform appears as shown in the illustration. HINT: As the engine speed becomes higher, the waveform cycle gets shorter. NG REPLACE SUSPENSION CONTROL ECU SC–63 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1779/79 Crankshaft Position Sensor Circuit DTC C1797/97 Crankshaft Position Sensor Circuit DESCRIPTION The suspension control ECU receives the engine speed signal from ECM. DTC No. C1779/79 DTC Detection Condition Trouble Area TACH signal is not sent to suspension control ECU, and the vehicle is driven for 10 sec. or more at the speed of 30 km/h or higher. • • • • Crankshaft position sensor Crankshaft position sensor circuit ECM Suspension control ECU HINT: When DTC C1797/97 is output, follow the same procedure as that of DTC1779/79. WIRING DIAGRAM Suspension Control ECU ECM 1 TACH E7 B-W F J32 J/C G J31 J8 J/C B-W B-W F F 13 IC5 B-W 13 S14 TACH F043231E01 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - ECM) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and ECM (See page IN-38). NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR SC SC–64 2 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECT ECM (TACH SIGNAL) E6 E1 (a) Remove the ECM with connectors being connected. (b) Turn the ignition switch ON. (c) Connect an oscilloscope to terminals E7-1 (TACH) and E6-1 (E1) of the ECM harness side connector. E7 TACH I034219E17 Normal Signal Waveform About 13 V SC GND 5 V/Division (d) With the engine idling, check the signal waveform. Standard: Signal waveform appears as shown in the illustration. HINT: As the engine speed becomes higher, the waveform cycle gets shorter. NG 10 ms/Division F044950E04 OK REPLACE SUSPENSION CONTROL ECU REPLACE ECM SC–65 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1782/82 Stop Light Switch Circuit DESCRIPTION When the brake pedal is depressed, the stop light comes on and the signal is input to the STP terminal of the suspension control ECU. HINT: This DTC is output only when the sensor signal check is done. DTC No. C1782/82 DTC Detecting Condition Trouble Area • • • The signal from the stop light switch assembly does not change. Stop light switch assembly Stop light switch circuit Suspension control ECU WIRING DIAGRAM SC Suspension Control ECU Skid Control ECU with Actuator STOP LP CTRL Relay 2 To Battery 1 2 2 J4 J/C G-W 2 5 G-B 2 3 G-B E E 12 S14 STP 4 G-Y G-Y B B S12 Stop Light SW 2 B ALT STOP 2 2 1 2 2 1 G-W 2 1 2 2 B G-W Battery F050636E01 SC–66 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECTION PROCEDURE 1 INSPECT STOP LIGHT (a) Check that the stop light comes on when the brake pedal is depressed and goes off when the brake pedal is released. OK: Stop light operates normally. NG Go to step 3 OK 2 INSPECT SUSPENSION CONTROL ECU (a) Remove the suspension control ECU with connectors still connected. (b) Measure the voltage between terminal S14-12 (STP) of the suspension control ECU and body ground when the stop light switch is ON and OFF. Standard voltage SC S14 STP (+) Switch condition Specified condition Brake pedal depressed (ON) 10 to 14 V Brake pedal released (OFF) Below 1 V F043242E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE SUSPENSION CONTROL ECU 3 INSPECT STOP LIGHT SWITCH (a) Disconnect the stop light switch assembly connector. (b) Check resistance between terminals 1 and 2 of the stop light switch assembly. Standard resistance 1 Free 2 Tester connection Specified condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher Pushed in E065594E53 OK Switch condition NG REPLACE STOP LIGHT SWITCH SC–67 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM 4 INSPECT SUSPENSION CONTROL ECU (a) Remove the suspension control ECU with connectors still connected. (b) Measure the voltage between terminal S14-12 (STP) of the suspension control ECU and body ground when the stop light switch is ON and OFF. Standard voltage S14 Switch condition STP (+) Specified condition Brake pedal depressed (ON) 10 to 14 V Brake pedal released (OFF) Below 1 V F043242E05 NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC SC–68 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1783/83 Door Courtesy Switch Circuit DESCRIPTION The door courtesy light switch turns on when the door is opened and turns off when the door is closed. The signal is sent from the body ECU and the back door ECU into the DOOR terminal of the suspension control ECU when all the doors are open. DTC No. C1783/83 DTC Detecting Condition Door courtesy light switch signal does not change. Trouble Area • • • • • • Door courtesy light switch Back door lock assembly (Back door courtesy light switch) Door courtesy light switch circuit Body ECU Back door ECU Suspension control ECU WIRING DIAGRAM SC Body ECU 20 ACTY B5 Suspension Control ECU 12 IC5 R-G R-G 4 S15 DOOR F043233E01 INSPECTION PROCEDURE 1 INSPECT COURTESY LIGHT SWITCH (a) Check that the open door warning light comes on when any door or back door is opened and goes off when all the doors are closed. OK: Courtesy light operates normally. NG OK CHECK OPEN DOOR WARNING LIGHT SC–69 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM 2 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - BODY ECU) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and the body ECU (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT BODY ECU (ACTY OUTPUT) (a) Remove the body ECU with connectors still connected. (b) Measure the voltage between terminal B5-20 (ACTY) of the body ECU and body ground when door is opened and closed. Standard voltage B5 ACTY (+) Door condition Specified condition Each door opened Below 1.5 V All doors closed 10 to 14 V F044280E01 NG OK REPLACE SUSPENSION CONTROL ECU REPLACE BODY ECU SC SC–70 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1786/86 Height Control Switch Circuit DESCRIPTION Vehicle height can be chosen by pressing the height control switch. By pressing the "UP" side, vehicle height goes up. By pressing the "DOWN" side, vehicle height goes down. DTC No. DTC Detecting Condition C1786/86 Height control switch signal does not change. Trouble Area • • • Height control switch Height control switch circuit Suspension control ECU WIRING DIAGRAM H12 Height Control SW SC Suspension Control ECU L 10 IC5 L 16 S14 UPSW L-W 9 IC5 L-W 15 S14 DNSW HSW 3 W-B 6 E LOSW 5 A J24 J/C II F043234E01 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the intelligent tester and start from step 2 when not using the intelligent tester. 1 READ VALUE OF DATA LIST (HEIGHT SW DOWN AND HEIGHT SW UP) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON, and turn the intelligent tester main switch ON. (c) Select the item "HEIGHT SW DOWN" or "HEIGHT SW UP" in the DATA LIST, and read its value displayed on the intelligent tester. (d) Check that the value displayed on the intelligent tester changes by pressing the height control switch "UP" or "DOWN". SC–71 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM OK: Height control switch value changes. OK REPLACE SUSPENSION CONTROL ECU NG 2 INSPECT HEIGHT CONTROL SWITCH (a) Remove the height control switch connector. (b) Check continuity between each terminal of the height control switch when the height control switch "UP" or "DOWN" button is pressed. Standard resistance Tester connection 6 3 5 UP Button Height Control Switch NG Switch condition Specified condition 2-3 "UP" button Below 1 Ω 2-3 "DOWN" button 10 kΩ or higher 2-4 "UP" button 10 kΩ or higher 2-4 "DOWN" button Below 1 Ω REPLACE HEIGHT CONTROL SWITCH DOWN Button F043252E01 OK 3 CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL SWITCH - SUSPENSION CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between the height control switch and the suspension control ECU (See page IN-38). NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC SC–72 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1788/88 Height Control OFF Switch Circuit DESCRIPTION Height control can be operated or suspended by pressing the height control OFF switch. By pressing the switch once, height control can be suspended. By pressing the switch one more time, height control can be operated. DTC No. DTC Detecting Condition Trouble Area Height control OFF switch signal does not change. C1788/88 • • • Height control OFF switch Height control OFF switch circuit Suspension control ECU WIRING DIAGRAM H19 Height Control Mode Select SW (Height Control OFF Switch) SC W-B G 4 HEIGHT OFF CONTROL 3 Suspension Control ECU 11 IC5 G 24 S14 TD A J24 J/C II F043235E01 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the intelligent tester and start from step 2 when not using the intelligent tester. 1 READ VALUE OF DATA LIST (HEIGHT SW HOLD) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON, and turn the intelligent tester main switch ON. (c) Select the item "HEIGHT SW HOLD" in the DATA LIST, and read its value displayed on the intelligent tester. (d) Check that the value displayed on the intelligent tester changes by pressing the height control mode select switch. OK: Height control mode select switch value changes. SC–73 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM OK REPLACE SUSPENSION CONTROL ECU NG 2 INSPECT HEIGHT CONTROL OFF SWITCH (a) Disconnect the height control OFF switch connector. (b) Check continuity between terminals 3 and 4 of the height control mode select switch when the height control OFF switch is pushed in and free. Standard resistance 3 Switch condition Specified condition Pushed in Below 1 Ω Free 10 kΩ or higher 4 Height Control OFF Switch NG REPLACE HEIGHT CONTROL OFF SWITCH SC Pushed In Free C123983E02 OK 3 CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL OFF SWITCH - SUSPENSION CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between the height control OFF switch and the suspension control ECU (See page IN-38). NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC–74 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Height Control Indicator Light Circuit DESCRIPTION The height control indicator light indicates the target height, not the actual height. It blinks when the height control is operated by pressing the height control switch and stays on when the operation is completed. SC SC–75 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM Suspension Control ECU Combination Meter Assembly DRIVE CIRCUIT 15 C10 R-L LO 4 C8 BR-B 3 IC5 BR-B 18 S15 LO N 3 C8 Y-B 2 IC5 Y-B 17 S15 NR HI 2 C8 Y 1 IC5 Y 16 S15 HI OFF 5 C8 Y-G 4 IC5 Y-G 15 S15 VN 13 C10 BR 7 IM1 16 C10 R F J9 J/C H J8 J7 J/C R R D D Driver Side J/B GAUGE 4 1G W 2 6 1D 1 2 6 IG2 2 1 AM2 7 R 2 R 2 Battery Short Pin 2 C2 IC4 B-R DOME 2 BR I18 Ignition SW AM2 1 SC 2 B ED Engine Room R/B F050634E01 SC–76 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECTION PROCEDURE 1 INSPECT HEIGHT CONTROL INDICATOR LIGHT (a) Turn the ignition switch to the ON position. (b) Check that the height control indicator light comes on. OK: Height control indicator light comes on, and then goes off after 2 seconds. NG GO TO COMBINATION METER SYSTEM OK 2 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - COMBINATION METER) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and the combination meter (See page IN-38). SC NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC–19 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM PROBLEM SYMPTOMS TABLE HINT: • If a normal system code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. • Inspect the fuse before inspecting the suspected areas as shown in the chart below. • Inspect each malfunction circuit in numerical order for the corresponding symptom. • If the malfunction still exists even after checking and confirming that all the circuits are normal, replace the suspension control ECU. AIR SUSPENSION SYSTEM Symptom Vehicle height control function does not operate. Illuminated position of height control indicator light does not change by height control switch operation. Hunting of vehicle height occurs. Vehicle height control operates, but vehicle height uneven. Vehicle height control operates, but vehicle height height or low (Vehicle height in NORMAL mode differs from standard value). Suspected area See page 1. Freezing of the air tube - 2. Power source circuit SC-52 3. Crankshaft position sensor circuit SC-60 4. Height control OFF switch circuit SC-69 5. Height control switch circuit SC-67 6. Height control sensor circuit SC-30 7. Height control solenoid valve circuit SC-35 8. Gate solenoid valve circuit SC-35 9. Exhaust solenoid valve circuit SC-35 10. AIR SUS relay circuit SC-40 11. Height control compressor circuit SC-44 12. Suspension control ECU - 1. Power source circuit SC-54 2. Crankshaft position sensor circuit SC-60 3. Height control OFF switch circuit SC-69 4. Height control switch circuit SC-67 5. Height control sensor circuit SC-35 6. Height control solenoid valve circuit SC-35 7. Gate solenoid valve circuit SC-35 8. Exhaust solenoid valve circuit SC-35 9. AIR SUS relay circuit SC-40 10. Height control compressor circuit SC-44 11. Speed sensor circuit SC-57 12. Suspension control ECU - 1. Air leakage (Height control cylinder assembly rear) SC-28 2. Height control sensor circuit SC-30 3. Suspension control ECU - 1. Air leakage SC-28 2. Clogging of air tube - 3. Height control sensor link sub-assembly - 4. Height control sensor circuit SC-30 5. Gate solenoid valve circuit SC-35 6. Suspension control ECU - 1. Height control sensor link sub-assembly - 2. Height control sensor circuit SC-30 3. Suspension control ECU - SC SC–20 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Symptom When vehicle height control adjusted, it stops at extremely high or low position. Height control manual indicator light condition abnormal. Height control indicator light condition abnormal. DTC check cannot completed. SC Input signal check (test mode) cannot completed. Vehicle height extremely low when vehicle parked. (*1) Compressor motor continues to operate. (*2) Suspected area See page 1. Height control sensor circuit SC-30 2. Height control sensor link sub-assembly - 3. Suspension control ECU - 1. Power source circuit SC-52 2. Height control OFF switch circuit SC-69 3. Height control manual indicator light circuit SC-74 4. Suspension control ECU - 1. Power source circuit SC-52 2. Height control indicator light circuit SC-71 3. Suspension control ECU - 1. Power source circuit SC-52 2. TC terminal circuit SC-78 3. Height control OFF light circuit SC-74 4. Suspension control ECU - 1. Power source circuit SC-52 2. TS terminal circuit SC-80 3. Suspension control ECU - 1. Air leakage SC-28 2. Height control cylinder assembly rear - 3. Height control sensor link sub-assembly - 4. Height control solenoid valve circuit SC-35 5 Exhaust valve circuit SC-35 1. Air leakage SC-28 2. Air tube clogged - 3. Height control cylinder assembly rear - 4. Height control sensor link sub-assembly - 5. Height control solenoid valve circuit SC-35 6. Exhaust valve circuit SC-35 7. Tank solenoid valve circuit - 8. AIR SUS relay circuit SC-40 9. Height control compressor circuit SC-44 10. Suspension control ECU - HINT: • *1: Although, especially in a cold district, the vehicle height may become lower due to the air temperature drop in the height control cylinder assembly, that is not abnormal. • *2: Due to the air tube freezing, vehicle may not rase all the time. SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–77 Height Control OFF Indicator Light Circuit DESCRIPTION If the suspension control ECU detects a problem, the height control OFF indicator light comes on while suspending the height control function at the same time. At the same time, the suspension control ECU records a DTC in the memory. Connect terminals TC and CG of the DLC3 to make the height control manual indicator light blink and output DTCs. SC SC–78 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM Suspension Control ECU Combination Meter Assembly DRIVE CIRCUIT 15 C10 R-L SC LO 4 C8 BR-B 3 IC5 BR-B 18 S15 LO N 3 C8 Y-B 2 IC5 Y-B 17 S15 NR HI 2 C8 Y 1 IC5 Y 16 S15 HI OFF 5 C8 Y-G 4 IC5 Y-G 15 S15 VN 13 C10 BR 7 IM1 16 C10 R F J9 J/C H J8 J7 J/C R R D D Driver Side J/B GAUGE 4 1G W 2 6 1D B-R 6 IG2 1 2 2 1 R 2 Battery Short Pin 2 AM2 7 R 2 DOME 2 C2 IC4 I18 Ignition SW AM2 1 BR 2 B ED Engine Room R/B F050634E01 SC–79 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECTION PROCEDURE 1 INSPECT HEIGHT CONTROL OFF INDICATOR LIGHT (a) Turn the ignition switch to the ON position. (b) Check that the height control manual indicator light comes on. OK: Height control manual indicator light comes on, and then goes off after 2 seconds. NG GO TO COMBINATION METER SYSTEM OK 2 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - COMBINATION METER) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and the combination meter (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE SUSPENSION CONTROL ECU 3 CHECK CONNECTORS (a) Check that the connectors are properly connected to the suspension control ECU. OK: The connectors are properly connected. NG CONNECT CONNECTORS OK 4 CHECK DTC (a) Clear and check the DTC (See page SC-23). Result Result Proceed to Normal system code is output. A DTC is output. B NG REPAIR CIRCUIT INDICATED BY OUTPUT DTC SC SC–80 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM OK 5 CHECK HARNESS AND CONNECTOR (SUSPENSION CONTROL ECU - COMBINATION METER) (a) Check for open and short circuit in the harness and the connector between the suspension control ECU and the combination meter (See page IN-38). NG OK REPLACE SUSPENSION CONTROL ECU SC REPAIR OR REPLACE HARNESS OR CONNECTOR SC–81 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC is output when there is a short circuit between terminals TC and CG of DLC3. WIRING DIAGRAM D1 DLC3 Suspension Control ECU J18 J/C TC 13 P-L H H 5 IC5 P-L P-L 6 S15 TC J22 J/C CG 4 W-B E W-B E SC J5 J/C A IG F043237E01 INSPECTION PROCEDURE 1 CHECK DLC3 TERMINAL VOLTAGE (TC TERMINAL) (a) Turn the ignition switch to the ON position. (b) Measure voltage between terminals TC and CG of DLC3. Standard voltage: 10 to 14 V TC OK Go to step 3 DLC3 CG B124401E92 NG 2 CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) (a) Check for open and short circuit in the harness and the connector between terminal CG of DLC3 and body ground (See page IN-38). SC–82 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (DLC3 - SUSPENSION CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between terminal TC of DLC3 and the suspension control ECU (See page IN-38). NG OK SC REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC–9 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM AIR SUSPENSION SYSTEM SUSPENSION CONTROL & AXLE PARTS LOCATION AIR SUS FUSE ENGINE ROOM R/B NO. 4: SUSPENSION CONTROL RELAY AIR SUS FUSE NO. 2 SC ENGINE ROOM R/B: ENGINE ROOM R/B NO. 4 ENGINE ROOM R/B RIGHT FRONT SPEED SENSOR LEFT FRONT SPEED SENSOR CRANKSHAFT POSITION SENSOR C131560E01 SC–10 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM ECU-IG FUSE COMBINATION METER ASSEMBLY: DRIVER SIDE J/B: SC SKID CONTROL ECU ASSEMBLY STOP LIGHT SWITCH ASSEMBLY SUSPENSION CONTROL ECU ECM HEIGHT CONTROL OFF SWITCH DRIVER SIDE J/B DLC3 COMBINATION METER ASSEMBLY BODY ECU HEIGHT CONTROL SWITCH C119708E01 SC–11 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAR HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY REAR REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY HEIGHT CONTROL CYLINDER ASSEMBLY REAR SC HEIGHT CONTROL RESERVOIR ASSEMBLY HEIGHT CONTROL VALVE HEIGHT CONTROL COMPRESSOR ASSEMBLY LEVELING SOLENOID VALVE DRYER BACK DOOR ECU WITH MOTOR BACK DOOR ASSEMBLY TANK SOLENOID VALVE CYLINDER RH CYLINDER LH COMPRESSOR HEIGHT CONTROL DRYER ASSEMBLY EXHAUST SOLENOID VALVE GATE SOLENOID VALVE C119709E01 SC–83 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM TS and CG Terminal Circuit DESCRIPTION After making short circuit between terminal TS and CG of DLC3 with the ignition switch is turned to the OFF position, the mode will change from normal mode to test mode when the ignition switch is turned to the ON position, and then DTC is output. After the ignition switch is turned to the ON position, there will be DTC output. WIRING DIAGRAM D1 DLC3 Suspension Control ECU TS 4 IC2 R-B 12 J4 J/C R-B D R-B D 5 S15 TS J22 J/C CG W-B 4 E SC W-B E J5 J/C A IG F050635E01 INSPECTION PROCEDURE 1 CHECK DLC3 TERMINAL VOLTAGE (TS TERMINAL) (a) Turn the ignition switch to the ON position. (b) Measure voltage between terminals TS and CG of DLC3. Standard voltage: 10 to 14 V TS OK DLC3 CG B124401E93 NG Go to step 3 SC–84 2 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) (a) Check for open and short circuit in the harness and the connector between terminal CG of DLC3 and body ground (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (DLC3 - SUSPENSION CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between terminal TS of DLC3 and the suspension control ECU (See page IN-38). SC NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR SC–84 SUSPENSION CONTROL – HEIGHT CONTROL COMPRESSOR REMOVAL SC 1. REMOVE REAR DISC WHEEL 2. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 3. REMOVE REAR BUMPER (See page ET-10) 4. REMOVE FUEL TANK FILLER PIPE PROTECTOR (a) Remove the 4 clips and the fuel tank filler pipe protector. 5. REMOVE SPARE DISC WHEEL 6. REMOVE HEIGHT CONTROL COMPRESSOR COVER (a) Remove the 3 clips and the height control compressor cover. 7. REMOVE HEIGHT CONTROL FILTER (a) Disconnect the 2 clips and the 2 hoses. (b) Remove the 2 bolts and the height control filter. 8. DISCONNECT HEIGHT CONTROL TUBE NO. 2 (a) Remove the holder. (b) Spread the clip and slowly pull the height control tube No. 2 straight out. NOTICE: Do not remove the clip from the union except when replacing it. (c) Remove the 2 O-rings. 9. REMOVE HEIGHT CONTROL COMPRESSOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 clamps. C099145 C099146 (c) Remove the 3 bolts. (d) Disconnect the clip and remove the No. 1 hose. C099147 SUSPENSION CONTROL – HEIGHT CONTROL COMPRESSOR SC–85 (e) Remove the 3 bolts, the height control compressor and the dryer with the bracket. (f) Remove the bolt, the dryer and the O-ring. (g) Remove the 3 bushings from the height control compressor assembly. C099148 SC SC–86 SUSPENSION CONTROL – HEIGHT CONTROL COMPRESSOR INSTALLATION SC 1. INSTALL HEIGHT CONTROL COMPRESSOR ASSEMBLY (a) Install the 3 bushings to the height control compressor assembly. (b) Install the bolt, the dryer and the new O-ring. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) (c) Assemble the height control compressor, the dryer and the bracket as a unit to the vehicle, and tighten the 3 bolts to fix the bracket to the frame. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) (d) Install the height control compressor assembly to the bracket with the 3 bolts. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) (e) Install the 3 clamps. (f) Connect the connector. (g) Connect the No. 1 hose with a new clip. 2. CONNECT HEIGHT CONTROL TUBE NO. 2 (a) Coat 2 new O-rings with MP grease. (b) Push the height control tube No. 2 in straight to connect it until the clip makes "click" sound. NOTICE: Do not get scratches or foreign particles on the O-ring, O-ring seal and flare section. (c) Install the holder. 3. INSTALL HEIGHT CONTROL FILTER (a) Install the height control filter with the new 2 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) (b) Connect 2 new clips and 2 hoses. 4. INSTALL HEIGHT CONTROL COMPRESSOR COVER (a) Install the height control compressor cover with 3 new clips. 5. CHECK AIR LEAK 6. INSTALL SPARE DISC WHEEL 7. INSTALL FUEL TANK FILLER PIPE PROTECTOR (a) Install the fuel tank filler pipe protector with the 4 clips. 8. INSTALL REAR BUMPER (See page ET-14) 9. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 10. INSTALL REAR DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) SC–88 SUSPENSION CONTROL – HEIGHT CONTROL DRYER REMOVAL SC 1. REMOVE REAR DISC WHEEL 2. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 3. REMOVE REAR BUMPER (See page ET-10) 4. REMOVE FUEL TANK FILLER PIPE PROTECTOR (See page SC-84) 5. REMOVE SPARE DISC WHEEL 6. REMOVE HEIGHT CONTROL COMPRESSOR COVER (See page SC-84) 7. REMOVE HEIGHT CONTROL FILTER (See page SC84) 8. DISCONNECT HEIGHT CONTROL TUBE NO. 2 (See page SC-84) 9. REMOVE HEIGHT CONTROL DRYER ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts. C099147 (c) Remove the 3 bolts, the height control compressor and the dryer with the bracket. (d) Remove the bolt and the dryer. (e) Remove the O-ring. C099148 SUSPENSION CONTROL – HEIGHT CONTROL DRYER SC–89 INSTALLATION 1. INSTALL HEIGHT CONTROL DRYER ASSEMBLY (a) Install the bolt, the dryer and a new O-ring. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) (b) Assemble the height control compressor, the dryer and the bracket as a unit to the vehicle, and tighten the 3 bolts to fix the bracket to the frame. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) (c) Install the height control compressor assembly to the bracket with the 3 bolts. Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) (d) Connect the connector. 2. CONNECT HEIGHT CONTROL TUBE NO. 2 (See page SC-85) 3. INSTALL HEIGHT CONTROL FILTER (See page SC85) 4. INSTALL HEIGHT CONTROL COMPRESSOR COVER (See page SC-85) 5. CHECK AIR LEAK (See page SC-28) 6. INSTALL SPARE DISC WHEEL 7. INSTALL FUEL TANK FILLER PIPE PROTECTOR (See page SC-85) 8. INSTALL REAR BUMPER (See page ET-14) 9. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 10. INSTALL REAR DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) SC SC–92 SUSPENSION CONTROL – HEIGHT CONTROL RESERVOIR REMOVAL 1. REMOVE SPARE DISC WHEEL 2. DISCONNECT HEIGHT CONTROL TUBE NO. 2 (a) Remove the holder. (b) Spread the clip and slowly pull the height control tube No. 2 straight out. (c) Remove the 2 O-rings. 3. DISCONNECT HEIGHT CONTROL TUBE NO. 6 (a) Using SST, disconnect the height control tube No. 6. SST 09730-00010 NOTICE: Refer to PRECAUTION of removal and installation of the height control tube (See page SC-1). (b) Remove the 2 O-rings, the plate and the plug. 4. DISCONNECT HEIGHT CONTROL TUBE NO. 7 (a) Using SST, disconnect the height control tube No. 7. SST 09730-00010 NOTICE: Refer to PRECAUTION of removal and installation of the height control tube (See page SC-1). (b) Remove the 2 O-rings, the plate and the plug. 5. REMOVE HEIGHT CONTROL RESERVOIR ASSEMBLY (a) Remove the 2 bolts and the height control reservoir assembly. SC SUSPENSION CONTROL – HEIGHT CONTROL RESERVOIR SC–93 INSTALLATION 1. INSTALL HEIGHT CONTROL RESERVOIR ASSEMBLY (a) Install the height control reservoir assembly with the 2 bolts. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) 2. CONNECT HEIGHT CONTROL TUBE NO. 7 (a) Install 2 new O-rings, a new plate, a new plug and connect the height control tube No. 7. NOTICE: Refer to PRECAUTION of removal and installation of the height control tube (See page SC-1). 3. CONNECT HEIGHT CONTROL TUBE NO. 6 (a) Install 2 new O-rings, a new plate, a new plug, and connect the height control tube No. 6. NOTICE: Refer to PRECAUTION of removal and installation of the height control tube (See page SC-1). 4. CONNECT HEIGHT CONTROL TUBE NO. 2 (a) Coat 2 new O-rings with MP grease. (b) Push the height control tube No. 2 in straight to connect it until the clip makes "click" sound. (c) Install the holder. 5. CHECK AIR LEAK (See page SC-28) 6. INSTALL SPARE DISC WHEEL SC SC–96 SUSPENSION CONTROL – HEIGHT CONTROL SENSOR INSTALLATION SC 1. INSTALL HEIGHT CONTROL SENSOR SUBASSEMBLY REAR LH (a) Install the height control sensor with the 2 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) (b) Align the matchmarks on the link and the bracket. (c) Connect the sensor link with the nut. (d) Connect the connector to the height control sensor. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 2. INSTALL REAR DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) 3. MEASURE VEHICLE HEIGHT (See page SP-4) 4. ADJUST VEHICLE HEIGHT (See page SC-6) SC–100 SUSPENSION CONTROL – SUSPENSION CONTROL ECU REMOVAL SC G020175 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-9) 3. REMOVE COWL SIDE TRIM BOARD LH (See page IP9) 4. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 1 (See page IP-9) 5. REMOVE INSTRUMENT PANEL FINISH PLATE (See page IP-9) 6. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-8) 7. REMOVE INSTRUMENT PANEL LOWER LH 8. REMOVE SUSPENSION CONTROL ECU (a) Disconnect the 3 suspension control ECU connectors. (b) Remove the 2 bolts and the suspension control ECU. SUSPENSION CONTROL – SUSPENSION CONTROL ECU SC–101 INSTALLATION 1. INSTALL SUSPENSION CONTROL ECU (a) Install the suspension control ECU with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Connect the 3 suspension control ECU connectors. 2. INSTALL INSTRUMENT PANEL LOWER LH 3. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 4. INSTALL INSTRUMENT PANEL FINISH PLATE 5. INSTALL INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 1 6. INSTALL COWL SIDE TRIM BOARD LH 7. INSTALL FRONT DOOR SCUFF PLATE LH SC SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–21 TERMINALS OF ECU S15 S14 S13 F043241E03 Symbols (Terminals No.) Wiring Color SLRL (S13-1) - GND (S15-1) V-W - W-B SLRR (S13-2) - GND (S15-1) V - W-B SLLO (S13-7) - GND (S15-1) P-G - W-B SLEX (S13-8) - GND (S15-1) LG - W-B RC (S13-18) - GND (S15-1) BR-Y - W-B Condition Specified Condition IG switch ON Below 1.0 V Engine idling, button of height control switch is pushed from "N" to "UP" or "DOWN" 8 V or more IG switch ON Below 1.0 V Engine idling, button of height control switch is pushed from "N" to "UP" or "DOWN" 8 V or more IG switch ON Below 1.0 V Engine idling, button of height control switch from "UP" to "DOWN" 8 V or more IG switch ON Below 1.0 V Engine idling, button of height control switch from "UP" to "DOWN" 8 V or more IG switch ON Below 1.0 V Engine idling, button of height control switch is pushed from "N" to "UP" or "DOWN" 8 V or more SGR2 (S13-19) - GND (S15-1) GR - W-B Always Below 1 Ω SBR2 (S13-20) - GND (S15-1) G-R - W-B IG switch ON 4.5 to 5.5 V Always Below 1 Ω IG switch ON 4.5 to 5.5 V IG switch ON 0.5 to 4.5 V SGL2 (S13-21) - GND (S15-1) R-W - W-B SBL2 (S13-22) - GND (S15-1) BR-W - W-B SHRL (S13-23) - GND (S15-1) GR-G - W-B SHRR (S13-24) - GND (S15-1) W - W-B RM+ (S13-25) - GND (S15-1) O - W-B Engine idling, vehicle height is changing from "NORMAL" to "HIGH" by pressing the height control switch (While height control compressor assembly is working). RM- (S13-26) - GND (S15-1) P - W-B Always Below 1 Ω GND2 (S14-5) - Body ground W-B - Body ground Always Below 1 Ω B (S14-6) - GND (S15-1) GR - W-B IG switch ON 10 to 14 V STP (S14-12) - GND (S15-1) G-B - W-B TACH (S14-13) - GND (S15-1) B-W - W-B Engine idling L-W - W-B IG switch ON, "DOWN" button of height control switch pushed in Engine idling, vehicle height is changed from "HIGH" to "NORMAL" by pressing the height control switch IG switch ON DNSW (S14-15) - GND (S15-1) Engine idling, vehicle height is changed from "HIGH" to "NORMAL" by pressing the height control switch Brake pedal depressed Brake pedal released IG switch ON, "DOWN" button of height control switch free UPSW (S14-16) - GND (S15-1) L - W-B IG switch ON, "UP" button of height control switch pushed in IG switch ON, "DOWN" button of height control switch free Approx. 2.5 V 0.5 to 4.5 V Approx. 2.5 V Below 1.0 V 10 to 14 V Below 1.5 V Pulse generation Below 1.5 V 10 to 14 V Below 1.5 V 10 to 14 V SC SC–22 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Symbols (Terminals No.) Wiring Color TD (S14-24) - GND (S15-1) G - W-B GND (S15-1) - Body ground W-B - Body ground DOOR (S15-4) - GND (S15-1) TS (S15-5) - GND (S15-1) SC R-G - W-B R-B - W-B TC (S15-6) - GND (S15-1) P-L - W-B FLO (S15-8) - GND (S15-1) L-O - W-B Specified Condition Condition IG switch ON, height control OFF switch push in Below 1.5 V IG switch ON, height control OFF switch released 10 to 14 V Below 1 Ω Always IG switch ON, each door opened Below 1.5 V IG switch ON, all door closed 10 to 14 V IG switch ON and terminals TS - CG connected Below 1.0 V IG switch ON and terminals TS - CG not connected 10 to 14 V IG switch ON and terminals TC - CG connected Below 1.0 V IG switch ON and terminals TC - CG not connected 10 to 14 V Vehicle speed 20 km/h (12 mph) or higher Pulse generation Pulse generation FRO (S15-9) - GND (S15-1) L-R - W-B Vehicle speed 20 km/h (12 mph) or higher IG (S15-10) - GND (S15-1) B-R - W-B IG switch ON 10 to 14 V MOD2 (S15-11) - GND (S15-1) W-B - W-B Always Below 1 Ω MOD1 (S15-12) - GND (S15-1) W-B - W-B Always Below 1 Ω VN (S15-15) - GND (S15-1) Y-G - W-B HI (S15-16) - GND (S15-1) Y - W-B NR (S15-17) - GND (S15-1) Y-B - W-B LO (S15-18) - GND (S15-1) BR-B - W-B SIL (S15-20) - GND (S15-1) R-Y - W-B IG switch ON, height control OFF indicator light ON 8 V or more IG switch ON, height control OFF indicator light OFF Below 1.5 V IG switch ON, height control "HI" indicator light ON 8 V or more IG switch ON, height control "N" or "LO" indicator light ON Below 1.5 V IG switch ON, height control "N" indicator light ON 8 V or more IG switch ON, height control "LO" or "HI" indicator light ON Below 1.5 V IG switch ON, height control "LO" indicator light ON 8 V or more IG switch ON, height control "HI" or "N" indicator light ON Below 1.5 V IG switch ON 8 V or more DIAGNOSIS SYSTEM DLC3: 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 F100115E31 Symbols (Terminal No.) DIAGNOSIS SYSTEM (a) Inspect the battery voltage. Battery voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding. (b) Check DLC3. The suspension control ECU uses the ISO 9141-2 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. Verify the conditions listed in the table below: Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During communication Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V HINT: If the intelligent tester display shows UNABLE TO CONNECT TO VEHICLE when the cable of the intelligent tester is connected to the DLC3, the ignition switch is turned ON and the tester is operated, there is a problem on the vehicle side or tester side. SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–23 • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tester itself, so consult the service department listed in the tester's instruction manual. (c) DTCs (Normal mode) (1) DTCs are memorized in the suspension control ECU and read by using the SST check wire or the intelligent tester (See page SC-23). SST 09843-18040 (d) Test mode (Input signal check) (1) By switching from normal mode into test mode, you can inspect the height control switch, height control mode select switch, door courtesy light switch, and stop light switch (See page SC-13). (e) Check the indicator light. (1) Turn the ignition switch to the ON position. (2) Check that the height control manual indicator light and the height control indicator light come on for 2 seconds. If the indicator check result is not normal, proceed to troubleshooting for the height control indicator light circuit (See page SC-71) and the height control OFF indicator light circuit (See page SC-74). F041674 DLC3: DTC CHECK / CLEAR CG 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC CHECK DTC (USING SST CHECK WIRE) (a) Checking DTCs using the SST check wire. SST 09843-18040 (1) Using the SST, connect terminals TC and CG of the DLC3. (2) Turn the ignition switch to the ON position. F100115E02 (3) Read and record any DTCs from the height control OFF indicator light on the combination meter. F041674 SC SC–24 Normal: SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (4) As examples, the blinking patterns of a normal system code and codes 13 and 33 are shown in the illustration. HINT: • If the height control OFF indicator light does not blink any DTC or a normal system code, inspect the height control OFF indicator light circuit (See page SC-74) and the TC terminal circuit (See page SC-78). • If 2 or more malfunctions are indicated at the same time, the lowest numbered DTC is displayed first. (5) Refer to the Diagnostic Trouble Code Chart (See page SC-26) for DTC information. (6) After completing the check, remove the SST check wire from the DLC3. SST 09843-18040 0.25 sec. ON OFF 0.25 sec. Codes 13 and 33: 1.5 sec. 0.5 sec. 2.5 sec. 4.5 sec. ON OFF SC 1.5 sec. 0.5 sec. Repeat C123990E01 DLC3: (b) Clearing the DTCs using the SST check wire. SST 09843-18040 (1) Using SST, connect terminals TC and CG of the DLC3. (2) Turn the ignition switch to the ON position. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E02 (3) Clear DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the height control OFF indicator light shows a normal system code. (5) Remove the SST check wire from the DLC3. SST 09843-18040 HINT: Disconnecting the battery cable during the operation will not erase DTCs in the ECU. F042949 2. Intelligent Tester DLC3 A066288E03 CHECK DTC (USING INTELLIGENT TESTER) (a) Checking DTCs using the intelligent tester. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Read DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (b) Clearing the DTCs using the intelligent tester. (1) Connect the intelligent tester to the DLC3 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–25 (2) Turn the ignition switch to the ON position. (3) Erase the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. SC SC–82 SUSPENSION CONTROL – HEIGHT CONTROL COMPRESSOR HEIGHT CONTROL COMPRESSOR SUSPENSION & CONTROL AXLE COMPONENTS SC REAR BUMPER SPARE DISC WHEEL QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR LH FUEL TANK FILLER PIPE PROTECTOR C119695E01 SC–83 SUSPENSION CONTROL – HEIGHT CONTROL COMPRESSOR HEIGHT CONTROL FILTER SC 6.4 (65, 57 in.*lbf) CLIP CLIP 29 (300, 21) HEIGHT CONTROL TUBE NO. 2 HOSE NO. 1 BRACKET CLIP HOSE BUSHING 29 (300, 21) 5.9 (60, 52 in.*lbf) 29 (300, 21) HOLDER HEIGHT CONTROL COMPRESSOR COVER O-RING BUSHING BUSHING O-RING 5.9 (60, 52 in.*lbf) CLIP CLIP CLIP 6.4 (65, 57 in.*lbf) HEIGHT CONTROL DRYER ASSEMBLY HEIGHT CONTROL COMPRESSOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131576E01 SC–26 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM FAIL-SAFE CHART 1. SC FAIL-SAFE FUNCTION (a) In the normal operation, if there is short or open in the sensor etc., the suspension control ECU suspend the vehicle height control operation. SC–27 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: By accessing the DATA LIST displayed by the intelligent tester, you can read the value of the switches and sensors and so on without removing any parts. Reading the DATA LIST is the first step of troubleshooting and is one method to shorten labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Following the display on the tester, read the DATA LIST. AIR SUSPENSION Item Measurement Item / Range (Display) Normal Condition Diagnostic Note VEHICLE SPD Vehicle speed reading / min.: 0 km/ h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed IG VOLTAGE ECU power supply voltage / min.: 0 V, max.: 25.5 V Actual ECU power supply voltage: 10 to 14 V ENGINE SPD Cam position sensor reading / min.: 0 rpm, max.: 25,500 rpm Actual engine revolutional speed HEIGHT SW DOWN Height control switch (DOWN) / ON or OFF ON: Height control switch "DOWN" button pressed OFF: - - HEIGHT SW UP Height control switch (UP) / ON or OFF ON: Height control switch "UP" button pressed OFF: - - HEIGHT SW HOLD Height control mode select switch / ON or OFF ON: Height control mode select switch pressed OFF: - - STOP LIGHT SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - DOOR SW Door courtesy light switch / ON or OFF ON: Open each door OFF: Close all doors - DAMPER SW1 Damping force switch 1 / ON or OFF The same as height control switch position TS TS terminal / ON or OFF ON: During test mode OFF: Normal mode - TC TC terminal / ON or OFF ON: DTC recorded OFF: No DTC recorded - SOL SLRL Height control valve solenoid (SLRL) / ON or OFF ON or OFF - SOL SLRG Height control valve solenoid (SLRG) / ON or OFF ON or OFF - LOW PRS TNK SOL Tank solenoid valve (SLLO) / ON or OFF ON or OFF - MOTOR RELAY AIR SUS relay / ON or OFF ON: Compressor operated OFF: Compressor not operated - EXHAUST SOL Exhaust solenoid valve (SLEX) / ON or OFF ON or OFF - RR HEIGHT Right rear height control sensor reading / min.: -3276.7 mm (129.004 in.), max.: 3276.8 mm (129.008 in.) Min.: -20 mm (-0.79 in.) Max.: 40 mm (-1.57 in.) - Speed indicated on the speedometer Engine revolutional speed indicated on the combination meter Operate the height control switch SC SC–28 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Measurement Item / Range (Display) Item Normal Condition Diagnostic Note RL HEIGHT Left rear height control sensor reading / min.: -3276.7 mm (129.004 in.), max.: 3276.8 mm (129.008 in.) Min.: -20 mm (-0.79 in.) Max.: 40 mm (1.57 in.) - #CODES Number of DTC recorded / min.: 0, max.: 255 Min.: 0, Max.: 255 - 2. SC ACTIVE TEST LIST HINT: Perform the ACTIVE TEST using the intelligent tester to operate the sensors, relays and solenoids without removing any parts. Performing the ACTIVE TEST is the first step of troubleshooting and is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Following the display on the tester, perform the ACTIVE TEST. AIR SUSPENSION Item Vehicle Condition / Test Details Diagnostic Note RR HEIGHT Turn height control switch / UP or DOWN MOTOR RELAY Turn AIR SUS relay / ON or OFF - EXHAUST SOL Turn exhaust solenoid valve / ON or OFF Operation of solenoid (clicking sound) can be heard LEVEL SOL REAR Turn leveling solenoid valve / ON or OFF Operation sound of solenoid (clicking sound) can be heard GATE SOL REAR Turn gate solenoid valve / ON or OFF Operation sound of solenoid (clicking sound) can be heard LOW PRS TNK SOL Turn tank solenoid valve / ON or OFF Operation of solenoid (clicking sound) can be heard Operation of motor can be heard SC–86 SUSPENSION CONTROL – HEIGHT CONTROL DRYER HEIGHT CONTROL DRYER SUSPENSION & CONTROL AXLE COMPONENTS SC REAR BUMPER SPARE DISC WHEEL QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR LH FUEL TANK FILLER PIPE PROTECTOR C119695E01 SC–87 SUSPENSION CONTROL – HEIGHT CONTROL DRYER HEIGHT CONTROL FILTER SC 6.4 (65, 57 in.*lbf) CLIP CLIP 29 (300, 21) HEIGHT CONTROL TUBE NO. 2 HOSE NO. 1 BRACKET CLIP HOSE BUSHING 29 (300, 21) 5.9 (60, 52 in.*lbf) 29 (300, 21) HOLDER HEIGHT CONTROL COMPRESSOR COVER O-RING BUSHING BUSHING O-RING 5.9 (60, 52 in.*lbf) CLIP CLIP CLIP 6.4 (65, 57 in.*lbf) HEIGHT CONTROL DRYER ASSEMBLY HEIGHT CONTROL COMPRESSOR ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131576E01 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–29 DIAGNOSTIC TROUBLE CODE CHART HINT: • Inspect the fuse before inspecting the suspected areas as shown in the chart below. • If no abnormality is found when the parts are inspected, inspect the suspension control ECU. • If a trouble code is displayed during the DTC check, check the circuit listed for that code. For details of each code, refer to the "See page" in the table below. AIR SUSPENSION SYSTEM DTC No. Detection Item Trouble Area OFF Indicator Light (*1) Memory (*2) See page C1713/13 Right Rear Height Control Sensor Circuit 1. Height control sensor subassembly rear RH 2. Right rear height control sensor circuit 3. Suspension control ECU Comes on (*3) DTC stored SC-30 C1714/14 Left Rear Height Control Sensor Circuit 1. Height control sensor subassembly rear LH 2. Left rear height control sensor circuit 3. Suspension control ECU Comes on (*3) DTC stored SC-30 C1733/33 Rear Height Control Gate Solenoid Valve Circuit Malfunction 1. Gate solenoid valve 2. Gate solenoid valve circuit 3. Suspension control ECU Comes on DTC stored SC-35 C1734/34 Rear Height Control Leveling Solenoid Valve Circuit Malfunction 1. Leveling solenoid valve 2. Leveling solenoid valve circuit 3. Suspension control ECU Comes on DTC stored SC-35 C1735/35 Exhaust Solenoid Valve Circuit 1. Exhaust solenoid valve 2. Exhaust solenoid valve circuit 3. Suspension control ECU Comes on DTC stored SC-35 C1741/41 Air Suspension Relay Circuit 1. AIR SUS relay 2. AIR SUS relay circuit 3. Suspension control ECU Comes on DTC stored SC-40 C1742/42 Height Control Compressor Circuit 1. Height control compressor assembly 2. Height control compressor circuit 3. Suspension control ECU Comes on DTC stored SC-44 C1744/44 Tank Solenoid Valve Circuit 1. Tank solenoid valve 2. Tank solenoid valve circuit 3. Suspension control ECU Goes off DTC stored SC-35 C1751/51 (*4) Continuous Electric Current to Height Control Compressor 1. Height control compressor assembly 2. Height control compressor circuit 3. Height control sensor link subassembly rear 4. Height control sensor subassembly rear 5. Relief valve 6. AIR SUS relay comes off 7. Air leakage from the air tube or each valve 8. Clogging in the air tube or each valve 9. Suspension control ECU Comes on DTC stored SC-49 C1761/61 ECU Malfunction Suspension control ECU Comes on DTC stored SC-52 SC SC–30 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC No. Detection Item Trouble Area OFF Indicator Light (*1) Memory (*2) See page C1774/74 Power Source Circuit 1. Battery 2. Power source circuit 3. Suspension control ECU Goes off DTC stored SC-54 C1776/76 Speed Sensor Circuit 1. Speed sensor 2. Speed sensor circuit 3. Skid control ECU 4. Suspension control ECU Goes off DTC stored SC-57 C1794/94 Front Speed Sensor RH Circuit Malfunction 1. Right front speed sensor 2. Right front speed sensor circuit 3. Skid control ECU assembly 4. Suspension control ECU Goes off DTC stored SC-57 C1795/95 Front Speed Sensor LH Circuit Malfunction 1. Left front speed sensor 2. Left front speed sensor circuit 3. Skid control ECU assembly 4. Suspension control ECU Goes off DTC stored SC-57 C1779/79 Crankshaft Position Sensor Circuit 1. Crankshaft position sensor 2. Crankshaft position sensor circuit 3. ECM 4. Suspension control ECU Goes off DTC stored SC-60 C1797/97 Crankshaft Position Sensor Circuit 1. Crankshaft position sensor 2. Crankshaft position sensor circuit 3. ECM 4. Suspension control ECU Goes off DTC stored SC-60 C1782/82 Stop Light Switch Circuit 1. Stop light switch assembly 2. Stop light switch circuit 3. Suspension control ECU SC-62 C1783/83 Door Courtesy Switch Circuit 1. Door courtesy light switch assembly 2. Back door lock assembly (Back door courtesy light switch) 3. Door courtesy light switch circuit 4. Body ECU 5. Back door ECU 6. Suspension control ECU SC-65 C1786/86 Height Control Switch Circuit 1. Height control switch 2. Height control switch circuit 3. Suspension control ECU SC-67 C1788/88 Height Control OFF Switch Circuit 1. Height control OFF switch (Suspension control switch) 2. Height control OFF switch circuit 3. Suspension control ECU SC-69 SC HINT: • *1: For codes marked with a "Comes on" in the "OFF Indicator Light" column, the height control manual indicator light blinks at 1 second intervals. • *2: The codes marked with a "DTC stored" in the "Memory" column are stored in the memory even when the ignition switch is OFF, but the codes marked with "-" are not. • *3: Height control OFF indicator light blinks when the vehicle speed is at 3 km/h (1.9 mph) or higher. SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–31 • *4: Since the relief pressure of the compressed air is 980 kPa (10 kgf*cm2, 142 psi), if the vehicle height control is attempted on a steeply sloping road, when the vehicle is overloaded, or when the vehicle is jacked up with the engine running, code "C1751/51" may be output and the vehicle height control may be suspended (This is not abnormal). In this case, however, the vehicle height operation is resumed approx. 10 min. after the ignition switch is turned ON after the ECU detects the first error. If ECU detects another error , it takes 70 minutes until the vehicle height control is resumed. SC SC–90 SUSPENSION CONTROL – HEIGHT CONTROL RESERVOIR HEIGHT CONTROL RESERVOIR SUSPENSION & CONTROL AXLE COMPONENTS SC SPARE DISC WHEEL C119695E02 SC–91 SUSPENSION CONTROL – HEIGHT CONTROL RESERVOIR SC SPARE DISC WHEEL HEIGHT CONTROL TUBE NO. 2 CONNECTOR CONNECTOR HOLDER CLIP O-RING 29 (300, 21) O-RING PLUG 29 (300, 21) PLATE PLATE HEIGHT CONTROL TUBE NO. 7 O-RING HEIGHT CONTROL RESERVOIR ASSEMBLY PLUG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part HEIGHT CONTROL TUBE NO. 6 C119696E01 SC–32 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM ON-VEHICLE INSPECTION 1. CHECK FLUID LEAKAGE (a) Check the connections of tube and parts for fluid leakage. SC : Supply parts only C099149E01 SC–33 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1713/13 Rear Height Control Sensor RH Circuit Malfunction DTC C1714/14 Rear Height Control Sensor LH Circuit Malfunction DESCRIPTION Inside the sensor, a brush integrated with the control sensor rotor shaft moves above the resistor, providing linear output. Since the resistance value between the brush and resistor terminal changes in proportion to the shaft rotation angle, the fixed voltage applied to the resistor by ECU is modified by the sensor and output to the ECU as a voltage indicating the shaft rotation angle. DTC No. DTC Detecting Condition Trouble Area • C1713/13 With the ignition switch ON, a voltage of 4.7 V or more or 0.3 V or less at each height control sensor sub-assembly rear is detected for 1 sec. C1714/14 • • • • • Height control sensor sub-assembly rear RH Right rear height control sensor circuit Suspension control ECU Height control sensor sub-assembly rear LH Left rear height control sensor circuit Suspension control ECU HINT: • Once the ECU stores DTC C1713/13 or C1714/14 in the memory, vehicle height control is suspended and not carried out until a normal signal is input to the ECU from the height control sensor subassembly. However, the control resumes if the ignition switch is turned OFF, and then turned ON again. • When the suspension control ECU detects a malfunction in the height control sensor, the height control indicator light "N" comes on or blinks, and the height control switch ("HI" and "LO") is suspended. • When either one of the right or left height control sensor sub-assembly is faulty, the suspension control ECU uses the other one (functioning one) to adjust the vehicle height to the normal height. When both of the height control sensor sub-assembly are faulty, the suspension control ECU suspend the height control function immediately. SC SC–34 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM H15 Height Control Sensor Rear LH SHB SHRL SHG Suspension Control ECU BR-W 22 BC2 BR-W 22 S13 SBL2 GR-G 17 BC2 GR-G 23 S13 SHRL R-W 11 BC2 R-W 21 S13 SGL2 G-R 9 BC2 G-R 20 S13 SBR2 W 18 BC2 W 24 S13 SHRR GR 19 BC2 GR 19 S13 SGR2 1 2 3 H16 Height Control Sensor Rear RH SC SHB SHRR SHG 1 2 3 F043223E01 INSPECTION PROCEDURE HINT: • Proceed to troubleshooting following the flow chart, regardless of whether or not DTC C1713/13 or C1714/14 is displayed. • If DTC C1761/61 (ECU malfunction) and/or C1774/74 (power source circuit) is displayed, perform the inspection necessary for DTC C1761/61 (See page SC-52) and/or C1774/74 (See page SC-54) first. (If DTC C1761/61 and C1774/74 are output at the same time, perform the inspection necessary for DTC C1774/74 first.) • Start the inspection from step 1 when using the intelligent tester, and start from step 2 when not using the intelligent tester. 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position, and push the intelligent tester main switch ON. SC–35 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (c) Select the item "RL HEIGHT" or "RR HEIGHT" in the DATA LIST, and read its value displayed on the intelligent tester. (d) Check the vehicle height value of the height control sensor sub-assembly with the intelligent tester while pressing the height control switch "UP" or "DOWN". OK: Vehicle height value changes. OK REPLACE SUSPENSION CONTROL ECU NG 2 CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAR POWER SOURCE) (a) Disconnect the height control sensor sub-assembly rear LH and RH connectors. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: LH Side RH: LH: H16 H15 SHB SHG SHB SHG F044277E01 Tester connection Condition Specified condition H15-1 (SHB) - H15-3 (SHG) Ignition switch ON 4.5 to 5.5 V Tester connection Condition Specified condition H16-1 (SHB) - H16-3 (SHG) Ignition switch ON 4.5 to 5.5 V RH Side OK Go to step 4 NG 3 CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL SENSOR REAR SUSPENSION CONTROL ECU) (a) Disconnect the S13 suspension control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH Side Tester connection Specified condition S13-22 (SBL2) - H15-1 (SHB) Below 1 Ω S13-23 (SHRL) - H15-2 (SHRL) Below 1 Ω S13-21 (SGL2) - H15-3 (SHG) Below 1 Ω S13-22 (SBL2) - S13-23 (SHRL) 10 kΩ or higher S13-21 (SGL2) - S13-23 (SHRL) 10 kΩ or higher S13-21 (SGL2) - S13-22 (SBL2) 10 kΩ or higher RH Side SC SC–36 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM Tester connection Specified condition S13-20 (SBR2) - H16-1 (SHB) Below 1 Ω S13-24 (SHRR) - H16-2 (SHRR) Below 1 Ω S13-19 (SGR2) - H16-3 (SHG) Below 1 Ω S13-20 (SBR2) - S13-24 (SHRR) 10 kΩ or higher S13-19 (SGR2) - S13-24 (SHRR) 10 kΩ or higher S13-19 (SGR2) - S13-20 (SBR2) 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAR (a) Remove the height control sensor sub-assembly rear LH or RH. (b) Connect 3 dry batteries of 1.5 V in series. (c) Height control sensor sub-assembly rear LH: Connect terminal 1 (SHB) to the batteries' positive (+) terminal, and terminal 3 (SHG) to the batteries' negative (-) terminal, then apply approximately 4.5 V between terminal 2 (SHRL) and 3 (SHG) in the following conditions. Standard voltage Low SC Normal High LH: (+) 2 1 3 (-) (-) RH: Voltage High (0° to 45°) Approx. 2.53 to 4.33 V Normal (0°) Approx. 2.53 V Low (0° to -45°) Approx. 0.81 to 2.53 V Result (+) 2 3 (-) Position (+) (+) 1 (-) F044307E01 Result Proceed to OK A NG B (d) Height control sensor sub-assembly rear RH: Connect terminal 1 (SHB) to the batteries' positive (+) terminal, and terminal 3 (SHG) to the batteries' negative (-) terminal, then apply approximately 4.5 V between terminal 1 (SHG) and 2 (SHRR) in the following conditions. Standard voltage Position Voltage High (0° to 45°) Approx. 2.53 to 4.33 V Normal (0°) Approx. 2.53 V Low (0° to -45°) Approx. 0.81 to 2.53 V Result Result Proceed to OK A NG C SUSPENSION CONTROL – AIR SUSPENSION SYSTEM SC–37 B REPLACE HEIGHT CONTROL SENSOR SUBASSEMBLY REAR LH C REPLACE HEIGHT CONTROL SENSOR SUBASSEMBLY REAR RH A REPLACE SUSPENSION CONTROL ECU SC SC–94 SUSPENSION CONTROL – HEIGHT CONTROL SENSOR HEIGHT CONTROL SENSOR SUSPENSION & CONTROL AXLE COMPONENTS SC 5.4 (55, 48 in.*lbf) BRACKET 5.4 (55, 48 in.*lbf) 13 (133, 10) HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAR LH BRACKET 13 (133, 10) HEIGHT CONTROL SENSOR SUB-ASSEMBLY REAL RH N*m (kgf*cm, ft.*lbf) : Specified torque C134076E01 SUSPENSION CONTROL – HEIGHT CONTROL SENSOR SC–95 REMOVAL 1. REMOVE REAR DISC WHEEL 2. REMOVE HEIGHT CONTROL SENSOR SUBASSEMBLY REAR LH (a) Disconnect the connector from the height control sensor. (b) Place matchmarks on the link and bracket. (c) Remove the nut and disconnect the sensor link. (d) Remove the 2 bolts and height control sensor. Matchmarks G020167E01 SC SC–38 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1733/33 Rear Height Control Gate Solenoid Valve Circuit Malfunction DTC C1734/34 Rear Height Control Leveling Solenoid Valve Circuit Malfunction DTC C1735/35 Exhaust Solenoid Valve Circuit DTC C1744/44 Tank Solenoid Valve Circuit DESCRIPTION SC The suspension control ECU opens the height control valve to lead the compressed air to the height control cylinder (pneumatic cylinder) and to raise the vehicle height. When the vehicle height is lowered, the suspension control ECU opens the height control valve to store the compressed air in the low pressure tank temporarily, and then operates the exhaust solenoid valve to release the compressed air to the outside. Further, the height control solenoid valve (gate solenoid valve) opens and closes the passage between the right and left pneumatic cylinder. The height control valve is on the low pressure tank and consists of 3 valves in total, leveling solenoid valve, gate solenoid valve and tank solenoid valve. The leveling solenoid valve opens and closes the passage between the compressor and the pneumatic cylinder. The gate solenoid valve opens and closes the passage between the right and left pneumatic cylinder. The tank solenoid valve opens and closes the passage between pneumatic cylinder and the low pressure tank. The exhaust solenoid valve is on the compressor unit and has only one valve. DTC No. DTC Detecting Condition C1733/33 C1734/34 C1735/35 C1744/44 Either the condition 1. or 2. is detected: 1. With the height control solenoid valve (or exhaust solenoid valve) inactivated, an open signal of the height control solenoid valve is detected for 1 sec. or more. 2. With the height control solenoid valve (or exhaust solenoid valve) activated, a short signal of the valve is detected 8 times successively. Trouble Area • • • Gate solenoid valve Gate solenoid valve circuit Suspension control ECU • • • Leveling solenoid valve Leveling solenoid valve circuit Suspension control ECU • • • Exhaust solenoid valve Exhaust solenoid valve circuit Suspension control ECU • • • Tank solenoid valve Tank solenoid valve circuit Suspension control ECU HINT: • Once the ECU stores DTC C1733/33, C1734/34, C1735/35 or C1744/44 in the memory, the vehicle height control is suspended out until a normal signal is input to the ECU from the height control solenoid valves and the exhaust solenoid valve. However, control is resumed if the ignition switch is turned OFF, then ON again. • Malfunction in the gate solenoid valve and the leveling solenoid valve: The height control operation is suspended, and the height control indicator light does not change by operating the height control switch. • Malfunction in the exhaust solenoid valve: The vehicle height is lowered to the normal height within 30 sec., and then the height control operation is suspended. The height control indicator light "N" comes on or blinks, and that of "HI" and "LO" do not illuminated by operating the height control switch "UP" and "DOWN". • Abnormality of the tank solenoid valve: Although the height control is still possible, the vehicle lowering speed may be slower. SC–39 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM L1 Low Pressure Tank Valve (Tank Solenoid Valve) W-B 1 2 Suspension Control ECU 12 BC2 P-G 7 S13 SLLO V-W 14 BC2 V-W 1 S13 SLRL V 13 BC2 V 2 S13 SLRR 15 BC2 LG 8 S13 SLEX P-G H17 Height Control Valve (Gate Solenoid Valve and Leveling Solenoid Valve) LH+ W-B 2 W-B W-B E 2 RH+ 1 1 3 LG SC H13 Height Control Compressor (Exhaust Solenoid Valve) BN F050617E04 INSPECTION PROCEDURE HINT: • Proceed to troubleshooting following the flow chart, regardless of whether or not DTC C1733/33, C1734/34, C1735/35 or C1744/44 is displayed. • If DTC C1761/61 (ECU malfunction) and/or C1774/74 (power source circuit) is displayed, perform the inspection necessary for DTC C1761/61 (See page SC-52) and/or C1774/74 (See page SC-54) first. (If DTC C1761/61 and the C1774/74 are output at the same time, perform the inspection necessary for DTC C1774/74 first.) • Start the inspection from step 1 when using the intelligent tester, and start from step 2 when not using the intelligent tester. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON, and push the intelligent tester main switch ON. (c) Select the item "LEVEL SOL REAR", "GATE SOL REAR", "LOW PRS TNK SOL", "EXHAUST SOL" in the ACTIVE TEST, and operate it with the intelligent tester. (d) Check whether the solenoid makes sound. (e) Check whether the height control valve has continuity (will vibrate). SC–40 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM OK: The solenoid makes sound, and the height control valve has continuity (will vibrate). OK NG SC REPLACE SUSPENSION CONTROL ECU SC–41 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM 2 INSPECT HEIGHT CONTROL VALVE OR EXHAUST SOLENOID VALVE (a) Disconnect the valve connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Gate Solenoid Valve: Leveling Solenoid Valve: Solenoid valve Gate solenoid valve 3 2 Exhaust Solenoid Valve: 1 1 Gate Solenoid Valve: Leveling Solenoid Valve: (+) 3 2 1 (-) 10 to 14 Ω 1-2 10 to 14 Ω Tank solenoid valve 1-2 10 to 14 Ω 2 Battery positive Battery negative Gate solenoid valve 1 2 Leveling solenoid valve 3 2 Exhaust solenoid valve 1 2 Tank solenoid valve 2 1 NG REPLACE HEIGHT CONTROL RESERVOIR ASSEMBLY NG REPLACE HEIGHT CONTROL COMPRESSOR ASSEMBLY (+) Tank Solenoid Valve: 1 (+) 2-3 Exhaust solenoid valve OK: It should make an operating sound (click). HINT: • When a malfunction is found in the gate solenoid valve, the leveling valve or the tank solenoid valve, replace the height control reservoir assembly. • When a malfunction is found in the exhaust solenoid valve, replace the height control compressor assembly. (-) Exhaust Solenoid Valve: 2 17.5 to 21.5 Ω Leveling solenoid valve Solenoid valve 1 Specified condition 1-2 HINT: The height control solenoid valve has 2 connectors. • The gate solenoid valve and the leveling solenoid valve have a 3-pole connector. • Tank solenoid valve connector has a 2-pole connector. (c) Check the operating sound of the valves when battery positive voltage is applied to the terminals as shown below. Tank Solenoid Valve: 2 Tester connection (-) F044511E01 SC SC–42 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (a) Check for open and short circuit in the harness and the connectors between height control solenoid valve or the exhaust solenoid valve and the suspension control ECU (See page IN-38). NG OK REPLACE SUSPENSION CONTROL ECU SC REPAIR OR REPLACE HARNESS OR CONNECTOR SC–96 SUSPENSION CONTROL – SUSPENSION CONTROL ECU SUSPENSION CONTROL ECU SUSPENSION & CONTROL AXLE COMPONENTS SC FRONT DOOR SCUFF PLATE LH COWL SIDE TRIM BOARD LH C131332E02 SUSPENSION CONTROL – SUSPENSION CONTROL ECU SC–97 SC INSTRUMENT PANEL LOWER LH B120190E06 SC–98 SUSPENSION CONTROL – SUSPENSION CONTROL ECU INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PLATE SC B120191E08 SUSPENSION CONTROL – SUSPENSION CONTROL ECU SC–99 SC SUSPENSION CONTROL ECU C119708E02 SC–43 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC C1741/41 Air Suspension Relay Circuit DESCRIPTION When the "UP" side of the height control switch is pressed, a signal is sent from terminal RC of the suspension control ECU to the AIR SUS relay to turn it on. As a result, the current flows to the AIR SUS relay coil, closing the relay contact, and then the battery positive voltage is applied to the compressor, which causes the compressed air to raise the vehicle height. DTC No. DTC Detecting Condition C1741/41 Either of the following conditions is detected: 1. With the AIR SUS relay inactivated, an open signal of the AIR SUS relay is detected for 1 sec. or more. 2. With the AIR SUS relay activated, a short signal of the AIR SUS relay is detected 8 times successively. Trouble Area • • • AIR SUS relay AIR SUS relay circuit Suspension control ECU HINT: Once the ECU stores DTC C1741/41 in the memory, the vehicle height control is suspended until a normal signal is input to the ECU from the AIR SUS relay. However, the control resumes if the ignition switch is turned OFF, and then turned ON again. SC SC–44 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM Suspension Control ECU Engine Room R/B No. 4 AIR SUS Relay W-B SC To Height Control Compressor Assembly 4 1 IB1 L-B 4 2 1 3 5 4 18 S13 RC 5 BR-Y IB2 BR-Y 4 Engine Room R/B B AIR SUS ALT 2 2 1 2 1 2 L-Y 2 2 B J2 B J/C J3 B W-B Battery EB F050631E01 SC–45 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECTION PROCEDURE HINT: • If DTC C1761/61 (ECU malfunction) and/or C1774/74 (power source circuit) is displayed, perform the inspection necessary for DTC C1761/61 (See page SC-52) and/or C1774/74 (See page SC-54) first. (If DTC C1761/61 and C1774/74 are output at the same time, perform the inspection necessary for DTC C1774/74 first.) • Start the inspection from step 1 when using the intelligent tester, and start from step 2 when not using the intelligent tester. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON, and push the intelligent tester main switch ON. (c) Select the item "MOTOR RELAY" in the ACTIVE TEST, and operate it with the intelligent tester. (d) Check the operating sound of the AIR SUS relay when operating it with the intelligent tester. OK: The operating sound of the AIR SUS relay can be heard. OK REPLACE SUSPENSION CONTROL ECU NG 2 INSPECT AIR SUS RELAY 1 (a) Remove the AIR SUS relay from the engine room R/B No. 3. (b) Measure the resistance between each terminal of the AIR SUS relay. Standard resistance 3 1 3 5 2 2 Tester connection Resistance 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1-2) 4 5 C123965E01 NG REPLACE AIR SUS RELAY OK 3 CHECK HARNESS AND CONNECTOR (ENGINE ROOM R/B - SUSPENSION CONTROL ECU) (a) Check for an open or short circuit in the harness and the connector between the AIR SUS relay and the suspension control ECU (See page IN-38). OK: There is no open or short in the wire harness. SC SC–46 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (b) Check for an open circuit in the harness and the connector between the AIR SUS relay and the body ground. OK: There is no open in the wire harness. NG OK REPLACE SUSPENSION CONTROL ECU SC REPAIR OR REPLACE HARNESS OR CONNECTOR SUSPENSION CONTROL – AIR SUSPENSION SYSTEM DTC SC–47 C1742/42 Height Control Compressor Circuit DESCRIPTION When the "UP" side of the height control switch is pressed, a signal is sent from terminal RC of the suspension control ECU to switch the AIR SUS relay ON. As a result, the relay contacts close and the compressor motor turns on, producing compressed air. The suspension control ECU detects the amount of current flow to the compressor motor by means of the differences in potential at terminals RM+ and RM- of the suspension control ECU. In this way, the suspension control ECU monitors the compressor circuit for abnormalities. DTC No. DTC Detecting Condition C1742/42 With the AIR SUS relay activated, a lock, open or short signal of the height control compressor motor is detected for 4 sec. or more. Trouble Area • • • Height control compressor assembly Height control compressor circuit Suspension control ECU HINT: Once the ECU stores DTC C1742/42 in the memory, the vehicle height control is not carried out until the normal signal is input to the ECU from the compressor motor. However, the control automatically resumes approx. 70 min. after the ignition switch is turned ON. SC SC–48 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM WIRING DIAGRAM Suspension Control ECU 5 IB2 BR-Y Engine Room R/B No. 4 SC 4 5 1 W-B 4 2 1 IB1 L-B 4 3 18 S13 RC H14 Height Control Motor (Height Control Compressor Assembly) AIR SUS Relay 4 BR-Y L-B 1 20 L-B O BC1 B RM+ BC2 1 3 21 W-B P E RMBC2 2 4 O 25 S13 RM+ P 26 S13 RM- Engine Room R/B L-Y AIR SUS ALT 2 2 2 2 1 2 B 1 J/C 2 J2 B J3 B W-B B Battery EB BN F050632E01 SC–49 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Check if the other DTC is recorded (See page SC-23). Result Result Proceed to Other DTC is not output. A Other DTC is output. B B REPAIR CIRCUIT INDICATED BY OUTPUT DTC A 2 INSPECT HEIGHT CONTROL COMPRESSOR ASSEMBLY 2 (-) 1 (+) F043249E01 (a) Disconnect the height control compressor assembly connector. (b) Apply battery voltage between terminal 1 and 2 of the height control compressor assembly. Standard: Compressor motor operates. NOTICE: • Do not operate the height control compressor assembly 90 sec. or more. • Since short and lock inside the height control compressor assembly causes enormous current to flow, stop the operation immediately when it dose not rotate. NG REPLACE HEIGHT CONTROL COMPRESSOR ASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL COMPRESSOR ASSEMBLY SUSPENSION CONTROL ECU) (a) Check for open and short circuit in the harness and the connector between the height control compressor assembly and the suspension control ECU (See page IN-38). NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR SC SC–50 4 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM CHECK HARNESS AND CONNECTOR (HEIGHT CONTROL COMPRESSOR ASSEMBLY AIR SUS RELAY) (a) Check for open and short circuit in the harness and the connector between the height control compressor assembly and the AIR SUS relay (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 SC INSPECT HEIGHT CONTROL SOLENOID VALVE OR EXHAUST SOLENOID VALVE (a) When using intelligent tester: (1) Connect the intelligent tester to DLC3. (2) Turn the ignition switch ON, and push the intelligent tester main switch ON. (3) Select the item "LEVEL SOL REAR", "GATE SOL REAR", "LOW PRS TNK SOL", "EXHAUST SOL", in the ACTIVE TEST, and operate it with the intelligent tester. (4) Check whether the solenoid makes sound. (5) Check whether the height control solenoid valve has a continuity (will vibrate). OK: The solenoid makes sound, the height control solenoid valve has a continuity (will vibrate). SC–51 SUSPENSION CONTROL – AIR SUSPENSION SYSTEM (b) When not using intelligent tester: (1) Disconnect the valve connector. (2) Check the operating sound of the valves when battery positive voltage is applied to the terminals as shown below. Gate Solenoid Valve: Leveling Solenoid Valve: (+) 3 Solenoid valve 1 2 (-) Exhaust Solenoid Valve: 2 1 2 Leveling solenoid valve 3 2 Exhaust solenoid valve 1 2 Tank solenoid valve 2 1 OK: It should make an operating sound (click). HINT: • When a malfunction is found in the gate solenoid valve, the leveling valve or the tank solenoid valve, replace the height control reservoir assembly. • When a malfunction is found in the exhaust solenoid valve, replace the height control compressor assembly. (+) Tank Solenoid Valve: 2 1 (+) Battery negative Gate solenoid valve 1 (-) Battery positive (-) NG REPLACE HEIGHT CONTROL RESERVOIR ASSEMBLY NG REPLACE HEIGHT CONTROL COMPRESSOR ASSEMBLY F044510E01 OK 6 CHECK AIR TUBE CLOGGED (a) Check visually for clog, damage or breakage on the air tube (See page SC-28). NG OK REPLACE SUSPENSION CONTROL ECU REPAIR OR REPLACE AIR TUBE SC SP–3 SUSPENSION – SUSPENSION SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. FRONT SUSPENSION: Symptom Bottoming Sways/pitches Front wheel shimmy Abnormal tire wear Suspected area See page 1. Vehicle (Overloaded) - 2. Spring (Weak) SP-10 3. Shock absorber (Worn) SP-10 1. Tire (Worn or improperly inflated) TW-1 2. Stabilizer bar (Bent or broken) SP-28 3. Shock absorber (Worn) SP-10 1. Tire (Worn or improperly inflated) TW-1 2. Wheel (Out of balance) TW-1 3. Shock absorber (Worn) SP-10 4. Wheel alignment (Incorrect) SP-4 5. Ball joint (Worn) SP-22 SP 6. Hub bearing (Worn) AH-1 7. Steering linkage (Loose or worn) - 1. Tire (Worn or improperly inflated) TW-1 2. Wheel alignment (Incorrect) SP-4 3. Shock absorber (Worn) SP-10 4. Suspension parts (Worn) - REAR SUSPENSION: Symptom Wander/pulls Bottoming Sways/pitches Rear wheel shimmy Abnormal tire wear Suspected area See page 1. Tire (Worn or improperly inflated) TW-1 2. Wheel alignment (Incorrect) SP-4 3. Hub bearing (Worn) AH-26 4. Suspension parts (Worn) - 1. Vehicle (Overloaded) - 2. Spring (Weak) SP-30 3. Shock absorber (Worn) (with REAS) SP-33 4. Shock absorber (Worn) (without REAS) SP-38 1. Tire (Worn or improperly inflated) TW-1 2. Stabilizer bar (Bent or broken) SP-53 3. Shock absorber (Worn) (with REAS) SP-33 4. Shock absorber (Worn) (without REAS) SP-38 1. Tire (Worn or improperly inflated) TW-1 2. Wheel (Out of balance) TW-1 3. Shock absorber (Worn) (with REAS) SP-33 4. Shock absorber (Worn) (without REAS) SP-38 5. Wheel alignment (Incorrect) SP-4 5. Hub bearing (Worn) AH-26 1. Tire (Worn or improperly inflated) TW-1 2. Wheel alignment (Incorrect) SP-4 3. Shock absorber (Worn) (with REAS) SP-33 4. Shock absorber (Worn) (without REAS) SP-38 5. Suspension parts (Worn) - SP–12 SUSPENSION – FRONT SHOCK ABSORBER 12. REMOVE FRONT SUSPENSION SUPPORT SUBASSEMBLY LH 13. REMOVE FRONT SHOCK ABSORBER CUSHION RETAINER 14. REMOVE FRONT COIL SPRING LH 15. REMOVE FRONT SHOCK ABSORBER BUSH (a) Using SST and a press, remove the absorber bush. SST 09710-22021 (09710-01071, 09710-01081) SST C099164E01 INSPECTION 1. SP C099163 INSPECT SHOCK ABSORBER ASSEMBLY FRONT LH (a) Compress and extend the shock absorber rod, and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber assembly front LH with a new one. NOTICE: When disposing of the shock absorber assembly front LH, see DISPOSAL (See page SP-15). INSTALLATION 1. INSTALL FRONT SHOCK ABSORBER BUSH (a) Using SST and a press, install a new absorber bush. SST 09710-22021 (09710-01071, 09710-01081) 2. INSTALL FRONT COIL SPRING LH (a) Using SST, compress the front coil spring LH. SST 09727-30021 (09727-00010, 09727-00031), 09727-00060 NOTICE: Do not use an impact wrench. It will damage the SST. (b) Install the front coil spring LH to the shock absorber assembly front LH. HINT: Fit the lower end of the front coil spring LH into the gap of the spring lower seat. 3. INSTALL FRONT SHOCK ABSORBER CUSHION RETAINER SST C099164E01 SST C099165E01 SUSPENSION – FRONT SHOCK ABSORBER LH Front SP–13 4. INSTALL FRONT SUSPENSION SUPPORT SUBASSEMBLY LH 5. INSTALL FRONT SHOCK ABSORBER CUSHION NO. 1 6. INSTALL FRONT SHOCK ABSORBER CUSHION RETAINER 7. INSTALL FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT (a) Align the suspension support sub-assembly and the absorber bush as shown in the illustration. (b) Tighten the new lock nut. Torque: 25 N*m (260 kgf*cm, 18 ft.*lbf) NOTICE: Do not use an impact wrench. It will damage the shock absorber rod. (c) Release the coil spring while checking the position of the suspension support. 8. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (w/o REAS) (a) Install the coil spring on the body as the lower end of the coil spring faces rear side of the vehicle. RH Absorber Bush Suspension Support Sub-assembly C099166E01 Lower End Outer Side Rear Side G021681E01 (b) Install the 3 nuts on the upper side of the front shock absorber with coil spring. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) C099160 (c) Temporarily tighten the bolt, the nut and the washer as shown in the illustration. C099159 SP SP–14 SUSPENSION – FRONT SHOCK ABSORBER 9. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (w/ REAS) (a) Install the coil spring on the body as the lower end of the coil spring faces rear side of the vehicle. Lower End Outer Side Rear Side G021681E01 (b) Install the 3 nuts on the upper side of the front shock absorber with coil spring. Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) SP C099160 (c) Temporarily tighten the bolt, the nut and the washer as shown in the illustration. C099159 (d) Install the bolt. Torque: 29 N*m (300 kgf*cm, 21 ft.*lbf) NOTICE: Be sure to fit the detents attached to the bracket into a hole on the frame side. G020405 Turn (e) As shown in the illustration, tighten the nut of clearance to standard value. Clearance: 1 mm (0.04 in.) Torque: Reference torque 25 N*m (260 kgf*cm, 18 ft.*lbf) Hold 10. INSTALL STABILIZER BAR FRONT G020406E01 11. INSTALL FRONT STABILIZER BRACKET NO. 2 LH (See page SP-29) SUSPENSION – FRONT SHOCK ABSORBER SP–15 12. INSTALL FRONT STABILIZER BRACKET NO. 1 RH (See page SP-29) 13. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (a) Connect the stabilizer link with the nut to the steering knuckle. Torque: 70 N*m (710 kgf*cm, 52 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. C099158 14. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Install the RH side by the same procedures with the LH side. 15. INSTALL FRONT DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) 16. STABILIZE SUSPENSION (a) Jack down the vehicle. (b) Bounce the vehicle up and down several times to stabilize the suspension. 17. FULLY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (a) Fully tighten the nut. Torque: 135 N*m (1,380 kgf*cm, 100 ft.*lbf) 18. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) C099159 SP SP–16 SUSPENSION – FRONT SHOCK ABSORBER DISPOSAL HINT: Dispose the RH side by the same procedures with the LH side. 1. DISPOSE OF SHOCK ABSORBER ASSEMBLY FRONT LH (w/o REAS) (a) Fully extend the shock absorber piston rod, and fix it at a tilt in a vise or similar tool. (b) Using a drill or similar tool, slowly make a hole at approx. 5 cm from the top end of the shock absorber, and discharge the gas inside of it. CAUTION: • The gas is colorless, odorless and harmless. • Since the discharged gas may cause chips to fly off, cover the drill with a shop rag when making a hole. 2. DISPOSE OF SHOCK ABSORBER ASSEMBLY FRONT LH (w/ REAS) (a) Before the disposal, loosen the nut slowly to breed out the oil and to lower the pressure inside the absorber. NOTICE: Never loosen the nut of the eye union except the time of disposal. Approximately 50 mm (1.97 in.) G021673E01 SP G022707 SP–24 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM INSPECTION 1. G021680 REMOVE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 to 4 seconds per 1 turn and take the torque reading on the 5th turn. Torque: Turning torque 3.0 N*m (31 kgf*cm, 27 in.*lbf) or less (c) Check for any cracks and grease leaks on the ball joint dust cover. INSTALLATION 1. SST SP SST Bush Positioning Protrusion G020166E01 INSTALL FRONT LOWER ARM BUSH NO. 2 LH (a) Using SST and a press, install a new lower arm bush No. 2 LH. SST 09710-26010 (09710-05081), 09950-60020 (09951-00890) NOTICE: Press the lower arm bush No. 2 in the lower arm at the bush positioning protrusions become perpendicular to the lower arm as shown in the illustration. SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM 2. SST SP–25 INSTALL FRONT LOWER ARM BUSH NO. 1 LH (a) Using SST and a press, install a new lower arm bush No. 1 LH. SST 09223-00010, 09612-30012 NOTICE: Press the lower arm bush No. 1 in the lower arm at the bush positioning protrusions become parallel with the lower arm as shown in the illustration. Bush Positioning Protrusion SP G020165E01 3. TEMPORARILY TIGHTEN FRONT SUSPENSION ARM SUB-ASSEMBLY NO. 1 LH (a) Align the matchmarks on the camber adjust cam No. 2 and toe adjust cam sub-assembly, temporarily tighten the bolt and the nut. (b) Install the front lower ball joint attachment LH, a new nut and a new cotter pin. Torque: 140 N*m (1,430 kgf*cm, 103 ft.*lbf) Matchmarks G020160E03 (c) Install the front lower ball joint attachment LH with the 2 bolts. Torque: 60 N*m (1,630 kgf*cm, 118 ft.*lbf) G020159 C099159 4. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (a) Install the front shock absorber with coil spring, the bolt and the washer, and temporarily tighten the nut. 5. INSTALL FRONT DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) 6. STABILIZE SUSPENSION (See page SP-15) SP–26 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM 7. FULLY TIGHTEN FRONT SUSPENSION ARM SUBASSEMBLY NO. 1 LH (a) Fully tighten the bolt and the nut. Torque: 135 N*m (1,380 kgf*cm, 100 ft.*lbf) 8. FULLY TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING (a) Fully tighten the nut. Torque: 135 N*m (1,380 kgf*cm, 100 ft.*lbf) 9. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) G020160 SP C099159 SP–1 SUSPENSION – SUSPENSION SYSTEM SUSPENSION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: This is a flow chart for vehicle pull. START Preliminary Check ROAD TEST Tire pressure Does the vehicle pull? Vehicle height NO Is the steering off center? YES NO COMPLETE YES SP Brake dragging Adjust the front tie rods. YES Are the tires a uni-directional type? NO NO Interchange the front & wheel assemblies (left & right). ROAD TEST Does the vehicle still pull? YES Choose the front tire and wheel assembly position where pull is minimal. YES Does the vehicle pull in same direction as before? NO Check front wheel alignment. Is it YES NO Is the pull stronger than before? within specification? NO C YES C113980E04 SP–2 SUSPENSION – SUSPENSION SYSTEM Reverse the front left side tire and Adjust front wheel alignment. rebalance it. ROAD TEST ROAD TEST Does the vehicle still pull? NO SP COMPLETE NO Does the vehicle still pull? YES YES Does the vehicle pull to the left? YES NO Increase right front camber and decrease left Increase left front camber and decrease front camber until pull is eliminated. right front camber until pull is eliminated. NO ROAD TEST YES Contact your local retail tire distributor. Does the vehicle still pull? C C113981E03 SUSPENSION – FRONT STABILIZER BAR SP–29 INSTALLATION Bushing Stopper Protrusion 1. INSTALL STABILIZER BAR FRONT 2. INSTALL FRONT STABILIZER BAR BUSH NO. 1 (a) Install the 2 front stabilizer bar bush No. 1. HINT: • Install the bushing to the inner side of the bushing stopper on the stabilizer bar. • Install the stabilizer bush No. 1 as the protrusion to be on the inner side of the vehicle. 3. INSTALL FRONT STABILIZER BRACKET NO. 2 LH (a) Install the front stabilizer bracket No.2 LH with the 2 bolts. Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf) 4. INSTALL FRONT STABILIZER BRACKET NO. 1 RH HINT: Install the RH side by following the same procedures with the LH side. Outside Frontside G021678E04 G020162 5. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (a) Install the front stabilizer link assembly LH with the 2 nuts. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 6. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Install the RH side by following the same procedures with the LH side. 7. INSTALL FRONT WHEELS Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) G020161 SP SP–4 SUSPENSION – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT ADJUSTMENT Front: A B Rear: 1. INSPECT TIRE 2. MEASURE VEHICLE HEIGHT (a) Measure the vehicle height. Vehicle height: 2WD Except air suspension Front A - B Rear C - D UZN210L-GKAGKA 113.6 mm (4.47 in.) 71.7 mm (2.82 in.) UZN210L-GKAZKA 113.5 mm (4.47 in.) 72.3 mm (2.85 in.) GRN210L-GKPGKA 110.5 mm (4.35 in.) 70.9 mm (2.79 in.) GRN210L-GKPZKA 110.4 mm (4.35 in.) 71.3 mm (2.81 in.) 2WD Air suspension UZN210L-GKAZKA Front A - B Rear C - D 112.7 mm (4.44 in.) 81.4 mm (3.20 in.) 4WD Except air suspension SP D C D028453E01 Front A - B Rear C - D UZN215L-GKAGKA 99.9 mm (3.93 in.) 71.6 mm (2.82 in.) UZN215L-GKAZKA 99.8 mm (3.93 in.) 72.1 mm (2.84 in.) GRN215L-GKPGKA 99.8 mm (3.93 in.) 71.3 mm (2.81 in.) GRN215L-GKPZKA 99.8 mm (3.93 in.) 71.9 mm (2.83 in.) 4WD Air suspension UZN215L-GKAZKA Front A - B Rear C - D 99.2 mm (3.91 in.) 78.9 mm (3.11 in.) Measuring points: A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 set bolt center C: Ground clearance of rear wheel center D: Ground clearance of strut rod set bolt center NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. SP–5 SUSPENSION – FRONT WHEEL ALIGNMENT A B D 3. Front INSPECT TOE-IN (a) Inspect the toe-in. Toe-in: A + B: 0°05' +- 0°10' (0.08° +- 0.16°) C - D: 1 +- 2 mm (0.04 +- 0.08 in.) Toe-in (total) If the toe-in is not within the specified value, adjust it at the rack ends. 4. C SA03213E04 ADJUST TOE-IN (a) Remove the rack boot set clips. (b) Loosen the tie rod end lock nuts. (c) Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. (d) Make sure that the lengths of the right and left rack ends are the same. (e) Torque the tie rod end lock nuts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) (f) Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. (g) Perform VSC system calibration G020168 A B B 5. A Front A: Inside INSPECT WHEEL ANGLE (a) Turn the steering wheel fully, and measure the turning angle. Wheel angle: 2WD Inside wheel Outside wheel (Reference) 37°00' (35°00' to 38°00') 37.00° (35.00° to 38.00°) 32°30' 32.50° B: Outside 4WD SA00028E06 Inside wheel Outside wheel (Reference) 36°40' (34°40' to 37°40') 36.67° (34.67° to 37.67°) 32°53' 32.88° If the wheel angles differ from the standard of the specification, inspect the toe-in. 6. Alignment Tester Gauge INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Install the camber-caster-kingpin gauge or position vehicle on wheel alignment tester. (b) Inspect the camber, the caster and the steering axis inclination. Camber, caster and steering axis inclination: 2WD Except air suspension Area Z003382E06 Camber Specified Condition -0°28' +- 45' (-0.47° +- 0.75°) Right-left error 45' (0.75°) or less SP SP–6 SUSPENSION – FRONT WHEEL ALIGNMENT Area Specified Condition 3°23' +- 45' (3.38° +- 0.75°) Caster Right-left error Steering axis inclination 45' (0.75°) or less 12°58' +- 45' (12.97° +- 0.75°) Right-left error 45' (0.75°) or less 2WD Air suspension Area Specified Condition -0°30' +- 45' (-0.50° +- 0.75°) Camber Right-left error 45' (0.75°) or less 3°33' +- 45' (3.55° +- 0.75°) Caster Right-left error Steering axis inclination 45' (0.75°) or less 13° 00' +- 45' (13.00° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Except air suspension Area -0°09' +- 45' (-0.15° +- 0.75°) Camber SP Specified Condition Right-left error 45' (0.75°) or less 3°13' +- 45' (3.22° +- 0.75°) Caster Right-left error Steering axis inclination 45' (0.75°) or less 12°39' +- 45' (12.65° +- 0.75°) Right-left error 45' (0.75°) or less 4WD Air suspension Area Specified Condition -0°10' +- 45' (-0.17° +- 0.75°) Camber Right-left error 45' (0.75°) or less 3°22' +- 45' (3.37° +- 0.75°) Caster Right-left error Steering axis inclination 45' (0.75°) or less 12°40' +- 45' (12.67° +- 0.75°) Right-left error 45' (0.75°) or less If the steering axis inclination is not as specified after camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for distortion or looseness. 7. ADJUST CAMBER AND CASTER NOTICE: After the camber has been adjusted, inspect the toein. (a) Loosen the nut and bolt. (b) Turn the camber adjust cam No. 2 and toe adjust plate No. 2 in the circumference direction, and adjust the camber and the caster. HINT: Try to adjust the camber and caster to the center value. SUSPENSION – FRONT WHEEL ALIGNMENT SP–7 Front Front Cam (LH) Front FrontCam cam (RH) (RH) (Longer) (Shorter) (Shorter) (Longer) (Longer) (Shorter) (Shorter) (Longer) Rear Cam (LH) Rear Cam (RH) G020169E02 (Example) Caster Camber Calculated value 0 point G020414E02 (c) How to read adjustment chart (using examples). (1) Measure the present alignment. Camber: 0°15' (0.25°) Caster: 2°45' (2.75°) (2) Make the difference between the standard value (A) and the measured value (B) on the adjustment chart. Standard value: Camber: 0°35' (0.58°) Caster: 2°55' (2.92°) Formula: B-A=C Camber: 0°15' - (0 35') = - 0°20' Caster: 2°45' - (2°55') = - 0°10' (3) As shown in the chart, read the distance from the marked point to 0 point, and adjust the front and/or rear adjusting cams accordingly. Toe adjust cam: - (Shorter) 2.8 Camber adjust cam: - (Shorter) 1.8 SP SP–8 SUSPENSION – FRONT WHEEL ALIGNMENT Front Cam Graduation SP Rear Cam Graduation Caster Camber G020415E02 SUSPENSION – REAR SHOCK ABSORBER (w/ REAS) SP–35 INSTALLATION 1. INSTALL SHOCK ABSORBER ASSEMBLY REAR LH (a) Install the lower bracket to the shock absorber assembly rear LH. (b) Install the cushion retainer, cushion No. 1 and shock absorber assembly rear LH with the nut. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) D028457 (c) Refer to NOTICE below. NOTICE: • Be sure to fit the positioning protrusion of the bracket to a hole on the frame. • to a hole on the frame. Install the hose as it comes in the front. D028459 (d) Install the shock absorber assembly rear LH with the bolt. D028132 (e) Install the bracket with the bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) (f) Using a wrench to hold the bracket, install the joint. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.). Torque: Reference 25 N*m (255 kgf*cm, 18 ft.*lbf) 2. INSTALL REAR STABILIZER LINK ASSEMBLY (See page SP-54) 3. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 4. STABILIZE SUSPENSION (a) Jack down the vehicle. D028262 SP SP–36 SUSPENSION – REAR SHOCK ABSORBER (w/ REAS) (b) Bounce the vehicle up and down several times to stabilize the suspension. 5. FULLY TIGHTEN SHOCK ABSORBER ASSEMBLY REAR LH (a) Fully tighten the bolt. Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) 6. INSPECT FLUID LEAK HINT: (See page SC-3) D028132 DISPOSAL 1. SP D028135 DISPOSE OF SHOCK ABSORBER ASSEMBLY REAR LH (a) Loosen the bolt. (b) Drain absorber oil. SP–9 SUSPENSION – FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER SUSPENSION & AXLE COMPONENTS 64 (650, 47) with REAS: 70 (710, 52) Reference Torque: 25 (255, 18) FRONT SHOCK ABSORBER WITH COIL SPRING 29 (300, 21) FRONT SHOCK ABSORBER CUSHION RETAINER 25 (260, 18) FRONT SHOCK ABSORBER CUSHION NO. 1 FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH 70 (710, 52) FRONT STABILIZER LINK ASSEMBLY RH FRONT SHOCK ABSORBER CUSHION RETAINER 135 (1,380, 100) FRONT COIL SPRING LH STABILIZER BAR FRONT FRONT SHOCK ABSORBER BUSH 40 (410, 30) FRONT STABILIZER LINK ASSEMBLY LH FRONT SHOCK ABSORBER ASSEMBLY LH FRONT STABILIZER BRACKET NO. 1 RH FRONT STABILIZER BRACKET NO. 2 LH 40 (410, 30) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119710E01 SP SP–10 SUSPENSION – FRONT SHOCK ABSORBER REMOVAL 1. REMOVE FRONT DISC WHEEL 2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (a) Remove the nut and disconnect the stabilizer link from the steering knuckle. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 3. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Remove the RH side by following the same procedures with the LH side. 4. REMOVE FRONT STABILIZER BRACKET NO. 2 LH 5. REMOVE FRONT STABILIZER BRACKET NO. 1 RH 6. REMOVE STABILIZER BAR FRONT 7. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (w/o REAS) (a) Remove the bolt, the nut and the washer. C099158 SP C099159 (b) Remove the 3 nuts on the upper side of the front shock absorber with coil spring. (c) Remove the front shock absorber with coil spring. 8. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (w/ REAS) NOTICE: Conduct the operations as stretching all the shock absorbers out by jacking up the vehicle. C099160 (a) As shown in the illustration, loosen the nut and disconnect the tube. NOTICE: Never loosen the absorber hoses and the flare nuts at the joint parts. Hold Turn G020404E01 SUSPENSION – FRONT SHOCK ABSORBER SP–11 (b) Remove a bolt and the bracket. G020405 (c) Remove a bolt, the nut and the washer. SP C099159 (d) Remove the 3 nuts on the upper side of the front shock absorber with coil spring. (e) Remove the front shock absorber with coil spring. C099160 9. SST REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT (a) Using SST, compress the coil spring. SST 09727-30021 (09727-00010, 09727-00031), 09727-00060 NOTICE: Do not use an impact wrench. It will damage the SST. C099161E01 (b) Hold the shock absorber rod, remove the nut. NOTICE: Do not use an impact wrench. It will damage the shock absorber rod. 10. REMOVE FRONT SHOCK ABSORBER CUSHION RETAINER 11. REMOVE FRONT SHOCK ABSORBER CUSHION NO. 1 C099162 SP–17 SUSPENSION – FRONT UPPER SUSPENSION ARM FRONT UPPER SUSPENSION ARM SUSPENSION & AXLE COMPONENTS FRONT SUSPENSION UPPER ARM BUSH LH FRONT SUSPENSION UPPER ARM ASSEMBLY LH 115 (1,170, 85) WASHER WASHER FRONT SUSPENSION UPPER ARM BUSH LH SP 13 (130, 9) 5.8 (59, 51 in.*lbf) SKID CONTROL SENSOR WIRE 13 (130, 9) BRACKET 110 (1,120, 81) CLIP N*m (kgf*cm, ft.*lbf) Non-reusable part C119711E01 SP–18 SUSPENSION – FRONT UPPER SUSPENSION ARM REMOVAL 1. REMOVE FRONT DISC WHEEL 2. INSPECT FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Check that there is no looseness on the ball joint by shaking the upper arm up and down by hand. 3. REMOVE SKID CONTROL SENSOR WIRE (a) Remove the 2 bolts, and disconnect the skid control sensor wire. 4. REMOVE FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Support the front suspension lower arm LH with a jack. (b) Remove the clip and the nut. (c) Using SST, disconnect the upper ball joint from the steering knuckle. SST 09628-62011 C099168 SP SST G020151E02 (d) Remove the bolt and the bracket. G020152 (e) Remove the bolt, the 2 washers and the nut. (f) Remove the front suspension upper arm assembly. G020153 SUSPENSION – FRONT UPPER SUSPENSION ARM 5. SP–19 REMOVE FRONT SUSPENSION UPPER ARM BUSH LH (a) Using a hammer and chisel, raise the flange of the bushing diagonally as shown in the illustration. G020154 (b) Using SST and a press remove the front suspension upper arm bush LH (front side). SST 09613-26010, 09710-22021 (09710-01031), 09950-00020 (c) Replace the rear side by the same procedures with the front side. SST SST SP G020155E02 INSPECTION 1. G020170 INSPECT FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per 1 turn and take the torque reading on the 5th turn. Torque: Turning torque 4.5 N*m (46 kgf*cm, 40 in.*lbf) or less (c) Check for any cracks and grease leaks on the ball joint dust cover. INSTALLATION 1. SST G020156E02 INSTALL FRONT SUSPENSION UPPER ARM BUSH LH (a) Using SST and a press, install a new front suspension upper arm bush LH (front side). SST 09710-26010 (09710-05061) (b) Install the rear side by the same procedures with the front side. SP–20 SUSPENSION – FRONT UPPER SUSPENSION ARM 2. TEMPORARILY TIGHTEN FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Install the front suspension upper arm assembly, and temporarily tighten bolt, the 2 washers and the nut. G020153 (b) Install the bracket with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) SP G020152 (c) Install a new nut and a new clip. Torque: 110 N*m (1,120 kgf*cm, 81 ft.*lbf) G020157 3. CONNECT SKID CONTROL SENSOR WIRE (a) Install the connect skid control sensor wire with the 2 bolts. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 4. INSTALL FRONT DISC WHEEL Torque: 112 N*m (1,140 kgf*cm, 83 ft.*lbf) 5. STABILIZE SUSPENSION (See page SP-15) 6. FULLY TIGHTEN FRONT SUSPENSION UPPER ARM ASSEMBLY LH (a) Fully tighten the nut. Torque: 115 N*m (1,170 kgf*cm, 85 ft.*lbf) 7. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: (See page SP-4) C099168 G020158 SP–21 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM FRONT SUSPENSION LOWER NO. 1 ARM SUSPENSION & AXLE COMPONENTS FRONT SHOCK ABSORBER WITH COIL SPRING 135 (1,380, 100) SP CAMBER ADJUST CAM NO. 2 CAMBER ADJUST CAM ASSEMBLY TOE ADJUST PLATE NO. 2 135 (1,380, 100) TOE ADJUST CAM SUB-ASSEMBLY FRONT LOWER ARM BUSH NO. 2 LH 135 (1,380, 100) FRONT LOWER ARM BUSH NO. 1 LH FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH FRONT LOWER BALL JOINT ATTACHMENT LH 140 (1,430, 103) COTTER PIN N*m (kgf*cm, ft.*lbf) : Specified torque 160 (1,630, 118) Non-reusable part C119712E01 SP–22 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM REMOVAL 1. REMOVE FRONT DISC WHEEL 2. INSPECT FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH (a) Install the hub nuts to the disc. (b) Using a dial indicator, check the lower ball joint for excessive play when you push the hub nuts up and down with a force of 294 N (30 kgf, 66 lbf). Maximum: 0.5 mm (0.020 in.) HINT: If it is not within the specification, replace the lower arm. 3. SEPARATE FRONT SHOCK ABSORBER WITH COIL SPRING (a) Remove the bolt, nut and washer. (b) Separate the front shock absorber with coil spring from the suspension lower arm. 4. REMOVE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH (a) Remove the 2 bolts, and separate the front lower ball joint attachment LH from the front axle. G021682 SP C099159 G020159 (b) Place matchmarks on the camber adjust cam No. 2 and toe adjust cam sub-assembly. (c) Remove the nut, camber adjust cam No. 2, camber adjust cam assembly, bolt, toe adjust cam subassembly, toe adjust plate No. 2 and front suspension arm sub-assembly lower No. 1 LH. Matchmarks G020160E03 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM SP–23 (d) Remove the cotter pin and the nut. (e) Using SST, remove the front lower ball joint attachment LH. SST 09628-00011 SST G020416E02 5. REMOVE FRONT LOWER ARM BUSH NO. 1 LH (a) Using a hammer and a chisel, raise the flange of the bushing diagonally as shown in the illustration. SP G020164 (b) Using SST and a press, remove the lower arm bush No. 1 LH. SST 09632-36010, 09950-00020, 09950-60010 (09951-00400) SST SST G020412E01 6. REMOVE FRONT LOWER ARM BUSH NO. 2 LH (a) Using a hammer and a chisel, raise the flange of the bushing diagonally as shown in the illustration. G020164 (b) Using SST and a press, remove the lower arm bush No. 2 LH. SST 09632-36010, 09950-00020, 09950-60010 (09951-00400) SST SST G020413E01 SUSPENSION – FRONT STABILIZER BAR SP–27 FRONT STABILIZER BAR SUSPENSION & AXLE COMPONENTS 70 (710, 52) FRONT STABILIZER LINK ASSEMBLY RH SP 70 (710, 52) 70 (710, 52) STABILIZER BAR FRONT 70 (710, 52) FRONT STABILIZER LINK ASSEMBLY LH 40 (410, 30) FRONT STABILIZER BAR BUSH NO. 1 FRONT STABILIZER BRACKET NO. 1 RH FRONT STABILIZER BRACKET NO. 2 LH 40 (410, 30) N*m (kgf*cm, ft.*lbf) : Specified torque C119713E01 SP–28 SUSPENSION – FRONT STABILIZER BAR REMOVAL 1. REMOVE FRONT DISC WHEEL 2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (a) Remove the 2 nuts and the front stabilizer link assembly LH. HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 3. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Remove the RH side by following the same procedures withe the LH side. 4. REMOVE FRONT STABILIZER BRACKET NO. 2 LH (a) Remove the 2 bolts and front stabilizer bracket No. 2 LH. 5. REMOVE FRONT STABILIZER BRACKET NO. 1 RH HINT: Remove the RH side by following the same procedures withe the LH side. 6. REMOVE FRONT STABILIZER BAR BUSH NO. 1 (a) Remove the 2 front stabilizer bar bush No. 1. 7. REMOVE STABILIZER BAR FRONT G020161 SP G020162 INSPECTION 1. G021679 INSPECT FRONT STABILIZER LINK ASSEMBLY LH (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn. Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) or less (c) Check for any cracks and grease leaks on the ball joint dust cover. SP–30 SUSPENSION – REAR COIL SPRING REAR COIL SPRING SUSPENSION & AXLE COMPONENTS COIL SPRING REAR LH 15 (155, 11) 15 (155, 11) CLIP SP SHOCK ABSORBER ASSEMBLY REAR LH 98 (1,000, 72) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119735E01 SUSPENSION – REAR COIL SPRING SP–31 REMOVAL 1. REMOVE REAR WHEEL 2. SEPARATE SHOCK ABSORBER ASSEMBLY REAR LH (a) Support the rear axle housing. (b) Remove the bolt, separate the shock absorber assembly rear LH from the rear axle. 3. DISCONNECT REAR BRAKE TUBE FLEXIBLE HOSE (a) Using SST, disconnect the 2 rear brake tubes from each of the flexible hoses. Use a container to catch brake fluid as it drains out. SST 09023-00101 (b) Remove the 2 clips and disconnect the 2 flexible hoses. D028132 SST 4. D028273E02 REMOVE COIL SPRING REAR LH (a) Start to lower the rear axle housing. NOTICE: Be careful not to snap the brake line and parking brake cable. (b) While lowering the rear axle housing, remove the coil spring rear LH. INSTALLATION 1. INSTALL COIL SPRING REAR LH (a) Install the coil spring rear LH to the rear axle housing. HINT: Fit the lower end of the coil spring into the gap of the spring lower seat 2. CONNECT SHOCK ABSORBER ASSEMBLY REAR LH (a) Install the shock absorber, temporarily tighten the bolt. 3. STABILIZE SUSPENSION (See page SP-39) D028471 D028132 SP SP–32 SUSPENSION – REAR COIL SPRING 4. FULLY TIGHTEN SHOCK ABSORBER ASSEMBLY REAR LH (a) Fully tighten the bolt. Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) 5. CONNECT REAR BRAKE TUBE FLEXIBLE HOSE (a) Install the 2 clips with the 2 flexible hoses. (b) Using SST, connect the break tubes to the flexible hose. Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) SST 09023-00101 6. FILL RESERVOIR WITH BRAKE FLUID 7. BLEED BRAKE LINE 8. CHECK FLUID LEVEL IN RESERVOIR 9. CHECK BRAKE FLUID LEAKAGE D028132 SST SP D028273E03 10. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) SUSPENSION – REAR SHOCK ABSORBER (w/ REAS) SP–33 REAR SHOCK ABSORBER (w/ REAS) SUSPENSION & AXLE COMPONENTS SP CUSHION RETAINER CUSHION NO. 1 25 (255, 18) 15 (153, 11) SHOCK ABSORBER ASSEMBLY REAR LH RETAINER CUSHION 70 (714, 52) LOWER BRACKET 29 (296, 21) REFERENCE TPRQUE: 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque 98 (1,000, 72) REAR STABILIZER LINK ASSEMBLY Non-reusable part C119734E01 SP–34 SUSPENSION – REAR SHOCK ABSORBER (w/ REAS) REMOVAL NOTICE: Be sure to read PRECAUTIONS before performing this procedure (See page SC-1). 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSEMBLY (See page SP-53) 3. REMOVE SHOCK ABSORBER ASSEMBLY REAR LH (a) Remove the bolt and disconnect the bracket. D028262 SP (b) Using a wrench to hold the bracket, remove the joint. NOTICE: Check that all shock absorbers are fully extended to the normal suspension rebound point. D028263 D028132 (c) Remove the bolt and disconnect the shock absorber assembly rear LH from the rear axle housing. NOTICE: Ensure that the rear axle housing is supported so that the shock absorber assembly rear LH is not extended beyond the normal suspension rebound point. (d) Remove the nut, cushion retainer, cushion No.1 and shock absorber assembly rear LH. NOTICE: • Remove the shock absorber assembly rear LH with the shock absorber rod fully extended. • Be sure to hold the body part of the shock absorber assembly rear LH when carrying it. (e) Remove the lower bracket from the shock absorber assembly rear LH. SUSPENSION – REAR SHOCK ABSORBER (w/o REAS) SP–37 REAR SHOCK ABSORBER (w/o REAS) SUSPENSION & AXLE COMPONENTS SP 25 (255, 18) CUSHION RETAINER CUSHION NO. 1 SHOCK ABSORBER ASSEMBLY REAR LH CUSHION NO. 2 CUSHION RETAINER 98 (1,000, 72) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119733E01 SP–38 SUSPENSION – REAR SHOCK ABSORBER (w/o REAS) REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE SHOCK ABSORBER ASSEMBLY REAR LH (a) Support the rear axle housing. (b) Remove the bolt and separate the shock absorber assembly rear LH from the rear axle housing. D028132 (c) Remove the nut, 3 cushion retainers, cushion No. 1, cushion No. 2 and shock absorber assembly rear LH. SP D028133 INSPECTION 1. SA00627 INSPECT SHOCK ABSORBER ASSEMBLY REAR LH (a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL (See page SP-39). INSTALLATION 1. D028133 INSTALL SHOCK ABSORBER ASSEMBLY REAR LH (a) Install the 3 cushion retainers, cushion No. 1, cushion No. 2 and shock absorber assembly rear LH with the nut. SUSPENSION – REAR SHOCK ABSORBER (w/o REAS) SP–39 (b) Install the shock absorber assembly rear LH with the bolt. D028132 (c) Fully tighten the nut. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 2. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 3. STABILIZE SUSPENSION (a) Jack down the vehicle. (b) Bounce the vehicle up and down several times to stabilize the suspension. SP D028133 4. FULLY TIGHTEN SHOCK ABSORBER ASSEMBLY REAR LH (a) Fully tighten the bolt. Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) D028132 DISPOSAL 100 mm (3.9 in.) 55 mm (2.2 in.) D028629E03 1. DISPOSE OF SHOCK ABSORBER ASSEMBLY REAR LH (a) Fully extend the shock absorber rod. (b) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: • When drilling, chips may fly out, and so work carefully. • The gas is colorless, odorless and nonpoisonous. SP–48 SUSPENSION – REAR LOWER CONTROL ARM INSTALLATION 1. INSTALL LOWER CONTROL ARM ASSEMBLY LH (a) Install the lower control arm assembly, temporarily tighten the nut, washer and bolt. (b) Install the rear axle housing, temporarily tighten the bolt, washer and nut. 2. CONNECT PARKING BRAKE CABLE ASSEMBLY NO. 3 (a) Connect the parking brake cable assembly No.3 with the bolt. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) 3. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 4. STABILIZE SUSPENSION (See page SP-39) 5. FULLY TIGHTEN LOWER CONTROL ARM ASSEMBLY LH (a) Fully tighten the 2 bolts. Torque: 130 N*m (1,326 kgf*cm, 96 ft.*lbf) HINT: While fixing the nut, turn and remove the bolt. D028142 SP D028252 SP–54 SUSPENSION – REAR STABILIZER BAR INSTALLATION 1. INSTALL STABILIZER BAR REAR (a) Install the 2 stabilizer bushes to the stabilizer bar. HINT: Install the stabilizer bush to the inner side of the stabilizer bush stopper on the stabilizer bar. Outer Side D028261E02 (b) Install the stabilizer bar and the 2 stabilizer brackets with the 4 bolts. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) SP D028260 2. INSTALL REAR STABILIZER LINK ASSEMBLY (a) Install the stabilizer link with the nut (LH side). Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. (b) Install the 2 retainers and the cushion to the stabilizer link. D028258 (c) Hold the stabilizer bar link with a wrench, and install the nut, retainer, cushion and link. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) D028259 3. REMOVE REAR STABILIZER LINK ASSEMBLY HINT: Install the RH side by following the same procedures with the LH side. 4. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) SP–40 SUSPENSION – REAR PNEUMATIC CYLINDER REAR PNEUMATIC CYLINDER SUSPENSION & AXLE COMPONENTS AIR TUBE CLIP PNEUMATIC CYLINDER ASSEMBLY REAR LH SP C119736E01 SUSPENSION – REAR PNEUMATIC CYLINDER SP–41 REMOVAL 1. REMOVE PNEUMATIC CYLINDER ASSEMBLY REAR LH (a) Jack up vehicle and support the frame with safety stands. NOTICE: • Do the work with the rear axle assembly lowered. • Do the work with the shock absorber installed. (b) Disconnect the height control tube (See page SC1). (c) Remove the clip on the upper side of the pneumatic cylinder (See page SC-1). HINT: If the clip cannot easily be removed, thread a wire through the hole to pull it. (d) Discharge air from the pneumatic cylinder assembly to retract it. D028275 (e) Turn the pneumatic cylinder assembly 90 degrees and remove it from the rear axle assembly. NOTICE: Do not extend the pneumatic cylinder assembly. HINT: If the pneumatic cylinder assembly is to be reused, 2 new o-rings as well as a new plate and height control plug must be used (See page SC-1). Rear Axle Assembly D028279E01 INSTALLATION 1. Clip D028276E01 INSTALL PNEUMATIC CYLINDER ASSEMBLY REAR LH (a) Install the pneumatic cylinder assembly with the clip. NOTICE: Make sure that the clip is secured tightly onto the cylinder. (b) Connect the height control tube (See page SC-1). SP SP–42 SUSPENSION – REAR PNEUMATIC CYLINDER (c) When using safety stands and jack: (1) Jack up the rear axle assembly until the bottom of the pneumatic cylinder assembly touches the rear axle assembly and install the clip at the lower side of the pneumatic cylinder assembly into the keyhole in the rear axle assembly. NOTICE: • Do not extend the pneumatic cylinder assembly for clip installation. • Make sure that the clip at the lower side of the pneumatic cylinder assembly fits in the keyhole in the rear axle assembly. (2) Remove the safety stands with care not to extend the pneumatic cylinder assembly when jacking down the vehicle till it sits on the ground. NOTICE: • Do not extend the pneumatic cylinder assembly by lowering the rear axle assembly with safety stands installed. • Make sure that the diaphragm of the pneumatic cylinder assembly is not deformed. (d) When using a swing arm type lift: (1) Lower the vehicle till the tires hit the ground, and continue lowering slowly until the bottom of the pneumatic cylinder assembly touches the rear axle assembly. (2) Align the seating pin on the cylinder with the keyhole in the rear axle assembly and install the pneumatic cylinder assembly on the rear axle assembly. (3) Lower the lift carefully so as not to extend the pneumatic cylinder assembly. NOTICE: • Do not extend the pneumatic cylinder assembly by lifting up the rear axle housing after installing the clip. • Make sure that the diaphragm of the pneumatic cylinder assembly is not deformed. (e) Start the engine and replenish the pneumatic cylinder assembly with air. Do not extend the pneumatic cylinder assembly Seating Pin Keyhole SP G026946E01 2. INSPECT AIR LEAK HINT: (See page SC-3) 3. INSPECT VEHICLE HEIGHT HINT: (See page SC-3) SUSPENSION – CENTER CONTROL ABSORBER (w/ REAS) SP–57 INSTALLATION 1. INSTALL CENTER CONTROL ABSORBER ASSEMBLY LH (a) Install the center control absorber assembly with the 3 nuts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) D028265 (b) Install the bracket with the bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) SP D028264 (c) Using a spanner to hold the bracket, install the joint. D028263 (d) Refer to HINT below. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.). Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 1 mm (0.04 in.) D028267E01 (e) Using a spanner to hold the center control absorber assembly, install the joint. D028266 SP–58 SUSPENSION – CENTER CONTROL ABSORBER (w/ REAS) (f) 1 mm (0.04 in.) Refer to HINT below. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.). Torque: Reference 25 N*m (255 kgf*cm, 18 ft.*lbf) 2. INSTALL REAR STABILIZER LINK ASSEMBLY HINT: (See page SP-54) 3. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 4. INSPECT FLUID LEAK HINT: (See page SC-3) D028267E01 DISPOSAL 1. SP D028472 DISPOSE OF CENTER CONTROL ABSORBER ASSEMBLY LH (a) Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. (b) Remove the flare nut. (c) Drain absorber oil. SUSPENSION – REAR UPPER CONTROL ARM SP–43 REAR UPPER CONTROL ARM SUSPENSION & AXLE COMPONENTS SP 80 (816, 59) WITH AIR SUSPENSION: 5.4 (55, 48 in.*lbf) 80 (816, 59) HEIGHT CONTROL SENSOR LINK UPPER CONTROL ARM ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119737E01 SP–44 SUSPENSION – REAR UPPER CONTROL ARM REMOVAL 1. REMOVE REAR WHEEL 2. DISCONNECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY REAR (w/ Air Suspension) HINT: (See page SC-94) 3. REMOVE UPPER CONTROL ARM ASSEMBLY (a) Remove the nut, washer and bolt from rear axle housing. HINT: While fixing the bolt, turn and remove the nut. D028137 (b) Remove the nut, washer and bolt with the upper control arm assembly. HINT: While fixing the bolt, turn and remove the nut. SP D028138 INSTALLATION 1. With Air Suspension: Front Outer Side D028458E01 INSTALL UPPER CONTROL ARM ASSEMBLY (a) Install the upper control arm assembly, temporarily tighten the nut, washer and bolt. HINT: In the case of the air suspensions, install them by referring to the illustration. SUSPENSION – REAR UPPER CONTROL ARM SP–45 (b) Install the rear axle housing, temporarily tighten the nut, washer and bolt. 2. CONNECT HEIGHT CONTROL SENSOR LINK SUBASSEMBLY REAR (w/ Air Suspension) HINT: (See page SC-95) 3. INSTALL REAR WHEEL 4. STABILIZE SUSPENSION (See page SP-39) 5. FULLY TIGHTEN UPPER CONTROL ARM ASSEMBLY (a) Fully tighten the 2 nuts. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) HINT: While fixing the bolt, turn and install the nut. D028137 SP D028140 SUSPENSION – CENTER CONTROL ABSORBER TUBE (w/ REAS) SP–61 REMOVAL NOTICE: Be sure to read PRECAUTIONS before performing this procedure (See page SC-1). 1. REMOVE TUBE PROTECTOR LH (a) Remove the bolt and the tube protector LH. 2. REMOVE CENTER CONTROL ABSORBER TUBE LH (a) Using a spanner to hold the center control absorber assembly LH, disconnect the joint. NOTICE: Check that all four shock absorbers are fully extended to the normal suspension rebound point. D028462 D028266 (b) Using a spanner to hold the bracket, remove the joint. D028268 (c) Using a pliers, cut the center control absorber tube. Use a container to catch absorber as it drains out. (d) Remove the center control absorber tubes from the frame. D028470 SP SP–62 SUSPENSION – CENTER CONTROL ABSORBER TUBE (w/ REAS) INSTALLATION 1. INSTALL CENTER CONTROL ABSORBER TUBE LH (a) Install the center control absorber tube (Rear side) with the bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) D028474 (b) Using a spanner to hold the counter control absorber assembly, install the joint. SP D028266 (c) Refer to HINT below. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.) Torque: Reference 25 N*m (255 kgf*cm, 18 ft.*lbf) 1 mm (0.04 in.) D028267E01 (d) Pass through the center control absorber tube (Front side) between the body and the frame. D028476 (e) Pass the opposite side of the center control absorber tube over the frame. NOTICE: Do not bend the center control tube excessively. D028475 SUSPENSION – CENTER CONTROL ABSORBER TUBE (w/ REAS) (f) SP–63 Using a spanner to hold the bracket, install the joint. D028473 (g) Refer to HINT below. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.) Torque: Reference 25 N*m (255 kgf*cm, 18 ft.*lbf) 1 mm (0.04 in.) SP D028267E01 (h) Using a spanner to hold the bracket, install the joint. D028268 (i) 1 mm (0.04 in.) Refer to HINT below. HINT: Tighten the joint so that the gap spacing becomes 1 mm (0.04 in.) Torque: Reference 25 N*m (255 kgf*cm, 18 ft.*lbf) D028267E01 D028462 2. INSTALL TUBE PROTECTOR LH (a) Install the tube protector LH with the bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 3. INSPECT FLUID LEAK HINT: (See page SC-3) SP–46 SUSPENSION – REAR LOWER CONTROL ARM REAR LOWER CONTROL ARM SUSPENSION & AXLE COMPONENTS SP 130 (1,326, 96) 13 (127, 9) 130 (1,326, 96) PARKING BRAKE CABLE ASSEMBLY NO. 3 LOWER CONTROL ARM ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque C119738E02 SUSPENSION – REAR LOWER CONTROL ARM SP–47 REMOVAL 1. REMOVE REAR WHEEL 2. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO. 3 (a) Remove the bolt, separate the parking brake cable assembly No.3. 3. REMOVE LOWER CONTROL ARM ASSEMBLY LH (a) Remove the nut, washer and bolt from rear axle housing. HINT: While fixing the nut, turn and remove the bolt. D028142 (b) Remove the nut, washer, bolt and the lower control arm assembly. HINT: While fixing the nut, turn and remove the bolt. D028250 SP SP–49 SUSPENSION – REAR LATERAL CONTROL ROD REAR LATERAL CONTROL ROD SUSPENSION & AXLE COMPONENTS 130 (1,326, 96) REAR LATERAL CONTROL ROD ASSEMBLY SP 130 (1,326, 96) N*m (kgf*cm, ft.*lbf) : Specified torque C119739E01 SP–50 SUSPENSION – REAR LATERAL CONTROL ROD REMOVAL 1. REMOVE REAR LATERAL CONTROL ROD ASSEMBLY (a) Remove the bolt. D028254 (b) Remove the bolt, nut and lateral control rod assembly. HINT: While fixing the nut, turn and remove the bolt. SP D028255 INSTALLATION 1. INSTALL REAR LATERAL CONTROL ROD ASSEMBLY (a) Install the lateral control rod assembly with the bolt. D028254 (b) Install the bolt and the nut. 2. D028255 STABILIZE SUSPENSION (See page SP-39) SUSPENSION – REAR LATERAL CONTROL ROD 3. D028256 SP–51 FULLY TIGHTEN REAR LATERAL CONTROL ROD ASSEMBLY (a) Fully tighten the 2 bolts. Torque: 130 N*m (1,326 kgf*cm, 96 ft.*lbf) HINT: While fixing the nut, turn and install the bolt. SP SP–52 SUSPENSION – REAR STABILIZER BAR REAR STABILIZER BAR SUSPENSION & AXLE COMPONENTS 15 (153, 11) RETAINER CUSHION SP 70 (714, 52) STABILIZER BAR REAR STABILIZER BUSH 70 (714, 52) STABILIZER BRACKET 15 (153, 11) RETAINER CUSHION STABILIZER BUSH 30 (306, 22) STABILIZER BRACKET RETAINER 30 (306, 22) N*m (kgf*cm, ft.*lbf) : Specified torque CUSHION REAR STABILIZER LINK ASSEMBLY Non-reusable part C119740E01 SUSPENSION – REAR STABILIZER BAR SP–53 REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSEMBLY (a) Remove the nut and disconnect the stabilizer bar from the stabilizer link (LH side). HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. D028258 (b) Hold the stabilizer bar link with a wrench and remove the nut, retainer, cushion and link. (c) Remove the 2 retainers and cushion from the stabilizer link. 3. REMOVE REAR STABILIZER LINK ASSEMBLY HINT: Remove the RH side by following the same procedures with the LH side. D028259 4. REMOVE STABILIZER BAR REAR (a) Remove the 4 bolts, the 2 stabilizer brackets and the stabilizer bar. (b) Remove the 2 stabilizer bushes from the stabilizer bar. D028260 INSPECTION 1. D028478 INSPECT REAR STABILIZER LINK ASSEMBLY (a) As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn, and take the torque reading on the 5th turn. Torque: 0.05 - 2.0 N*m (0.5 -20 kgf*cm, 0.4 - 17.7 in.*lbf) SP SP–55 SUSPENSION – CENTER CONTROL ABSORBER (w/ REAS) CENTER CONTROL ABSORBER (w/ REAS) SUSPENSION & AXLE COMPONENTS REFERENCE TORQUE: 25 (255, 18) 15 (153, 11) RETAINER CUSHION SP 70 (714, 52) 29 (296, 21) REAR STABILIZER LINK ASSEMBLY CENTER CONTROL ABSORBER ASSEMBLY LH REFERENCE TORQUE: 25 (255, 18) 29 (296, 21) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119741E01 SP–56 SUSPENSION – CENTER CONTROL ABSORBER (w/ REAS) REMOVAL NOTICE: Be sure to read PRECAUTIONS before performing this procedure (See page SC-1). 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSEMBLY HINT: (See page SP-53) 3. REMOVE CENTER CONTROL ABSORBER ASSEMBLY LH (a) Using a spanner to hold the bracket, remove the joint. NOTICE: Check that all four shock absorbers are fully extended to the normal suspension rebound point. D028263 SP (b) Remove the bolt and disconnect the bracket. D028264 (c) Using a spanner to hold the center control absorber assembly, remove the joint. NOTICE: • Do not loosen the flare nut. • Do not deform or damage the tubes. D028266 (d) Remove the 3 nuts and the center control absorber assembly. NOTICE: • Do not deform or damage the tubes. • Be sure to hold the body part to carry the center control absorber assembly. D028265 SUSPENSION – CENTER CONTROL ABSORBER TUBE (w/ REAS) SP–59 CENTER CONTROL ABSORBER TUBE (w/ REAS) SUSPENSION & AXLE COMPONENTS CENTER CONTROL ABSORBER TUBE RH REFERENCE REFERENCE TORQUE: TORQUE: 25 25 (255, (255, 18) 18) TUBE PROTECTOR RH 29 (296, 21) REFERENCE REFERENCE TORQUE: TORQUE: 25 25 (255, (255, 18) 18) CENTER CONTROL ABSORBER TUBE LH 29 (296, 21) TUBE PROTECTOR LH REFERENCE REFERENCE TORQUE: TORQUE: 25 25 (255, (255, 18) 18) REFERENCE REFERENCE TORQUE: TORQUE: 25 25 (255, (255, 18) 18) N*m (kgf*cm, ft.*lbf) : Specified torque C119742E01 SP SP–60 SUSPENSION – CENTER CONTROL ABSORBER TUBE (w/ REAS) SUPPLIED PARTS: CENTER CONTROL ABSORBER TUBE RH (REAR SIDE) CENTER CONTROL ABSORBER TUBE RH (FRONT SIDE) 29 (296, 21) SP REFERENCE TORQUE: 25 (255, 18) REFERENCE TORQUE: 25 (255, 18) REFERENCE TORQUE: 25 (255, 18) 29 (296, 21) REFERENCE TORQUE: 25 (255, 18) CENTER CONTROL ABSORBER TUBE LH (REAR SIDE) REFERENCE TORQUE: 25 (255, 18) CENTER CONTROL ABSORBER TUBE LH (FRONT SIDE) N*m (kgf*cm, ft.*lbf) : Specified torque C119743E01 TW–6 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM PARTS LOCATION TIRE PRESSURE WARNING VALVE AND TRANSMITTER (for Spare) TIRE PRESSURE WARNING ANTENNA AND RECEIVER TIRE PRESSURE WARNING VALVE AND TRANSMITTER (for Rear RH) TW TIRE PRESSURE WARNING VALVE AND TRANSMITTER (for Front RH) TIRE PRESSURE WARNING VALVE AND TRANSMITTER (for Rear LH) TIRE PRESSURE WARNING VALVE AND TRANSMITTER (for Front LH) C131565E03 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–7 COMBINATION METER - TIRE PRESSURE WARNING LIGHT DRIVER SIDE JUNCTION BLOCK GAUGE FUSE TW ECU-IG FUSE TIRE PRESSURE WARNING ECU C131373E03 TW–8 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM SYSTEM DIAGRAM Combination Meter - Vehicle Speed Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU Combination Meter - Tire Pressure Warning Light Tire Pressure Warning Valve and Transmitter (for Front LH) TW Tire Pressure Warning Valve and Transmitter (for Front RH) DLC3 Tire Pressure Warning Valve and Transmitter (for Rear LH) Tire Pressure Warning Valve and Transmitter (for Rear RH) Tire Pressure Warning Valve and Transmitter (for Spare) : Radio Signal C141685E03 HINT: The tire pressure warning valve and transmitter sends information on the temperature inside the tire, the ID, and the tire pressure. TW–9 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM SYSTEM DESCRIPTION 1. DESCRIPTION OF SYSTEM (a) Each tire pressure warning valve and transmitter is equipped with a tire pressure sensor and a transmitter and is installed in each tire wheel assembly. The sensor measures the tire pressure. The measured value and transmitter ID are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU from the tire pressure warning antenna and receiver. If the transmitter ID has already been registered, the ECU compares the measured air pressure value with the standard value. When the value is less than the standard value registered in the tire pressure warning ECU, the warning light on the combination meter comes on. Combination Meter Tire Pressure Warning Valve and Transmitter - Tire Pressure Warning Light TW Front Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU Tire Pressure Warning Valve and Transmitter C150461E01 2. Normal on 3 seconds off Defect on off INITIAL CHECK (a) The tire pressure warning light turns on for 3 seconds after the ignition switch is turned ON, and then goes off. HINT: If the warning light does not turn on for 3 seconds, troubleshoot the pressure warning light circuit. Trouble Area Tire pressure warning light circuit Ignition Switch ON C124985E03 Proceed to TW-58 TW–10 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3. TW 4. Components WHEN TIRE PRESSURE WARNING LIGHT IS LIT (a) When the tire pressure warning light does not go off, or when it comes on during driving, check the tire pressure. If the tire pressure warning light comes on within several hours after adjusting the tire pressure, the tire may have a slow air leak. (b) Under the following conditions, the system may not function properly. • Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. • A radio device of similar frequency is used in the vehicle. • A large amount of snow or ice is stuck to the vehicle, especially onto the wheels and around the wheel houses. • The battery of the sensor has been depleted. • Tires without a tire pressure warning valve and transmitter are used. • Tire chains are used. • When the full-size spare tire is not within the receivable range of the electric wave, a signal may not be received because the spare tire is fixed. Accordingly, the system may not function properly. If there is a possibility that the tire pressure warning system does not receive a signal from the spare tire, rotate the tire 90°. • If any wheels other than the specified ones are used, the system may not function properly because interference may prevent the radio waves from being correctly transmitted from the tire pressure sensor. • Depending on the tire type, the system may not function properly even though the specified wheels are used. (c) The average usage life of the grommet of the tire pressure warning valve and transmitter is approximately 5 years, at which time it must be replaced. If air is leaking from the tire but the tire is less than 5 years old and there is no problem with grommets, retighten the valve nut. (d) After removing and installing the ECU or a sensor, check for a diagnostic trouble code and verify that it is a normal code. FUNCTION OF COMPONENTS Function Tire pressure warning valve and transmitter Combined as a single unit with a disc wheel air valve, it measures tire pressure and temperature and transmits an ID number for measurement value and identification. Has a built-in battery. Tire pressure warning antenna and receiver Receives and transmits a necessary signal from the transmitter to the tire pressure warning ECU. Tire pressure warning ECU Receives the signal from the receiver and identifies it as vehicle's own signal. If the measured value is equal to or lower than the specified value, it transmits a signal so that the tire pressure warning light on the combination meter comes on. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Components Tire pressure warning light TW–11 Function Located in the combination meter, it informs the driver of lowered tire air pressure and system failure. TW TW–12 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the tire pressure warning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble. HINT: It is important to collect as much specific information as possible from the customer to allow for a quick repair. TW NEXT 3 ADJUST TIRE PRESSURE* (a) (b) (c) (d) Turn the ignition switch OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON and the tester ON. Following the display on the intelligent tester, read "DATA LIST" (see page TW-25). (e) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. (f) Adjust all tire pressures to the standard values (see page TW-1). (g) Check the DATA LIST (see page TW-25). HINT: • It takes about 2 or 3 minutes to display the updated tire pressure data. • If the problem is that the tire pressure decreases, wait until all of the tire pressure data is received by the ECU. If the data is received, the tire pressure warning light will turn off. Result Condition A Tire pressure warning light remains on. B A B Proceed to Tire pressure warning light goes off. Go to step 9 TW–13 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 4 CHECK FOR DTC* (a) Check for DTC (see page TW-23). Result Condition Proceed to DTC is output A DTC is not output B B Go to step 6 A 5 DTC CHART (a) Refer to DIAGNOSTIC TROUBLE CODE CHART (see page TW-27). NEXT TW Go to step 8 6 PROBLEM SYMPTOMS TABLE (a) Refer to PROBLEM SYMPTOMS TABLE (see page TW19). NEXT 7 CIRCUIT INSPECTION* (a) Refer to ELECTRONIC CIRCUIT INSPECTION PROCEDURE (see page IN-38). NEXT 8 REPAIR OR REPLACE (a) Repair or replace parts based on the diagnosis result. NEXT 9 CONFIRMATION TEST* (a) Check the DATA LIST to confirm that the tire inflation pressure has been received (see page TW-25). TW–14 NEXT END TW TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–50 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2165/65 Abnormal Temperature Inside ID1 Tire DTC C2166/66 Abnormal Temperature Inside ID2 Tire DTC C2167/67 Abnormal Temperature Inside ID3 Tire DTC C2168/68 Abnormal Temperature Inside ID4 Tire DTC C2169/69 Abnormal Temperature Inside ID5 Tire DESCRIPTION Each tire pressure warning valve and transmitter measures the internal temperature of its tire as well as tire pressure, and transmits the information to the tire pressure warning ECU along with the transmitter ID. If the measured temperature is out of the specified range, the tire pressure warning ECU recognizes it as a malfunction, outputs DTCs, and blinks the tire pressure warning light. DTC Code C2165/65 C2166/66 C2167/67 C2168/68 C2169/69 TW Detection Condition Trouble Area Temperature inside the tire exceeds 119°C (246.2°F) more than once. • • • Tires Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. 1 CHECK TIRES (a) Check that the tires are not flat, and have no indication of air pressure drop. OK: Tires are normal. HINT: If a tire is damaged, the tire pressure warning valve and transmitter may also have been damaged at the same time. NG OK REPLACE TIRE AND TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–51 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the specified value (see page TW-1). (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON and turn the tester ON. (e) Display the "TIREPRESS" data for each wheel using the intelligent tester. (f) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.4 kgf/cm2, 5.8 psi) within 30 seconds. (g) Check the DATA LIST. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition Diagnostic Note ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS1 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 537.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* kPa (5.4 kgf/cm2, 78 psi) TW ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS2 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 537.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* kPa (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS3 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure 2 kgf/cm , 92.5 psi), Relative pressure / 537.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* kPa (5.4 kgf/cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS4 cm2 , -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 537.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* kPa (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS5 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 Actual tire inflation pressure If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* kPa (5.4 kgf/cm2, 78 psi) HINT: *: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34). TW–52 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Result Condition Detection Condition One of "TIREPRESS" data (ID1 to ID5) changed. Normal No "TIREPRESS" data changed. TW Transmitter corresponding to DTC NOTICE: • It takes about 2 or 3 minutes to display the updated tire pressure data. • When no "TIREPRESS" data has changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270°. Then forcibly transmit the transmitter ID and recheck it. • Record the transmitter ID and position of transmitters that are normal. (h) When the "TIREPRESS" data (ID1 to ID5) has changed, repeat this procedure to identify the tire pressure warning valve and transmitter that corresponds to a DTC. (i) When all of the "TIREPRESS" data (ID1 to ID5) has changed, identify the malfunctioning tire pressure warning valve and transmitter based on the recorded ID numbers and output DTC. NEXT 3 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Replace the identified tire pressure warning valve and transmitter with a new one (see page TW-73). HINT: • Before installing a new tire pressure warning valve and transmitter, read and write down its transmitter ID. • The IDs for the tire pressure warning valve and transmitters that are not replaced should be checked using tester and recorded. NEXT 4 CHECK REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID for all wheels (see page TW13). (b) Set the tire pressure of all wheels to the specified value. NEXT 5 READ VALUE OF DATA LIST (a) Turn the ignition switch OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and turn the tester ON. TW–53 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (d) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition Diagnostic Note ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS1 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS2 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS3 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS4 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), Relative pressure / -100 kPa (-1 kgf/ TIREPRESS5 cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 Actual tire inflation pressure kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) HINT: *: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34). Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values are not displayed. B B A END REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TW TW–54 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2171/71 Transmitter ID not Registered DESCRIPTION The IDs of each tire pressure warning valve and transmitter are registered to the tire pressure warning ECU. When the ECU detects that an ID is not one of the registered IDs, or cannot receive an ID signal, a DTC is output. DTC Code C2171/71 Detection Condition Trouble Area Transmitter ID code is not registered. (When an ID code is unregistered for 51 minutes or more) Tire pressure warning ECU INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. TW 1 CONFIRM REGISTRATION CONDITION (REGISTERED ID CODES) (a) (b) (c) (d) Turn the ignition switch OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON and turn the tester on. Select "REGIT ID CODE" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID1 is displayed *: Displayed only when the ID No. is not registered. REGIT ID2 CODE Registered ID2 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID2 is displayed *: Displayed only when the ID No. is not registered. REGIT ID3 CODE Registered ID3 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID3 is displayed *: Displayed only when the ID No. is not registered. REGIT ID4 CODE Registered ID4 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID4 is displayed *: Displayed only when the ID No. is not registered. REGIT ID5 CODE Registered ID5 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID5 is displayed *: Displayed only when the ID No. is not registered. OK: The registered transmitter ID codes are displayed on the intelligent tester screen. OK REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) NG 2 PERFORM REGISTRATION (TRANSMITTER ID) (a) Register the transmitter IDs for all the wheels (see page TW-13). TW–55 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM NEXT 3 READ VALUE ON DATA LIST (a) (b) (c) (d) (e) Turn the ignition switch OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON and turn the tester ON. Check the DATA LIST. Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or - cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS1 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Diagnostic Note Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or - cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS2 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or - cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS3 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or - cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS4 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or - cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS5 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / Actual tire inflation pressure 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) HINT: *: It may take about 2 or 3 minutes until the values are displayed. Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values not display B TW TW–56 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM B A END TW REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–1 TIRE AND WHEEL SYSTEM PRECAUTION 1. 2. IN CASE OF REMOVAL AND INSTALLATION OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) When installing a tire, make sure that the tire pressure warning valve and transmitter does not interfere with the tire bead so that damage to the sensor is prevented. (b) After completing the operation, remove the valve core to rapidly release air and check that the warning light is lit. If not, the system may be defective. (c) If there is air leakage, tighten the nut with a force of 4.0 N*m (41 kgf*cm, 35 in.*lbf) and push the valve core 2 or 3 times to remove any dirt attached on the valve core. If there is still air leakage, replace the grommet, the washer and the nut all together. (d) When installing the tire pressure warning valve and transmitter, check whether the rim, grommet, washer and nut are clean. Use a manufacturerspecified cap. (e) When putting air into the tire, first install the tire pressure valve straight onto the stem of the tire pressure warning valve and transmitter. IN CASE OF TIRE AND WHEEL REPLACEMENT OR TIRE ROTATION (a) When replacing tires, be sure to check if the grommet of the tire valve is damaged or not. If so, replace the grommet together with the washer and nut. (b) When tires and wheels are replaced, register the transmitter ID without fail. TW TW–2 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Cold tire inflation pressure: Except MEXICO Tire size Pressure P265/60R18 109H P265/65R17 110S P265/70R16 111S 220 kPa (2.2 kgf/cm2, 32 psi) MEXICO Tire size Pressure P265/65R17 112S P265/70R16 111S 200 kPa (2.0 kgf/cm2, 29 psi) (b) Using a dial indicator, check the tire runout. Tire runout: 3.0 mm (0.118 in.) or less TW R003031 2. ROTATE TIRE (a) Rotate tires as shown in the illustration. HINT: See the illustration for where to rotate each tire when you include the spare tire in rotation. 3. INSPECT WHEEL BALANCE (a) Check and adjust the Off-the-car balance. (b) If necessary, check and adjust the On-the-car balance. Imbalance after adjustment: 265/70R16: 8 g (0.018 lb) or less 265/65R17: 7 g (0.015 lb) or less 4. INSPECT FRONT AXLE HUB (See page AH-1) 5. INSPECT REAR AXLE HUB (See page AH-1) Front G022181E01 C080976 TW–57 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2176/76 Receiver Error DESCRIPTION The signals are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. DTC Code Detection Condition C2176/76 DTC is stored when any of the following is detected: • Malfunction in the tire pressure warning ECU internal circuit. • Terminal RF5V is shorted to ground. • Malfunction in the tire pressure warning antenna and receiver internal circuit. Trouble Area • • • Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU WIRING DIAGRAM +5V 5 8 RF5V TW RDA GND 1 7 4 16 T17 Tire Pressure Warning Antenna and Receiver RDA GND2 T16 Tire Pressure Warning ECU E133110E07 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. TW–58 1 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR (ECU - RECEIVER) Rear view of wire harness connector: (to Tire Pressure Warning ECU) 7 (RDA) Rear view of wire harness connector: (to Tire Pressure Warning Antenna and Receiver) T16 T17 8 (RF5V) 5 (+5V) 1 (RDA) 16 (GND2) 4 (GND) C150484E01 (a) Disconnect the T16 ECU connector. (b) Disconnect the T17 receiver connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TW Tester Connection Specified Condition T16-7 (RDA) - T17-1 (RDA) Always Below 1 Ω T16-8 (RF5V) - T17-5 (+5V) Always Below 1 Ω T16-16 (GND2) - T17-4 (GND) Always Below 1 Ω T16-7 (RDA) or T17-1 (RDA) - Body ground Always 10 kΩ or higher T16-8 (RF5V) or T17-5 (+5V) - Body ground Always 10 kΩ or higher T16-16 (GND2) or T17-4 (GND) Body ground Always 10 kΩ or higher NG OK Condition REPAIR OR REPLACE HARNESS OR CONNECTOR TW–59 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2 CHECK TIRE PRESSURE WARNING ECU Component with harness connected: (Tire Pressure Warning ECU) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Switch Condition Specified Condition T16-8 (RF5V) - T16-16 (GND2) Ignition switch ON 4.5 to 5.5 V NG 8 (RF5V) REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) T16 16 (GND2) C150486E01 OK TW REPLACE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (See page TW-70) TW–60 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2191/91 Vehicle Speed Signal Error (Test Mode DTC) DESCRIPTION The tire pressure warning ECU receives a speed signal from the combination meter. This DTC is stored upon entering test mode, and cleared when a vehicle speed signal of 20 km/h (12 mph) is detected for 3 seconds or more. This DTC is output only in test mode. DTC Code C2191/91 Detection Condition Trouble Area • • • • Speed sensor circuit malfunction Vehicle speed sensor Combination meter Wire harness or connector Tire pressure warning ECU WIRING DIAGRAM TW 5 3 SPD T16 Tire Pressure Warning ECU C9 Combination Meter E115290E45 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU have been replaced. 1 READ VALUE ON INTELLIGENT TESTER (a) Turn the ignition switch OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON, and turn the intelligent tester on. TW–61 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (d) Select the item below in the Data List, and read the value displayed on the intelligent tester. Tire pressure warning ECU Tester Display VEHICLE SPD Measurement Item/Range Normal Condition Vehicle speed/ min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Diagnostic Note Almost same as actual vehicle speed - (e) Check that the values indicated on the tester and on the combination meter are the same. OK: The vehicle speed displayed on the tester changes depending on the actual vehicle speed. NG GO TO METER / GAUGE SYSTEM (See page ME-4) OK 2 CHECK HARNESS AND CONNECTOR (ECU - COMBINATION METER) T16 TW Front view of wire harness connector: (to Combination Meter) Front view of wire harness connector: (to Tire Pressure Warning ECU) 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10111213141516 C9 111213 141516171819 20 SPD C150489E01 (a) Disconnect the T16 ECU connector. (b) Disconnect the C9 meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition T16-3 (SPD) - C9-5 Always Below 1 Ω T16-3 (SPD) or C9-5 - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TW–62 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tire Pressure Warning Light Circuit DESCRIPTION If the ECU detects trouble, the tire pressure warning light blinks and the tire pressure monitor is canceled at the same time. At this time, the ECU records a DTC in the memory. Connecting terminals TC and CG of the DLC3 makes the tire pressure warning light blink and output the DTC. WIRING DIAGRAM 1 6 IND TW C8 Combination Meter T16 Tire Pressure Warning ECU E115290E47 INSPECTION PROCEDURE NOTICE: It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU has been replaced. TW–63 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 1 CHECK HARNESS AND CONNECTOR (COMBINATION METER - TIRE PRESSURE WARNING ECU) Front view of wire harness connector: (to Combination Meter) Front view of wire harness connector: (to Tire Pressure Warning ECU) T16 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10111213141516 C8 111213 141516171819 20 IND C150489E02 (a) Disconnect the C8 combination meter connector. (b) Disconnect the T16 tire pressure warning ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition T16-6 (IND) - C8-1 Always Below 1 Ω T16-6 (IND) or C8-1 - Body ground Always 10 kΩ or higher NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR TW TW–64 2 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK COMBINATION METER Component without harness connected: (Tire Pressure Warning ECU) (a) Disconnect the connector from the tire pressure warning ECU. (b) Turn the ignition switch ON, and check the condition of the tire pressure warning light illumination. Result Condition Illuminates A Does not illuminate B B T16 Proceed to REPLACE COMBINATION METER (See page ME-59) C150492E01 A TW REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TW–65 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM ECU Power Source Circuit DESCRIPTION This is the power source for the tire pressure warning ECU. WIRING DIAGRAM 2 from Ignition Switch IG ECU-IG 11 GND T16 Tire Pressure Warning ECU C150493E01 INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (see page TW-13). 1 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the instrument panel junction block. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection ECU-IG fuse NG OK Condition Specified Condition Always Below 1 Ω Go to step 4 TW TW–66 2 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR (ECU - BATTERY AND BODY GROUND) Rear view of wire harness connector: (to Tire Pressure Warning ECU) (a) Disconnect the T16 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection T16-2 (IG) - Body ground NG Switch Condition Specified Condition Ignition switch ON 10 to 14 V Ignition switch OFF Below 1 V REPAIR OR REPLACE HARNESS OR CONNECTOR T16 2 (IG) C150492E04 OK TW 3 CHECK HARNESS AND CONNECTOR (ECU - BODY GROUND) Rear view of wire harness connector: (to Tire Pressure Warning ECU) (a) Disconnect the T16 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection T16-11 (GND) - Body ground NG Condition Specified Condition Always Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR T16 11 (GND) C150492E03 OK REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 4 TW–67 CHECK HARNESS AND CONNECTOR (ECU - BODY GROUND) Rear view of wire harness connector: (to Tire Pressure Warning ECU) (a) Disconnect the T16 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection T16-2 (IG) - Body ground NG Condition Specified Condition Always 10 kΩ or higher REPLACE FUSE AND REPAIR OR REPLACE HARNESS OR CONNECTOR T16 2 (IG) C150492E04 OK TW REPLACE FUSE TW–68 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals 13 (TC) and 4 (CG) of the DLC3. The DTCs are indicated by the blinking of the tire pressure warning light. WIRING DIAGRAM TC CG 12 13 TC 4 D1 DLC3 T16 Tire Pressure Warning ECU TW C150494E01 HINT: When each warning light blinks continuously, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in an ECU connected to this circuit may have occurred. INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (see page TW-13). TW–69 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 1 CHECK HARNESS AND CONNECTOR (DLC3 - TIRE PRESSURE WARNING ECU) DLC3 CG D1 TC Front view of wire harness connector: (to Tire Pressure Warning ECU) T16 (a) Disconnect the T16 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition T16-12 (TC) - D1-13 (TC) Always Below 1 Ω T16-12 (TC) or D1-13 (TC) - Body ground Always 10 kΩ or higher D1-4 (CG) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR 1 2 3 4 5 6 7 8 9 10111213141516 TW TC C150495E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TW–71 REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (a) Disconnect the negative terminal. 2. REMOVE REAR NO. 2 SEAT (for 50/50 Split Seat Type) (See page SE-36) 3. REMOVE REAR NO. 2 SEAT ASSEMBLY LH (for 60/ 40 Split Seat Type LH Side) (See page SE-41) 4. REMOVE REAR NO. 2 SEAT ASSEMBLY RH (for 60/ 40 Split Seat Type RH Side) (See page SE-49) 5. REMOVE ROOF HEADLINING ASSEMBLY HINT: Refer to the instructions for removal of the roof headlining assembly (See page IR-7). 6. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Disconnect the connector. (b) Remove the 2 bolts and receiver assembly. TW F046094 INSTALLATION F046094 1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Install the receiver assembly with the 2 bolts. Torque: 6.8 N*m (69 kgf*cm, 60 in.*lbf) (b) Connect the connector. 2. INSTALL ROOF HEADLINING ASSEMBLY 3. INSTALL REAR NO. 2 SEAT (for 50/50 Split Seat Type) (See page SE-38) 4. INSTALL REAR NO. 2 SEAT ASSEMBLY LH (for 60/40 Split Seat Type LH Side) (See page SE-46) 5. INSTALL REAR NO. 2 SEAT ASSEMBLY RH (for 60/40 Split Seat Type RH Side) (See page SE-53) 6. CONNECT BATTERY NEGATIVE TERMINAL 7. REGISTRATION OF TRANSMITTER ID HINT: (See page TW-13) 8. PERFORM INITIALIZATION TW–78 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (a) Disconnect the negative terminal. 2. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-9) 3. REMOVE COWL SIDE TRIM BOARD RH (See page IP9) 4. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 (See page IP-9) 5. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the connector. (b) Remove the 2 screws and tire pressure warning ECU. F046450 TW INSTALLATION F046450 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the tire pressure warning ECU with the 2 screws. (b) Connect the connector. 2. INSTALL INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 3. INSTALL COWL SIDE TRIM BOARD RH 4. INSTALL FRONT DOOR SCUFF PLATE RH 5. CONNECT BATTERY NEGATIVE TERMINAL 6. REGISTRATION OF TRANSMITTER ID HINT: (See page TW-13) 7. PERFORM INITIALIZATION TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–15 REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION It is necessary to register the transmitter ID in the tire pressure warning ECU when replacing the tire pressure warning valve and transmitter and/or tire pressure warning ECU. Prepare all transmitter ID data before starting registration. (a) Before registration (1) In case of tire pressure warning ECU replacement. • Read the registered transmitter IDs that are stored in the old ECU using the intelligent tester and note them down. • If reading stored transmitter IDs is impossible due to malfunctions of components such as the tire pressure warning antenna and receiver, remove the tires from the wheels and check the IDs located on the tire pressure warning valves and transmitters (see page TW-3). (2) In case of tire pressure warning valve and transmitter replacement. • Take a note of the 7 digit number (transmitter ID) written on the tire pressure warning valve and transmitter. Tire Pressure Warning Valve and Transmitter: Transmitter ID (7 Digit Number) E128762E10 NOTICE: The transmitter ID is written on the tire pressure warning valve and transmitter. It will be unable to be read after installing the tire pressure warning valve and transmitter on the tire and wheel. Therefore, take a note of the transmitter ID before installing the tire pressure warning valve and transmitter. TW TW–16 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2. REGISTER TRANSMITTER ID (a) Set the air pressure of all wheels to the specified value (see page TW-1). (b) Connect the intelligent tester to the DLC3 (Procedure "A"). (c) Turn the ignition switch ON (Procedure "B"). (d) Select the REGIST TIRE following the intelligent tester screen (UTILITY - REGIST TIRE) (Procedure "C"). DLC3 Intelligent Tester C150424E01 (e) Input the IDs (ID1 to ID5) using the intelligent tester and transmit them to the tire pressure warning ECU (Procedure "D"). TW F100622 (f) C107265 Set the ID transmission condition to "ID Registration is complete" (Procedure "E"). HINT: • The previously registered IDs will be deleted from the memory when the registration is completed. • If the procedures "C" to "D" are not completed within 5 minutes, the mode will return to normal operation mode. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–17 Registration Procedure TW C153431E01 3. CONFIRMATION OF TRANSMITTER ID REGISTRATION (a) Connect the intelligent tester to the DLC3 (ignition switch is OFF). (b) Turn the ignition switch ON. (c) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. TW–18 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (d) Confirm that the data of tire pressure of all tires (including the spare tire) are displayed on the intelligent tester screen. NOTICE: • It may take up to about 2 or 3 minutes to update the tire pressure data. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34) • DTC C2171/71 is set in the tire pressure warning ECU if all of the following occur: 1) the IDs have not been registered for 51 minutes or more; 2) vehicle speed of 8 km/h (5 mph) or more is detected; and 3) no signals are received for another 12 minutes or more. • If normal pressure values are displayed, the IDs have been registered correctly. • If the tire pressure values are not displayed after a few minutes, the IDs may be incorrect or the system may have a malfunction. TEST MODE PROCEDURE TW 1. DLC3 Intelligent Tester C150424E01 ENTER TEST MODE (a) Make sure that the ignition switch is OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON. (d) Check that the tire pressure warning light comes on for 3 seconds and then goes off. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–19 (e) Select the TEST MODE on the intelligent tester. C122887 (f) 2. 0.125 sec. ON OFF 0.125 sec. F100632E04 Confirm that the tire pressure warning light in the combination meter blinks at 0.125 second intervals. PERFORM SIGNAL CHECK HINT: • When entering signal check mode, the tire pressure warning ECU sets all the signal check DTCs first. After completing the signal check for each inspection item, the DTCs for systems that are determined to be normal by the tire pressure warning ECU will be erased. The DTCs for other inspection items may not be erased when only a certain signal is inspected. • When signal check returns to normal mode, all the signal check DTCs will be erased. (a) (b) (c) (d) DLC3 Intelligent Tester C150424E01 Make sure that the ignition switch is OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON. Select the SIGNAL CHECK on the intelligent tester. HINT: Every time the test mode DTC erasure conditions are satisfied, the tire pressure warning light comes on for 1 second. Then, the tire pressure warning light blinks at 0.125 second intervals. TW TW–20 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW C110644 (e) Drive the vehicle at 20 km/h (12 mph) or more for 10 seconds or more to check the vehicle speed signal (C2191/91). (f) Loosen the valve core and rapidly reduce the pressure (at least 40 kPa (0.4 kgf/cm2, 5.8 psi) within 30 seconds or more) to check the transmitter data (C2181/81 to C2185/85). HINT: The transmitter ID can be transmitted by rapidly reducing the tire pressure. (g) Check that the tire pressure warning system test mode DTCs are erased. Test Mode DTC Test Signal Test Mode DTC Clear Condition C2181/81 to C2185/85 Transmitter Data Receive data from the transmitter which has a registered ID in the tire pressure warning ECU C2191/91 Vehicle Speed Signal Vehicle speed of 20 km/h (12 mph) or more is detected for 3 seconds or more (h) Result HINT: After the signal check is completed, check for a signal check DTC to confirm the system status. Condition Procedure Test mode DTC is output Repair the faulty part and enter SIGNAL CHECK again Test mode DTCs are cleared No problem TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (i) (j) DTC No. TW–21 End of SIGNAL CHECK After completing the test mode (SIGNAL CHECK), turn the ignition switch OFF and disconnect the tester. DTC of SIGNAL CHECK (TEST DIAGNOSIS) If a trouble code is displayed during the test mode DTC check, check the circuit listed for that code. For details of each code, refer to the "See page" below. Detection Item Trouble Area See page C2181/81 Transmitter ID1 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU TW-34 C2182/82 Transmitter ID2 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU TW-34 C2183/83 Transmitter ID3 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU TW-34 C2184/84 Transmitter ID4 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU TW-34 C2185/85 Transmitter ID5 not received • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU TW-34 C2191/91 Vehicle speed signal error • • • • Vehicle speed sensor Combination meter assembly Wire harness or connector Tire pressure warning ECU TW-56 TW TW–3 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING SYSTEM PRECAUTION 1. Tire Pressure Warning Light C150462E01 TIRE PRESSURE WARNING SYSTEM PRECAUTION (a) When the tire pressure warning light comes on, immediately check the tire pressure of the tire and adjust it to the specified value. (The tire pressure warning light will blink if there is an open in the tire pressure warning light circuit.) NOTICE: Check the spare tire as well since this system monitors pressure of all tires including the spare tire. Standard cold tire inflation pressure Tire size Pressure P265/60R18 109H P265/65R17 110S 220 kPa (2.2 kgf/cm2, 32 psi) P265/70R16 111S (b) When the tire pressure warning light blinks, there is a malfunction in the system. Check for DTCs. (c) It is necessary to register the transmitter ID in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and/or tire pressure warning ECU (see page TW-13). (d) When replacing the tire pressure warning ECU: (1) Using the DATA LIST, read the transmitter IDs registered in the ECU and make a note of them before removing the tire pressure warning ECU. (2) Register the transmitter IDs after installing a new tire pressure warning ECU. TW TW–4 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (e) When replacing the tire pressure warning valve and transmitter: (1) Take a note of the 7 digit number (transmitter ID) written on the new tire pressure warning valve and transmitter when replacing it. Register the transmitter IDs in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and installing the tires and wheels on the vehicle. Tire Pressure Warning Valve and Transmitter: Transmitter ID (7 Digit Number) TW E128762E10 2. 3. NOTICE: The transmitter ID is written on the tire pressure warning valve and transmitter. It will be unable to be read after installing the tire pressure warning valve and transmitter on the tire and wheel. Therefore, take a note of the transmitter ID before installing the tire pressure warning valve and transmitter. (f) Precautions about the tire pressure: • The tire pressures decrease naturally. • In winter, tire pressure may decrease due to low ambient temperatures (tire pressure decreases by approximately 10 kPa (0.1 kgf/cm2, 1.45 psi) for every 10°C (50°F) drop in the ambient temperature). Therefore, the tire pressure warning is more likely to operate if the tire pressures are not adjusted appropriately. If the daily temperature variation is large, pressurize the tires high so that the tire pressures are suitable under cold conditions. Incorrect tire pressure warning operation becomes less likely. IN CASE OF TIRE AND WHEEL REPLACEMENT (a) When tires and wheels are replaced, always ensure that each transmitter ID is correctly registered. FAIL-SAFE FUNCTION (a) When a system malfunction occurs in the tire pressure warning system, the tire pressure warning light blinks and informs the driver of the system failure. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 4. TW–5 (b) The result of this diagnosis is stored in the tire pressure warning ECU. CHECK TIRE PRESSURE AFTER REPAIRS (a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST (see page TW-25). TW TW–22 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Tire pressure warning system Symptom See page Tire pressure warning light does not illuminate, despite tire pressure decreasing TW-25 ID code check (Registration) TW-13 Tire pressure warning light illuminated (Goes off during initial check) ECU power source circuit TW-61 Tire pressure warning light circuit TW-58 Check DATA LIST (Tire inflation pressure) TW-25 Tire pressure warning light circuit TW-58 ID code check (Registration) TW-13 TC and CG terminal circuit TW-64 ECU power source circuit TW-61 Tire pressure warning light illuminated (Comes on during initial check) TW Suspected Area Check DATA LIST (Tire inflation pressure) DTC check cannot be done TW–23 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TERMINALS OF ECU HINT: Inspect the connectors from the backside while the connectors are connected. 1. CHECK TIRE PRESSURE WARNING ECU T16 F045856E02 Terminal No. (Symbols) Wiring Color Terminal Description Condition Specified Condition T16-2 (IG) - T16-11 (GND) B-R - W-B IG power source Ignition switch ON 10 to 16 V T16-3 (SPD) - T16-11 (GND) V-R - W-B Vehicle speed signal Ignition switch ON Pulse generation (see waveform 1) T16-4 (SIL) - T16-11 (GND) R-Y - W-B Diagnostic communication terminal T16-6 (IND) - T16-11 (GND) P-B - W-B Tire pressure warning light signal Ignition switch ON 8 to 15 V Ignition switch ON 4.5 to 5.5 V • • Ignition switch ON Intelligent tester is connected to DLC3 8 to 15 V T16-8 (RF5V) - T16-11 (GND) L - W-B Tire pressure warning antenna and receiver power source T16-7 (RDA) - T16-11 (GND) GR - W-B Tire pressure warning antenna and receiver signal LG-B - W-B Tire pressure warning antenna and receiver ground Always Below 1 Ω Ground Always Below 1 Ω TC terminal When terminal TC is not connected T16-16 (GND2) - T16-11 (GND) T16-11 (GND) - Body ground W-B - Body ground T16-12 (TC) - T16-11 (GND) P-L - W-B 2. F047507E05 Ignition switch ON Tire pressure warning antenna and receiver is not connected 10 to 14 V 8 to 15 V Waveform 1 (Reference) (a) Waveform Item GND • • Contents Terminal No. (Symbols) T16-3 (SPD) - T16-11 (GND) Tool setting 5 V/DIV., 200 ms/DIV. Vehicle condition While driving at approximately 20 km/h (12 mph). TW TW–66 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TIRE PRESSURE WARNING RECEIVER (w/ Antenna) SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS TIRE PRESSURE WARNING ANTENNA AND RECEIVER 6.8 (69, 60 in.*lbf) TW TIRE PRESSURE WARNING ECU TIRE PRESSURE WARNING VALVE AND TRANSMITTER NUT 4.0 (41, 35 in.*lbf) GROMMET WASHER VALVE CORE CAP N*m (kgf*cm, ft.*lbf) : Specified torque C131379E11 TW–67 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) LH HEADREST REAR NO. 2 SEAT ASSEMBLY LH SEAT NO. 2 BACK PAD LH SEAT NO. 2 LEG COVER TW SEAT NO. 2 BACK COVER SUB-ASSEMBLY LH SEAT NO. 2 LEG COVER SEAT NO. 3 LEG COVER SEAT NO. 2 CUSHION COVER LH SUB-ASSEMBLY HOG RING SEAT NO. 2 CUSHION PAD LH HOG RING Non-reusable part B120237E03 TW–68 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) RH SEAT NO. 2 LEG COVER HEADREST SEAT NO. 3 LEG COVER SEAT NO. 2 LEG COVER TW SEAT NO. 2 BACK PAD RH SEAT NO. 2 BACK COVER SUB-ASSEMBLY RH REAR NO. 2 SEAT ASSEMBLY RH SEAT NO. 2 CUSHION COVER RH SUB-ASSEMBLY HOG RING SEAT NO. 2 CUSHION PAD RH HOG RING Non-reusable part B120239E02 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) TW–69 ASSIST GRIP ASSEMBLY COAT HOOK RH ROOF HEADLINING ASSEMBLY FRONT ASSIST GRIP PLUG TW ROOF CONSOLE BOX ASSEMBLY ROOM LIGHT ASSEMBLY NO. 1 VISOR SUB-ASSEMBLY RH ROOM LIGHT ASSEMBLY NO. 1 ASSIST GRIP ASSEMBLY VISOR SUB-ASSEMBLY LH COAT HOOK LH VISOR HOLDER FRONT ASSIST GRIP PLUG FRONT ASSIST GRIP PLUG RH VISOR ASSEMBLY LH VISOR ASSEMBLY B120189E05 TW–70 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER (w/ Antenna) W/ SLIDING ROOF ROOF HEADLINING ASSEMBLY TW W/ RSE TELEVISION DISPLAY ASSEMBLY DOME LIGHT ASSEMBLY DOME LIGHT LENS B134263E02 TW–24 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSIS SYSTEM 1. CHECK BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. 2. CHECK DLC3 (a) The ECU uses the ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Terminal No. (Symbols) 7 (SIL) - 5 (SG) TW Terminal Description Bus "+" line Condition Specified Condition During transmission Pulse generation 4 (CG) - Body ground Chassis ground Always Below 1 Ω 5 (SG) - Body ground Signal ground Always Below 1 Ω 16 (BAT) - Body ground Battery positive Always 11 to 14 V 6 (CANH) - 14 (CANL) CAN bus line Ignition switch OFF* 54 to 69 Ω HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher 6 (CANH) - 4 (CG) 14 (CANL) - 4 (CG) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher 6 (CANH) - 16 (BAT) HIGH-level CAN bus line Ignition switch OFF* 6 kΩ or higher 14 (CANL) - 16 (BAT) LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. TW–25 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3. DIAGNOSIS SYSTEM (a) DTCs (Normal mode) (1) DTCs are memorized in the tire pressure warning ECU and read by the blinks of the tire pressure warning light or by using the intelligent tester (see page TW-23). (b) Test mode (1) By switching from normal mode into test mode (input signal check), you can inspect the tire pressure warning antenna and receiver, each tire pressure warning valve and transmitter, and each vehicle speed sensor (see page TW-16). 4. CHECK WARNING LIGHT (a) Turn the ignition switch ON. (b) Check that the tire pressure warning light comes on for 3 seconds. If the warning check result is not normal, proceed to the troubleshooting for the tire pressure warning light circuit. Trouble Area See procedure Tire pressure warning light circuit 5. Tire Pressure Warning Light TW-58 TIRE PRESSURE WARNING LIGHT CHART HINT: The table below indicates the state of the tire pressure warning light after the ignition switch is turned ON. C150462E01 Always Immediately after turning ignition switch ON Warning light output pattern Comes on for 3 sec. Goes off Comes on Blinks (*1) Blinks (*2) Blinks (*3) Blinks (*4) Outputs DTC Normal { { - - - - - - Low tire pressure { - { - - - - - System fail { - - { - - - - Test mode { - - - { - - - ECU connector poorly connected - - - { - - - - TC ground (DTC is output) { - - - - - - { TC ground (DTC is not output) { - - - - - { - TW TW–26 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM *1: Comes on and goes off repeatedly at 0.5 second intervals. 0.5 sec. ON OFF 0.5 sec. F046782E02 *2: Comes on and goes off repeatedly at 0.125 second intervals. 0.125 sec. ON OFF 0.125 sec. C110635E01 *3: Blinks 3 times (1 second on, 1 second off). TW 1 sec. ON OFF 1 sec. C110636E01 *4: Comes on and goes off repeatedly at 0.25 second intervals. 0.25 sec. ON OFF 0.25 sec. C145821E01 TW–72 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING VALVE AND TRANSMITTER SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS TIRE PRESSURE WARNING ANTENNA AND RECEIVER 6.8 (69, 60 in.*lbf) TW TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING ECU NUT 4.0 (41, 35 in.*lbf) GROMMET WASHER VALVE CORE CAP N*m (kgf*cm, ft.*lbf) : Specified torque C131379E12 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–73 REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE REAR WHEEL 3. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Remove the valve core, cap, and release air from the tire. (b) After ensuring that air is sufficiently released, remove the nut, washer that is used to fix the tire pressure warning valve and transmitter and drop the sensor inside the tire. (c) After dropping the tire pressure warning valve and transmitter into the tire, disengage the bead using the shoe of the tire remover. NOTICE: Be careful not to damage the tire pressure warning valve and transmitter due to interference between the sensor and tire bead. (d) Remove the bead on the upper side as in usual operation. (e) Take out the sensor from the tire and remove the bead on the lower side as in usual operation. (f) Remove the inner grommet from the tire pressure warning valve and transmitter. HINT: Check that no crack or damage is identified on the grommet. If so, replace the grommet together with the washer and nut. Tire Shoe 10 to 20 mm (0.39 to 0.79 in.) F046444E01 INSTALLATION Print Surface F046445E02 1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tire pressure warning valve and transmitter into the valve installation hole. Insert from the inside of the rim so that the print surface can be seen. NOTICE: • Check that there is no visible deformation, damage or other abnormalities on the transmitter. • Check that there is no foreign matter on the inner grommet and around the rim hole. • If installed in the reverse direction, the tire pressure warning valve and transmitter may be damaged or fail to transmit signals when running at high speed. TW TW–74 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER (b) Install the washer on the tire pressure warning valve and transmitter from the rim side and tighten with a nut. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) NOTICE: • Check that there is no foreign matter on the washer and nut. • When removing the tire pressure warning valve and transmitter if the tire is removed for replacement, check that there is no damage or cuts, and no foreign matter such as mud, dirt or sand attached to the grommet. Replace the grommet with a new one if any of the defects mentioned above are found. • Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve and transmitter, washer and nut. Failing to do so may result in improper installation. (c) After the tire is inflated, the valve nut may be loose. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Grommet Nut Rim Sensor Cap Washer F046446E03 TW (d) Set the wheel disc to the mounting machine and install the lower tire bead. At the time, position the main body of the sensor to the shaded area shown in the illustration. NOTICE: If the sensor is positioned outside this area, it generates interference with the tire bead, causing possible damage to the sensor. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the sensor and that the sensor is not clamped by the bead. Rim Rim rotating direction Area for the sensor Rim Rim rotating direction Area for the sensor F046447E05 2. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSPECT TIRE 5. REGISTRATION OF TRANSMITTER ID HINT: (See page TW-13) TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–75 DISPOSAL HINT: The tire pressure warning valve and transmitter is powered by a lithium battery. When disposing the tire pressure warning valve and transmitter, remove the battery and dispose it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Insert the tip of a screwdriver into the clearance and pry off the cover. Remove the back cover. F046448 Lithium battery (b) The battery and base board covered with silicone resin are exposed. While taking out the battery, cut off the 2 terminals which connects the battery and base board. Terminal F046449E02 TW TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–27 DTC CHECK / CLEAR 1. CHECK DTC (USING INTELLIGENT TESTER) (a) Turn the ignition switch OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and the tester ON. (d) Read the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DLC3 Intelligent Tester C150424E01 2. CG DLC3 CHECK DTC (USING SST CHECK WIRE) (a) Turn the ignition switch OFF. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 TC H100769E05 (2) Turn the ignition switch ON. Tire Pressure Warning Light C150462E01 TW TW–28 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (3) Read and record any DTCs from the tire pressure warning light on the combination meter. Refer to the illustration for examples of a normal system code and codes 13 and 33. HINT: • If the tire pressure warning light does not indicate any DTCs or the normal system code, inspect the tire pressure warning light circuit or TC and CG terminal circuit. Normal System Code: 0.25 sec. ON OFF 0.25 sec. Code 13 and 33: Trouble Area 1.5 sec. 0.5 sec. 2.5 sec. 4.5 sec. Tire pressure warning light circuit TW-58 TC and CG terminal circuit TW-64 ON OFF 1.5 sec. 0.5 sec. Repeat F050628E02 3. TW See procedure • If 2 or more malfunctions are indicated at the same time, the lowest numbered DTC is displayed first. (4) Refer to the Diagnostic Trouble Code Chart (see page TW-27) for DTC information. (5) After completing the check, turn the ignition switch OFF and remove SST from the DLC3. SST 09843-18040 CLEAR DTC HINT: After repairing the malfunctions, clear the DTCs. (a) Turn the ignition switch OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and the tester ON. (d) Clear the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DLC3 Intelligent Tester C150424E01 TW–76 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TIRE PRESSURE WARNING ECU SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS TIRE PRESSURE WARNING ANTENNA AND RECEIVER 6.8 (69, 60 in.*lbf) TW TIRE PRESSURE WARNING ECU TIRE PRESSURE WARNING VALVE AND TRANSMITTER NUT 4.0 (41, 35 in.*lbf) GROMMET WASHER VALVE CORE CAP N*m (kgf*cm, ft.*lbf) : Specified torque C131379E13 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TW–77 TW COWL SIDE TRIM BOARD RH FRONT DOOR SCUFF PLATE RH INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO. 2 B120192E08 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–29 DATA LIST / ACTIVE TEST 1. Tester Display DATA LIST (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Following the display on the intelligent tester, read "DATA LIST". Measurement Item/Range Normal Condition Diagnostic Note MODE STATUS Tire pressure warning system mode/NORMAL or REG 2nd or REG M or TEST NORMAL: Normal mode TEST: Test mode - MAIN TIRE Number of main tire IDs to be registered/ 0 or 1 or 2 or 3 or 4 or 5 0 to 5 should be displayed - VEHICLE SPD Vehicle speed reading/ min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed Speed indicated on the combination meter REGIT ID1 CODE Registered ID1 code/min.: 0, max.: FFFFFFF*1 The ID No. registered in the transmitter ID1 is displayed - REGIT ID2 CODE Registered ID2 code/min.: 0, max.: FFFFFFF*1 The ID No. registered in the transmitter ID2 is displayed - REGIT ID3 CODE Registered ID3 code/min.: 0, max.: FFFFFFF*1 The ID No. registered in the transmitter ID3 is displayed - REGIT ID4 CODE Registered ID4 code/min.: 0, max.: FFFFFFF*1 The ID No. registered in the transmitter ID4 is displayed - REGIT ID5 CODE Registered ID5 code/min.: 0, max.: FFFFFFF*1 The ID No. registered in the transmitter ID5 is displayed - TRANS STATUS ID code transmission status/ FINISH or NOW FINISH or NOW - ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 TIREPRESS1 psi), Relative pressure / -100 kPa (-1 kgf/cm2, 14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.*2 (5.4 kgf/cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 2, TIREPRESS2 psi), Relative pressure / -100 kPa (-1 kgf/cm 14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.*2 (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 TIREPRESS3 psi), Relative pressure / -100 kPa (-1 kgf/cm2, 14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or Actual tire inflation pressure -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.*2 TW TW–30 Tester Display TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Measurement Item/Range Normal Condition Diagnostic Note ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 TIREPRESS4 psi), Relative pressure / -100 kPa (-1 kgf/cm2, 14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.*2 (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 2 TIREPRESS5 psi), Relative pressure / -100 kPa (-1 kgf/cm , 14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.*2 (5.4 kgf/cm2, 78 psi) TW TIRE TEMP1 ID1 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature If -40°C (-40°F) is displayed, the data have not been received. TIRE TEMP2 ID2 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature If -40°C (-40°F) is displayed, the data has not been received. TIRE TEMP3 ID3 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature If -40°C (-40°F) is displayed, the data has not been received. TIRE TEMP4 ID4 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature If -40°C (-40°F) is displayed, the data has not been received. TIRE TEMP5 ID5 temperature in tire/ min.: -40°C (-40°F), max.: 215°C (419°F) Actual tire temperature If -40°C (-40°F) is displayed, the data has not been received. BATT VOLT1 ID1 battery voltage/ OVER or LESS OVER - BATT VOLT2 ID2 battery voltage/ OVER or LESS OVER - BATT VOLT3 ID3 battery voltage/ OVER or LESS OVER - BATT VOLT4 ID4 battery voltage/ OVER or LESS OVER - BATT VOLT5 ID5 battery voltage/ OVER or LESS OVER - # CODES Number of DTC recorded/ min.: 0, max.: 255 0 - HINT: *1: Displayed only when the ID No. is not registered. *2: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW34). TW–31 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If no abnormality is found when the parts are inspected, inspect the tire pressure warning ECU. • If a trouble code is displayed during the DTC check, inspect the trouble areas listed for that code. For details of the code, refer to the "See page" below. Tire pressure warning system DTC Code Detection Item Trouble Area See page C2111/11 Transmitter ID1 Operation Stop - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-30 C2112/12 Transmitter ID2 Operation Stop - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-30 C2113/13 Transmitter ID3 Operation Stop - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-30 C2114/14 Transmitter ID4 Operation Stop - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-30 C2115/15 Transmitter ID5 Operation Stop - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-30 No Signal from Transmitter ID1 in Main Mode - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 No Signal from Transmitter ID2 in Main Mode - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 No Signal from Transmitter ID3 in Main Mode - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 No Signal from Transmitter ID4 in Main Mode - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 C2125/25 No Signal from Transmitter ID5 in Main Mode - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 C2141/41 Transmitter ID1 Error - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-42 C2142/42 Transmitter ID2 Error - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-42 C2121/21 C2122/22 C2123/23 C2124/24 TW TW–32 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC Code Detection Item Trouble Area See page TW-42 C2143/43 Transmitter ID3 Error - Tire pressure warning valve and transmitter - Tire pressure warning ECU C2144/44 Transmitter ID4 Error - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-42 C2145/45 Transmitter ID5 Error - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-42 C2165/65 Abnormal Temperature Inside ID1 Tire - Tires - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-46 C2166/66 Abnormal Temperature Inside ID2 Tire - Tires - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-46 C2167/67 Abnormal Temperature Inside ID3 Tire - Tires - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-46 C2168/68 Abnormal Temperature Inside ID4 Tire - Tires - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-46 C2169/69 Abnormal Temperature Inside ID5 Tire - Tires - Tire pressure warning valve and transmitter - Tire pressure warning ECU TW-46 C2171/71 Transmitter ID not Registered Tire pressure warning ECU TW-50 Receiver Error - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-53 Transmitter ID1 not Received (Test Mode DTC) - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 Transmitter ID2 not Received (Test Mode DTC) - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 Transmitter ID3 not Received (Test Mode DTC) - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 Transmitter ID4 not Received (Test Mode DTC) - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU TW-34 TW C2176/76 C2181/81 C2182/82 C2183/83 C2184/84 TW–33 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC Code Detection Item Trouble Area See page TW-34 TW-56 C2185/85 Transmitter ID5 not Received (Test Mode DTC) - Tire pressure warning valve and transmitter - Tire pressure warning antenna and receiver - Wire harness or connector - Tire pressure warning ECU C2191/91 Vehicle Speed Signal Error (Test Mode DTC) - Vehicle speed sensor - Tire pressure warning ECU - Combination meter - Wire harness or connector TW TW–34 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2111/11 Transmitter ID1 Operation Stop DTC C2112/12 Transmitter ID2 Operation Stop DTC C2113/13 Transmitter ID3 Operation Stop DTC C2114/14 Transmitter ID4 Operation Stop DTC C2115/15 Transmitter ID5 Operation Stop DESCRIPTION TW The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressures of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. The tire pressure warning ECU stores a DTC when the tire pressure warning valve and transmitter stops transmitting signals. At this time, forcibly transmit the signals by releasing the tire pressure rapidly. The stored DTC is cleared when the signal transmission is resumed. DTC Code Detection Condition C2111/11 C2112/12 C2113/13 C2114/14 C2115/15 Tire pressure warning valve and transmitters stop transmitting signals Trouble Area • • Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. TW–35 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning Valve and Receiver (for Front RH) Tire Pressure Warning Valve and Receiver (for Front LH) Tire Pressure Warning Valve and Receiver (for Rear RH) 11 Tire Pressure Warning Valve and Receiver (for Rear LH) GND TW Tire Pressure Warning Valve and Receiver (for Spare) 5 8 RF5V +5V 7 1 RDA GND RDA 16 4 GND2 T17 Tire Pressure Warning Antenna and Receiver T16 Tire Pressure Warning ECU C150483E01 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. TW–36 1 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM PERFORM FORCED TRANSMISSION OF TRANSMITTER ID OF ALL WHEELS (a) Set the tire pressure to the specified value (see page TW-1). (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and turn the tester ON. (d) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Range Normal Condition ID1 tire inflation pressure / min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS1 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Diagnostic Note Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID2 tire inflation pressure / min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure cm2, 0 psi), Relative pressure / -100 kPa TW TIREPRESS2 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure / min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS3 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID4 tire inflation pressure / min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS4 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 Actual tire inflation pressure kgf/cm2, 92.5 psi), Relative pressure / or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure / min.: Absolute pressure / 0 kPa (0 kgf/ If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure cm2, 0 psi), Relative pressure / -100 kPa TIREPRESS5 (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / Actual tire inflation pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* 537.5 kPa (5.4 kgf/cm2, 78 psi) HINT: *: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34). (e) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.4 kgf/cm2, 5.8 psi) within 30 seconds. (1) Check that each tire pressure data displayed on the intelligent tester screen has changed. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–37 OK: Each tire pressure data displayed on the intelligent tester screen will change to the value of the tire pressure. NOTICE: • It takes about 2 or 3 minutes to display the updated tire pressure data. • When the "TIREPRESS" data has not changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees (including the spare tire). Then rapidly release the tire pressure and recheck it. (2) After confirming that all of the tire pressure data displayed on the intelligent tester screen has changed, set the tire pressure to the appropriate specified values. HINT: If the tire pressure data displayed on the intelligent tester screen has not changed after rechecking, inspect the other problem (malfunction in transmission or reception function) (see page TW34) NG OK END INSPECT OTHER PROBLEM (MALFUNCTION IN TRANSMISSION OR RECEPTION FUNCTION) (See page TW-34) TW TW–38 TW TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2121/21 No Signal from Transmitter ID1 in Main Mode DTC C2122/22 No Signal from Transmitter ID2 in Main Mode DTC C2123/23 No Signal from Transmitter ID3 in Main Mode DTC C2124/24 No Signal from Transmitter ID4 in Main Mode DTC C2125/25 No Signal from Transmitter ID5 in Main Mode DTC C2181/81 Transmitter ID1 not Received (Test Mode DTC) DTC C2182/82 Transmitter ID2 not Received (Test Mode DTC) DTC C2183/83 Transmitter ID3 not Received (Test Mode DTC) DTC C2184/84 Transmitter ID4 not Received (Test Mode DTC) DTC C2185/85 Transmitter ID5 not Received (Test Mode DTC) DESCRIPTION The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressure of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. The tire pressure warning valve and transmitters constantly send radio waves to the tire pressure warning antenna and receiver. Under the conditions below, the tire pressure warning antenna and receiver is unable to receive the signals from the tire pressure warning valves and transmitters, and a DTC is stored. • Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. • Devices using similar radio frequencies are used in the vehicle. HINT: When no signals are received for 51 minutes or more, a DTC is output. DTCs from C2121/21 to C2125/25 can only be cleared by using the tester. DTCs from C2181/81 to C2185/85 can be cleared when the transmitter in the tire pressure warning valve and transmitter sends a forced transmission signal or test mode ends. DTCs from C2181/81 to C2185/85 are output only in test mode. DTC Code Detection Condition C2121/21 C2122/22 C2123/23 C2124/24 C2125/25 These DTCs are detected when no signals are received for 51 minutes or more, and then vehicle is driven at 8 km/h (5 mph) or higher and the ECU receives no signals for 12 minutes or more. • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU Test mode procedure is performed. • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Wire harness or connector Tire pressure warning ECU C2181/81 C2182/82 C2183/83 C2184/84 C2185/85 Trouble Area TW–39 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HINT: It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. WIRING DIAGRAM Tire Pressure Warning Valve and Receiver (for Front RH) Tire Pressure Warning Valve and Receiver (for Front LH) Tire Pressure Warning Valve and Receiver (for Rear RH) 11 Tire Pressure Warning Valve and Receiver (for Rear LH) TW GND Tire Pressure Warning Valve and Receiver (for Spare) 5 8 RF5V +5V 7 1 RDA GND RDA 16 4 GND2 T17 Tire Pressure Warning Antenna and Receiver T16 Tire Pressure Warning ECU C150483E01 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. TW–40 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. 1 CHECK FREQUENCY RECEIVING CONDITION (a) Check if the vehicle is located in areas such as the ones described below: (1) Facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. HINT: If the vehicle is located in areas described above, the tire pressure warning light may come on only in a particular area. (2) Devices using similar radio frequencies are used in the vehicle. OK: Facilities, or devices that use similar radio frequencies are not located in the vicinity of the vehicle. HINT: Radio frequency may be interrupted due to surroundings or devices installed by user. TW NG CHECK IF ANY DEVICE IS INSTALLED BY USER OK 2 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the appropriate specified values (see page TW-1). (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch ON and turn the tester ON. (e) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS1 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS2 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ cm2, 78 psi) Actual tire inflation pressure Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* TW–41 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tester Display Measurement Item/Display Normal Condition ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), 2 TIREPRESS3 Relative pressure / -100 kPa (-1 kgf/cm , -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), 2 TIREPRESS4 Relative pressure / -100 kPa (-1 kgf/cm , -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS5 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* HINT: *: It may take about 2 or 3 minutes until the values are displayed. (f) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.4 kgf/cm2, 5.8 psi) within 30 seconds. (g) Check the DATA LIST. NOTICE: • It may take about 2 or 3 minutes until the values are displayed. • When no "TIREPRESS" data has changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees. Then rapidly release the tire pressure and recheck it. • Record the "TIREPRESS" data transmitter ID that corresponds to each tire. (h) After confirming that "TIREPRESS" data for one tire (ID1 to ID5) has changed, repeat this procedure one by one. Identify the transmitter that corresponds to the DTC. Result Condition One or more of transmitters abnormal A All normal B All abnormal C A B C Proceed to Go to step 4 END TW TW–42 3 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR (ECU - RECEIVER) Rear view of wire harness connector: (to Tire Pressure Warning ECU) 7 (RDA) Rear view of wire harness connector: (to Tire Pressure Warning Antenna and Receiver) T16 T17 8 (RF5V) 5 (+5V) 1 (RDA) 16 (GND2) 4 (GND) C150484E01 (a) Disconnect the T16 ECU connector. (b) Disconnect the T17 receiver connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance TW Tester Connection Condition T16-7 (RDA) - T17-1 (RDA) Always T16-8 (RF5V) - T17-5 (+5V) Always T16-16 (GND2) - T17-4 (GND) Always T16-7 (RDA) or T17-1 (RDA) - Body ground Always T16-8 (RF5V) or T17-5 (+5V) - Body ground Always T16-16 (GND2) or T17-4 (GND) Body ground Always NG Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT TIRE PRESSURE WARNING ECU (a) (b) (c) (d) Turn the ignition switch OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON and turn the tester ON. Select REGIT ID CODE by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID1 is displayed *: Displayed only when the ID No. is not registered. REGIT ID2 CODE Registered ID2 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID2 is displayed *: Displayed only when the ID No. is not registered. TW–43 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tester Display Measurement Item/Display Normal Condition Diagnostic Note REGIT ID3 CODE Registered ID3 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID3 is displayed *: Displayed only when the ID No. is not registered. REGIT ID4 CODE Registered ID4 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID4 is displayed *: Displayed only when the ID No. is not registered. REGIT ID5 CODE Registered ID5 code/ min.: 0, max.: FFFFFF* The ID No. registered in the transmitter ID5 is displayed *: Displayed only when the ID No. is not registered. (e) Check the ID number on the identified transmitter by removing it from the tire and wheel. Tire Pressure Warning Valve and Transmitter: Transmitter ID (7 Digit Number) TW E128762E10 (f) Confirm that the ID number on the transmitter and recorded transmitter ID match. Result Result Proceed to Match A Do not match B B Go to step 6 A 5 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Replace the pressure warning valve and transmitter (see page TW-73). NEXT 6 REGISTRATION OF TRANSMITTER ID (a) Perform registration (see page TW-13). NEXT 7 READ VALUE OF DATA LIST (a) Turn the ignition switch OFF. TW–44 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and turn the tester ON. (d) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS1 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS2 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS3 TW Relative pressure / -100 kPa (-1 kgf/cm 2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS4 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS5 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ cm2, 78 psi) Actual tire inflation pressure Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* HINT: *: It may take about 2 or 3 minutes until the values are displayed. Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values are not displayed. B A END B 8 REPLACE TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Replace the tire pressure warning antenna and receiver (see page TW-70). NEXT TW–45 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 9 READ VALUE OF DATA LIST (a) (b) (c) (d) Turn the ignition switch OFF. Connect the intelligent tester to the DLC3. Turn the ignition switch ON and turn the tester ON. Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS1 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS2 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS3 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS4 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ Actual tire inflation pressure cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS5 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/ cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/cm2, 78 psi) Actual tire inflation pressure Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* HINT: *: It may take about 2 or 3 minutes until the values are displayed. Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values are not displayed. B B A END REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TW TW–46 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2141/41 Transmitter ID1 Error DTC C2142/42 Transmitter ID2 Error DTC C2143/43 Transmitter ID3 Error DTC C2144/44 Transmitter ID4 Error DTC C2145/45 Transmitter ID5 Error DESCRIPTION The tire pressure warning valve and transmitters that are installed in the tire and wheel assemblies measure the air pressure of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure value is less than this threshold, the warning light in the combination meter comes on. When the internal circuit of a tire pressure warning valve and transmitter is malfunctioning, one of these DTCs are output. TW DTC Code C2141/41 C2142/42 C2143/43 C2144/44 C2145/45 Detection Condition Trouble Area If an "ERROR" signal is received 3 times consecutively, the tire pressure warning valve and transmitter will be judged as defective and a DTC will be output. This will happen in situations where the inflation pressure is outside the absolute pressure range 0 to 637.5 kPa (0 to 6.5 kgf/cm2, 0 to 92.5 psi), outside the relative pressure range -100 to 537.5 kPa (-1 • • Tire pressure warning valve and transmitter Tire pressure warning ECU to 5.4 kgf/cm2, -14 to 78 psi), the temperature inside the tire is outside the specified range -40 to 120°C (-40 to 253°F), or an error occurs in the tire pressure warning valve and transmitter or the surrounding area. HINT: It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and write them down before removal. • It is necessary to perform registration (see page TW-13) of the transmitter IDs into the tire pressure warning ECU after the ECU and/or valve and transmitter has been replaced. 1 IDENTIFY TRANSMITTER CORRESPONDING TO DTC (a) Set the tire pressure to the specified value (see page TW-1). (b) Display the "TIREPRESS" data for each wheel using the intelligent tester. TW–47 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (c) Rapidly reduce the tire pressure for each wheel at least 40 kPa (0.4 kgf/cm2, 5.8 psi) within 30 seconds. If "TIREPRESS" data displayed on the tester (ID1 to ID5) does not change, the tire pressure warning valve and transmitter corresponding to the unchanged "TIREPRESS" data was the cause of the output DTC. HINT: • Identify the malfunctioning tire pressure warning valve and transmitter by repeatedly decreasing the tire pressure for each tire. • Record which "TIREPRESS" data (ID1 to ID5) corresponds to which tire. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS1 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS2 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS3 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS4 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), 2 TIREPRESS5 Relative pressure / -100 kPa (-1 kgf/cm , -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or 100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* HINT: *: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34). (d) Check the DATA LIST. Result Condition Detection Condition One of "TIREPRESS" data (ID1 to ID5) changed. Normal "TIREPRESS" data did not change. Transmitter corresponding to DTC TW TW–48 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM NOTICE: • When "TIREPRESS" data has not changed, reset the tire pressure to the appropriate specified value and rotate the tire 90 to 270 degrees. Then forcibly transmit the transmitter ID and recheck. • Record the transmitter ID and position of transmitters that are normal. (e) When the "TIREPRESS" data (ID1 to ID5) has changed, repeat this procedure to identify the tire pressure warning valve and transmitter that corresponds to the DTC. (f) When all of the "TIREPRESS" data (ID1 to ID5) have changed, identify the malfunctioning tire pressure warning valve and transmitter using recorded ID numbers and output DTC. (g) Set the tire pressures to the appropriate specified values. NEXT 2 REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW (a) Replace the identified tire pressure warning valve and transmitter with a new one (see page TW-73). HINT: • Before installing a new tire pressure warning valve and transmitter, read and write down its transmitter ID. • The IDs for the tire pressure warning valve and transmitters that are not replaced should be checked using the tester and recorded. NEXT 3 REGISTRATION OF TRANSMITTER ID (a) Register the transmitter ID for all wheels (see page TW13). NEXT 4 READ VALUE OF DATA LIST (a) Turn the ignition switch OFF. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch ON and turn the tester ON. TW–49 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (d) Select "TIREPRESS" by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Tester Display Measurement Item/Display Normal Condition ID1 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS1 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID2 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS2 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID3 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS3 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID4 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS4 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ Actual tire inflation pressure cm2, 78 psi) ID5 tire inflation pressure/ min.: Absolute pressure / 0 kPa (0 kgf/cm2, 0 psi), TIREPRESS5 Relative pressure / -100 kPa (-1 kgf/cm2, -14 psi) max.: Absolute pressure / 637.5 kPa (6.5 kgf/cm2, 92.5 psi), Relative pressure / 537.5 kPa (5.4 kgf/ cm2, 78 psi) Actual tire inflation pressure Diagnostic Note If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* If 0 kPa (0 kgf/cm2, 0 psi) is displayed for absolute pressure or -100 kPa (-1 kgf/cm2, -14 psi) is displayed for relative pressure, data has not been received.* HINT: *: It may take about 2 or 3 minutes until the values are displayed. If the values are not displayed after a few minutes, perform troubleshooting according to the inspection procedure for DTCs C2121/21 to C2125/25 (see page TW-34). Result Condition Proceed to All tire pressure readings are equal to specified values. A Tire pressure values are not displayed. B B A END REPLACE TIRE PRESSURE WARNING ECU (See page TW-78) TW BC–4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM SYSTEM DIAGRAM Hydraulic Brake Booster Assembly Speed Sensor (with Each Wheel) Motor Relay Pump Motor Stop Light Switch Master Cylinder Pressure Sensor BC Stop Light Operation Relay Accumulator Pressure Sensor Parking Brake Switch Solenoid Relay Solenoid (Switching) Brake Fluid Level Warning Switch Solenoid (Control) AUTO LSD Switch (*1) Skid Control ECU Master Cylinder Solenoid C132864E01 BC–5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Combination Meter Assembly Downhill Assist Control Switch (*3) ABS Warning Light Skid Control ECU VSC TRAC Warning Light 4WD Control (L4) Switch (*3) BRAKE Warning Light SLIP Indicator Light 4WD Control (4WD) Switch (*3) VSC OFF Indicator Light (*2) AUTO LSD Indicator Light (*1) Park/Neutral Position Switch Downhill Assist Control Indicator Light (*3) Center Differential Lock Switch (*2) BC Speedometer Center Differential Lock Indicator Light (*2) Skid Control Buzzer Throttle Position Sensor Steering Angle Sensor Yaw Rate and Acceleration Sensor ECM Engine Revolution Sensor Accelerator Pedal Position Sensor CAN Communication System (*1): 2WD (*2): 4WD (*3): Multi Mode 4WD C149935E01 Transmitting ECU (Transmitter) Receiving ECU Signals Communication Method ECM Skid control ECU Throttle position signal CAN communication system ECM Skid control ECU Engine revolution signal CAN communication system ECM Skid control ECU Accelerator pedal position signal CAN communication system BC–6 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Transmitting ECU (Transmitter) Receiving ECU Signals Communication Method Skid control ECU ECM Yaw rate and acceleration signal CAN communication system Skid control ECU ECM Steering angle signal CAN communication system Skid control ECU ECM Engine torque request signal CAN communication system BC–7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM SYSTEM DESCRIPTION 1. 2. SYSTEM DESCRIPTION HINT: • The skid control ECU is a single unit with hydraulic brake booster. • The yaw rate and acceleration sensors are combined in a single unit. This unit communicates with the skid control ECU through CAN communication. (a) ABS with EBD, BA, TRAC and VSC operation (1) The skid control ECU calculates vehicle stability tendency based on the signals from the speed sensor, yaw rate and acceleration sensor and steering angle sensor. In addition, it evaluates the results of the calculations to determine whether any control actions (control of the engine output torque by electronic throttle control and of the wheel brake pressure by the brake actuator) should be implemented. (2) The SLIP indicator blinks and the skid control buzzer sounds to inform the driver that the VSC system is operating. The SLIP indicator also blinks when TRAC is operating, and the operation being performed is displayed. ACTIVE SAFETY (a) ABS (Anti-lock Brake System) The ABS helps prevent the wheels from locking when the brakes are applied firmly or when braking on a slippery surface. Hydraulic Brake Booster Assembly Pump Motor Each Wheel Cylinder Each Speed Sensor Skid Control ECU Solenoid Valve ABS Warning Light C124752E02 BC BC–8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Operation description The skid control ECU detects wheel lock condition by receiving vehicle speed signals from each speed sensor, and sends control signals to the pump motor and solenoid valve. The pump motor and solenoid valve avoid wheel lock by controlling the oil pressure of each wheel cylinder. The ABS warning light comes on when the ABS system is malfunctioning. (b) EBD (Electronic Brake force Distribution) The EBD control utilizes ABS, realizing proper brake force distribution between the front and rear wheels in accordance with driving conditions. In addition, when braking while cornering, it also controls the brake forces of the right and left wheels, helping to maintain vehicle behavior. Hydraulic Brake Booster Assembly Solenoid Valve BC Each Speed Sensor Skid Control ECU Rear Wheel Cylinder ABS Warning Light BRAKE Warning Light C124753E02 Operation description The skid control ECU receives the speed signal from each speed sensor to detect the slip condition of the wheels and sends the control signal to the solenoid. The solenoid valve controls oil pressure of the rear wheel cylinder and splits the control power properly between the rear wheels and the right and left wheels. Both of the ABS and BRAKE warning lights come on to indicate a malfunction in the EBD system. BC–9 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (c) BA (Brake Assist) The primary purpose of the brake assist system is to provide an auxiliary brake force to assist the driver who cannot generate a large enough brake force during emergency braking, thus helping to maximize the vehicle's braking performance. Hydraulic Brake Booster Assembly Pump Motor Each Wheel Cylinder Solenoid Valve Each Speed Sensor Skid Control ECU Master Cylinder Pressure Sensor BC ABS Warning Light C124754E02 Operation description The skid control ECU receives the speed signal from each speed sensor and the oil pressure signal from the master cylinder pressure sensor to determine whether brake assist is necessary or not. If brake assist is deemed necessary, the ECU sends control signals to the pump motor and solenoid. The pump and the solenoid valve then control the pressure applied to each wheel cylinder. The ABS warning light comes on to indicate a malfunction in the BA system. BC–10 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (d) VSC (Vehicle Stability Control) The VSC system helps prevent the vehicle from slipping sideways as a result of strong front wheel skid or strong rear wheel skid during cornering. Hydraulic Brake Booster Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder Solenoid Valve Yaw Rate and Acceleration Sensor VSC TRAC Warning Light Skid Control ECU VSC OFF Indicator Light (*1) Steering Angle Sensor BC SLIP Indicator Light ECM Skid Control Buzzer (*1): 4WD  CAN Communication System C124755E03 Operation description The skid control ECU determines vehicle condition by receiving signals from the speed sensor, yaw rate and acceleration sensor and steering angle sensor. The skid control ECU controls engine torque through the ECM via CAN communication, and oil pressure through the pump and solenoid valve. The SLIP indicator light blinks and the skid control buzzer sounds when the system is operating. Both of the VSC TRAC warning light and the VSC OFF indicator light (4WD) come on to indicate a malfunction in the VSC system. BC–11 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 3. DRIVING PERFORMANCE (a) TRAC (Traction Control) The TRAC system helps prevent the drive wheels from slipping if the driver presses down on the accelerator pedal excessively when starting off or accelerating on a slippery surface. Hydraulic Brake Booster Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder Solenoid Valve Yaw Rate and Acceleration Sensor Skid Control ECU VSC TRAC Warning Light Steering Angle Sensor BC SLIP Indicator Light ECM  CAN Communication System C124756E03 Operation description The skid control ECU detects vehicle's slip condition by receiving signals from the speed sensor and ECM via CAN communication. The skid control ECU controls engine torque through the ECM via CAN communication, and oil pressure through the pump and solenoid valve. The SLIP indicator light blinks when the system is operating. Both of the VSC TRAC warning light and SLIP indicator light come on to indicate a malfunction in the TRAC system. BC–12 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (b) A-TRAC (Active Traction Control) (Multi Mode 4WD) During rugged off-road driving, this function controls the engine output and the brake fluid pressure that is applied to the slipping wheel, and distributes the drive force that would have been lost through the slippage to the remaining wheels in order to achieve a LSD (Limited Slip Differential) effect. As a result, the vehicle's off-road drivability and ability to free itself from mogul have been increased. Hydraulic Brake Booster Assembly Pump Motor Each Wheel Cylinder Each Speed Sensor Solenoid Valve Skid Control ECU BC ECM VSC TRAC Warning Light SLIP Indicator Light  CAN Communication System C124757E03 Operation description The SLIP indicator light blinks when the system is operating. Both of the VSC TRAC warning light and SLIP indicator light come on to indicate a malfunction in the A-TRAC system. (c) AUTO-LSD (Auto Limited Slip Differential) (2WD) The AUTO LSD will operate with the AUTO LSD switch on and the accelerator pedal depressed. The TRAC system is used to restrain brake pressure and reduce differential move, thus transmitting drive torque to the other drive wheel to ensure startability under the following conditions: • Wheels run off the road. • Drive wheels run idle when starting on a slope with one wheel on snow/ice. HINT: Depressing the brake pedal cancels control of the AUTO LSD system. BC–13 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Hydraulic Brake Booster Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder AUTO LSD Switch Solenoid Valve VSC TRAC Warning Light Yaw Rate and Acceleration Sensor Skid Control ECU SLIP Indicator Light Steering Angle Sensor BC AUTO LSD Indicator Light ECM  CAN Communication System C132863E02 Operation description The SLIP indicator light blinks and the AUTO LSD indicator light comes on when the system is operating. Both of the VSC TRAC warning light and SLIP indicator light come on to indicate a malfunction in the AUTO LSD system. (d) Downhill Assist Control (Multi Mode 4WD) When the downhill assist control switch is pressed with transfer in low (L4) range and without accelerator and brake pedals operation, downhill assist control activates to effect 4-wheel hydraulic pressure control, in order to maintain a constant low vehicle speed without causing the wheels to become locked. Thus, the vehicle can descend a steep hill in a stable manner. HINT: Depressing the accelerator and brake pedal cancels control of the downhill assist control system. BC–14 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Begins operating when driving down on a slope at a speed of 16 mph (25 km/h) or less with the engine brake applied. Hydraulic Brake Booster Assembly Each Speed Sensor Pump Motor Each Wheel Cylinder Solenoid Valve Downhill Assist Control Switch VSC TRAC Warning Light Skid Control ECU BC 4WD Control (L4) Switch SLIP Indicator Light ECM : CAN Communication System C124758E07 Operation description The SLIP indicator light blinks and the downhill assist control indicator light and stop light come on when the system is in operation. The VSC TRAC warning light comes on and the downhill assist control indicator light blinks to indicate a malfunction in the downhill assist control system. BC–15 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (e) Hill-start Assist Control When the vehicle starts off on a steep hill, hill-start assist control detects the backward descent of the vehicle and effects 4-wheel hydraulic pressure control to reduce the backward speed of the vehicle. Maximum 5 seconds after the control has started, fluid pressure is gradually released and control will be complete. HINT: Depressing the brake pedal cancels control of the hill-start assist control system. Does not operate when the shift lever is in the P or N position, or when the vehicle is running/rolling back up a slope with the shift lever in the R position. Hydraulic Brake Booster Assembly Pump Motor BC Each Wheel Cylinder Each Speed Sensor Solenoid Valve VSC TRAC Warning Light Skid Control ECU SLIP Indicator Light ECM Skid Control Buzzer : CAN Communication System C124759E04 Operation description The SLIP indicator light blinks, the stop light comes on, and the skid control buzzer sounds when the system is in operation. The VSC TRAC warning light comes on when the hill-start assist control system is malfunctioning. BC–16 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used at step 3, 5, 6, 9, 12, and 15. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 DTC CHECK AND CLEAR AND FREEZE FRAME DATA NEXT BC 4 PROBLEM SYMPTOM CONFIRMATION NEXT 5 CHECK CAN COMMUNICATION SYSTEM (a) Check for output DTCs. HINT: The ECM of this system is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Condition Proceed to CAN communication system DTC is not output A CAN communication system DTC is output B B A 6 NEXT DTC CHECK AND CLEAR INSPECT CAN COMMUNICATION SYSTEM BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 7 BC–17 PROBLEM SYMPTOM SIMULATION Result Condition Proceed to Symptom does not occur A Symptom occurs B B GO TO STEP 9 A 8 SYMPTOM SIMULATION NEXT 9 DTC CHECK (OTHER THAN CAN SYSTEM DTC) Result Condition Proceed to DTC is not output A DTC is output B B A 10 PROBLEM SYMPTOMS TABLE NEXT GO TO STEP 12 11 DTC CHART NEXT 12 NEXT CIRCUIT INSPECTION GO TO STEP 11 BC BC–18 13 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM IDENTIFICATION OF PROBLEM NEXT 14 REPAIR OR REPLACE NEXT 15 NEXT END BC CONFIRMATION TEST BC–52 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, turn to the page for the respective DTC No. in the DTC chart. • Inspect the fuse and relay before investigating the trouble areas as shown in the table below. DTC Chart of ABS: DTC No. Detection Item Trouble Areas See page BC-53 Front Speed Sensor RH Circuit 1. Right front speed sensor 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Master cylinder solenoid BC-53 Front Speed Sensor LH Circuit 1. Left front speed sensor 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Master cylinder solenoid BC-62 Rear Speed Sensor RH Circuit 1. Right rear speed sensor 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Master cylinder solenoid BC-62 Rear Speed Sensor LH Circuit 1. Left rear speed sensor 2. Speed sensor circuit 3. Speed sensor rotor 4. Sensor installation 5. Master cylinder solenoid C0226/21 SFR Solenoid Circuit 1. Master cylinder solenoid 2. SFRH or SFRR circuit BC-71 C0236/22 SFL Solenoid Circuit 1. Master cylinder solenoid 2. SFLH or SFLR circuit BC-71 C0246/23 SRR Solenoid Circuit 1. Master cylinder solenoid 2. SRRH or SRRR circuit BC-71 C0256/24 SRL Solenoid Circuit 1. Master cylinder solenoid 2. SRLH or SRLR circuit BC-71 C0278/11 1. ABS SOL fuse 2. ABS solenoid relay 3. ABS solenoid relay circuit 4. Master cylinder solenoid BC-74 Open or Short Circuit in ABS Solenoid Relay Circuit C0279/12 1. ABS SOL fuse 2. ABS solenoid relay 3. ABS solenoid relay circuit 4. Master cylinder solenoid BC-74 Short to B+ in ABS Solenoid Relay Circuit 1. Brake fluid level 2. Brake fluid level warning switch 3. Brake fluid level warning switch circuit BC-79 C1202/58 Brake Fluid Level Low / Open Circuit in Brake Fluid Level Warning Switch Circuit C1225/25 SMC Solenoid Circuit 1. Master cylinder solenoid 2. SMCF circuit BC-71 C1226/26 SPC Solenoid Circuit 1. Master cylinder solenoid 2. SREA circuit BC-71 C1227/27 SRC Solenoid Circuit 1. Master cylinder solenoid 2. SREC circuit BC-71 C1228/28 STR Solenoid Circuit 1. Master cylinder solenoid 2. STR circuit BC-71 C0200/31 (*1) C0205/32 (*1) C0210/33 (*1) BC C0215/34 (*1) BC–53 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. Detection Item Trouble Areas See page BC-53 C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH 1. Master cylinder solenoid 2. Right front speed sensor 3. Speed sensor rotor 4. Sensor installation C1236/36 1. Master cylinder solenoid 2. Left front speed sensor 3. Speed sensor rotor 4. Sensor installation BC-53 Foreign Object is Attached on Tip of Front Speed Sensor LH C1238/38 1. Master cylinder solenoid 2. Right rear speed sensor 3. Speed sensor rotor 4. Sensor installation BC-62 Foreign Object is Attached on Tip of Rear Speed Sensor RH C1239/39 1. Master cylinder solenoid 2. Left rear speed sensor 3. Speed sensor rotor 4. Sensor installation BC-62 Foreign Object is Attached on Tip of Rear Speed Sensor LH BC-94 Low Battery Positive Voltage 1. Battery 2. ECU-IG fuse 3. Charging system 4. Power source circuit BC-98 IG2 Power Source Circuit 1. Battery 2. IC regulator 3. Power source circuit 4. IGN fuse BC-91 Acceleration Sensor Stuck Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. CAN communication system 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. CAN communication system BC-91 Open or Short in Deceleration Sensor Circuit BC-91 Acceleration Sensor Output Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. CAN communication system BC-101 C1246/46 Master Cylinder Pressure Sensor Malfunction 1. Master cylinder pressure sensor 2. Master cylinder pressure sensor circuit 3. Master cylinder solenoid 4. Stop light switch circuit Open in Stop Light Switch Circuit 1. Stop light switch 2. Stop light switch circuit 3. Rear combination light (stop light) assembly BC-104 C1249/49 C1251/51 (*1, 3) Open in Pump Motor Circuit Hydraulic brake booster pump motor circuit BC-109 C1252/52 (*2, 3) 1. Hydraulic brake booster pump motor 2. Hydraulic brake booster pump motor circuit 3. Accumulator pressure sensor BC-111 Brake Booster Pump Motor on Time Abnormally Long 1. Hydraulic brake booster pump motor 2. Hydraulic brake booster pump motor circuit BC-115 Hydro Booster Pump Motor Relay Malfunction C1241/41 C1242/42 C1243/43 (*1) C1244/44 C1245/45 (*1) C1253/53 (*2) BC BC–54 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. Trouble Areas See page BC-119 Pressure Switch Circuit 1. Hydraulic brake booster 2. Accumulator pressure sensor 3. Master cylinder pressure sensor BC-122 Accumulator Low Pressure 1. Hydraulic brake booster 2. Hydraulic brake booster pump motor 3. Hydraulic brake booster pump motor circuit 4. Accumulator pressure sensor C1257/57 (*2) IG Power Source Hydraulic brake booster pump motor circuit BC-125 Transfer "L4" Position Switch Circuit 1. 4WD control (L4) switch 2. 4WD control (L4) switch circuit 3. 4WD control ECU BC-132 C1268/68 (*4) Different Diameter Tire Malfunction 1. Speed sensor 2. Speed sensor rotor 3. Speed sensor circuit 4. Tire size BC-137 C1337/37 C1381/97 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor power source circuit 3. CAN communication system BC-91 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction U0073/94 Control Module Communication Bus OFF Wire harness U0124/95 Lost Communication with Lateral Acceleration Sensor Module 1. Wire harness 2. Yaw rate and acceleration sensor C1254/54 C1256/56 (*2, 3) BC Detection Item BC-156 BC-156 (*1), (*2): Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed. • (*1): (a) Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (b) Clear the DTC. • (*2): (a) Keep the vehicle in a stationary condition for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (b) Repeat the above operations 3 times or more and check that the ABS warning light goes off. (c) Clear the DTC. HINT: • In some cases, the intelligent tester cannot be used when the ABS warning light remains on. • When U0073/94, U0100/65, U0123/62, U0124/95 or U0126/63 is output, inspect and repair the trouble areas indicated by these codes first. * ( 3): The skid control buzzer sounds. (*4): Multi Mode 4WD DTC Chart of VSC: DTC No. C1201/51 Detection Item Engine Control System Malfunction Trouble Areas Engine control system See page BC-78 BC–55 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. Trouble Areas See page BC-79 C1202/52 Brake Fluid Level Low / Open Circuit in Brake Fluid Level Warning Switch Circuit 1. Brake fluid level 2. Brake fluid level warning switch 3. Brake fluid level warning switch circuit C1203/53 ECM Communication Circuit Malfunction ECM BC-83 C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone 1. Yaw rate and acceleration sensor 2. Zero point calibration undone 3. Park / Neutral position switch (P) circuit C1223/43 ABS Control System Malfunction ABS control system BC-87 BC-88 Steering Angle Sensor Circuit Malfunction 1. Steering angle sensor 2. Steering angle sensor circuit 3. Steering angle sensor power supply 4. CAN communication system BC-91 Stuck in Deceleration Sensor 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. CAN communication system BC-91 Yaw Rate Sensor Malfunction 1. Yaw rate and acceleration sensor 2. Yaw rate and acceleration sensor circuit 3. CAN communication system BC-126 Transfer 4WD Position Switch Circuit 1. 4WD control (4WD) switch 2. 4WD control (4WD) switch circuit 3. 4WD control ECU C1290/66 Steering Angle Sensor Zero Point Malfunction Steering angle sensor C1336/39 1. Yaw rate and acceleration sensor 2. Zero point calibration undone 3. Park / Neutral position switch (P) circuit BC-83 Zero Point Calibration of Acceleration Sensor Undone BC-139 Center Differential Lock Circuit 1. Center diff. lock switch 2. Center diff. lock switch circuit 3. Center diff. lock indicator light circuit 4. 4WD control ECU C1380/64 Stop Light Control Relay Malfunction 1. Stop light operation relay 2. Stop light operation relay circuit BC-147 U0100/65 Lost Communication with ECM / PCM Wire harness Lost Communication with Yaw Rate Sensor Module 1. Wire harness 2. Yaw rate and acceleration sensor BC-156 U0123/62 U0126/63 Lost Communication with Steering Angle Sensor Module 1. Wire harness 2. Steering angle sensor BC-156 C1231/31 C1232/32 C1234/34 C1258/58 (*4) C1340/47 (*5) Detection Item BC-82 BC-88 BC-156 (*4): Multi Mode 4WD (*5): 4WD HINT: In some cases, the intelligent tester cannot be used when the VSC TRAC warning light remains on. BC BC–56 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C0200/31 Front Speed Sensor RH Circuit DTC C0205/32 Front Speed Sensor LH Circuit DTC C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH DTC C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist and hill-start assist control systems. This speed sensor contains a sensor IC, which consists of 2 MREs (Magnetic Resistance Element). The speed sensor rotor, which consists of 48 sets of N and S poles that are arranged in a circle, is integrated with the inner race of the hub bearing. To detect the rotation direction, the output waves are used to determine the relationship of the pulses that are generated by 2 MREs. Upon receiving this signal, the sensor IC outputs a forward or backward wave to the ECU. BC Speed Sensor MRE A (+) Sensor IC To ECU MRE B (-) Speed Sensor Rotor (Bearing Inner Race) Low speed High speed 2.6 V 1.4 V 0.7 V Backward Forward I042838E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. DTC Detection Condition C0200/31 C0205/32 When any of the following conditions is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, pulses are not input for 1 second. 2. Momentary interruption of the speed sensor signal occurs at least 255 times when switching the ignition switch ON and OFF. 3. Continuous noise occurs in speed sensor signals at a vehicle speed of 12 mph (20 km/h) or more. 4. Speed sensor signal circuit is open for 0.12 seconds or more. 5. 3 of the wheel sensors detect normal reversing signals, and the other wheel sensor detects malfunction signals 75 times with IG ON while reversing at 3 km/h. 6. Rotating direction of each wheel changes 7 times within 0.006 seconds with IG ON while driving at 10 km/ h or more. 7. Rotating direction of one of the wheels is not the same as that of the other wheels for 1 second while driving at 30 km/h or more. 8. Reversing signal is output for 1 second or more while driving at 100 km/h or more. 9. Rotating direction of one of the wheels is not detected normally, and the rotating direction of each of the other wheels is not the same for 1 second while driving at 30 km/h or more. • • • • • Right front and left front speed sensor Each speed sensor circuit Speed sensor rotor Sensor installation Master cylinder solenoid C1235/35 C1236/36 Continuous noise occurs in speed sensor signals when vehicle speed is 12 mph (20 km/h) or more for 5 seconds or more. • • • • Right front and left front speed sensor Speed sensor rotor Sensor installation Master cylinder solenoid BC–57 Trouble Area HINT: • DTC C0200/31 and C1235/35 are for the right front speed sensor. • DTC C0205/32 and C1236/36 are for the left front speed sensor. BC BC–58 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Front Speed Sensor RH 1 3 S28 FR+ 17 S28 FR- 18 S28 FL+ 4 S28 FL- 2 Front Speed Sensor LH 1 2 BC C114554E04 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 READ VALUE OF INTELLIGENT TESTER (MOMENTARY INTERRUPTION OF FRONT SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN FR Speed sensor open detection (FR)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN FL Speed sensor open detection (FL)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - (d) Check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-18). OK: There are no momentary interruptions. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–59 HINT: Perform the above inspection before removing the sensor and connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SPEED SENSOR CIRCUIT) OK 2 READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) Item Measurement Item / Range (Display) WHEEL SPD FR Wheel speed sensor (FR) reading /Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD FL Wheel speed sensor (FL) reading/ Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer Normal Condition Diagnostic Note (a) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. NG Go to step 4 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected. Result Condition Proceed to Test mode (signal check) DTC is output A Test mode (signal check) DTC is not output B B A Go to step 10 BC BC–60 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the speed sensor installation. OK: The installation bolt is tightened properly. There is no clearance between the sensor and the front steering knuckle. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-23). 8.3 N*m (85 kgf*cm, 73 in.*lbf) No clearance OK NG I044006E04 NG INSTALL FRONT SPEED SENSOR CORRECTLY OK 5 INSPECT SPEED SENSOR TIP (a) Remove the front speed sensor (See page BC-211). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning/ replacement (See page BC-23). BC NG CLEAN OR REPLACE FRONT SPEED SENSOR OK 6 INSPECT FRONT SPEED SENSOR (a) (b) (c) (d) Front Speed Sensor: 2 1 A10 :RH A9 :LH I045651E01 Install the front speed sensor. Turn the ignition switch off. Disconnect the front speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance: RH Tester Connection Specified Condition A10-2 (FR+) - Body ground 10 kΩ or higher A10-1 (FR-) - Body ground 10 kΩ or higher LH NG Tester Connection Specified Condition A9-2 (FL+) - Body ground 10 kΩ or higher A9-1 (FL-) - Body ground 10 kΩ or higher REPLACE FRONT SPEED SENSOR BC–61 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK 7 INSPECT SKID CONTROL SENSOR WIRE Skid Control Sensor Wire: Sensor Side Connector “A” Vehicle Side Connector “B” (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Tester Connection Specified Condition A10 ("A"-2) - A10 ("B"-2) Below 1 Ω A10 ("A"-2) - A10 ("B"-1) 10 kΩ or higher A10 ("A"-2) - Body ground 10 kΩ or higher A10 :RH A9 :LH I044003E01 A10 ("A"-1) - A10 ("B"-1) Below 1 Ω A10 ("A"-1) - A10 ("B"-2) 10 kΩ or higher A10 ("A"-1) - Body ground 10 kΩ or higher LH Tester Connection Specified Condition A9 ("A"-2) - A9 ("B"-2) Below 1 Ω A9 ("A"-2) - A9 ("B"-1) 10 kΩ or higher A9 ("A"-2) - Body ground 10 kΩ or higher A9 ("A"-1) - A9 ("B"-1) Below 1 Ω A9 ("A"-1) - A9 ("B"-2) 10 kΩ or higher A9 ("A"-1) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-23). NG OK REPLACE SKID CONTROL SENSOR WIRE BC BC–62 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU Harness Side Connector Front View: S28 FL- FR+ Tester Connection FR- FL+ Front Speed Sensor Harness Side Connector Front View: FR- S28-3 (FR+) - A10-2 (FR+) Below 1 Ω S28-3 (FR+) - Body ground 10 kΩ or higher S28-17 (FR-) - A10-1 (FR-) Below 1 Ω S28-17 (FR-) - Body ground 10 kΩ or higher LH Tester Connection Specified Condition S28-18 (FL+) - A9-2 (FL+) Below 1 Ω S28-18 (FL+) - Body ground 10 kΩ or higher S28-4 (FL-) - A9-1 (FL-) Below 1 Ω S28-4 (FL-) - Body ground 10 kΩ or higher A9 A10 FR+ FL- FL+ NG BC Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR I045084E02 OK 9 INSPECT MASTER CYLINDER SOLENOID Front Speed Sensor Harness Side Connector Front View: A9 A10 FR+ (a) Reconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: RH Tester Connection Specified Condition A10-2 (FR+) - Body ground 7.5 to 12 V FL+ I045852E02 LH NG Tester Connection Specified Condition A9-2 (FL+) - Body ground 7.5 to 12 V REPLACE MASTER CYLINDER SOLENOID OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 20 mph (32 km/h) or more for 60 seconds or more. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–63 (c) Check if the same pending DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output (When troubleshooting in accordance with the DTC CHART.) B DTC is not output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) C B END C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A 11 REPLACE FRONT SPEED SENSOR (a) Replace the front speed sensor (See page BC-211). NOTICE: Check the speed sensor signal after replacement (See page BC-23). NEXT 12 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 20 mph (32 km/h) or more for 60 seconds or more. (c) Check if the same pending DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END A 13 INSPECT SPEED SENSOR ROTOR (a) Remove the front axle with ABS rotor bearing assembly (See page AH-6 for 2WD, or AH-13 for 4WD). BC BC–64 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (b) Check the sensor rotor. OK: No scratches, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning/ replacement (See page BC-23). NG OK REPLACE MASTER CYLINDER SOLENOID BC CLEAN OR REPLACE FRONT AXLE ABS ROTOR BEARING ASSEMBLY (SPEED SENSOR ROTOR) BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–1 VEHICLE STABILITY CONTROL SYSTEM PRECAUTION • When there is a malfunction in the contact point of the terminals or installation problems with parts, removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. • In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by DTC output and freeze frame data output, and record it before disconnecting each connector or removing and installing parts. • Since the Vehicle Stability Control system may be influenced by a malfunction in the other systems, be sure to check for DTCs in the other systems. • Be sure to remove and install the hydraulic brake booster and each sensor with the ignition switch off unless specified in the inspection procedure. • When removing and installing the hydraulic brake booster and each sensor, be sure to check that the normal display is output in test mode inspection and in DTC output inspection after installing all the parts. • After replacing the master cylinder solenoid and/or the yaw rate and acceleration sensor, make sure to perform yaw rate and acceleration sensor zero point calibration (See page BC-20). • The CAN communication system is used for data communication between the skid control ECU (included in the actuator), the steering angle sensor, and the yaw rate sensor (the acceleration sensor is included). If there is trouble in the CAN communication line, the DTC of the communication line is output. • If the DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the Vehicle Stability Control system. • Since the CAN communication line has its own length and route, it cannot be repaired temporarily with the bypass wire, etc. BC BC–2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM PARTS LOCATION HYDRAULIC BRAKE BOOSTER - MASTER CYLINDER SOLENOID (SKID CONTROL ECU) - BRAKE FLUID LEVEL WARNING SWITCH REAR SPEED SENSOR PARK/NEUTRAL POSITION SWITCH BC ENGINE ROOM R/B - ABS SOL FUSE - STOP FUSE FRONT SPEED SENSOR - ABS MTR FUSE - STOP LIGHT OPERATION RELAY C119747E04 BC–3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM COMBINATION METER - ABS WARNING LIGHT - VSC TRAC WARNING LIGHT - BRAKE WARNING LIGHT - SLIP INDICATOR LIGHT - VSC OFF INDICATOR LIGHT (*2) STEERING ANGLE SENSOR - AUTO LSD INDICATOR LIGHT (*1) - DOWNHILL ASSIST CONTROL INDICATOR LIGHT (*3) 4WD CONTROL SWITCH - CENTER DIFFERENTIAL LOCK INDICATOR LIGHT (*2) SKID CONTROL BUZZER ECM CENTER DIFFERENTIAL LOCK SWITCH (*2) BC 4WD CONTROL ECU STOP LIGHT SWITCH DOWNHILL ASSIST CONTROL SWITCH (*3) AUTO LSD SWITCH (*1) DRIVER SIDE J/B - ECU-IG FUSE DLC3 - GAUGE FUSE YAW RATE AND ACCELERATION SENSOR - IGN FUSE PARKING BRAKE SWITCH (*1): 2WD (*2): 4WD (*3): Multi Mode 4WD C131293E04 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C0210/33 Rear Speed Sensor RH Circuit DTC C0215/34 Rear Speed Sensor LH Circuit DTC C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH DTC C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH BC–65 DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist and hill-start assist control systems. This speed sensor contains a sensor IC, which consists of 2 MREs (Magnetic Resistance Element). The speed sensor rotor, which consists of 48 sets of N and S poles that are arranged in a circle, is integrated with the inner race of the hub bearing. To detect the rotation direction, the output waves are used to determine the relationship of the pulses that are generated by 2 MREs. Upon receiving this signal, the sensor IC outputs a forward or backward wave to the ECU. BC Speed Sensor MRE A (+) Sensor IC To ECU MRE B (-) Speed Sensor Rotor (Bearing Inner Race) Low speed High speed 2.6 V 1.4 V 0.7 V Backward Forward I042838E01 BC–66 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. DTC Detection Condition Trouble Area C0210/33 C0215/34 When any of the following conditions is detected: 1. At a vehicle speed of 6 mph (10 km/h) or more, pulses are not input for 1 second. 2. Momentary interruption of the speed sensor signal occurs at least 255 times when switching the ignition switch ON and OFF. 3. Continuous noise occurs in speed sensor signals at a vehicle speed of 12 mph (20 km/h) or more. 4. Speed sensor signal circuit is open for 0.12 seconds or more. 5. 3 of the wheel sensors detect normal reversing signals, and the other wheel sensor detects malfunction signals 75 times with IG ON while reversing at 3 km/h. 6. Rotating direction of each wheel changes 7 times within 0.006 seconds with IG ON while driving at 10 km/ h or more. 7. Rotating direction of one of the wheels is not the same as that of the other wheels for 1 second while driving at 30 km/h or more. 8. Reversing signal is output for 1 second or more while driving at 100 km/h or more. 9. Rotating direction of one of the wheels is not detected normally, and the rotating direction of each of the other wheels is not the same for 1 second while driving at 30 km/h or more. • • • • • Right rear and left rear speed sensor Each speed sensor circuit Speed sensor rotor Sensor installation Master cylinder solenoid C1238/38 C1239/39 Continuous noise occurs in speed sensor signals when vehicle speed is 12 mph (20 km/h) or more for 5 seconds or more. • • • • Right rear and left rear speed sensor Speed sensor rotor Sensor installation Master cylinder solenoid HINT: • DTC C0210/33 and C1238/38 are for the right rear speed sensor. • DTC C0215/34 and C1239/39 are for the left rear speed sensor. BC–67 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Rear Speed Sensor RH Shielded 5 1 2 S28 RR+ 19 S28 RR- 20 S28 RL+ 6 S28 RL- Shielded Rear Speed Sensor LH 1 2 BC C132911E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 READ VALUE OF INTELLIGENT TESTER (MOMENTARY INTERRUPTION OF REAR SPEED SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN RR Speed sensor open detection (RR)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN RL Speed sensor open detection (RL)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - (d) Check for any momentary interruption in the wire harness and connector corresponding to a DTC (See page BC-18). OK: There are no momentary interruptions. BC–68 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HINT: Perform the above inspection before removing the sensor and connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR (SPEED SENSOR CIRCUIT) OK 2 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) Item Measurement Item / Range (Display) Normal Condition Diagnostic Note WHEEL SPD RR Wheel speed sensor (RR) reading /Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RL Wheel speed sensor (RL) reading /Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer (a) Check that there is no difference between the speed value output from the speed sensor displayed on the intelligent tester and the speed value displayed on the speedometer when driving the vehicle. OK: The speed value output from the speed sensor displayed on the intelligent tester is the same as the actual vehicle speed. BC NG Go to step 4 OK 3 PERFORM TEST MODE (SIGNAL CHECK) (a) Check if test mode (signal check) DTCs are detected. Result Condition Proceed to Test mode (signal check) DTC is output A Test mode (signal check) DTC is not output B B A Go to step 10 BC–69 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 INSPECT REAR SPEED SENSOR INSTALLATION (a) Check the speed sensor installation. OK: The installation nut is tightened properly. There is no clearance between the sensor and the rear axle. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) NOTICE: Check the speed sensor signal after replacement (See page BC-23). 8.3 N*m (85 kgf*cm, 73 in.*lbf) No clearance OK NG I044006E04 NG INSTALL REAR SPEED SENSOR CORRECTLY OK 5 INSPECT SPEED SENSOR TIP (a) Remove the rear speed sensor (See page BC-213). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after cleaning/ replacement (See page BC-23). NG CLEAN OR REPLACE REAR SPEED SENSOR OK 6 INSPECT REAR SPEED SENSOR (a) (b) (c) (d) Rear Speed Sensor: 2 1 A41 :RH A40 :LH I045651E03 Install the rear speed sensor. Turn the ignition switch off. Disconnect the rear speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance: RH Tester Connection Specified Condition A41-2 (RR+) - Body ground 10 kΩ or higher A41-1 (RR-) - Body ground 10 kΩ or higher LH Tester Connection Specified Condition A40-2 (RL+) - Body ground 10 kΩ or higher A40-1 (RL-) - Body ground 10 kΩ or higher NG REPLACE REAR SPEED SENSOR BC BC–70 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK 7 INSPECT SKID CONTROL SENSOR WIRE (a) Disconnect the skid control sensor wire. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control Sensor Wire: Sensor Side Connector “A”: Vehicle Side Connector “B”: A41 :RH Tester Connection Specified Condition A40 :LH A41 ("A"-2) - A41 ("B"-4) Below 1 Ω A41 ("A"-2) - A41 ("B"-3) 10 kΩ or higher A41 ("A"-2) - Body ground 10 kΩ or higher I044004E05 A41 ("A"-1) - A41 ("B"-3) Below 1 Ω A41 ("A"-1) - A41 ("B"-4) 10 kΩ or higher A41 ("A"-1) - Body ground 10 kΩ or higher LH Tester Connection BC Specified Condition A40 ("A"-2) - A40 ("B"-2) Below 1 Ω A40 ("A"-2) - A40 ("B"-1) 10 kΩ or higher A40 ("A"-2) - Body ground 10 kΩ or higher A40 ("A"-1) - A40 ("B"-1) Below 1 Ω A40 ("A"-1) - A40 ("B"-2) 10 kΩ or higher A40 ("A"-1) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (See page BC-23). NG OK REPLACE SKID CONTROL SENSOR WIRE BC–71 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: RH Skid Control ECU (harness side connector front view) S28 RR+ RL- Tester Connection RR- RL+ (harness side connector front view) A41 :RH RL- RL+ S28-5 (RR+) - A41 (A-4) (RR+) Below 1 Ω S28-5 (RR+) - Body ground 10 kΩ or higher S28-19 (RR-) - A41 (A-3) (RR-) Below 1 Ω S28-19 (RR-) - Body ground 10 kΩ or higher LH Rear Speed Sensor A40 :LH Specified Condition RR- Tester Connection Specified Condition S28-20 (RL+) - A40 (A-2) (RL+) Below 1 Ω S28-20 (RL+) - Body ground 10 kΩ or higher S28-6 (RL-) - A40 (A-1) (RL-) Below 1 Ω S28-6 (RL-) - Body ground 10 kΩ or higher NG RR+ REPAIR OR REPLACE HARNESS OR CONNECTOR F049552E18 OK 9 INSPECT MASTER CYLINDER SOLENOID (a) Reconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: RH Rear Speed Sensor (harness side connector front view) A40 :LH A41 :RH RL+ Tester Connection Specified Condition A41 (A-4) (RR+) - Body ground 7.5 to 12 V RR+ C110680E19 LH Tester Connection Specified Condition A40 (A-2) (RL+) - Body ground 7.5 to 12 V NG REPLACE MASTER CYLINDER SOLENOID OK 10 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 20 mph (32 km/h) or more for 60 seconds or more. BC BC–72 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (c) Check if the same pending DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output (When troubleshooting in accordance with the DTC CHART.) B DTC is not output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) C B END C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A 11 REPLACE REAR SPEED SENSOR (a) Replace the rear speed sensor (See page BC-213). NOTICE: Check the speed sensor signal after replacement (See page BC-23). BC NEXT 12 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 20 mph (32 km/h) or more for 60 seconds or more. (c) Check if the same pending DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END A 13 INSPECT SPEED SENSOR ROTOR (a) Remove the rear axle bearing assembly (See page AH23). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–73 (b) Check the sensor rotor. OK: No scratches, oil, or foreign matter on the rotors. NOTICE: Check the speed sensor signal after cleaning/ replacement (See page BC-23). NG CLEAN OR REPLACE REAR AXLE BEARING ASSEMBLY (SPEED SENSOR ROTOR) OK REPLACE MASTER CYLINDER SOLENOID BC BC–74 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C0226/21 SFR Solenoid Circuit DTC C0236/22 SFL Solenoid Circuit DTC C0246/23 SRR Solenoid Circuit DTC C0256/24 SRL Solenoid Circuit DTC C1225/25 SMC Solenoid Circuit DTC C1226/26 SPC Solenoid Circuit DTC C1227/27 SRC Solenoid Circuit DTC C1228/28 STR Solenoid Circuit DESCRIPTION BC The solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling braking force. DTC No. DTC Detection Condition Trouble Area C0226/21 Open or short circuit in SFRH or SFRR circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SFRH or SFRR circuit C0236/22 Open or short circuit in SFLH or SFLR circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SFLH or SFLR circuit C0246/23 Open or short circuit in SRRH or SRRR circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SRRH or SRRR circuit C0256/24 Open or short circuit in SRLH or SRLR circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SRLH or SRLR circuit C1225/25 Open or short circuit in SMCF circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SMCF circuit C1226/26 Open or short circuit in SREA circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SREA circuit C1227/27 Open or short circuit in SREC circuit continues for 0.05 seconds or more. • • Master cylinder solenoid SREC circuit C1228/28 Open or short circuit in STR circuit continues for 0.05 seconds or more. • • Master cylinder solenoid STR circuit BC–75 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Skid Control ECU ABS SOL 1 2 S28 31 Solenoid Relay +BS STR SREC SFRH SFLH BC SRRH SRLH SFRR S28 GND1 SFLR 1 SRRR S28 GND2 32 S29 Battery SRLR GND3 SREA 4 SMCF C132912E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–76 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM RECONFIRM DTC HINT: These codes are detected when a problem is determined in the master cylinder solenoid. The solenoid circuit is in the master cylinder solenoid. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if any DTC is output before replacing the master cylinder solenoid. (a) Clear the DTCs (See page BC-39). (b) Check if the same DTCs are detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B A BC REPLACE MASTER CYLINDER SOLENOID END BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–77 Open or Short Circuit in ABS Solenoid Relay Circuit DTC C0278/11 DTC C0279/12 Short to B+ in ABS Solenoid Relay Circuit DESCRIPTION The ABS solenoid relay is built in the master cylinder solenoid. This relay supplies power to each ABS solenoid. If the initial check is OK, after the ignition switch is turned to the ON position, the relay goes on. DTC No. DTC Detection Condition C0278/11 When either of the following conditions is detected: 1. Both of the following conditions continue for at least 0.2 seconds. (a) IG voltage is between 9.5 V and 17 V. (b) Relay contact is open when the relay is ON 2. Both of the following conditions continue for at least 0.2 seconds. (a) IG voltage is 9.5 V or less when the relay is ON. (b) Relay contact remains open. Trouble Area • • • • ABS SOL fuse ABS solenoid relay ABS solenoid relay circuit Master cylinder solenoid C0279/12 The following condition continues for at least 0.2 seconds. • Relay contact is closed immediately after turning IG switch to the ON position when the relay is OFF. • • • • ABS SOL fuse ABS solenoid relay ABS solenoid relay circuit Master cylinder solenoid BC BC–78 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Skid Control ECU ABS SOL 1 2 S28 31 Solenoid Relay +BS STR SREC SFRH SFLH BC SRRH SRLH SFRR S28 GND1 SFLR 1 SRRR S28 GND2 32 S29 Battery SRLR GND3 SREA 4 SMCF C132912E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–79 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 1 INSPECT ABS SOL FUSE (a) Remove the ABS SOL fuse from the engine room R/B. (b) Check the ABS SOL fuse. Standard resistance: Below 1 Ω NG REPLACE ABS SOL FUSE OK 2 INSPECT SKID CONTROL ECU (+BS TERMINAL) (a) Install the ABS SOL fuse. (b) Disconnect the skid control ECU connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-31 (+BS) - Body ground Always 10 to 14 V NG +BS C121700E96 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BS CIRCUIT) BC BC–80 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Disconnect the skid control ECU (S29) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG GND1 GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND3 S29 BC C124799E12 OK 4 RECONFIRM DTC HINT: These codes are detected when a problem is determined in the master cylinder solenoid. The ABS solenoid relay is in the master cylinder solenoid. Therefore, solenoid relay circuit inspection and relay unit inspection cannot be performed. Be sure to check if any DTC is output before replacing the master cylinder solenoid. (a) Clear the DTCs (See page BC-39). (b) Check if the same DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC BC–81 C1201/51 Engine Control System Malfunction DESCRIPTION If trouble occurs in the engine control system, the ECM transmits the abnormality to the skid control ECU. The skid control ECU sets this DTC and prohibits TRAC and VSC control. DTC No. DTC Detection Condition C1201/51 Malfunction signal is received from ECM. Trouble Area Engine control system INSPECTION PROCEDURE 1 CHECK DTC (FOR ENGINE CONTROL SYSTEM) (a) Check if the engine control system DTC is output (See page ES-31 for 1GR-FE, or ES-35 for 2UZ-FE). Result Condition Proceed to DTC is not output A DTC is output B B A REPLACE ECM INSPECT ENGINE CONTROL SYSTEM BC BC–82 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1202/52 Brake Fluid Level Low / Open Circuit in Brake Fluid Level Warning Switch Circuit DTC C1202/58 Brake Fluid Level Low / Open Circuit in Brake Fluid Level Warning Switch Circuit DESCRIPTION The brake fluid level warning switch sends the appropriate signal to the skid control ECU when the brake fluid level drops. DTC No. DTC Detection Condition C1202/52 C1202/58 BC Trouble Area When either of the following conditions is detected: 1. With ECU terminal IG1 voltage at 9.5 V to 17.2 V, an open in the brake fluid level warning switch circuit continues for 2 seconds or more. 2. Fluid level of the reservoir tank is LOW for 4 seconds or 40 seconds after the ignition switch is turned ON, of for 7 seconds during pump motor operation. • • • Brake fluid level Brake fluid level warning switch Brake fluid level warning switch circuit HINT: If the code (C1202/52) is output, the following situations will occur: • The VSC TRAC and BRAKE warning lights, and the VSC OFF indicator light will come on. • Control of all systems other than ABS and EBD is canceled. If the code (C1202/58) is output, the following situations will occur: • The ABS, VSC TRAC, and BRAKE warning lights, and the SLIP and VSC OFF indicator lights will come on. • Control of all systems other than EBD is canceled. WIRING DIAGRAM Master Cylinder Solenoid ECU-IG from Ignition Switch 46 S28 IG1 Brake Fluid Level Warning Switch 41 1 2 S28 LBL C132913E03 BC–83 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). HINT: When C1241/41 is output together with C1202/52 or C1202/58, inspect and repair the trouble areas indicated by C1241/41 first. 1 CHECK BRAKE FLUID LEVEL (a) Turn the ignition switch off. (b) Depress the brake pedal 20 times or more (until the pedal reaction feels light and pedal stroke becomes longer). (c) Check the amount of fluid in the brake reservoir. HINT: When the ignition switch is turned to the ON position, brake fluid is sent to the accumulator and the fluid level decreases by approximately 5 mm from the level when the ignition switch is off (normal). NOTICE: Do not move the wheels with the ignition switch off. OK: Brake fluid level is proper. NG CHECK AND REPAIR BRAKE FLUID LEAKAGE OK 2 INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Disconnect the brake fluid level warning switch connector. (b) Measure the resistance according to the value(s) in the table below. HINT: • A float is placed inside the reservoir. Its position can be changed by increasing/decreasing the level of brake fluid. • The warning switch is switched ON/OFF at +- 5mm from the MIN level. Standard resistance B14 +-5mm Tester Connection Condition Specified Condition B14-1 - B14-2 Float UP (Switch OFF) 1.9 to 2.1 kΩ B14-1 - B14-2 Float DOWN (Switch ON) Below 1 Ω F052341E04 HINT: If there is no problem after finishing the above check, adjust the brake fluid level to the MAX level. NG REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY BC BC–84 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (BRAKE FLUID LEVEL WARNING SWITCH - SKID CONTROL ECU) Skid Control ECU Harness Side Connector Front View: S28 LBL Brake Fluid Level Warming Switch Harness Side Connector Front View: (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition S28-41 (LBL) - B14-2 Below 1 Ω S28-41 (LBL) - Body ground 10 kΩ or higher B14-1 - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR B14 BC I045330E03 OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC–85 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1203/53 ECM Communication Circuit Malfunction DESCRIPTION The circuit is used to send TRAC and VSC control information from the skid control ECU to the ECM, and engine control information from the ECM to the skid control ECU via the CAN communication system. DTC No. DTC Detection Condition Trouble Area Engine drive source and destination variation that are sent from the ECM do not match the one of the ECU. C1203/53 ECM WIRING DIAGRAM Master Cylinder Solenoid ECM CANH CANL 11 33 S28 CANH BC 25 34 S28 CANL C132914E01 INSPECTION PROCEDURE 1 CHECK DTC (FOR ENGINE CONTROL SYSTEM) (a) Check if the engine control system DTC is output (See page ES-31 for 1GR-FE, or ES-35 for 2UZ-FE). Result Condition Proceed to DTC is not output A DTC is output B B A REPLACE ECM INSPECT ENGINE CONTROL SYSTEM BC–86 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone DTC C1336/39 Zero Point Calibration of Acceleration Sensor Undone DESCRIPTION The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has a built-in acceleration sensor. If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTC U0123/62 (yaw rate sensor communication trouble) and U0124/95 (acceleration sensor communication trouble) are output. These DTCs are also output when the calibration has not been completed. DTC No. DTC Detection Condition Trouble Area C1210/36 When either of the following conditions is detected: 1. When battery terminal was connected, shift lever was moved to non-P position within 15 seconds after ECU terminal IG1 became ON first. 2. When the yaw rate sensor zero point recorded in ECU is deleted. • • • Yaw rate and acceleration sensor Zero point calibration undone Park/Neutral position switch (P) circuit C1336/39 When either of the following conditions is detected: 1. In test mode, shift lever is shifted to non-P position 2 seconds after ECU terminal IG1 is turned ON first. 2. When acceleration sensor zero point recorded in ECU is deleted. • • • Yaw rate and acceleration sensor Zero point calibration undone Park/Neutral position switch (P) circuit BC HINT: If these codes (C1210/36 and/or C1336/39) are output, the following situations will occur. • The VSC TRAC warning light and the VSC OFF and SLIP indicator lights will come on. • Control of all systems other than ABS, EBD, and BA is canceled. BC–87 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Yaw Rate and Acceleration Sensor Master Cylinder Solenoid 11 CANH S28 3 CANH 25 CANL S28 2 CANL Park/Neutral Position Switch 14 PL S28 6 P BC C132915E02 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). HINT: When U0073/94, U0100/65, U0123/62, U0124/95 or U0126/63 is output together with C1210/36 or C1336/39, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62, U0124/95 or U0126/63 first. 1 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR NEXT 2 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Check if the same DTCs are detected. (See page BC39). Result Condition Proceed to DTC is output A DTC is not output B BC–88 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HINT: The DTCs are recorded because zero point calibration has not been completed. End the procedure since the same DTCs are not recorded after completion of the zero point calibration. B END A 3 CHECK SENSOR INSTALLATION (a) Check that the yaw rate and acceleration sensor has been installed properly. OK: The sensor should be tightened to the specified torque. The sensor should not be tilted. NG INSTALL YAW RATE AND ACCELERATION SENSOR CORRECTLY OK BC 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - PARK/NEUTRAL POSITION SWITCH) Skid Control ECU Harness Side Connector Front View: S28 P (a) Disconnect the skid control ECU connector and Park/ Neutral position switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection NG Park/Neutral Position Switch Harness Side Connector Front View: P1 PL F052381E04 OK Specified Condition S28-14 (P) - P1-6 (PL) Below 1 Ω S28-14 (P) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR BC–89 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 5 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Park/Neutral Position Switch Harness Side Connector Front View: Tester Connection Condition Specified Condition 2 - 6, 4 - 5 P Below 1 Ω P1 C124790E05 NG 1-2 R Below 1 Ω 2 - 9, 4 - 5 N Below 1 Ω 2-7 D, 4 Below 1 Ω 2-3 3 Below 1 Ω 2-8 2, L Below 1 Ω REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 6 REPLACE YAW RATE AND ACCELERATION SENSOR (a) Replace the yaw rate and acceleration sensor (See page BC-91). NEXT 7 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR NEXT 8 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Check if the same DTCs are detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC BC–90 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1223/43 ABS Control System Malfunction DESCRIPTION DTC No. C1223/43 DTC Detection Condition Trouble Area ABS control system is abnormal ABS control system HINT: • This DTC is output when the VSC system detects a malfunction in the ABS system. • When DTC C1223/43 is memorized, there is no malfunction in the skid control ECU. INSPECTION PROCEDURE 1 CHECK DTC (FOR ABS SYSTEM) (a) Clear the DTC (See page BC-39). (b) Check if DTC is recorded. Result Condition Proceed to DTC is output A DTC is not output B BC B END A REPAIR REPAIR CIRCUIT INDICATED BY OUTPUT DTC BC–91 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1231/31 Steering Angle Sensor Circuit Malfunction DTC C1290/66 Steering Angle Sensor Zero Point Malfunction DESCRIPTION The steering angle sensor signal is sent to the skid control ECU through the CAN communication system. When there is a malfunction in the communication system, it will be detected by the diagnosis function. DTC No. DTC Detection Condition Trouble Area C1231/31 When ECU IG1 terminal voltage is 9.5 V or more, the steering angle sensor malfunction signal is received. • • • • Steering angle sensor Steering angle sensor circuit Steering angle sensor power supply CAN communication system C1290/66 The steering angle sensor zero point calibration position vastly differs from the recorded value. Steering angle sensor WIRING DIAGRAM Steering Angle Sensor CANL Master Cylinder Solenoid 11 CANH BC 25 S28 CANL 11 S28 CANH 3 ECU-B BAT 9 2 1 from Battery ECU-IG IG1 ESS 1 from Ignition Switch 2 C132916E05 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). HINT: • When U0073/94, U0100/65, U0123/62, U0124/95 or U0126/63 is output together with C1231/31and C1290/66, inspect and repair the trouble areas indicated by U0073/94, U0100/65, U0123/62, U0124/ 95 or U0126/63 first. BC–92 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM • When the speed sensor or the yaw rate and acceleration sensor has trouble, DTCs of the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs of the speed sensor (C0200/31, C0205/32, C0210/33, C0215/34, C1235/35, C1236/36, C1238/38, C1239/39) or yaw rate and acceleration sensor (C1232/32, C1234/34, C1243/43, C1244/44, C1245/45, C1381/97) are output together with other DTCs of the steering angle sensor, inspect and repair the speed sensor and yaw rate and acceleration sensor first, and then inspect and repair the steering angle sensor. 1 READ VALUE OF INTELLIGENT TESTER (STEERING ANGLE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. Item Measurement Item / Range (Display) STEERING ANG Steering angle sensor/ Min.: 1152 deg/s, Max.: 1150.875 deg/s Normal Condition Diagnostic Note Left turn: Increase Right turn: Decrease - (d) Check that the steering wheel turning angle value of the steering angle sensor displayed on the intelligent tester changes when turning the steering wheel. OK: Steering angle sensor value changes. BC Result Condition Proceed to OK (When troubleshooting in accordance with DTC CHART) A OK (When troubleshooting in accordance with PROBLEM SYMPTOMS TABLE) B NG C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C Go to step 3 A 2 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 6 mph (10 km/h) or more for 10 seconds or more. (c) Check if the same pending DTCs are detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B END BC–93 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM A REPLACE MASTER CYLINDER SOLENOID 3 INSPECT STEERING ANGLE SENSOR (POWER SOURCE AND GROUND TERMINAL) Steering Angle Sensor Harness View: ESS S11 IG1 BAT I046350E02 (a) Remove the steering wheel and the column cover lower. (b) Disconnect the steering angle sensor connector. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition S11-1 (IG1) - Body ground Ignition switch ON 10 to 14 V S11-9 (BAT) - Body ground Always 10 to 14 V (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition S11-2 (ESS) - Body ground Ignition switch OFF Below 1 Ω HINT: • When troubleshooting in accordance with the DTC CHART, check DTCs before replacing the steering angle sensor (See page BC-39). • When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE, be sure to follow the table before replacing the steering angle sensor (See page BC-33). NG OK REPLACE STEERING ANGLE SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE OR GROUND CIRCUIT) BC BC–94 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1232/32 Stuck in Deceleration Sensor DTC C1234/34 Yaw Rate Sensor Malfunction DTC C1243/43 Acceleration Sensor Stuck Malfunction DTC C1244/44 Open or Short in Deceleration Sensor Circuit DTC C1245/45 Acceleration Sensor Output Malfunction DTC C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction DESCRIPTION BC The skid control ECU receives signals from the yaw rate and acceleration sensor via the CAN communication system. The yaw rate sensor has a built-in acceleration sensor. If there is trouble in the bus lines between the yaw rate and acceleration sensor and the CAN communication system, the DTC U0123/62 (yaw rate sensor communication trouble) and U0124/95 (acceleration sensor communication trouble) are output. These DTCs are also output when the calibration has not been completed. DTC No. DTC Detection Condition C1232/32 At a vehicle speed of 6 mph (10 km/h) or more, the fluctuation range of the signal from either GL1 or GL2 is under 80 mV and the other is above 1.9 V for 30 seconds or more. Trouble Area • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit CAN communication system C1234/34 Sensor malfunction signal is received from yaw rate sensor. • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit CAN communication system C1243/43 The following condition repeats 16 times. • GL1 and GL2 do not change by more than 2LSB when the vehicle decelerates from 19 mph (30 km/ h) to 0 mph (0 km/h). • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit CAN communication system C1244/44 When either of the following conditions is detected: 1. Both of the following conditions continue for at least 60 seconds. • Vehicle is stopped. • Difference between GL1 and GL2 does not drop below 0.4 G once it reaches 0.6 G or more. 2. Data malfunction signal is received from acceleration sensor. • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit CAN communication system C1245/45 The following condition continues for at least 60 seconds. • Difference between the values calculated from acceleration sensor value and vehicle speed exceeds 0.35 G. • • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor circuit CAN communication system C1381/97 acceleration sensor power source malfunction signal is received for at least 10 seconds at a speed of more than 2 mph (3 km/h). • • Yaw rate and acceleration sensor Yaw rate and acceleration sensor power source circuit CAN communication system • BC–95 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Yaw Rate and Acceleration Sensor Master Cylinder Solenoid CANL 2 CANH 25 S28 CANL 11 S28 CANH 3 ECU-IG IG from Ignition Switch 5 GND 1 BC C132917E06 INSPECTION PROCEDURE NOTICE: When replacing the yaw rate and acceleration sensor, perform zero point calibration (See page BC-20). 1 CHECK DTC (a) (b) (c) (d) Clear the DTCs (See page BC-39). Turn the ignition switch off. Turn the ignition switch to the ON position. Check if the DTCs (U0073/94, U0123/62, C1210/36 and/ or C1336/39) are detected (See page BC-39). Result Condition Proceed to DTC U0073/94, U0123/62, C1210/36 and/or C1336/39 are not output A DTC U0073/94 and/or U0123/62 are output B DTC C1210/36 and/or C1336/39 are output C B INSPECT CAN COMMUNICATION SYSTEM C REPAIR CIRCUIT INDICATED BY OUTPUT DTC BC–96 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM A 2 INSPECT YAW RATE AND ACCELERATION SENSOR (IG AND GND TERMINAL) Yaw Rate and Acceleration Sensor Harness Side Connector Front View: Y1 GND IG F045082E24 (a) Disconnect the yaw rate and acceleration sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition Y1-5 (IG) - Body ground Ignition switch ON 10 to 14 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition Y1-1 (GND) - Body ground Ignition switch OFF Below 1 Ω Result Condition BC Proceed to OK (When troubleshooting in accordance with the DTC CHART) A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPAIR OR REPLACE HARNESS OR CONNECTOR (IG OR GND CIRCUIT) A REPLACE YAW RATE AND ACCELERATION SENSOR BC–97 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1241/41 Low Battery Positive Voltage DESCRIPTION If the voltage supplied to the IG1 terminal is not within the DTC detection threshold due to malfunctions in such as the battery and alternator circuit, this DTC is stored. DTC No. DTC Detection Condition C1241/41 When either of the following conditions is detected: 1. Both of the following conditions continue for at least 10 seconds. • Vehicle speed is more than 2 mph (3 km/m). • IG1 terminal voltage is less than 9.5 V. 2. All of the following conditions continue for at least 0.2 seconds. • Solenoid relay remains ON. • IG1 terminal voltage is less than 9.5 V. • Relay contact is open. Trouble Area • • • • Battery ECU-IG fuse Charging system Power source circuit WIRING DIAGRAM Master Cylinder Solenoid BC Ignition Switch ECU-IG 2 AM1 IG1 4 46 S28 IG1 1 2 AM1 S28 GND1 1 32 2 S28 GND2 4 S29 GND3 ALT 1 Battery C132918E01 BC–98 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 2 INSPECT ECU-IG FUSE (a) Remove the ECU-IG fuse from the driver side J/B. (b) Check the ECU-IG fuse. Standard resistance: Below 1 Ω NG BC REPLACE ECU-IG FUSE OK 3 READ VALUE OF INTELLIGENT TESTER (IG1 POWER SUPPLY) (a) Install the ECU-IG fuse. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (d) Start the engine. (e) Select "DATA LIST" mode on the intelligent tester. Item IG VOLTAGE Measurement Item / Range (Display) ECU-IG power supply voltage / TOO LOW / NORMAL / TOO HIGH (f) TOO LOW: 9.5 V or less NORMAL: 9.5 V or 14.0 V TOO HIGH: 14.0 V or more Diagnostic Note - Measure the voltage output from the ECU displayed on the intelligent tester. OK: "Normal" is displayed. NG OK Normal Condition REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–99 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) (b) (c) (d) Skid Control ECU Harness Side Connector Front View: Install the ECU-IG fuse. Disconnect the skid control ECU connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Specified Condition S28-46 (IG1) - Body ground 10 to 14 V NG S28 REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) IG1 C121700E79 OK 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Disconnect the skid control ECU (S29) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG GND1 BC GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND3 S29 C124799E13 OK 6 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). BC–100 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output (When troubleshooting in accordance with the DTC CHART) B DTC is not output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) C B END C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A REPLACE MASTER CYLINDER SOLENOID BC BC–19 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK FOR INTERMITTENT PROBLEMS 1. Intelligent Tester CHECK FOR INTERMITTENT PROBLEMS HINT: A momentary interruption (open circuit) in the connectors and/or wire harness between the sensors and ECUs can be detected in the ECU data monitor function of the intelligent tester. (a) Turn the ignition switch off and connect the intelligent tester to the DLC3. DLC3 I042828E01 (b) Turn the ignition switch on. Follow the on-screen directions on the intelligent tester to display the DATA LIST and select areas where momentary interruption should be monitored. Harness Signal: OK Momentary interruption 1 sec. 1 sec. 1 sec. Intelligent Tester Display: OPN DET NORMAL C106657E11 Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN FR Speed sensor open detection (FR) / OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN FL Speed sensor open detection (FL) / OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN RR Speed sensor open detection (RR) / OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN RL Speed sensor open detection (RL) / OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - HINT: • A momentary interruption (open circuit) cannot be detected for 3 seconds after the ignition switch is turned on (initial check). BC BC–20 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM • If the intelligent tester status remains on, check the continuity between the ECU and the sensors, or between ECUs. • The OPN DET display on the intelligent tester remains on for 1 second after the harness signal changes from momentary interruption (open circuit) to normal condition. (c) While observing the screen, gently jiggle the connector or wire harness between the ECU and sensors, or between ECUs. Result: OPN DET display does not change. HINT: The connector and/or wire harness will be in momentary interruption (open circuit) if the display changes. Repair or replace connector and/or wire harness as one of them is faulty. F047126 BC BC–101 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1242/42 IG2 Power Source Circuit DESCRIPTION If there is a problem with the master cylinder solenoid power supply circuit, the skid control ECU outputs DTCs and prohibits operation under the fail safe function. If the voltage supplied to the IG2 terminal is not within the DTC detection threshold due to malfunctions in such as the battery and alternator circuit, this DTC is stored. DTC No. DTC Detection Condition C1242/42 Vehicle speed is 1.9 mph (3 km/h) or more and voltage of ECU IG2 terminal remains at below 6.5 V for more than 7 seconds. Trouble Area • • • • Battery IGN fuse IC regulator Power source circuit WIRING DIAGRAM Master Cylinder Solenoid Ignition Switch IGN 7 AM2 IG2 6 BC 1 S29 IG2 1 S28 2 GND1 32 AM2 S28 GND2 1 4 S29 GND3 Battery C132919E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–102 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 2 INSPECT IGN FUSE (a) Remove the IGN fuse from the driver side J/B. (b) Check the IGN fuse. Standard resistance: Below 1 Ω NG REPLACE IGN FUSE OK BC 3 INSPECT SKID CONTROL ECU (IG2 TERMINAL) (a) (b) (c) (d) Skid Control ECU Harness Side Connector Front View: Install the IGN fuse. Disconnect the skid control ECU (S29) connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage S29 NG IG2 C124800E03 OK Tester Connection Specified Condition S29-1 (IG2) - Body ground 10 to 14 V REPAIR OR REPLACE HARNESS OR CONNECTOR (IG2 CIRCUIT) BC–103 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Disconnect the skid control ECU connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG GND1 GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND3 S29 BC C124799E14 OK 5 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC–104 DTC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM C1246/46 Master Cylinder Pressure Sensor Malfunction DESCRIPTION The master cylinder pressure sensor is connected to the skid control ECU in the master cylinder solenoid. Master Cylinder Solenoid Skid Control ECU from Battery BC from Stop Light Switch to Body Ground Master Cylinder Pressure Sensor IG1 VM/C1 (VCM) VC STP PM/C1 (PMC) VOUT GND M/C1 GND GND VM/C1 (VCM): Master Cylinder Pressure Sensor Power Supply Output PM/C1 (PMC ): Master Cylinder Pressure Sensor Signal Input M/C1 GND: Master Cylinder Pressure Sensor Ground C124773E06 BC–105 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC No. DTC Detection Condition Trouble Area C1246/46 When any of the following conditions is detected: 1. Both of the following conditions continue for at least 30 seconds. • Vehicle speed is more than 4 mph (7 km/h). • PMC terminal voltage does not change by more than 0.005 V once it exceeds 0.86 V. 2. PMC terminal receives interference at least 7 times within 5 seconds. 3. Both of the following conditions continue for at least 1.2 seconds. • Stop light switch is OFF. • PMC terminal voltage is more than 0.86 V or less than 0.3 V. 4. Both of the following conditions continue for at least 1.2 seconds. • IG1 terminal voltage is between 9.5 and 17 V. • VCM terminal voltage is not between 4.4 and 5.6 V. 5. Both of the following conditions continue for at least 1.2 seconds. • VCM terminal voltage is between 4.4 and 5.6 V. • PMC terminal voltage is not between 0.14 and 4.85 V. • • • • Master cylinder pressure sensor Master cylinder pressure sensor circuit Stop light switch circuit Master cylinder solenoid INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. Item Measurement Item / Range (Display) Normal Condition • MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / Min.: 0 V, Max.: 5 V • Diagnostic Note When brake pedal is released: 0.3 to 0.9 V When stop light is turned on: 0.3 to 0.9 V Reading increases when brake pedal is depressed (d) Check that the master cylinder pressure value of the master cylinder pressure sensor displayed on the intelligent tester changes when depressing the brake pedal. Result Condition Proceed to Master cylinder pressure sensor value does not change A Master cylinder pressure sensor value changes but it is not normal B Master cylinder pressure sensor value becomes normal C A C B REPLACE MASTER CYLINDER SOLENOID Go to step 4 BC BC–106 2 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK BRAKE PEDAL AND STOP LIGHT SWITCH INSTALLATION (a) Check the brake pedal height. (b) Check the stop light switch installation. OK: The brake pedal and stop light switch are normal. NG ADJUST BRAKE PEDAL AND/OR STOP LIGHT SWITCH OK 3 INSPECT SKID CONTROL ECU (STP TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: Tester Connection Condition Specified Condition S28-7 (STP) - Body ground Stop light switch ON (Brake pedal depressed) 8 to 14 V S28-7 (STP) - Body ground Stop light switch OFF (Brake pedal released Below 1.5 V S28 BC NG STP REPAIR OR REPLACE HARNESS OR CONNECTOR (STP CIRCUIT) C121700E80 OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC–210 BRAKE CONTROL – FRONT SPEED SENSOR FRONT SPEED SENSOR BRAKE CONTROL COMPONENTS BC SPEED SENSOR FRONT LH C119747E01 BRAKE CONTROL – FRONT SPEED SENSOR BC–211 REMOVAL HINT: Replacement of RH side is same as that of LH side. 1. REMOVE FRONT WHEEL 2. REMOVE SPEED SENSOR FRONT LH (a) Disconnect the speed sensor connector. F044160 (b) Using a hexagon wrench (5 mm), remove the bolt and front speed sensor from the steering knuckle. SST 99999-60011 NOTICE: • Do not stick and foreign matter on the sensor tip. • Do not let the foreign matter into the sensor installation hole. F043112 INSTALLATION 1. INSTALL SPEED SENSOR FRONT LH (a) Using a hexagon wrench (5 mm), install the front speed sensor with the bolt to the steering knuckle. SST 99999-60011 Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) NOTICE: Make sure the sensor tip is clean. F043112 (b) Connect the speed sensor connector. F044160 2. INSTALL FRONT WHEEL Torque: 110 N*m (1.122 kgf*cm, 81 ft.*lbf) 3. CHECK ABS SPEED SENSOR SIGNAL HINT: (See page BC-23) BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC BC–107 C1249/49 Open in Stop Light Switch Circuit DESCRIPTION The skid control ECU inputs the stop light switch signal and detects the status of brake operation. The skid control ECU has an open detection circuit. If an open in the stop light switch input line or GND side stop light circuit is detected when the stop light switch is off, this DTC is output. DTC No. C1249/49 DTC Detection Condition ECU terminal IG1 voltage is 9.5 to 17.0 V, ABS is in non-operation, and an open in stop light switch circuit continues for 0.3 seconds or more. Trouble Area • • • Stop light switch Stop light switch circuit Rear combination light (stop light) assembly BC BC–108 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Stop Light Switch 45 S28 1 2 STP2 4 7 5 BC 3 1 2 S28 STP 16 S28 STPO Stop Light Operation (STOP LP CTRL) 2 STOP IG1 1 Rear Combination Light LH 6 STOP 1 from Ignition Switch Rear Combination Light RH from Battery 6 STOP 1 to High Mounted Stop Light C132920E06 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–109 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 1 CHECK STOP LIGHT SWITCH OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK: Stop light switch function is normal. HINT: Check the stop light bulb as it may have burnt out. NG Go to step 4 OK 2 INSPECT SKID CONTROL ECU (STP TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: STP S28 Tester Connection Condition Specified Condition S28-7 (STP) - Body ground Stop light switch ON (Brake pedal depressed) 8 to 14 V S28-7 (STP) - Body ground Stop light switch OFF (Brake pedal released) Below 1.5 V C121700E81 Result Condition Proceed to OK (When troubleshooting in accordance with the DTC CHART) A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE) B NG C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPAIR OR REPLACE HARNESS OR CONNECTOR (STP CIRCUIT) A 3 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). BC BC–110 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END A REPLACE MASTER CYLINDER SOLENOID 4 INSPECT STOP LIGHT SWITCH ASSEMBLY (POWER SOURCE TERMINAL) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch Harness Side Connector Front View: BC Tester Connection Condition Specified Condition S12-2 - Body ground Always 10 to 14 V S12 NG I042363E23 REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK 5 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 2 1 Pushed in 4 3 S12 C124796E06 OK Specified Condition S12-1 - S12-2 Switch pin free Below 1 Ω S12-1 - S12-2 Switch pin pushed in 10 kΩ or higher NG Free Condition REPLACE STOP LIGHT SWITCH ASSEMBLY BC–111 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6 INSPECT STOP LIGHT OPERATION RELAY (a) Remove the stop light operation relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance NG Tester Connection Specified Condition 3-4 Below 1 Ω REPLACE STOP LIGHT OPERATION RELAY E068810 OK 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - STOP LIGHT SWITCH) Skid Control ECU Harness Side Connector Front View: S28 (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Harness Side Connector Front View:   Specified Condition Below 1 Ω S28-7 (STP) - Body ground 10 kΩ or higher HINT: • When troubleshooting in accordance with the DTC CHART, check DTCs before replacing the master cylinder solenoid (See page BC-39). • When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE, be sure to follow the table before replacing the master cylinder solenoid (See page BC-33). STP S12 Tester Connection S28-7 (STP) - S12-1  NG  C121702E08 OK REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR BC BC–112 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1251/51 Open in Pump Motor Circuit DESCRIPTION The motor relay (semiconductor relay) is built in the master cylinder solenoid and drives the pump motor based on a signal from the skid control ECU. DTC No. DTC Detection Condition C1251/51 Trouble Area Open in motor system circuit (motor input circuit) Hydraulic brake booster pump motor circuit WIRING DIAGRAM Hydraulic Brake Booster Assembly Master Cylinder Solenoid Skid Control ECU 2 BC S28 ABS MTR 1 2 +BM1 Motor Relay 2 +BM2 S29 1 S28 32 S28 4 S29 GND1 GND2 GND3 M+1 M+2 Battery MT- MT+ Pump Motor C132922E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). HINT: Remove the hydraulic brake booster before the inspection (See page BR-25). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 1 BC–113 CHECK CONNECTION OF PUMP MOTOR WIRE HARNESS (MT+ / MT-) (a) Using a screwdriver, remove the 2 plugs from the hydraulic brake booster assembly (See page BR-25). (b) Check the tightening torque of the 2 screws which tighten the wire harness connecting the hydraulic brake booster assembly and the brake booster pump (See page BR-25). OK: The harness is tightened to the specific torque. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) NG RETIGHTEN SCREWS UP OK 2 CHECK RESISTANCE OF PUMP MOTOR WIRE HARNESS (MT+ / MT-) (a) Using a screwdriver, remove the 2 screws and pull the wire harness from the hydraulic brake booster assembly (See page BR-25). (b) Measure the resistance between the red wire (MT+) and the black wire (MT-). Standard resistance: 2Ω Rear Wire (MT+) NG Black Wire (MT-) F051186E01 REPLACE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY OK 3 RECONFIRM DTC (a) Reassemble the hydraulic brake booster assembly (See page BR-31). (b) Install the hydraulic brake booster assembly (See page BR-35). (c) Clear the DTC (See page BC-39). (d) Check if the same DTC is detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC BC–114 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC Brake Booster Pump Motor on Time Abnormally Long C1252/52 DESCRIPTION The motor relay (semiconductor relay) is built in the master cylinder solenoid and drivers the pump motor based on a signal from the skid control ECU. DTC No. DTC Detection Condition C1252/52 Trouble Area • • • Motor operates for 5 minutes or more. Hydraulic brake booster pump motor Hydraulic brake booster pump motor circuit Accumulator pressure sensor HINT: The pump motor continues operation for the first 3 minutes, then repeats start and stop. WIRING DIAGRAM Hydraulic Brake Booster Assembly Master Cylinder Solenoid BC Skid Control ECU 2 S28 ABS MTR 1 2 +BM1 Motor Relay 2 +BM2 S29 1 S28 32 S28 4 S29 GND1 GND2 GND3 M+1 M+2 Battery MT- MT+ Pump Motor C132922E02 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–115 HINT: When C1253/53, C1254/54, or C1256/56 is output together with C1252/52, inspect and repair the trouble area indicated by C1253/53, C1254/54, or C1256/56 first. 1 CHECK PUMP MOTOR OPERATION (a) (b) (c) (d) Turn the ignition switch off. Depress the brake pedal more than 20 times. Turn the ignition switch to the ON position. Check how the pump motor operates. Result Condition Proceed to Pump motor does not operate A Pump motor operates continuously, and does not stop B Pump motor operates intermittently C Pump motor operates, then stops D B REPLACE MASTER CYLINDER SOLENOID AND BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY C Go to step 4 D Go to step 5 A 2 CHECK CONNECTION OF PUMP MOTOR WIRE HARNESS (MT+ / MT-) (a) Using a screwdriver, remove the 2 plugs from the hydraulic brake booster assembly (See page BR-25). (b) Check the tightening torque of the 2 screws which tighten the wire harness connecting the hydraulic brake booster assembly and the brake booster pump (See page BR-25). OK: The harness is tightened to the specific torque. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) NG OK RETIGHTEN SCREWS UP BC BC–116 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK RESISTANCE OF PUMP MOTOR WIRE HARNESS (MT+ / MT-) (a) Using a screwdriver, remove the 2 screws and pull the wire harness from the hydraulic brake booster assembly (See page BR-25). (b) Measure the resistance between the red wire (MT+) and the black wire (MT-). Standard resistance: 2Ω Rear Wire (MT+) NG Black Wire (MT-) F051186E01 REPLACE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY OK 4 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. BC Measurement Item / Range (Display) Item ACC PRESS Accumulator pressure sensor reading / Min.: 0 V, Max.: 5 V Normal Condition Diagnostic Note If the value is constant regardless of pump operation, accumulator pressure sensor malfunction is suspected. 3.58 to 5 V (d) Check the accumulator output value. Result Condition Proceed to Output value is within the "Normal Condition" range A Output value is out of the "Normal Condition" range B Output value is constant regardless of pump operation C B REPLACE HYDRAULIC BRAKE BOOSTER C REPLACE MASTER CYLINDER SOLENOID AND BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY A 5 RECONFIRM DTC (a) (b) (c) (d) (e) Clear the DTC (See page BC-39). Turn the ignition switch off. Turn the ignition switch to the ON position. Wait for more than 5 minutes. Check if the same DTC is detected (See page BC-39). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–117 HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B REPLACE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY A REPLACE MASTER CYLINDER SOLENOID AND BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY BC BC–118 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1253/53 Hydro Booster Pump Motor Relay Malfunction DESCRIPTION The motor relay (semiconductor relay) is built in the master cylinder solenoid and drives the pump motor based on a signal from the skid control ECU. DTC No. DTC Detection Condition C1253/53 Trouble Area • • Motor system circuit (motor input circuit) Hydraulic brake booster pump motor Hydraulic brake booster pump motor circuit WIRING DIAGRAM Hydraulic Brake Booster Assembly Master Cylinder Solenoid Skid Control ECU 2 BC S28 ABS MTR 1 2 +BM1 Motor Relay 2 +BM2 S29 1 S28 32 S28 4 S29 GND1 GND2 GND3 M+1 M+2 Battery MT- MT+ Pump Motor C132922E03 INSPECTION PROCEDURE NOTICE: When replacing the hydraulic brake booster (master cylinder solenoid), perform zero point calibration (See page BC-20). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (H/B MOTOR RELAY) (a) Connect the intelligent tester to the DLC3. BC–119 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Start the engine. (d) Select "ACTIVE TEST" mode on the intelligent tester. Item H/B MOT RELAY Vehicle Condition / Test Details Diagnostic Note Operation sound of motor can be heard Turns H/B motor relay ON / OFF (e) Check operation sound of the H/B motor individually when operating it with the intelligent tester. OK: The operation sound of the H/B motor can be heard. OK Go to step 4 NG 2 INSPECT SKID CONTROL ECU (+BM TERMINAL) (a) Disconnect the skid control ECU connectors. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-2 (+BM1) - Body ground 10 to 14 V S29-2 (+BM2) - Body ground 10 to 14 V NG +BM1 +BM2 S29 C124799E15 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (+BM CIRCUIT) BC BC–120 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28 S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG GND1 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) GND2 GND3 S29 BC C124799E16 OK 4 RECONFIRM DTC (a) (b) (c) (d) (e) (f) Clear the DTC (See page BC-39). Turn the ignition switch off. Depress the brake pedal more than 20 times. Turn the ignition switch to the ON position. Wait until the pump motor stops. Depress the brake pedal several times until the pump motor turns on. (g) Wait until the pump stops. (h) Repeat (f) and (g) 3 more times. (i) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–121 A REPLACE HYDRAULIC BRAKE BOOSTER BC BC–122 DTC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM C1254/54 Pressure Switch Circuit DESCRIPTION The accumulator pressure sensor is connected to the skid control ECU in the master cylinder solenoid. Master Cylinder Solenoid Skid Control ECU IG1 BC GND Accumulator Pressure Sensor VACC VACC PACC PACC ACCGND ACCGND VACC: Accumulator Pressure Sensor Power Supply Output PACC: Accumulator Pressure Sensor Signal Input ACCGND: Accumulator Pressure Sensor Ground C124776E02 HINT: If the code (C1254/54) is output, the following conditions will occur: • The ABS, VSC TRAC, and BRAKE warning lights and SLIP and VSC OFF indicator lights will come on. • The skid control buzzer sounds. • Control of all systems other than EBD is canceled. DTC No. C1254/54 DTC Detection Condition Accumulator pressure sensor malfunction (Fluid pressure does not change when the pump operates or when the brake is applied.) Trouble Area • • • Hydraulic brake booster Accumulator pressure sensor Master cylinder pressure sensor BC–123 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the ignition switch off. Depress the brake pedal more than 20 times. Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (e) Select "DATA LIST" mode on the intelligent tester. Item ACC PRESS Measurement Item / Range (Display) Accumulator pressure sensor reading / Min.: 0 V, Max.: 5 V (f) Normal Condition Diagnostic Note If the value is constant regardless of pump operation, accumulator pressure sensor malfunction is suspected. 3.58 to 5 V Check the accumulator output value. Result Condition Proceed to Output value is within the "Normal Condition" range A Output value is out of the "Normal Condition" range B Output value is constant regardless of pump operation B B BC REPLACE MASTER CYLINDER SOLENOID A 2 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) (a) Turn the ignition switch off. (b) Depress the brake pedal more than 20 times. (c) Install the brake pedal effort gauge (SST), and bleed air. SST 09709-29018 (d) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (e) Select "DATA LIST" mode on the intelligent tester. Item MAS CYL PRESS 1 Measurement Item / Range (Display) Master cylinder pressure sensor 1 reading / Min.: 0 V, Max.: 5 V (f) 0.3 to 1.95 V With pedal effort of 49 N (5 kgf, 11 in.*Ibf) Diagnostic Note Front brake pressure: 1220 to 2320 kPa (11.4 to 23.7 kgf/cm2, 162 to 337 psi) Check that the master cylinder pressure sensor's output value is normal. OK: Master cylinder pressure sensor value is normal. NG OK Normal Condition REPLACE MASTER CYLINDER SOLENOID BC–124 3 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM RECONFIRM DTC (a) (b) (c) (d) (e) (f) (g) (h) Clear the DTC (See page BC-39). Turn the ignition switch off. Depress the brake pedal more than 20 times. Turn the ignition switch to the ON position. Wait until the pump motor stops. Depress the brake pedal and release it. Wait for 25 minutes. Check if the same DTC is detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID BC END BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC BC–125 C1256/56 Accumulator Low Pressure DESCRIPTION The accumulator pressure sensor is connected to the skid control ECU in the master cylinder solenoid. Master Cylinder Solenoid Skid Control ECU IG1 VACC VACC PACC PACC ACCGND GND Accumulator Pressure Sensor BC ACCGND VACC: Accumulator Pressure Sensor Power Supply Output PACC: Accumulator Pressure Sensor Signal Input ACCGND: Accumulator Pressure Sensor Ground C124776E03 DTC No. C1256/56 DTC Detecting Condition Fluid pressure inside the accumulator is below the standard value. Trouble Areas • • • • Hydraulic brake booster Hydraulic brake booster pump motor Hydraulic brake booster pump motor circuit Accumulator pressure sensor INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–126 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM HINT: When C1251/51, C1253/53, or C1254/54 is output together with C1256/56, inspect and repair the trouble area indicated by C1251/51, C1253/53, or C1254/54 first. 1 RECONFIRM DTC (a) (b) (c) (d) (e) (f) Clear the DTC (See page BC-39). Turn the ignition switch off. Depress the brake pedal more than 20 times. Turn the ignition switch to the ON position. Wait for 99 seconds. Check if the same DTC is detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B HINT: Excessive brake pedal operation results in abnormal accumulator pressure consumption. This is normal. B BC END A 2 CHECK HYDRAULIC CIRCUIT (a) Check the hydraulic circuit (See page BR-17). OK: Hydraulic circuit is normal (No leakage). NG REPAIR HYDRAULIC CIRCUIT OK 3 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "DATA LIST" mode on the intelligent tester. Item ACC PRESS Measurement Item / Range (Display) Accumulator pressure sensor reading / Min.: 0 V, Max.: 5 V Normal Condition 3.58 to 5 V Diagnostic Note If the value is constant regardless of pump operation, accumulator pressure sensor malfunction is suspected. (d) Check that the accumulator's output value is normal. OK: Accumulator pressure sensor value is normal. NG REPLACE MASTER CYLINDER SOLENOID BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–127 OK 4 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B END A REPLACE MASTER CYLINDER SOLENOID BC BC–128 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1257/57 IG Power Source DESCRIPTION The motor relay (semiconductor relay) is built in the master cylinder solenoid and drives the pump motor based on a signal from the skid control ECU. DTC No. C1257/57 DTC Detection Condition Trouble Area Open in motor system circuit (motor input circuit). Hydraulic brake booster pump motor circuit INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 CHECK PUMP MOTOR OPERATION (a) (b) (c) (d) BC Turn the ignition switch off. Disconnect the skid control ECU (S28) connector. Depress the brake pedal more than 20 times. Check pump motor operation. OK: Pump motor normally operates. NG REPLACE MASTER CYLINDER SOLENOID OK 2 RECONFIRM DTC (a) (b) (c) (d) (e) Turn the ignition switch off. Reconnect the skid control ECU (S28) connector. Turn the ignition switch to the ON position. Clear the DTC (See page BC-39). Check if the same DTC is detected (See page BC-39). Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC–129 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1258/58 Transfer 4WD Position Switch Circuit DESCRIPTION Transfer condition (2WD or 4WD) is detected. DTC No. DTC Detection Condition Trouble Area C1258/58 The difference in 2WD/4WD information sent from the ECM via CAN and the 4WD control switch (EXI3 signal) continues for 5 seconds. • • • 4WD control (4WD) switch 4WD control (4WD) switch circuit 4WD control ECU WIRING DIAGRAM ECM 4WD Master Cylinder Solenoid 26 S28 8 EXI3 BC 4WD Control ECU ADD 4WD Control (4WD) Switch H4 18 GND 4 H2 2-4 8 5 2-4 C132923E01 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–130 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (EXI3 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-26 (EXI3) - Body ground 4WD control (4WD) switch ON (Transfer 4WD position) Below 1.5 V S28-26 (EXI3) - Body ground 4WD control (4WD) switch ON (Transfer 2WD position) 8 to 14 V EXI3 C121700E82 Result BC Condition Proceed to OK (When troubleshooting in accordance with the DTC CHART.) A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) B NG C B C A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE Go to step 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 2 BC–131 INSPECT ECM (4WD TERMINAL) (a) (b) (c) (d) ECM Harness Side View: Turn the ignition switch off. Disconnect the ECM connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition E6-8 (4WD) - Body ground 4WD control (4WD) switch ON (Transfer 4WD position) Below 1.5 V E6-8 (4WD) - Body ground 4WD control (4WD) switch ON (Transfer 2WD position) 8 to 14 V NG Go to step 4 E6-8 (4WD) BC I044051E04 OK 3 RECONFIRM DTC (a) Start the engine. (b) Clear the DTC (See page BC-39). (c) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B NG A REPLACE MASTER CYLINDER SOLENOID END BC–132 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT 4WD CONTROL SWITCH (GND TERMINAL) (a) Disconnect the 4WD control (4WD) switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 4WD Control (4WD) Switch Harness Side Connector Front View: F11 Tester Connection Specified Condition F11-4 (GND) - Body ground Below 1 Ω NG GND B059092E11 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 5 INSPECT 4WD CONTROL SWITCH (a) Check the select 2-4 and high-low system (See page TF46). NG BC REPLACE 4WD CONTROL SWITCH OK 6 INSPECT 4WD CONTROL ECU (a) Check the select 2-4 and high-low system (See page TF46). NG OK REPLACE 4WD CONTROL ECU BC–133 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 7 CHECK HARNESS AND CONNECTOR (4WD CONTROL ECU - 4WD CONTROL SWITCH) (a) Disconnect the 4WD control ECU (F9) connector and 4WD control (4WD) switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 4WD Control ECU Harness View: Tester Connection F9-8 (2-4) NG 4WD Control (4WD) Switch Harness Side Connector Front View: Specified Condition F9-8 (2-4) - F11-5 (2-4) Below 1 Ω F9-8 (2-4) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR F11 2-4 BC I045763E05 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - 4WD CONTROL ECU) (a) Disconnect the 4WD control ECU (F10) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection EXI3 4WD Control ECU Harness View: S28 F10-18 (ADD) I045764E03 OK Specified Condition S28-26 (EXI3) - F10-18 (ADD) Below 1 Ω S28-26 (EXI3) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC–134 9 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - ECM) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-26 (EXI3) - B6-8 (4WD) Below 1 Ω S28-26 (EXI3) - Body ground 10 kΩ or higher S28 EXI3 ECM Harness View: BC E6-8 (4WD) I045573E03 Result Condition Proceed to OK (When troubleshooting in accordance with the DTC CHART.) A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) B NG C A END B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPAIR OR REPLACE HARNESS OR CONNECTOR BC–135 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1268/68 Transfer "L4" Position Switch Circuit DESCRIPTION After confirming that the transfer is in the L4 position, A-TRAC and downhill assist control will be activated according to the vehicle conditions (See page BC-6). DTC No. DTC Detection Condition Trouble Area • • • The L4 signal input to the ECU does not match the L4 signal output from the ECM. C1268/68 4WD control (L4) switch 4WD control (L4) switch circuit 4WD control ECU WIRING DIAGRAM Master Cylinder Solenoid ECM L4 21 S28 13 EXI4 BC 4WD Control ECU L4 4WD Control (4WD) Switch H4 24 GND 4 L4 LO 15 2 LO C132923E03 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–136 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (EXI4 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: EXI4 S28 Tester Connection Condition Specified Condition S28-21 (EXI4) - Body ground 4WD control (L4) switch ON (Transfer L4 position) Below 1.5 V S28-21 (EXI4) - Body ground 4WD control (L4) switch OFF (Any transfer position except L4) 8 to 14 V NG Go to step 4 C121700E97 OK BC 2 PERFORM TEST MODE (SIGNAL CHECK) (a) Check if the test mode (signal check) DTC is detected. Result Condition Proceed to Test mode (signal check) DTC is output A Test mode (signal check) DTC is not output (When troubleshooting in accordance with the DTC CHART.) B Test mode (signal check) DTC is not output (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) C B REPAIR OR REPLACE HARNESS OR CONNECTOR (L4 CIRCUIT) C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A 3 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B BC–137 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM B END A REPLACE MASTER CYLINDER SOLENOID 4 INSPECT 4WD CONTROL SWITCH (GND TERMINAL) (a) Disconnect the 4WD control (4WD) switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 4WD Control (4WD) Switch Harness Side Connector Front View: F11 Tester Connection Specified Condition F11-4 (GND) - Body ground Below 1 Ω NG GND B059092E12 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) OK 5 BC INSPECT 4WD CONTROL SWITCH (a) Check the select high-low system (See page TF-43) or the select 2-4 and high-low system (See page TF-46). NG REPLACE 4WD CONTROL SWITCH OK 6 INSPECT 4WD CONTROL ECU (a) Check the select high-low system (See page TF-43) or the select 2-4 and high-low system (See page TF-46). NG OK REPLACE 4WD CONTROL ECU BC–138 7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (4WD CONTROL ECU - 4WD CONTROL SWITCH) (a) Disconnect the 4WD control ECU connector and 4WD control (L4) switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 4WD Control ECU Harness View: Tester Connection F9-15 (LO) NG 4WD Control (L4) Switch Harness Side Connector Front View: Specified Condition F9-15 (LO) - F11-2 (LO) Below 1 Ω F9-15 (LO) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR F11 BC LO I045763E06 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - 4WD CONTROL ECU) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-21 (EXI4) - F9-24 (L4) Below 1 Ω S28-21 (EXI4) - Body ground 10 kΩ or higher NG EXI4 S28 4WD Control ECU Harness View: F9-24 (L4) I045765E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BC–139 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 9 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - ECM) (a) Disconnect the ECM connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-21 (EXI4) - E6-13 (L4) Below 1 Ω S28-21 (EXI4) - Body ground 10 kΩ or higher S28 EXI4 ECM Harness View: BC E6-13 (L4) I045573E04 Result Condition Proceed to OK (When troubleshooting in accordance with the DTC CHART.) A OK (When troubleshooting in accordance with the PROBLEM SYMPTOMS TABLE.) B NG C A END B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–21 CALIBRATION 1. Replacement / Adjustment Parts DESCRIPTION • After replacing the VSC relevant components or performing "Front wheel alignment adjustment", clearing and reading the sensor calibration data are necessary. • Follow the chart to perform calibration. HINT: For a rear air suspension vehicle, it is necessary to obtain zero point calibration data (again) after adjusting vehicle height. Necessary Operations Master cylinder solenoid (Skid control ECU) Yaw rate and acceleration sensor zero point calibration. Yaw rate and acceleration sensor 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. Front wheel alignment 1. Clearing zero point calibration data. 2. Yaw rate and acceleration sensor zero point calibration. Rear air suspension 1. Clearing zero point calibration data 2. Yaw rate and acceleration sensor zero point calibration 2. DLC3: CLEAR ZERO POINT CALIBRATION (SST CHECK WIRE) HINT: After replacing the yaw rate and acceleration sensor, make sure to clear zero point calibration data in the skid control ECU and perform zero point calibration. (a) Turn the ignition switch to the ON position. (b) Using SST, connect and disconnect terminals TS and CG of the DLC3 4 times or more within 8 seconds. SST 09843-18040 CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS F100115E01 Normal System Code: 0.25 sec. 0.25 sec. ON 3. OFF BR03904E50 (c) Check that the warning light indicates the normal system code. (d) Remove the SST from the terminals of the DLC3. (e) Using a check wire, perform zero point calibration of the yaw rate and acceleration sensor. PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (SST CHECK WIRE) After replacing the master cylinder solenoid and/or yaw rate and acceleration sensor, make sure to perform yaw rate and acceleration sensor zero point calibration. NOTICE: • While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it in a stationary condition. (Do not start the engine.) BC BC–22 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM • Be sure to do this on a level surface (with an inclination of less than 1 degree). (a) Procedures for test mode: (1) Turn the ignition switch off. DLC3: (2) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (3) Check that the steering wheel is in the straightahead position and more the shift lever to the P position. NOTICE: DTC C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (See page BC-83). (4) Turn the ignition switch to the ON position. (5) Keep the vehicle in a stationary condition on a level surface for 2 seconds or more. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS F100115E01 (6) Check that the VSC TRAC warning light is blinking in test mode. NOTICE: The VSC TRAC warning light stays on when obtaining the zero point. HINT: • If the VSC TRAC warning light does not blink, perform the zero point calibration again. • The zero point calibration is performed only once after the system enters test mode. • Calibration cannot be performed again until the stored data is cleared once. Test Mode: 0.13 sec. 0.13 sec. ON BC OFF BR03904E54 Intelligent Tester DLC3 4. CLEAR ZERO POINT CALIBRATION (INTELLIGENT TESTER) After replacing the yaw rate and acceleration sensor, make sure to clear zero point calibration data in the skid control ECU and perform zero point calibration. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Operate the intelligent tester to erase the codes. I042828E01 F052309 (d) Using the intelligent tester, perform zero point calibration of the yaw rate and acceleration sensor. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 5. Intelligent Tester DLC3 BC–23 PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (INTELLIGENT TESTER) After replacing the master cylinder solenoid and/or yaw rate and acceleration sensor, make sure to perform yaw rate and acceleration sensor zero point calibration. NOTICE: • While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it in a stationary condition. (Do not start the engine.) • Be sure to do this on a level surface (with an inclination of less than 1 degree). (a) Procedures for test mode. (1) Check that the steering wheel is in the straightahead position and move the shift lever to the P position. NOTICE: DTC C1210/36 and C1336/39 will be recorded if the shift lever is not in the P position (See page BC-83). (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch to the ON position. (4) Set the intelligent tester in test mode ("TEST MODE"). HINT: Refer to the intelligent tester operator's manual for further details. (5) Keep the vehicle in a stationary condition on a level surface for 2 seconds or more. I042828E01 Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E55 (6) Check that the VSC TRAC warning light is blinking in test mode. NOTICE: The VSC TRAC warning light stays on when obtaining the zero point. HINT: • If the VSC TRAC warning light does not blink, perform the zero point calibration again. • The zero point calibration is performed only once after the system enters test mode. • Calibration cannot be performed again until the stored data is cleared once. BC BC–140 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DTC C1337/37 Different Diameter Tire Malfunction DESCRIPTION The skid control ECU measures the speed of each wheel by receiving signals from the speed sensor. These signals are used for recognizing that all 4 wheels are operating properly. Therefore, all wheel signals must be equal. DTC No. C1337/37 DTC Detection Condition Trouble Area When either of the following condition is detected: • Diameter is different between the 2 front wheels and the 2 rear wheels. • Wheel speed sensor fault • • • • Speed sensor Speed sensor rotor Speed sensor circuit Tire size INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 CHECK TIRE SIZE (a) Check tire size and condition of all 4 wheels. NG BC REPLACE TIRES SO THAT ALL 4 TIRES ARE SAME IN SIZE OK 2 INSPECT SPEED SENSOR ROTOR (a) Check the front speed sensor circuit (See page BC-53) and rear speed sensor circuit (See page BC-62). NG REPLACE SPEED SENSOR ROTOR OK 3 INSPECT SPEED SENSOR (a) Check the front speed sensor circuit (See page BC-53) and rear speed sensor circuit (See page BC-62). NG REPLACE SPEED SENSOR OK 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - SPEED SENSOR) (a) Check the front speed sensor circuit (See page BC-53) and rear speed sensor circuit (See page BC-62). NG REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–141 OK 5 RECONFIRM DTC (a) Clear the DTCs (See page BC-39). (b) Drive the vehicle at a speed of approximately 13 mph (20 km/h) or more for 60 seconds or more. (c) Check if the same pending DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END A REPLACE MASTER CYLINDER SOLENOID BC BC–142 DTC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM C1340/47 Center Differential Lock Circuit DESCRIPTION When the center differential is locked, VSC control turns off and the VSC OFF indicator illuminates. DTC No. DTC Detection Condition • C1340/47 BC • When the terminal IG1 voltage is between 10 and 14 V, there is an open in the center differential lock circuit for 2 seconds or more. A center diff. lock indicator OFF signal is continuously output for 5 seconds or more with the center differential locked (Multi Mode 4WD). Trouble Area • • • • Center diff. lock switch Center diff. lock switch circuit Center diff. lock indicator light circuit 4WD control ECU BC–143 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 10 S28 6 Center Diff. Lock NEO 4WD Control ECU IND2 P1 BC 20 27 S28 22 EXI Center Diff. Lock Switch DL 16 3 4 GAUGE 15 from Ignition Switch C132924E02 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–144 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (EXI TERMINAL) (a) (b) (c) (d) Skid Control ECU Harness Side Connector Front View: S28 EXI Transfer is in 4WD mode (Multi Mode 4WD only). Disconnect the skid control ECU connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition S28-27 (EXI) - Body ground Center diff. locked Below 1.5 V S28-27 (EXI) - Body ground Center diff. free 10 to 14 V NG Go to step 4 C121700E84 OK BC 2 INSPECT SKID CONTROL ECU (NEO TERMINAL) (a) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-10 (NEO) - Body ground Center diff. locked Below 2 V S28-10 (NEO) - Body ground Center diff. free 10 to 14 V HINT: The center diff. lock indicator light comes on while the center differential is being switched to lock. Therefore, perform the measurement after confirming that the indicator light comes on and the center differential is actually locked by driving the vehicle. NEO C139796E03 NG Go to step 9 OK 3 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. BC–145 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Result Condition Proceed to DTC is output A DTC is not output B B END A REPLACE MASTER CYLINDER SOLENOID 4 INSPECT CENTER DIFFERENTIAL LOCK SWITCH (GROUND TERMINAL) Center Diff. Lock Switch Harness Side Connector Front View: (a) Disconnect the center diff. lock switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance D4 NG I044042E02 Tester Connection Specified Condition D4-4 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR (GROUND CIRCUIT) OK 5 INSPECT CENTER DIFFERENTIAL LOCK SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Push-lock Type: Not Pushed in Pushed in D4 Tester Connection Condition Specified Condition D4-3 - D4-4 Switch is pushed in Below 1 Ω D4-3 - D4-4 Switch is not pushed in 10 kΩ or higher NG I044044E03 REPLACE CENTER DIFFERENTIAL LOCK SWITCH OK 6 INSPECT 4WD CONTROL ECU (a) Check the select high-low system (See page TF-43) or the select 2-4 and high-low system (See page TF-46). NG OK REPLACE 4WD CONTROL ECU BC BC–146 7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (4WD CONTROL ECU - CENTER DIFFERENTIAL LOCK SWITCH) (a) Disconnect the 4WD control ECU (F9) connector and center diff. lock switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance 4WD Control ECU Harness View: F9-16 (DL) NG Center Diff. Lock Switch Harness Side Connector Front View: Tester Connection Specified Condition F9-16 (DL) - D4-3 Below 1 Ω F9-16 (DL) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR D4 BC I045789E02 OK 8 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - 4WD CONTROL ECU) (a) Disconnect the 4WD control ECU (F10) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-27 (EXI) - F10-22 (P1) Below 1 Ω S28-27 (EXI) - Body ground 10 kΩ or higher OK EXI 4WD Control ECU Harness View: F10-22 (P1) I045768E02 Go to step 12 BC–147 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR 9 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - 4WD CONTROL ECU) (a) Disconnect the 4WD control ECU (F9) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-10 (NEO) - F9-20 (IND2) Below 1 Ω S28-10 (NEO) - Body ground 10 kΩ or higher NG NEO REPAIR OR REPLACE HARNESS OR CONNECTOR 4WD Control ECU Harness View: BC F9-20 (IND2) I046170E02 OK BC–148 10 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-10 (NEO) - C11-6 Below 1 Ω S28-10 (NEO) - Body ground 10 kΩ or higher S28 NEO NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C11-6 BC I045338E14 OK 11 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG REPLACE COMBINATION METER ASSEMBLY OK 12 RECONFIRM DTC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B END BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–149 A REPLACE MASTER CYLINDER SOLENOID BC BC–212 BRAKE CONTROL – REAR SPEED SENSOR REAR SPEED SENSOR BRAKE CONTROL COMPONENTS BC SPEED SENSOR REAR LH C119747E02 BRAKE CONTROL – REAR SPEED SENSOR BC–213 REMOVAL HINT: Replacement of RH side is same as that of LH side. 1. REMOVE REAR WHEEL 2. REMOVE SPEED SENSOR REAR LH (a) Disconnect the speed sensor connector. F043111 (b) Remove the nut and speed sensor rear from the axle hub. NOTICE: • Do not stick and foreign matter on the sensor tip. • Do not let the foreign matter into the sensor installation hole. F043113 INSTALLATION 1. INSTALL SPEED SENSOR REAR LH (a) Install the rear speed sensor with the nut to the steering knuckle. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) NOTICE: Make sure the sensor tip is clean. F043113 (b) Connect the speed sensor connector. F043111 2. INSTALL REAR WHEEL Torque: 110 N*m (1.122 kgf*cm, 81 ft.*lbf) 3. CHECK VSC SENSOR SIGNAL HINT: (See page BC-23) BC BC–150 DTC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM C1380/64 Stop Light Control Relay Malfunction DESCRIPTION Upon receiving the downhill assist control or hill-start assist control operating signal from the skid control ECU, the relay contact turns on and the stop light comes on. DTC No. DTC Detection Condition • C1380/64 BC • When the voltage at the IG1 terminal is between 10 V and 14 V and the stop light driving output (STPO) is on, a signal has not been input to the STP terminal for 5 seconds or more. When the voltage at the IG1 terminal is between 10 V and 14 V and the stop light driving output (STPO) is off, the input signal at the STP is different from the input signal at the STP2 for 5 seconds or more. Trouble Area • • Stop light operation relay Stop light operation relay circuit BC–151 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM WIRING DIAGRAM Master Cylinder Solenoid Stop Light Switch 45 S28 1 2 STP2 4 7 5 3 1 2 S28 STP 16 S28 STPO BC Stop Light Operation (STOP LP CTRL) 2 STOP IG1 1 Rear Combination Light LH 6 STOP 1 from Ignition Switch Rear Combination Light RH from Battery 6 STOP 1 to High Mounted Stop Light C132920E07 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–152 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK STOP LIGHT SWITCH OPERATION (a) Check that the stop light comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK: Stop light switch function is normal. HINT: Check the stop light bulb as it may have burnt out. NG Go to step 9 OK 2 INSPECT SKID CONTROL ECU (STP TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: BC S28 STP Tester Connection Condition Specified Condition S28-7 (STP) - Body ground Stop light switch ON (Brake pedal depressed) 8 to 14 V S28-7 (STP) - Body ground Stop light switch OFF (Brake pedal released) Below 1.5 V NG C121700E86 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (STP CIRCUIT) BC–153 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 3 INSPECT SKID CONTROL ECU (STP2 TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: STP Tester Connection Specified Condition S28-7 (STP) - S28-45 (STP2) Below 1 Ω S28 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STP2 CIRCUIT) STP2 C121700E87 OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (STOP LIGHT OPERATION RELAY) (a) Reconnect the skid control ECU connector. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (d) Select "ACTIVE TEST" mode on the intelligent tester. Item STOP LIGHT RELAY Vehicle Condition / Test Details Turns stop light operation relay ON / OFF Diagnostic Note Observe rear combination light (Does not come on for 5 sec. or more) (e) Check that "ON" and "OFF" of the stop light can be shown on the rear combination light by the intelligent tester. OK: The stop light turns on or off in accordance with the intelligent tester. OK NG Go to step 8 BC BC–154 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT STOP LIGHT OPERATION RELAY (POWER SOURCE TERMINAL) (a) Remove the stop light operation relay. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room R/B: Stop Light Operation Relay Tester Connection Specified Condition 1 - Body ground 8 to 14 V 5 - Body ground 8 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) I045958E01 OK BC 6 INSPECT STOP LIGHT OPERATION RELAY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (When battery positive voltage is applied to terminal 1 and battery negative voltage to terminal 2.) 3-5 Below 1 Ω (When battery positive voltage is applied to terminal 1 and battery negative voltage to terminal 2.) F052359E01 NG OK REPLACE STOP LIGHT OPERATION RELAY BC–155 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 7 INSPECT SKID CONTROL ECU (STPO TERMINAL) (a) (b) (c) (d) Skid Control ECU Harness Side Connector Front View: STPO S28 Instal the stop light operation relay. Disconnect the skid control ECU connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Specified Condition S28-16 (STPO) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STPO CIRCUIT) C121700E88 OK 8 RECONFIRM DTC BC (a) Clear the DTC (See page BC-39). (b) Check if the same DTC is detected (See page BC-39). HINT: Reinstall the sensors, connectors, etc. and restore the previous vehicle conditions before rechecking for DTCs. Result Condition Proceed to DTC is output A DTC is not output B B A REPLACE MASTER CYLINDER SOLENOID END BC–156 9 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT STOP LIGHT SWITCH ASSEMBLY (POWER SOURCE TERMINAL) (a) Disconnect the stop light switch connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Stop Light Switch Harness Side Connector Front View:  S12    Tester Connection Condition Specified Condition S12-2 Body ground Always 10 to 14 V NG C124801E03 REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK 10 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance BC 2 1 Tester connection Condition Specified condition S12-1 - S12-2 Switch pin free Below 1 Ω S12-1 - S12-2 Switch pin pushed in 10 kΩ or higher NG Pushed in 3 4 Free S12 C124796E07 OK REPLACE STOP LIGHT SWITCH ASSEMBLY BC–157 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 11 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH - STOP LIGHT OPERATION RELAY) (a) Remove the stop light operation relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stop Light Switch Harness Side Connector Front View: Tester Connection S12 Specified Condition S12-1 - 4 Below 1 Ω S12-1 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Engine Room R/B: Stop Light Operation Relay BC I046068E02 OK 12 INSPECT STOP LIGHT OPERATION RELAY (a) Measure the resistance according to the value(s) in the table below. Standard resistance NG F052359E01 OK Tester Connection Specified Condition 3-4 Below 1 Ω REPLACE STOP LIGHT OPERATION RELAY BC–158 13 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (REAR COMBINATION LIGHT - STOP LIGHT OPERATION RELAY) Rear Combination Light Harness Side Connector Front View: (a) Disconnect the rear combination light connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: LH R14 :LH R15 :RH Tester Connection Specified Condition R14-1 - 3 Below 1 Ω R14-1 - Body ground 10 kΩ or higher R14-6 - Body ground Below 1 Ω RH Engine Room R/B: Stop Light Operation Relay BC I046069E04 OK END NG Tester Connection Specified Condition R15-1 - 3 Below 1 Ω R15-1 - Body ground 10 kΩ or higher R15-6 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–159 DTC U0073/94 Control Module Communication Bus OFF DTC U0100/65 Lost Communication with ECM / PCM DTC U0123/62 Lost Communication with Yaw Rate Sensor Module DTC U0124/95 Lost Communication with Lateral Acceleration Sensor Module DTC U0126/63 Lost Communication with Steering Angle Sensor Module INSPECTION PROCEDURE Refer to CAN communication system (See page CA-6). BC BC–160 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM ABS Warning Light Remains ON DESCRIPTION If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the harness between the combination meter and skid control ECU. HINT: There is a case that the intelligent tester cannot be used when the skid control ECU is abnormal. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 4 ECU-IG BC ABS GAUGE 29 S28 WA 46 S28 IG1 from Ignition Switch 15 1 S28 GND1 32 S28 GND2 4 S29 GND3 C132925E04 BC–161 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU OK 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM BC OK 3 INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-46 (IG1) -Body ground 10 to 14 V S28 NG IG1 C121700E89 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) BC–162 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Disconnect the skid control ECU (S29) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 GND1 Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG GND2 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) S29 GND3 BC C124799E17 OK 5 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-29 (WA) - C11-4 Below 1 Ω S28-29 (WA) - Body ground 10 kΩ or higher S28 WA NG Combination Meter (Right Side of the Vehicle) Connector Front View: C11-4 I045766E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6 BC–163 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG REPLACE COMBINATION METER ASSEMBLY OK REPLACE MASTER CYLINDER SOLENOID BC BC–164 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM ABS Warning Light does not Come ON DESCRIPTION If any of the following is detected, the ABS warning light remains on. • The skid control ECU connectors are disconnected from the skid control ECU. • There is a malfunction in the skid control ECU internal circuit. • There is an open in the harness between the combination meter and skid control ECU. HINT: There is a case that the intelligent tester cannot be used when the skid control ECU is abnormal. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 4 ECU-IG BC ABS GAUGE 29 S28 WA 46 S28 IG1 from Ignition Switch 15 1 S28 GND1 32 S28 GND2 4 S29 GND3 C132925E05 BC–165 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT ABS WARNING LIGHT (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Check that the ABS warning light comes on. OK: ABS warning light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-29 (WA) - C11-4 Below 1 Ω S28-29 (WA) - Body ground 10 kΩ or higher S28 WA NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C11-4 I045766E04 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK END REPLACE COMBINATION METER ASSEMBLY BC BC–166 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM VSC TRAC Warning Light Remains ON DESCRIPTION If the skid control ECU stores DTCs to shut down VSC and TRAC operation, the VSC TRAC warning light comes on in the combination meter. WIRING DIAGRAM Master Cylinder Solenoid Combination Meter Assembly 36 S28 18 VSCW VSC TRAC BC GAUGE 15 from Ignition Switch C132926E08 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. BC–167 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM NG CONNECT CONNECTOR TO ECU OK 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the skid control ECU connector and combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection VSCW S28 Combination Meter (Right Side of the Vehicle) Connector Front View: Specified Condition S28-36 (VSCW) - C10-18 Below 1 Ω S28-36 (VSCW) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR C10-18 I045338E15 OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE MASTER CYLINDER SOLENOID REPLACE COMBINATION METER ASSEMBLY BC BC–168 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM VSC TRAC Warning Light does not Come ON DESCRIPTION If the skid control ECU stores DTCs to shut down VSC and TRAC operation, the VSC TRAC warning light comes on in the combination meter. WIRING DIAGRAM Master Cylinder Solenoid Combination Meter Assembly 36 S28 18 VSCW VSC TRAC BC GAUGE 15 from Ignition Switch C132926E09 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT VSC TRAC WARNING LIGHT (a) (b) (c) (d) Disconnect the skid control ECU connector. Ground terminal VSCW of the skid control ECU. Turn the ignition switch to the ON position. Check that the VSC TRAC warning light comes on. BC–169 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK: VSC TRAC warning light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: VSCW S28 Tester Connection Specified Condition S28-36 (VSCW) - C10-18 Below 1 Ω S28-36 (VSCW) - Body ground 10 kΩ or higher NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR BC C10-18 I045338E16 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK END REPLACE COMBINATION METER ASSEMBLY BC–170 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Brake Warning Light Remains ON DESCRIPTION The BRAKE warning light comes on when brake fluid is insufficient, the parking brake is applied or the EBD is defective. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 19 C8 ECU-IG BRAKE 3 S29 BRL 46 S28 IG1 28 S28 PKB 41 S28 LBL 1 S28 GND1 32 S28 GND2 4 S29 GND3 Parking Brake Switch 1 BC 15 GAUGE from Ignition Switch C10 Brake Fluid Level Warning Switch 1 2 C149936E01 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–171 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 CHECK DTC (a) Check the DTCs (See page BC-39). Result Condition Proceed to DTC is not output A DTC is output B B REPAIR CIRCUIT INDICATED BY OUTPUT DTC A 2 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU OK 3 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG OK INSPECT CHARGING SYSTEM BC BC–172 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (IG1 TERMINAL) (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Specified Condition S28-46 (IG1) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 CIRCUIT) IG1 C121700E90 OK BC 5 INSPECT SKID CONTROL ECU (GND TERMINAL) (a) Disconnect the skid control ECU (S29) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: GND1 GND2 S28 S29 GND3 C124799E20 OK Tester Connection Specified Condition S28-1 (GND1) - Body ground Below 1 Ω S28-32 (GND2) - Body ground Below 1 Ω S29-4 (GND3) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT) BC–173 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance P4 Free Tester Connection Condition Specified Condition P4-1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω P4-1 - Body ground Parking brake switch OFF (Switch pin pushed in) 10 kΩ or higher Pushed in I044058E01 NG REPLACE PARKING BRAKE SWITCH OK 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - PARKING BRAKE SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection S28-28 (PKB) - P4-1 Below 1 Ω S28-28 (PKB) - Body ground 10 kΩ or higher NG PKB Parking Brake Switch Harness Side Connector Front View: P4 1 C124797E05 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BC BC–174 8 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S29 Tester Connection Specified Condition S29-3 (BRL) - C8-19 Below 1 Ω S29-3 (BRL) - Body ground 10 kΩ or higher NG BRL Combination Meter (Left Side of the Vehicle) Connector Front View: BC REPAIR OR REPLACE HARNESS OR CONNECTOR C8-19 I045767E04 OK 9 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE MASTER CYLINDER SOLENOID REPLACE COMBINATION METER ASSEMBLY BC–175 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Brake Warning Light does not Come ON DESCRIPTION The BRAKE warning light comes on when brake fluid is insufficient, the parking brake is applied or the EBD is defective. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 19 C8 ECU-IG BRAKE 3 S29 BRL 46 S28 IG1 28 S28 PKB 41 S28 LBL 1 S28 GND1 32 S28 GND2 4 S29 GND3 Parking Brake Switch 1 15 GAUGE BC from Ignition Switch C10 Brake Fluid Level Warning Switch 1 2 C149936E02 BC–176 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT BRAKE WARNING LIGHT (a) Disconnect the skid control ECU (S29) connector. (b) Turn the ignition switch to the ON position. (c) Check that the BRAKE warning light comes on. OK: BRAKE warning light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V BC NG INSPECT CHARGING SYSTEM OK 3 INSPECT GAUGE FUSE (a) Remove the GAUGE fuse from the driver side J/B. (b) Check the GAUGE fuse. Standard resistance: Below 1 Ω NG OK REPLACE GAUGE FUSE BC–177 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Install the GAUGE fuse. (b) Disconnect the combination meter connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection S29 BRL Combination Meter (Right Side of the Vehicle) Connector Front View: C8-19 Specified Condition S29-3 (BRL) - C8-19 Below 1 Ω S29-3 (BRL) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC I045767E05 OK 5 INSPECT COMBINATION METER ASSEMBLY (a) Reconnect the skid control ECU (S29) connector and combination meter connector. (b) Check if the indicators (shift position, airbag etc.) other than BRAKE warning light operate normally. Result Condition Proceed to Indicators OK A Indicators NG B B A REPLACE COMBINATION METER ASSEMBLY GO TO COMBINATION METER SYSTEM BC–178 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM VSC OFF Indicator Light Remains ON DESCRIPTION When the center differential is locked, VSC control turns off and the VSC OFF indicator illuminates. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 17 35 S28 WT 27 S28 EXI VSC OFF GAUGE 15 from Ignition Switch BC 4WD Control ECU P1 22 Center Diff. Lock Switch DL 16 3 4 C132928E03 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 CHECK DTC (a) Check the DTCs (See page BC-39). Result Condition Proceed to DTC is not output A DTC is output B BC–179 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM B REPAIR CIRCUIT INDICATED BY OUTPUT DTC A 2 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU OK 3 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM BC OK 4 INSPECT SKID CONTROL ECU (EXI TERMINAL) (a) (b) (c) (d) Skid Control ECU Harness Side Connector Front View: S28 Transfer is in 4WD mode (Multi Mode 4WD only). Disconnect the skid control ECU connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition S28-27 (EXI) - Body ground Center diff. free 10 to 14 V NG EXI C121700E91 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EXI CIRCUIT) BC–180 5 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-35 (WT) - C10-17 Below 1 Ω S28-35 (WT) - Body ground 10 kΩ or higher S28 WT NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C10-17 BC I045338E17 OK 6 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE MASTER CYLINDER SOLENOID REPLACE COMBINATION METER ASSEMBLY BC–24 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM TEST MODE PROCEDURE 1. DLC3: BC TEST MODE (SIGNAL CHECK) PROCEDURE (SST CHECK WIRE) When having replaced the master cylinder solenoid and/ or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from the ON to the ACC or LOCK position during test mode, DTCs of the signal check function will be erased. • During test mode, the ECU records all DTCs of the signal check function. By performing the signal check, the codes are erased if normality is confirmed. The codes left over are the codes where an abnormality was found. (a) Turn the ignition switch off. (b) Check that the steering wheel is in the straightahead position and move the shift lever to the P position. (c) Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 (d) Turn the ignition switch to the ON position. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS F100115E01 (e) Check that the ABS and VSC TRAC warning lights blink in test mode. HINT: If the ABS and VSC TRAC warning lights do not blink, inspect the TS and CG terminal circuit and the ABS and VSC TRAC warning light circuits. Test Mode: 0.13 sec. 0.13 sec. ON Trouble Area TS and CG terminal circuit OFF See procedure BC-207 ABS warning light circuit BC-157 or BC-161 VSC TRAC warning light circuit BC-163 or BC-165 BR03904E52 (f) Start the engine. (g) Using a check wire, perform the ABS sensor (acceleration sensor, master cylinder pressure sensor, center diff. lock detection switch, L4 detection switch and speed sensor) and VSC sensor (yaw rate sensor and downhill assist control operation switch) signal checks in test mode (ABS sensor: See procedure "A" to "F", VSC sensor: See procedure "G" to "I"). BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 2. ACCELERATION SENSOR SIGNAL CHECK (SST CHECK WIRE) (Procedure "A") (a) Check that the ABS warning light is blinking in test mode. (b) Keep the vehicle in a stationary condition on a level surface for 1 second or more. 3. MASTER CYLINDER PRESSURE SENSOR SIGNAL CHECK (SST CHECK WIRE) (Procedure "B") (a) Check that the ABS warning light is blinking in test mode. (b) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second or more. HINT: • At this time, the ABS warning light stays on for 3 seconds. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time the brake pedal operation above is performed. Test Mode: 0.13 sec. BC–25 0.13 sec. ON OFF BR03904E52 Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 4. CENTER DIFF. LOCK DETECTION SWITCH SIGNAL CHECK (4WD) (SST CHECK WIRE) (Procedure "C") (a) Check that the ABS warning light is blinking in test mode. (b) Check the center diff. lock switch. (1) Push the center diff. lock switch on to lock the center differential. (2) Push the center diff. lock switch off to unlock the center differential. 5. L4 DETECTION SWITCH SIGNAL CHECK (4WD) (SST CHECK WIRE) (Procedure "D") (a) Check that the ABS warning light is blinking in test mode. (b) Check the 4WD control (L4) switch. (1) Turn the H-L switch to the L position to put the vehicle in L4 mode. (2) Turn the H-L switch to the H position to put the vehicle in H4 mode. Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 BC BC–26 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6. SPEED SENSOR SIGNAL CHECK (SST CHECK WIRE) (Procedure "E") (a) Check that the ABS warning light is blinking in test mode. (b) Check the backward signal. (1) Drive the vehicle in reverse for more than 1 second at 2 mph (3 km/h) or higher. HINT: Drive the vehicle in reverse and check the speed sensor signal. Note that the signal check cannot be completed if the vehicle speed is 28 mph (45 km/h) or more. (c) Check the forward signal. (1) Drive the vehicle straight forward. Drive the vehicle at a speed of 28 mph (45 km/h) or higher for several seconds and check that the ABS warning light goes off. HINT: The signal check may not be completed if the vehicle has its wheels spun or the steering wheel turned during this check. (d) Stop the vehicle. NOTICE: • Before performing the speed sensor signal check, complete the acceleration sensor, master cylinder pressure sensor, center diff. lock detection switch and L4 detection switch signal checks. • The speed sensor signal check may not be completed if the speed sensor signal check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off, if the vehicle speed exceeds 50 mph (80 km/h), signal check code will be stored again. Decelerate or stop before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. HINT: When the signal check has been completed, the ABS warning light goes off while driving and blinks in the test mode pattern while stationary. 7. READ DTC OF ABS SENSOR (SST CHECK WIRE) (Procedure "F") (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (b) Read the number of blinks of the ABS warning light. HINT: • See the list of DTC (See procedure "J"). Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 BC DLC3: CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E02 BC–27 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM • If every sensor is normal, the normal system code is output. (A cycle of 0.25 second ON and 0.25 second OFF is repeated.) • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. Trouble Code (Example Codes 72 and 76): 1.5 sec. 0.5 sec. 2.5 sec. 0.5 sec. 4 sec. Repeat ON OFF Code 72 Code 76 I042842E04 (c) After the check, disconnect the SST from terminals TC and CG of the DLC3. 8. Test Mode: 0.13 sec. 0.13 sec. ON YAW RATE SENSOR SIGNAL CHECK (SST CHECK WIRE) (Procedure "G") (a) Check that the VSC TRAC warning light is blinking in test mode. (b) Check the zero point voltage of the yaw rate sensor. (1) Keep the vehicle in a stationary condition on a level surface for 1 second or more. OFF BR03904E52 Start Position Within +- 5ᶟ End Position F002135E16 (c) Check the output of the yaw rate sensor and the direction of the steering angle sensor. (1) Shift the shift lever to the D position and drive the vehicle at a vehicle speed of approximately 3 mph (5 km/h), turn the steering wheel either to the left or right 90° or more, and turn the vehicle through 180 degrees. (2) Stop the vehicle and shift the shift lever to the P position. Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the signal check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-200), then perform the signal check again. • If the skid control buzzer still will not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Drive the vehicle in a 180° circle. At the end of the turn, the direction of the vehicle should be within 180°+- 5° of its start position. • Do not spin the wheels. BC BC–28 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 9. Test Mode: 0.13 sec. 0.13 sec. ON OFF DOWNHILL ASSIST CONTROL OPERATION SWITCH SIGNAL CHECK (4WD) (SST CHECK WIRE) (Procedure "H") (a) Check that the VSC TRAC warning light is blinking in test mode. (b) Check the downhill assist control switch. (1) Push the downhill assist control switch on. (2) Push the downhill assist control switch off. BR03904E52 DLC3: CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E02 BC Trouble Code (Example Codes 71 and 72): 10. READ DTC OF VSC SENSOR (SST CHECK WIRE) (Procedure "I") (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (b) Read the number of blinks of the VSC TRAC warning light. HINT: • See the list of DTC (See procedure "J"). • If every sensor is normal, the normal system code is output. (A cycle of 0.25 second ON and 0.25 second OFF is repeated.) • If more than 1 malfunction is detected at the same time, the lowest numbered code will be displayed first. 1.5 sec. 2.5 sec. 0.5 sec. 0.5 sec. 4 sec. Repeat ON OFF Code 71 Code 72 I042841E01 (c) After performing the check, disconnect the SST from terminals TS and CG, TC and CG of the DLC3 and turn the ignition switch off. 11. DTC OF SIGNAL CHECK FUNCTION (SST CHECK WIRE) (Procedure "J") ABS sensor: Code No. Diagnosis Trouble Area C1271/71 Low output voltage of right front speed sensor • • • Right front speed sensor Sensor installation Speed sensor rotor C1272/72 Low output voltage of left front speed sensor • • • Left front speed sensor Sensor installation Speed sensor rotor C1273/73 Low output voltage of right rear speed sensor • • • Right rear speed sensor Sensor installation Speed sensor rotor C1274/74 Low output voltage of left rear speed sensor • • • Left rear speed sensor Sensor installation Speed sensor rotor BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Code No. Diagnosis C1275/75 Abnormal change in output voltage of right front speed sensor Speed sensor rotor C1276/76 Abnormal change in output voltage of left front speed sensor Speed sensor rotor C1277/77 Abnormal change in output voltage of right rear speed sensor Speed sensor rotor C1278/78 Abnormal change in output voltage of left rear speed sensor Speed sensor rotor C1279/79 Acceleration sensor is faulty Yaw rate and acceleration sensor C1281/81 Master cylinder pressure sensor output signal is faulty Master cylinder pressure sensor C1282/82 1) Center differential lock position switch malfunction Center diff. lock switch C1283/83 (*1) L4 position switch malfunction 4WD control (L4) switch (* BC–29 Trouble Area (*1): 4WD VSC sensor: Code No. Diagnosis Trouble Area C0371/71 Yaw rate sensor output signal malfunction Yaw rate and acceleration sensor C1379/74 Malfunction in downhill assist control operation switch Downhill assist control switch HINT: The codes in this table are output only in test mode (signal check). 12. TEST MODE (SIGNAL CHECK) PROCEDURE (INTELLIGENT TESTER) When having replaced the master cylinder solenoid and/ or yaw rate and acceleration sensor, perform zero point calibration of the yaw rate and acceleration sensor. HINT: • If the ignition switch is turned from the ON to the ACC or LOCK position during test mode, DTCs of the signal check function will be erased. • During test mode, the ECU records all DTCs of the signal check function. By performing the signal check, the codes are erased if normality is confirmed. The codes left over are the codes where an abnormality was found. (a) Turn the ignition switch off. (b) Check that the steering wheel is in the straightahead position and move the shift lever to the P position. Intelligent Tester DLC3 I042828E01 (c) Connect the intelligent tester to the DLC3. (d) Turn the ignition switch to the ON position. BC BC–30 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (e) Operate the intelligent tester in test mode ("SIGNAL CHECK"). I044074 (f) Test Mode: 0.13 sec. 0.13 sec. ON Check that the ABS and VSC TRAC warning lights blink in test mode. HINT: If the ABS and VSC TRAC warning lights do not blink, inspect the TS and CG terminal circuit and the ABS and VSC TRAC warning light circuits. Trouble Area TS and CG terminal circuit OFF See procedure BC-207 ABS warning light BC-157 or BC-161 VSC TRAC warning light BC-163 or BC-165 BR03904E52 BC (g) Start the engine. (h) Using the intelligent tester, perform the ABS sensor (acceleration sensor, master cylinder pressure sensor, center diff. lock detection switch, L4 detection switch and speed sensor) and VSC sensor (yaw rate sensor and downhill assist control operation switch) signal checks in test mode (ABS sensor: See procedure "K" to "P", VSC sensor: See procedure "Q" to "S"). 13. ACCELERATION SENSOR SIGNAL CHECK (INTELLIGENT TESTER) (Procedure "K") (a) Check that the ABS warning light is blinking in test mode. (b) Keep the vehicle in the stationary condition on a level surface for 1 second or more. Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 14. MASTER CYLINDER PRESSURE SENSOR SIGNAL CHECK (INTELLIGENT TESTER) (Procedure "L") (a) Check that the ABS warning light is blinking in test mode. Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–31 (b) Leave the vehicle in a stationary condition and release the brake pedal for 1 second or more, and quickly depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second or more. HINT: • At this time, the ABS warning light stays on for 3 seconds. • While the ABS warning light stays on, continue to depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more. • The ABS warning light comes on for 3 seconds every time the brake pedal operation above is performed. Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 16. L4 DETECTION SWITCH SIGNAL CHECK (4WD) (INTELLIGENT TESTER) (Procedure "N") (a) Check that the ABS warning light is blinking in test mode. (b) Check the 4WD control (L4) switch. (1) Turn the H-L switch to the L position to put the vehicle in L4 mode. (2) Turn the H-L switch to the H position to put the vehicle in H4 mode. Test Mode: 0.13 sec. 15. CENTER DIFF. LOCK DETECTION SWITCH SIGNAL CHECK (4WD) (INTELLIGENT TESTER) (Procedure "M") (a) Check that the ABS warning light is blinking in test mode. (b) Check the center diff. lock switch. (1) Push the center diff. lock switch on to lock the center differential. (2) Push the center diff. lock switch off to unlock the center differential. 0.13 sec. ON OFF BR03904E52 Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E56 17. SPEED SENSOR SIGNAL CHECK (INTELLIGENT TESTER) (Procedure "O") (a) Check that the ABS warning light is blinking in test mode. (b) Check the backward signal. (1) Drive the vehicle in reverse for more than 1 second at 2 mph (3 km/h) or higher. HINT: Drive the vehicle in reverse and check the speed sensor signal. Note that the signal check cannot be completed if the vehicle speed is 28 mph (45 km/h) or more. BC BC–32 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (c) Check the forward signal. (1) Drive the vehicle straight forward. Drive the vehicle at a speed of 28 mph (45 km/h) or higher for several seconds and check that the ABS warning light goes off. HINT: The signal check may not be completed if the vehicle has its wheels spun or the steering wheel turned during this check. (d) Stop the vehicle. NOTICE: • Before performing the speed sensor signal check, complete the acceleration sensor, master cylinder pressure sensor, center diff. lock detection switch and L4 detection switch signal checks. • The speed sensor signal check may not be completed if the speed sensor signal check is started while turning the steering wheel or spinning the wheels. • After the ABS warning light goes off, if the vehicle speed exceeds 50 mph (80 km/h), a signal check code will be stored again. Decelerate or stop before the speed reaches 50 mph (80 km/h). • If the signal check has not been completed, the ABS warning light blinks while driving and the ABS system does not operate. HINT: When the signal check has been completed, the ABS warning light goes off while driving and blinks in the test mode pattern while stationary. 18. READ DTC OF ABS SENSOR (INTELLIGENT TESTER) (Procedure "P") (a) Read the DTC(s) by following the tester screen. HINT: • Refer to the intelligent tester operator's manual for further details. • See the list of DTC (See procedure "T"). BC 19. YAW RATE SENSOR SIGNAL CHECK (INTELLIGENT TESTER) (Procedure "Q") (a) Check that the VSC TRAC warning light is blinking in test mode. (b) Check the zero point voltage of the yaw rate sensor. (1) Keep the vehicle in a stationary condition on a level surface for 1 second or more. Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (c) Check the output of the yaw rate sensor and the direction of the steering angle sensor. (1) Shift the shift lever to the D position and drive the vehicle at a vehicle speed of approximately 3 mph (5 km/h), turn the steering wheel either to the left or right 90° or more, and turn the vehicle through 180 degrees. (2) Stop the vehicle and shift the shift lever to the P position. Check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the signal check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (See page BC-200), then perform the signal check again. • If the skid control buzzer still will not sound, there is a malfunction in the yaw rate sensor, so check the DTC. • Drive the vehicle in a 180° circle. At the end of the turn, the direction of the vehicle should be within 180°+- 5° of its start position. • Do not spin the wheels. Start Position Within +- 5ᶟ End Position F002135E16 Test Mode: 0.13 sec. 0.13 sec. ON OFF BR03904E52 20. DOWNHILL ASSIST CONTROL OPERATION SWITCH SIGNAL CHECK (4WD) (INTELLIGENT TESTER) (Procedure "R") (a) Check that the VSC TRAC warning light is blinking in test mode. (b) Check the downhill assist control switch. (1) Push the downhill assist control switch on. (2) Push the downhill assist control switch off. 21. READ DTC OF VSC SENSOR (INTELLIGENT TESTER) (Procedure "S") (a) Read the DTC(s) by following the tester screen. HINT: • Refer to the intelligent tester operator's manual for further details. • See the list of DTC (See procedure "T"). 22. DTC OF SIGNAL CHECK FUNCTION (INTELLIGENT TESTER) (Procedure "T") ABS sensor: Code No. BC–33 Diagnosis Trouble Area C1271/71 Low output voltage of right front speed sensor • • • Right front speed sensor Sensor installation Speed sensor rotor C1272/72 Low output voltage of left front speed sensor • • • Left front speed sensor Sensor installation Speed sensor rotor C1273/73 Low output voltage of right rear speed sensor • • • Right rear speed sensor Sensor installation Speed sensor rotor C1274/74 Low output voltage of left rear speed sensor • • • Left rear speed sensor Sensor installation Speed sensor rotor BC BC–34 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Code No. Diagnosis C1275/75 Abnormal change in output voltage of right front speed sensor Speed sensor rotor C1276/76 Abnormal change in output voltage of left front speed sensor Speed sensor rotor C1277/77 Abnormal change in output voltage of right rear speed sensor Speed sensor rotor C1278/78 Abnormal change in output voltage of left rear speed sensor Speed sensor rotor C1279/79 Acceleration sensor is faulty Yaw rate and acceleration sensor C1281/81 Master cylinder pressure sensor output signal is faulty Master cylinder pressure sensor C1282/82 1) Center differential lock position switch malfunction Center diff. lock switch C1283/83 (*1) L4 position switch malfunction 4WD control (L4) switch (* Trouble Area (*1): 4WD VSC sensor: Code No. Diagnosis Trouble Area C0371/71 Yaw rate sensor output signal malfunction Yaw rate and acceleration sensor C1379/74 Malfunction in downhill assist control operation switch Downhill assist control switch HINT: The codes in this table are output only in test mode (signal check). BC BC–181 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM VSC OFF Indicator Light does not Come ON DESCRIPTION When the center differential is locked, VSC control turns off and the VSC OFF indicator illuminates. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 35 S28 17 WT VSC OFF GAUGE 15 from Ignition Switch BC 4WD Control ECU P1 27 S28 22 EXI Center Diff. Lock Switch DL 16 4 3 C132928E04 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT VSC OFF INDICATOR LIGHT (a) (b) (c) (d) Disconnect the skid control ECU connector. Ground terminal WT of the skid control ECU. Turn the ignition switch to the ON position. Check that the VSC OFF indicator light comes on. OK: VSC OFF indicator light comes on. BC–182 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-35 (WT) - C10-17 Below 1 Ω S28-35 (WT) - Body ground 10 kΩ or higher S28 WT NG Combination Meter (Right Side of the Vehicle) Connector Front View: BC REPAIR OR REPLACE HARNESS OR CONNECTOR C10-17 I045338E18 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK END REPLACE COMBINATION METER ASSEMBLY BC–183 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Slip Indicator Light Remains ON DESCRIPTION The SLIP indicator blinks during VSC, TRAC, A-TRAC, AUTO LSD, downhill assist control or hill-start assist control operation. When the system fails, the SLIP indicator comes on to warn the driver (See page BC-38). WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 34 S28 20 IND BC SLIP GAUGE 15 from Ignition Switch C132926E06 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. BC–184 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM NG CONNECT CONNECTOR TO ECU OK 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the skid control ECU connector and combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection BC IND S28 Combination Meter (Right Side of the Vehicle) Connector Front View: Specified Condition S28-34 (IND) - C10-20 Below 1 Ω S28-34 (IND) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR C10-20 I045338E19 OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE MASTER CYLINDER SOLENOID REPLACE COMBINATION METER ASSEMBLY BC–214 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR YAW RATE AND ACCELERATION SENSOR BRAKE CONTROL COMPONENTS BC YAWRATE SENSOR C131293E01 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR BC–215 CONSOLE UPPER PANEL GARNISH NO. 1 CONSOLE UPPER PANEL GARNISH NO. 2 CONSOLE UPPER REAR PANEL SUB-ASSEMBLY CONSOLE PANEL SUB-ASSEMBLY UPPER BC CONSOLE BOX ASSEMBLY REAR B120191E03 BC–185 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Slip Indicator Light does not Come ON DESCRIPTION The SLIP indicator blinks during VSC, TRAC, A-TRAC, AUTO LSD, downhill assist control or hill-start assist control operation. When the system fails, the SLIP indicator comes on to warn the driver (See page BC-38). WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 34 S28 20 IND BC SLIP GAUGE 15 from Ignition Switch C132926E07 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT SLIP INDICATOR LIGHT (a) (b) (c) (d) Disconnect the skid control ECU connector. Ground terminal IND of the skid control ECU. Turn the ignition switch to the ON position. Check that the SLIP indicator light comes on. BC–186 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK: SLIP indicator light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: IND Tester Connection Specified Condition S28-34 (IND) - C10-20 Below 1 Ω S28-34 (IND) - Body ground 10 kΩ or higher S28 NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR BC C10-20 I045338E20 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK END REPLACE COMBINATION METER ASSEMBLY BC–187 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Downhill Assist Control Indicator Light Remains ON DESCRIPTION The downhill assist control indicator light comes on when the downhill assist control is ready (See page BC-6). HINT: Even if the downhill assist control switch is pressed, the downhill assist control indicator light will blink and downhill assist control will not be activated under the following conditions: • Transfer is in 2WD or H4 mode. • ABS system is malfunctioning. • Temperature of the hydraulic brake booster increases and downhill assist control is temporarily canceled. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 33 12 S28 HDCW 44 S28 HDCS BC Downhill Assist Control GAUGE 15 from Ignition Switch Downhill Assist Control Switch 4 3 C132929E06 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–188 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU OK 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK BC 3 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) Skid Control ECU Harness Side Connector Front View: S28 (a) Disconnect the skid control ECU connector and combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition S28-33 (HDCW) - C11-12 Below 1 Ω S28-33 (HDCW) - Body ground 10 kΩ or higher HDCW Combination Meter (Right Side of the Vehicle) Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR C11-12 I045338E30 OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). BC–189 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM NG REPLACE COMBINATION METER ASSEMBLY OK 5 INSPECT SKID CONTROL ECU (HDCS TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-44 (HDCS) - Body ground Downhill assist control switch is not pushed in 10 kΩ or higher OK REPLACE MASTER CYLINDER SOLENOID HDCS C121700E95 BC NG 6 INSPECT DOWNHILL ASSIST CONTROL SWITCH (a) Disconnect the downhill assist control switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Push-lock Type: Not Pushed in Pushed in Condition Specified Condition D5-3 - D5-4 Switch is pushed in Below 1 Ω D5-3 - D5-4 Switch is not pushed in 10 kΩ or higher D5 I044044E04 OK Tester Connection NG REPLACE DOWNHILL ASSIST CONTROL SWITCH BC–190 7 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - DOWNHILL ASSIST CONTROL SWITCH) Skid Control ECU Harness Side Connector Front View: S28 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Downhill Assist Control Switch Harness Side Connector Front View: END Below 1 Ω 10 kΩ or higher D5-4 - Body ground Below 1 Ω NG F052063E07 BC S28-44 (HDCS) - D5-3 S28-44 (HDCS) - Body ground HDCS D5 OK Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR BC–191 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Downhill Assist Control Indicator Light does not Come ON DESCRIPTION The downhill assist control indicator light comes on when the downhill assist control is ready (See page BC-6). HINT: Even if the downhill assist control switch is pressed, the downhill assist control indicator light will blink and downhill assist control will not be activated under the following conditions: • Transfer is in 2WD or H4 mode. • ABS system is malfunctioning. • Temperature of the hydraulic brake booster increases and downhill assist control is temporarily canceled. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 33 12 S28 HDCW 44 S28 HDCS BC Downhill Assist Control GAUGE 15 from Ignition Switch Downhill Assist Control Switch 4 3 C132929E07 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–192 1 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT DOWNHILL ASSIST CONTROL INDICATOR LIGHT (a) (b) (c) (d) Disconnect the skid control ECU connector. Ground terminal HDCW of the skid control ECU. Turn the ignition switch to the ON position. Check that the downhill assist control indicator light comes on. OK: downhill assist control indicator light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: BC Tester Connection Specified Condition S28-33 (HDCW) - C11-12 Below 1 Ω S28-33 (HDCW) - Body ground 10 kΩ or higher S28 HDCW NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C11-12 I045338E31 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 BC–193 INSPECT SKID CONTROL ECU (HDCS TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-44 (HDCS) - Body ground Downhill assist control switch is pushed in Below 1 Ω OK REPLACE MASTER CYLINDER SOLENOID HDCS C121700E92 NG 5 INSPECT DOWNHILL ASSIST CONTROL SWITCH (a) Disconnect the downhill assist control switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Push-lock Type: Not Pushed in Pushed in Tester Connection Condition Specified Condition D5-3 - D5-4 Switch is pushed in Below 1 Ω D5-3 - D5-4 Switch is not pushed in 10 kΩ or higher D5 I044044E04 OK BC NG REPLACE DOWNHILL ASSIST CONTROL SWITCH BC–194 6 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - DOWNHILL ASSIST CONTROL SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Downhill Assist Control Switch Harness Side Connector Front View: HDCS D5 F052063E08 OK BC END Specified Condition S28-44 (HDCS) - D5-3 Below 1 Ω S28-44 (HDCS) - Body ground 10 kΩ or higher D5-4 - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR BC–195 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM AUTO LSD Indicator Light Remains ON DESCRIPTION Engaging the AUTO LSD switch causes the AUTO LSD indicator light to come on when the AUTO LSD is ready (See page BC-6). The AUTO LSD will not operate even if the AUTO LSD switch is pressed under the following conditions: • TRAC and VSC system is faulty. • Temperature inside the hydraulic brake booster increases and the AUTO LSD is halted. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 15 17 S28 INFR AUTO LSD BC GAUGE 15 from Ignition Switch AUTO LSD Switch 4 3 43 S28 CSW C132929E08 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED (a) Check the skid control ECU Connector's connecting condition. BC–196 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU OK 2 INSPECT BATTERY (a) Check the battery voltage. Standard voltage: 11 to 14 V NG INSPECT CHARGING SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the skid control ECU connector and combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: BC S28 Tester Connection Specified Condition S28-15 (INFR) - C10-17 Below 1 Ω S28-15 (INFR) - Body ground 10 kΩ or higher INFR Combination Meter (Right Side of the Vehicle) Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR C10-17 I045338E23 OK 4 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-4). NG OK REPLACE COMBINATION METER ASSEMBLY BC–197 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 5 INSPECT SKID CONTROL ECU (CSW TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester Connection Condition Specified Condition S28-43 (CSW) - Body ground AUTO LSD switch is not pushed in 10 kΩ or higher OK REPLACE MASTER CYLINDER SOLENOID CSW C121700E93 NG 6 INSPECT AUTO LSD SWITCH (a) Disconnect the AUTO LSD switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Momentary Type: Not Pushed in Pushed in Tester Connection Condition Specified Condition A42-3 - A42-4 Switch is pushed in Below 1 Ω A42-3 - A42-4 Switch is not pushed in 10 kΩ or higher A42 I044055E05 OK BC NG REPLACE AUTO LSD SWITCH BC–198 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - AUTO LSD SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 AUTO LSD Switch Harness Side Connector Front View: A42 I045574E03 OK END Specified Condition Below 1 Ω S28-43 (CSW) - Body ground 10 kΩ or higher A42-4 - Body ground Below 1 Ω NG CSW BC Tester Connection S28-43 (CSW) - A42-3 REPAIR OR REPLACE HARNESS OR CONNECTOR BC–199 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM AUTO LSD Indicator Light does not Come ON DESCRIPTION Engaging the AUTO LSD switch causes the AUTO LSD indicator light to come on when the AUTO LSD is ready (See page BC-6). The AUTO LSD will not operate even if the AUTO LSD switch is pressed under the following conditions: • TRAC and VSC system is faulty. • Temperature inside the hydraulic brake booster increases and the AUTO LSD is halted. WIRING DIAGRAM Combination Meter Assembly Master Cylinder Solenoid 15 17 S28 INFR AUTO LSD BC GAUGE 15 from Ignition Switch AUTO LSD Switch 4 3 43 S28 CSW C132929E09 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 INSPECT AUTO LSD INDICATOR LIGHT (a) Disconnect the skid control ECU connector. (b) Ground terminal INFR of the skid control ECU. BC–200 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (c) Turn the ignition switch to the ON position. (d) Check that the AUTO LSD indicator light comes on. OK: AUTO LSD indicator light comes on. OK REPLACE MASTER CYLINDER SOLENOID NG 2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) (a) Disconnect the combination meter connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: Tester Connection Specified Condition S28-15 (INFR) - C10-17 Below 1 Ω S28-15 (INFR) - Body ground 10 kΩ or higher S28 INFR NG Combination Meter (Right Side of the Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR BC C10-17 I045338E24 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (see page ME-4). NG OK REPLACE COMBINATION METER ASSEMBLY BC–201 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 INSPECT SKID CONTROL ECU (CSW TERMINAL) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: S28 Tester connection Condition Specified Condition S28-43 (CSW) - Body ground Auto LSD switch is pushed in Below 1 Ω OK REPLACE MASTER CYLINDER SOLENOID CSW C121700E94 NG 5 INSPECT AUTO LSD SWITCH (a) Disconnect the AUTO LSD switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Momentary Type: Not Pushed in Pushed in Tester Connection Condition Specified Condition A42-3 - A42-4 Switch is pushed in Below 1 Ω A42-3 - A42-4 Switch is not pushed in 10 kΩ or higher A42 I044055E05 OK BC NG REPLACE AUTO LSD SWITCH BC–202 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - AUTO LSD SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: CSW AUTO LSD Switch Harness Side Connector Front View: A42 I045574E04 OK END Specified Condition Below 1 Ω S28-43 (CSW) - Body ground 10 kΩ or higher A42-4 - Body ground Below 1 Ω NG S28 BC Tester Connection S28-43 (CSW) - A42-3 REPAIR OR REPLACE HARNESS OR CONNECTOR BC–203 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds while the accumulator pressure is abnormally low or an abnormality causing low fluid pressure occurs, and then VSC is activated. WIRING DIAGRAM Master Cylinder Solenoid Skid Control Buzzer ECU-IG 2 1 30 S28 BZ from Ignition Switch BC C132930E06 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. (c) Select "ACTIVE TEST" mode on the intelligent tester. Item Vehicle Condition / Test Details VSC / BR WARN BUZ Turns skid control buzzer ON /OFF Diagnostic note Buzzer can be heard (d) Check that the buzzer sounds/stops when turning the skid control buzzer on/off by using the intelligent tester. Result Condition Proceed to Buzzer sounds/stops A Buzzer does not sound or sounds constantly B A END BC–204 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM B 2 INSPECT SKID CONTROL BUZZER (POWER SOURCE TERMINAL) (a) Disconnect the skid control buzzer connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Skid Control Buzzer Harness Side Connector Front View: Tester Connection Specified Condition V5-2 - Body ground 10 to 14 V V5 I044040E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK 3 BC INSPECT SKID CONTROL BUZZER 2 1 (+) (-) (a) Apply battery negative voltage to terminal 1, and battery positive voltage to terminal 2 of the skid control buzzer, and then check that the buzzer sounds. OK: Skid control buzzer sounds. NG F002192E15 OK REPLACE SKID CONTROL BUZZER BC–205 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 4 CHECK HARNESS AND CONNECTOR (SKID CONTROL BUZZER - SKID CONTROL ECU) (a) Disconnect the skid control ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Front View: BZ S28 Tester Connection Specified Condition S28-30 (BZ) - V5-1 Below 1 Ω S28-30 (BZ) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Skid Control Buzzer Harness Side Connector Front View: V5 C124803E04 OK REPLACE MASTER CYLINDER SOLENOID BC BC–206 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. The DTCs are displayed by blinking the ABS and VSC TRAC warning lights. WIRING DIAGRAM DLC3 Master Cylinder Solenoid ECM CANH TC 13 23 TC CANL BC CG 33 34 11 S28 CANH 25 S28 CANL 4 C114570E05 HINT: When each warning light stays blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in each ECU is suspected. INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). 1 DLC3: INSPECT DLC3 (DLC3 (TC) - DLC3 (CG)) (a) Turn the ignition switch to the ON position. (b) Measure the voltage according to the value(s) in the table below. Standard voltage CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 D1 OK NG TC F100115E45 Tester Connection Specified Condition D1-13 (TC) - D1-4 (CG) 10 to 14 V Go to step 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 2 BC–207 CHECK DTC (FOR CAN COMMUNICATION SYSTEM) (a) Check for CAN communication system DTC. Result Condition Proceed to DTC is not output A DTC is output B B REPAIR CAN COMMUNICATION SYSTEM A 3 DLC3: CHECK ECM (DLC3 (TC) INPUT) (a) Using SST, connect terminal TC and CG of the DLC3. SST 09843-18040 (b) Check if the engine warning light is blinking. OK: Engine warning light is blinking. CG 1 2 3 4 5 6 7 8 NG 9 10 11 12 13 14 15 16 D1 TC F100115E45 OK REPLACE MASTER CYLINDER SOLENOID REPLACE ECM BC BC–208 4 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (ECM - DLC3 (TC)) (a) Turn the ignition switch off. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Harness View: NG Tester Connection Specified Condition E8-23 (TC) - D1-13 (TC) Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR E8-23 (TC) BC DLC3: 1 2 3 4 5 6 7 8 D1 9 10 11 12 13 14 15 16 TC C140803E04 OK 5 CHECK HARNESS AND CONNECTOR (DLC3 (CG) - BODY GROUND) DLC3: D1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NG CG F100115E46 OK Tester Connection Specified Condition D1-4 (CG) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 6 BC–209 CHECK ECM (DLC3 (TC) INPUT) DLC3: (a) Using SST, connect terminals TC and CG of the DLC3. (b) Check if the engine warning light is blinking. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 D1 TC F100115E45 Result Condition Proceed to Engine warning light is blinking A Engine warning light is not blinking B B REPAIR OR REPLACE WIRE HARNESS OR ECM (TC AND/OR ECM CIRCUIT) A 7 BC CHECK DTC (FOR CAN COMMUNICATION SYSTEM) (a) Check for CAN communication system DTC. Result Condition Proceed to DTC is not output A DTC is output B B A REPLACE MASTER CYLINDER SOLENOID REPAIR CAN COMMUNICATION SYSTEM BC–210 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM TS and CG Terminal Circuit DESCRIPTION The signal check circuit detects trouble in the sensor or switch signal which cannot be detected by the DTC check. Connecting terminals TS and CG of the DLC3 starts the check. WIRING DIAGRAM Master Cylinder Solenoid DLC3 TS BC CG 12 24 S28 TS 4 C114571E07 INSPECTION PROCEDURE NOTICE: When replacing the master cylinder solenoid, perform zero point calibration (See page BC-20). BC–211 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 1 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - DLC3 (TS)) (a) Turn the ignition switch off. (b) Disconnect the skid control ECU connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Skid Control ECU Harness Side Connector Fornt View: NG S28 TS Tester Connection Specified condition S28-24 (TS) - D1-12 (TS) Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR DLC3: 1 2 3 4 5 6 7 8 D1 9 10 11 12 13 14 15 16 TS BC C124792E05 OK 2 CHECK HARNESS AND CONNECTOR (BODY GROUND - DLC3 (CG)) DLC3: D1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NG CG F100115E46 OK Tester Connection Specified condition D1-4 (CG) - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR BC–212 3 DLC3: BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (BODY GROUND - DLC3 (TS)) TS D1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NG F100115E47 OK REPLACE MASTER CYLINDER SOLENOID BC Tester Connection Specified Condition D1-12 (TS) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR BC–35 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM PROBLEM SYMPTOMS TABLE If there are no DTCs output but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing the master cylinder solenoid, sensor, etc., turn the ignition switch off. VEHICLE STABILITY CONTROL SYSTEM Symptom ABS, BA and/or EBD does not operate ABS, BA and/or EBD does not operate efficiently VSC and/or TRAC does not operate Sensor and switch signal check cannot be done DTC check cannot be performed ABS warning light abnormal (Remains on) ABS warning light abnormal (Does not come on) VSC TRAC warning light abnormal (Remains on) Suspected Area See page 1. Check the DTC again and make sure that the normal system code is output. BC-39 2. IG power source circuit BC-94 3. Front speed sensor circuit BC-53 4. Rear speed sensor circuit BC-62 5. Check the hydraulic brake booster using intelligent tester. If abnormal, check the hydraulic circuit for leakage BR-17 6. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the master cylinder solenoid. BR-25 1. Check the DTC again and make sure that the normal system code is output. BC-39 2. Front speed sensor circuit BC-53 3. Rear speed sensor circuit BC-62 4. Stop light switch circuit BC-104 5. Check the hydraulic brake booster using intelligent tester. If abnormal, check the hydraulic circuit for leakage BR-17 6. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the master cylinder solenoid. BR-25 1. Check the DTC again and make sure that the normal system code is output. BC-39 2. IG power source circuit BC-94 3. Check the hydraulic circuit for leakage - 4. Front speed sensor circuit BC-53 5. Rear speed sensor circuit BC-62 6. Yaw rate and acceleration sensor circuit BC-91 7. Steering angle sensor circuit BC-88 8. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the master cylinder solenoid. BR-25 1. TS and CG terminal circuit BC-207 2. Master cylinder solenoid BR-25 1. Check the DTC again and make sure that the normal system code is output. BC-39 2. TC and CG terminal circuit BC-203 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the master cylinder solenoid. BR-25 1. ABS warning light circuit BC-157 2. Master cylinder solenoid BR-25 1. ABS warning light circuit BC-161 2. Master cylinder solenoid BR-25 1. VSC TRAC warning light circuit BC-163 2. Master cylinder solenoid BR-25 BC BC–36 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Symptom VSC TRAC warning light abnormal (Does not come on) BRAKE warning light abnormal (Remains on) BRAKE warning light abnormal (Does not come on) VSC OFF indicator light abnormal (Remains on) (*2) VSC OFF indicator light abnormal (Does not come on) (*2) AUTO LSD indicator light abnormal (Remains on) (*1) AUTO LSD indicator light abnormal (Does not come on) (*1) Downhill assist control indicator light abnormal (Remains on) (*3) BC Downhill assist control indicator light abnormal (Does not come on) (*3) SLIP indicator light abnormal (Remains on) SLIP indicator light abnormal (Does not come on) Skid control buzzer abnormal Suspected Area See page 1. VSC TRAC warning light circuit BC-165 2. Master cylinder solenoid BR-25 1. BRAKE warning light circuit BC-167 2. Master cylinder solenoid BR-25 1. BRAKE warning light circuit BC-172 2. Master cylinder solenoid BR-25 1. 4WD control (4WD) switch circuit (*3) BC-126 2. VSC OFF indicator light circuit BC-175 3. Master cylinder solenoid BR-25 1. 4WD control (4WD) switch circuit (*3) BC-126 2. VSC OFF indicator light circuit BC-178 3. Master cylinder solenoid BR-25 1. AUTO LSD indicator light circuit BC-192 2. Master cylinder solenoid BR-25 1. AUTO LSD indicator light circuit BC-196 2. Master cylinder solenoid BR-25 1. 4WD control (L4) switch circuit BC-132 2. 4WD control (4WD) switch circuit BC-126 3. Downhill assist control indicator light circuit BC-184 4. Master cylinder solenoid BR-25 1. 4WD control (L4) switch circuit BC-132 2. 4WD control (4WD) switch circuit BC-126 3. Downhill assist control indicator light circuit BC-188 4. Master cylinder solenoid BR-25 1. SLIP indicator light circuit BC-180 2. Master cylinder solenoid BR-25 1. SLIP indicator light circuit BC-182 2. Master cylinder solenoid BR-25 1. Skid control buzzer circuit BC-200 2. Master cylinder solenoid BR-25 (*1): 2WD (*2): 4WD (*3): Multi Mode 4WD BC–216 BRAKE CONTROL – YAW RATE AND ACCELERATION SENSOR REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 2. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 3. REMOVE CONSOLE UPPER PANEL GARNISH NO. 1 (See page IP-7) 4. REMOVE CONSOLE UPPER PANEL GARNISH NO. 2 5. REMOVE CONSOLE BOX ASSEMBLY REAR (See page IP-9) 6. REMOVE YAWRATE SENSOR (a) Disconnect the yawrate sensor connector. (b) Remove the 2 bolts and yawrate sensor. F043114 BC INSTALLATION F043114 1. INSTALL YAWRATE SENSOR (a) Install the yawrate sensor with 2 bolts. Torque: 13.3 N*m (136 kgf*cm, 10 ft.*lbf) (b) Connect the yawrate sensor connector. 2. INSTALL CONSOLE BOX ASSEMBLY REAR 3. INSTALL CONSOLE UPPER PANEL GARNISH NO. 2 4. INSTALL CONSOLE UPPER PANEL GARNISH NO. 1 5. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 6. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 7. PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION HINT: (See page BC-20) 8. CHECK VSC SENSOR SIGNAL HINT: (See page BC-23) BRAKE CONTROL – STEERING ANGLE SENSOR BC–217 STEERING ANGLE SENSOR BRAKE CONTROL COMPONENTS STEERING WHEEL ASSEMBLY STEERING WHEEL COVER LOWER NO. 2 SPIRAL CABLE SUB-ASSEMBLY HORN BUTTON ASSEMBLY TURN SIGNAL SWITCH ASSEMBLY STEERING WHEEL COVER LOWER NO. 3 BC STEERING SENSOR STEERING COLUMN COVER UPR C131331E04 BC–218 BRAKE CONTROL – STEERING ANGLE SENSOR REMOVAL 1. PRECAUTION (See page SR-8) 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO. 3 5. REMOVE STEERING WHEEL COVER LOWER NO. 2 6. REMOVE HORN BUTTON ASSEMBLY (See page SR8) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-9) 8. REMOVE STEERING COLUMN COVER UPR 9. REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page SR-9) 10. REMOVE TURN SIGNAL SWITCH ASSEMBLY (See page SR-10) 11. REMOVE STEERING SENSOR (a) Remove the steering sensor connector. BC C088509 (b) Remove the 2 claws, then remove the steering sensor. C088506 INSTALLATION 1. C088506 INSTALL STEERING SENSOR (a) Install the steering sensor. BRAKE CONTROL – STEERING ANGLE SENSOR BC–219 (b) Install the steering sensor connector. 2. INSTALL TURN SIGNAL SWITCH ASSEMBLY (See page SR-21) 3. INSPECT SPIRAL CABLE SUB-ASSEMBLY (See page RS-398) 4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 5. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page SR-21) 6. INSTALL STEERING COLUMN COVER UPR (See page SR-21) 7. INSTALL STEERING WHEEL ASSEMBLY (See page SR-21) 8. INSTALL HORN BUTTON ASSEMBLY (See page SR21) 9. INSTALL STEERING WHEEL COVER LOWER NO. 2 C088509 10. INSTALL STEERING WHEEL COVER LOWER NO. 3 11. INSPECT SRS WARNING LIGHT (See page SR-22) 12. PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION BC-20 13. CHECK VSC SENSOR SIGNAL BC-23 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–37 TERMINALS OF ECU 1. TERMINALS OF ECU Skid Control ECU: C110610E05 Symbols (Terminal No.) Terminal Description GND1 (1) Skid control ECU ground +BM1 (2) Power supply for motor FR+ (3) Front RH wheel speed sensor power supply output FL- (4) Front LH wheel speed sensor input RR+ (5) Rear RH wheel speed sensor power supply output RL- (6) Rear LH wheel speed sensor input STP (7) Stop light switch input NEO (10) (*2) Center diff. lock indicator light input CANH (11) CAN communication line H SP1 (12) Speed signal output to combination meter D/G (13) Diagnosis tester communication line P (14) Shift position indicator P signal input INFR (15) (*1) AUTO LSD indicator light output STPO (16) Stop light operation relay output FR- (17) Front RH wheel speed sensor input FL+ (18) Front LH wheel speed sensor power supply output RR- (19) Rear RH wheel speed sensor input RL+ (20) Rear LH wheel speed sensor power supply output *2) EXI4 (21) ( 4WD control (L4) switch input TS (24) Sensor test terminal (Signal check switch) input CANL (25) CAN communication line L EXI3 (26) (*2) ADD (Auto disconnected differential lock) change over actuator switch input (*3) Ground (*4) EXI (27) (*2) Center diff. lock switch input PKB (28) Parking brake switch input WA (29) ABS warning light output BZ (30) Skid control buzzer output +BS (31) Power supply for solenoid GND2 (32) * HDCW (33) ( 3) IND (34) Skid control ECU ground Downhill assist control indicator light output SLIP indicator light output *2) VSC OFF indicator light output VSCW (36) VSC TRAC warning light output FRO (37) Front RH wheel speed output FLO (38) Front LH wheel speed output LBL (41) Brake fluid level warning switch input WT (35) ( BC BC–38 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Symbols (Terminal No.) Terminal Description WFSE (42) Write flash enable input CSW (43) (*1) AUTO LSD switch input *3) Downhill assist control switch input HDCS (44) ( STP2 (45) Stop light switch input IG1 (46) IG1 power supply Skid Control ECU: C124763E02 BC Symbols (Terminal No.) Terminal Description IG2 (1) IG2 Power supply +BM2 (2) Power supply for motor BRL (3) BRAKE warning light output GND3 (4) Skid control ECU ground 2. (*1): 2WD (*2): 4WD (*3): Multi Mode 4WD (*4): Full Time 4WD TERMINAL INSPECTION Disconnect the connector and measure the voltage or resistance on the wire harness side. HINT: Voltage cannot be measured with the connector connected to the skid control ECU as the connector is water resistance. Skid Control ECU Harness Side Connector Front View: S28 S29 C124764E04 BC–39 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description +BM1 (S28-2) - GND (S28-1, 32) (S29-4) Y-B - W-B Power supply for motor (From battery) STP (S28-7) - GND (S28-1, 32) (S29-4) G-B - W-B Stop light switch input P (S28-14) - GND (S28-1, 32) (S29-4) G-B - W-B PKB (S28-28) - GND (S28-1, 32) (S29-4) Specified Condition Condition Always 10 to 14 V Stop light switch ON → OFF (Brake pedal depressed → released) 8 to 14 V → Below 1.5 V Shift position indicator P signal input Ignition switch ON, shift P position → any shift position except P 8 to 14 V → Below 1.5 V LG - W-B Parking brake switch input Ignition switch ON, parking brake switch ON → OFF Below 1.5 V → 10 to 14 V +BS (S28-31) - GND (S28-1, 32) (S29-4) Y - W-B Power supply for solenoid (From battery) Always LBL (S28-41) - GND (S28-1, 32) (S29-4) LG - W-B Brake fluid level warning switch input STP2 (S28-45) - GND (S28-1, 32) (S29-4) G-Y - W-B Stop light switch input IG1 (S28-46) - GND (S28-1, 32) (S29-4) B-R - W-B IG2 (S29-1) - GND (S28-1, 32) (S29-4) +BM2 (S29-2) - GND (S28-1, 32) (S29-4) 10 to 14 V Brake fluid level is - 5 mm from the minimum level → maximum level Below 1 Ω → 1.9 to 2.1 kΩ Stop light switch ON → OFF (Brake pedal depressed → released) 8 to 14 V → Below 1.5 V IG1 power supply Ignition switch OFF → ON Below 1 V → 10 to 14 V B-O - W-B IG2 power supply Ignition switch OFF → ON Below 1 V → 10 to 14 V Y-B - W-B Power supply for motor (From battery) Always 10 to 14 V DIAGNOSIS SYSTEM ABS Warning Light BRAKE Warning Light USA: USA/Canada: Canada/Mexico: Mexico: VSC TRAC Warning Light VSC OFF Indicator Light SLIP Indicator Light AUTO LSD Indicator Light 1. DIAGNOSIS (a) If the skid control ECU detects a malfunction, the ABS, BRAKE, VSC TRAC warning lights and the VSC OFF, SLIP, downhill assist control indicator lights will come on to warn the driver. The table below indicates which lights will come on when there is a malfunction in a particular function. Downhill Assist Control Indicator Light I042827E02 Item / Trouble Area ABS EBD BA VSC ABS Warning Light { { { - TRAC A-TRAC (4WD) - - AUTO LSD Downhill assist control (4WD) Hill-start assist control - - - BC BC–40 BC BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Item / Trouble Area ABS EBD BA VSC TRAC A-TRAC (4WD) AUTO LSD Downhill assist control (4WD) Hill-start assist control BRAKE Warning Light - { - - - - - - - VSC TARC Warning Light { { { { { { { { { VSC OFF Indicator Light (4WD) { { { { { { { { { SLIP Indicator Light { { { { { { { { { AUTO LSD Indicator Light - - - - - - - - - Downhill assist control Indicator Light (4WD) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) z (Downhill assist control switch ON) {: Light ON z: Light ON (Blinking) -: Light OFF • The DTCs are simultaneously stored in the memory. The DTCs can be read by connecting the SST between terminals TC and CG of the DLC3 and observing the blinking of the ABS and VSC TRAC warning lights, or by connecting the intelligent tester. • This system has a signal check function (test mode). The DTC can be read by connecting the intelligent tester and observing the blinking of the ABS and VSC TRAC warning lights. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM 2. ABS Warning Light BRAKE Warning Light USA: USA/Canada: Canada/Mexico: Mexico: VSC TRAC Warning Light VSC OFF Indicator Light SLIP Indicator Light AUTO LSD Indicator Light Downhill Assist Control Indicator Light WARNING LIGHT AND INDICATOR LIGHT BULB CHECK (a) Release the parking brake lever. NOTICE: When releasing the parking brake, set the chocks to hold the vehicle for safety. HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the ignition switch is turned to the ON position, check that the ABS, BRAKE, and VSC TRAC warning lights and the VSC OFF, SLIP, AUTO LSD, and downhill assist control indicator lights come on for approximately 3 seconds. HINT: If the warning light and indicator light check result is not normal, proceed to troubleshooting for the ABS, BRAKE, and VSC TRAC warning light circuits, and the VSC OFF, SLIP, AUTO LSD, and downhill assist control indicator light circuits. If the indicator remains on, proceed to troubleshooting for the light circuit below. Trouble area I042827E02 DLC3: See procedure ABS warning light circuit BC-157 BRAKE warning light circuit BC-167 VSC TRAC warning light circuit BC-163 VSC OFF indicator light circuit BC-175 SLIP indicator light circuit BC-180 AUTO LSD indicator light circuit BC-192 Downhill assist control indicator light circuit BC-184 DTC CHECK / CLEAR CG 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC BC–41 F100115E49 DTC CHECK / CLEAR (SST CHECK WIRE) (a) DTC check (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position. (3) Read the DTCs from the ABS and VSC TRAC warning lights on the combination meter. HINT: • If no code appears, inspect the TC and CG terminal circuit, and the ABS and VSC TRAC warning light circuits. Trouble Area TC and CG terminal circuit See procedure BC-203 ABS warning light circuit BC-157 or BC-161 VSC TRAC warning light circuit BC-163 or BC-165 • As examples, refer to the chart below for the blinking patterns of the normal system code and trouble codes 11 and 21. BC BC–42 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Normal System Code: Trouble Code (Example Codes 11 and 21): 2.5 sec. 0.25 sec. 2 sec. 0.5 sec. 1.5 sec. 0.25 sec. 0.5 sec. 4 sec. ON ON OFF OFF 4 sec. Code 11 Repeat Code 21 F100113E04 BC (4) Codes are explained in the code table (See page BC-48). (5) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. DLC3: (b) DTC clear (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position. CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E02 BR03890 (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) check that the warning light indicates the normal system code. (5) Remove the SST from the terminals of the DLC3. HINT: Clearing the DTCs cannot be performed by removing the battery cable or the ECU-IG fuse. BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Intelligent Tester 2. DLC3 I042828E01 3. BC–43 DTC CHECK / CLEAR (INTELLIGENT TESTER) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Read the DTCs following the prompts on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Operate the intelligent tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. END OF DTC CHECK / CLEAR (a) Turn the ignition switch to the ON position (b) Check that the ABS and VSC TRAC warning lights go off within approximately 3 seconds. BC BC–44 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM FREEZE FRAME DATA 1. BC Item (Display) FREEZE FRAME DATA (a) Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sensor) state as freeze frame data. The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to the ON position since the last time the ABS was activated. HINT: • However, if the vehicle was stopped or at low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will not count the number since then. • Freeze frame data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored when the ABS operated is erased. • Freeze frame data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) On the tester display, select the freeze frame data. Measurement Item Reference Value TROUBLE CODE Freeze DTC 0 to 65535 STOP LIGHT SW Stop light switch signal Stop light switch ON: ON, OFF: OFF Shift lever position FAIL P, N R D/M 4 3 2 L SYSTEM System status ABS activated: ABS VSC/TRAC activated: VSC/TRAC BA activated: BA No system activated: NO SYS # IG ON Number of operations of ignition switch ON after memorizing freeze frame data 0 to 31 Vehicle speed reading Min.: 0 km/h, Max.: 326.4 km/h Steering angle sensor reading Left turn: Increase Right turn: Drop Yaw rate sensor reading Min.: -128 deg/s, Max.: 127 deg/s MAS CYL PRESS Master cylinder pressure sensor reading Brake pedal released: 0.3 to 0.9 V Brake pedal depressed: 0.8 to 4.5 V MAS PRESS GRADE SHIFT POSITION VEHICLE SPD STEERING ANG YAW RATE Master cylinder pressure sensor change Min.: -30 MPa/s, Max.: 255 MPa/s G (RIGHT & LEFT) Right and left G Min.: -1.869 G, Max.: 1.869 G G (BACK & FORTH) Back and forth G Min.: -1.869 G, Max.: 1.869 G Front right wheel direction signal Front right wheel direction FORWARD: Forward, BACK: Back WHEEL DIR FR BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Item (Display) Measurement Item BC–45 Reference Value WHEEL DIR FL Front left wheel direction signal Front left wheel direction FORWARD: Forward, BACK: Back WHEEL DIR RR Rear right wheel direction signal Rear right wheel direction FORWARD: Forward, BACK: Back WHEEL DIR RL Rear left wheel direction signal Rear left wheel direction FORWARD: Forward, BACK: Back THROTTLE Throttle position sensor reading Accelerator pedal released: approx. 0% Accelerator pedal depressed: approx. 100% Skid control buzzer signal Skid control buzzer ON: ON, OFF: OFF Brake fluid level warning switch signal Brake fluid level warning switch ON: ON, OFF: OFF Parking brake switch signal Parking brake switch ON: ON, OFF: OFF BUZZER RESERVOIR SW PKB SW BC BC–46 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM FAIL-SAFE CHART 1. BC Malfunction Area FAIL SAFE OPERATION • If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator and informs the ECM of VSC system failure. The brake actuator turns off each solenoid and the ECM shuts off VSC control (traction control signal) from the skid control ECU accordingly, which turns out to be as if the ABS, TRAC and VSC systems were not installed. The ABS control will be prohibited, but EBD control continues as much as possible. If EBD control is impossible, the BRAKE warning light comes on to warn the driver (See page BC-38). • If system components have any malfunction before starting control, immediately stop the operation. If system components have any malfunction during control, gradually stop the control so as not to trigger a sudden change in vehicle conditions. If it is impossible to control the systems, the warning light comes on to inform the driver of termination of the systems (See page BC-38). HINT: If the hydraulic brake booster encounters a malfunction, brake performance is gradually lost and ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control system control is prohibited. (a) ABS, EBD and BA system: HINT: A malfunction in either the ABS or BA system will result in an identical operation, with ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control system control prohibited. Control Method ABS system ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control control is prohibited BA system ABS, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control control is prohibited EBD system ABS, EBD, BA, TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hillstart assist control control is prohibited (b) TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control system: HINT: As for the TRAC, A-TRAC, VSC, AUTO LSD, downhill assist control and hill-start assist control systems, different systems prohibit different controls according to a malfunctioning part. Malfunction Area Engine control system (TRAC, A-TRAC and VSC systems) Control Method Before control: Disables control During control: Uses only brakes to effect control BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Malfunction Area BC–47 Control Method Brake control system (VSC system) Before control: Disables control During control: Uses only engine to effect control Brake control system (TRAC, A-TRAC, AUTO LSD, downhill assist control and hill-start assist control system) Brake control: Disables control During control: Disables control (by gradually ending control) 2. System SYSTEM TEMPERATURE PROTECTION OPERATION If the TRAC, A-TRAC, AUTO LSD, downhill assist control, or hill-start assist control system has been used constantly for a long time, the temperature of the brake actuator, built in the hydraulic brake booster, may excessively increase. If the temperature excessively increases, the skid control buzzer will sound intermittently. If the temperature increases more, the skid control buzzer sounds for 3 seconds and the indicator light either comes on or blinks. Indicator Condition TRAC, A-TRAC, AUTO LSD and hill-start assist control systems SLIP indicator light comes on Downhill assist control system SLIP indicator light comes on Downhill assist control indicator light blinks HINT: • If the SLIP indicator light goes off (as for the downhill assist control system, the downhill assist control indicator light also comes on), the systems automatically return to normal operating conditions. • As this is not a malfunction, no DTC will be recorded. BC BC–48 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. Item BC DATA LIST HINT: While the intelligent tester is connected to the DLC3 with the ignition switch is turned to the ON position, the ABS, TRAC and VSC data list can be displayed. Follow the prompts on the tester screen to access the "DATA LIST". Measurement Item / Range (Display) Normal Condition Diagnostic Note HB MOT RELAY HB motor relay / ON or OFF ON : During pump motor operation OFF : No pump motor operation - SOL RELAY Solenoid relay / ON or OFF ON : Solenoid relay ON OFF : Solenoid relay OFF - IDLE SW Main idle switch / ON or OFF ON : Accelerator pedal released OFF : Accelerator pedal depressed - STOP LIGHT SW Stop light switch / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - PKB SW Parking brake switch / ON or OFF ON : Parking brake applied OFF : Parking brake released - RESERVOIR SW Brake fluid level warning switch / ON or OFF ON : Switch ON OFF : Switch OFF - AIR BLD SUPPORT Air bleed availability / SUPPORT or NOT SUP SUPPORT: Support ON NOT SUP: Support OFF - ABS OPERT FR ABS operation (FR) / BEFORE or OPERATE BEFORE : No ABS operation (FR) OPERATE : During ABS operation (FR) - ABS OPERT FL ABS operation (FL) / BEFORE or OPERATE BEFORE : No ABS operation (FL) OPERATE : During ABS operation (FL) - ABS OPERT RR ABS operation (RR) / BEFORE or OPERATE BEFORE : No ABS operation (RR) OPERATE : During ABS operation (RR) - ABS OPERT RL ABS operation (RL) / BEFORE or OPERATE BEFORE : No ABS operation (RL) OPERATE : During ABS operation (RL) - WHEEL SPD FR Wheel speed sensor (FR) reading / Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD FL Wheel speed sensor (FL) reading / Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RR Wheel speed sensor (RR) reading / Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RL Wheel speed sensor (RL) reading / Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual wheel speed Similar speed as indicated on speedometer DECELERAT SEN Acceleration sensor 1 reading / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +- 0.13G while stationary Reading changes when vehicle is bounced DECELERAT SEN2 Acceleration sensor 2 reading / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +- 0.13G while stationary Reading changes when vehicle is bounced IG VOLTAGE ECU IG power supply voltage / TOO LOW / NORMAL / TOO HIGH TOO LOW: 9.5 V or less NORMAL: 9.5 V or 14.0 V TOO HIGH: 14.0 V or more - BC–49 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SFRR ABS solenoid (SFRR) / ON or OFF ON: Operates - SFRH ABS solenoid (SFRH) / ON or OFF ON: Operates - SFLR ABS solenoid (SFLR) / ON or OFF ON: Operates - SFLH ABS solenoid (SFLH) / ON or OFF ON: Operates - SRRR (SRR) ABS solenoid (SRRR [SRR]) / ON or OFF ON: Operates - SRRH (SRH) ABS solenoid (SRRH [SRH]) / ON or OFF ON: Operates - SRLR ABS solenoid (SRLR) / ON or OFF ON: Operates - SRLH ABS solenoid (SRLH) / ON or OFF ON: Operates - SRCF (SA1) TRAC solenoid (SMCF) / ON or OFF - - SRCR (SA2) TRAC solenoid (SREA) / ON or OFF - - SRMF (SMCF, SA3) TRAC solenoid (SREC) / ON or OFF - - SRMR (SMCR, STR) TRAC solenoid (STR) / ON or OFF - - ECU CODE #4 ECU CODE 1 or 0 0 ECU CODE #3 ECU CODE 1 or 0 0 ECU CODE #2 ECU CODE 1 or 0 0 ECU CODE #1 ECU CODE 1 or 0 0 ENGINE SPD Engine Speed/ Min.: 0 rpm, Max.: 6000 rpm Actual engine speed - VEHICLE SPD Vehicle speed reading / Min.: 0 mph (0 km/h), Max.: 202 mph (326 km/h) Actual engine speed Speed indicated on speedometer YAW RATE Yaw rate sensor/ Min.: -128 deg/ s, Max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - YAW ZERO VALUE Memorized zero value/ Min.: -128 deg/s, Max.: 127 deg/s Min.: -128 deg/s Max.: 127 deg/s - STEERING ANG Steering angle sensor/ Min.: 1152 deg/s, Max.: 1150.875 deg/s Left turn: Increase Right turn: Decrease - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / Min.: 0V, Max.: 5V When brake pedal is released : 0.3 to 0.9 V When stop light is turned on: 0.3 to 0.9 V Reading increases when brake pedal is depressed ACC PRESS Accumulator pressure sensor / Min.: 0V, Max.: 5V 3.58 to 5 V If the value is constant regardless of pump operation, accumulator pressure sensor malfunction is suspected. WHEEL DIR FR Wheel direction (FR) / FORWARD or BACK BACK: Back, FORWARD: Forward - WHEEL DIR FL Wheel direction (FL) / FORWARD or BACK BACK: Back, FORWARD: Forward - WHEEL DIR RR Wheel direction (RR) / FORWARD or BACK BACK: Back, FORWARD: Forward - WHEEL DIR RL Wheel direction (RL) / FORWARD or BACK BACK: Back, FORWARD: Forward - BC BC–50 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Measurement Item / Range (Display) Item Normal Condition Diagnostic Note SPD SEN FR Speed sensor open detection (FR)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN FL Speed sensor open detection (FL)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN RR Speed sensor open detection (RR)/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - SPD SEN RL Speed sensor open detection (RL/OPN DET or NORMAL OPN DET: Momentary interruption NORMAL: Normal - ACCELERATOR % The difference of a present accelerator / Min.: 0%, Max.: 128% - - TORQUE Real output torque /Min.: -1024 Nm, Max.: 1016 Nm - - TEST MODE Test mode operation / NORMAL or TEST NORMAL: Normal mode TEST: During test mode - MAS CYL PRESS 1 Master cylinder pressure sensor 1 reading / min.: 0V, max.: 5V When brake pedal released: 0.3 to 0.9V #CODES Number of DTC recorded / Min.: 0, Max.: 255 - 2. BC Item Reading increases when brake pedal depressed - ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, actuator, etc. to operate without removing any parts. Performing the ACTIVE TEST as the first step of troubleshooting is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, perform the "ACTIVE TEST". HINT: The ignition switch must be turned to the ON position to proceed to the ACTIVE TEST using the intelligent tester. Vehicle Condition / Test Details Diagnostic Note SFRR Turns ABS solenoid (SFRR) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFRH Turns ABS solenoid (SFRH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFLR Turns ABS solenoid (SFLR) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFLH Turns ABS solenoid (SFLH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRRR Turns ABS solenoid (SRRR) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRRH Turns ABS solenoid (SRRH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRLR Turns ABS solenoid (SRLR) ON / OFF Operation sound of solenoid (clicking sound) can be heard BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Item Vehicle Condition / Test Details BC–51 Diagnostic Note SRLH Turns ABS solenoid (SFLH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRCF (SA1) Turns TRAC solenoid (SMCF) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRCR (SA2) Turns TRAC solenoid (SREA) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRMF (SMCF, SA3) Turns TRAC solenoid (SREC) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRMR (SMCR, STR) Turns TRAC solenoid (STR) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFRR & SFRH Turns ABS solenoid (SFRR and SFRH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFLR & SFLH Turns ABS solenoid (SFLR and SFLH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRH & SRR Turns ABS solenoid (SRRH and SRRR) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRLR & SRLH Turns ABS solenoid (SRLR and SRLH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SFRH & SFLH Turns ABS solenoid (SFRH and SFLH) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRCF & SRCR Turns TRAC solenoid (SMCF and SREA) ON / OFF Operation sound of solenoid (clicking sound) can be heard SRMF & SRMR Turns TRAC solenoid (SREC and STR) ON / OFF Operation sound of solenoid (clicking sound) can be heard ABS WARN LIGHT Turns ABS warning light ON / OFF Observe combination meter VSC WARN LIGHT Turns VSC TRAC warning light ON / OFF Observe combination meter VSC / TRC OFF IND Turns VSC OFF indicator light ON / OFF Observe combination meter SLIP INDI LIGHT Turn SLIP indicator light ON / OFF Observe combination meter BRAKE WRN LIGHT Turns BRAKE warning light ON / OFF Observe combination meter VSC / BR WARN BUZ Turns skid control buzzer ON / OFF Buzzer can be heard H/B MOT RELAY Turns H/B motor relay ON / OFF Operation sound of motor can be heard STOP LIGHT RELAY Turns stop light operation relay ON / OFF Observe rear combination light (Does not come on for 5 sec. or more BC BRAKE – BRAKE PEDAL BR–7 REMOVAL 1. REMOVE INSTRUMENT PANEL FINISH PLATE (See page IP-6) 2. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-7) 3. REMOVE INSTRUMENT PANEL LOWER LH (See page IP-8) 4. REMOVE PUSH ROD PIN (a) Remove the clip and push rod pin from the brake pedal lever. 5. REMOVE BRAKE PEDAL SUPPORT REINFORCEMENT (a) Remove the bolt from the brake pedal support reinforcement. F043151 (b) Remove the bolt and nut, then remove the brake pedal support reinforcement from brake pedal support sub-assembly. 6. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Disconnect the stop light switch connector from the stop light switch assembly. F043115 (b) Remove the 4 nuts and brake pedal support subassembly. F043116 7. REMOVE BRAKE PEDAL RETURN SPRING 8. REMOVE STOP LIGHT SWITCH ASSEMBLY (a) Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly. (b) Remove the cushion from brake pedal support subassembly. BR BR–8 BRAKE – BRAKE PEDAL 9. REMOVE BRAKE PEDAL SUB-ASSEMBLY (a) Remove the bolt and nut, then remove the brake pedal sub-assembly from brake pedal support subassembly. (b) Remove the 4 brake pedal bushes from the brake pedal and brake pedal lever. (c) Remove the 2 collars from brake pedal subassembly and brake pedal lever. F043117 DISASSEMBLY F043118E01 1. REMOVE BRAKE PEDAL LEVER (a) Using a screwdriver, remove the 2 E-rings from the brake pedal link pin. (b) Remove the 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal link. (c) Remove the brake pedal lever from brake pedal sub-assembly. 2. REMOVE BRAKE PEDAL PAD (a) Remove the brake pedal pad from the brake pedal sub-assembly. ADJUSTMENT Rod Operating Adapter BR Stop Light Switch Assembly Pedal Height F043109E02 1. CHECK BRAKE PEDAL HEIGHT (a) Check the brake pedal height. Pedal height from dash panel: 166.1 to 176.1 mm (6.539 to 6.933 in.) NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio. If the pedal height is incorrect, adjust the rod operating adapter length. BRAKE – BRAKE PEDAL (b) Adjust the rod operating adapter length. (1) Remove the clip and clevis pin. (2) Loosen the clevis lock nut. (3) Adjust the rod operating adapter length by turning the pedal push rod clevis. Rod operating adapter length "A": 232.5 to 242.5 mm (9.154 to 9.547 in.) (4) Tighten the clevis lock nut. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (5) Install the clip and clevis pin. If the pedal height is incorrect even if the rod operating adapter is adjusted, check that there is no damage in brake pedal, brake pedal lever, brake pedal bracket and dash panel. • Even if there is damage, there is no problem if the reserve distance is within the standard value. • If necessary, replace them. A Rod Operating Adapter Clevis Lock Nut 2. F044242E02 Cushion Stop Light Switch Assembly 0.5 to 2.5 mm (0.020 to 0.098 in.) F043108E12 BR–9 CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY HINT: If the pedal height is incorrect, check and adjust the stop light switch clearance. (a) Disconnect the stop light switch assembly connector from the stop light switch assembly. (b) Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly. (c) Insert the stop light switch assembly until the body hits the cushion. NOTICE: When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in. (d) Make a quarter turn clockwise to install the stop light switch assembly. NOTICE: The turning torque for installing the stop light switch assembly. HINT: Due to the inverse screw structure, if the stop light switch assembly is turned clockwise, the stop light switch assembly moves in the direction to be pulled out. (e) Connect the stop light switch connector to the stop light switch assembly. (f) Check the protrusion of the rod. Protrusion of the rod: 0.5 to 2.5 mm (0.020 to 0.098 in.) (g) Install the clevis pin and clip. (h) After adjusting the pedal height, check the pedal free play. BR BR–10 BRAKE – BRAKE PEDAL 3. CHECK PEDAL FREE PLAY (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown. Pedal free play: 1 to 6 mm (0.04 to 0.24 in.) 4. CHECK PEDAL RESERVE DISTANCE (a) Release the parking brake pedal. With engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 55 mm (2.17 in.) If incorrect, troubleshoot the brake system. Pedal Free Play F043110E01 BR Pedal Reserve Distance R000934E23 BRAKE – BRAKE PEDAL BR–11 REASSEMBLY 1. INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad to the brake pedal subassembly. 2. REMOVE BRAKE PEDAL LEVER (a) Apply the lithium soap base glycol grease to the 2 brake pedal link pins, pedal shaft collars and 2 brake pedal link. (b) Install the brake pedal lever with 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal link to the brake pedal sub-assembly. (c) Install the 2 new E-rings to each of brake pedal link pin. BR BR–12 BRAKE – BRAKE PEDAL INSTALLATION 1. INSTALL BRAKE PEDAL SUB-ASSEMBLY (a) Apply the lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes. (b) Install the 2 collars and 4 brake pedal bushes to the brake pedal sub-assembly and brake pedal lever. (c) Install the brake pedal sub-assembly with the bolt and nut to the brake pedal support sub-assembly. Torque: 34.3 N*m (350 kgf*cm, 25 ft.*lbf) 2. INSTALL STOP LIGHT SWITCH ASSEMBLY (a) Install the cushion to the brake pedal bracket. F043117 Cushion BR (b) Insert the stop lamp switch assembly until the body hits the cushion. NOTICE: When inserting the stop light switch, support the pedal from behind so that the pedal is not pushed in. (c) Make a quarter turn clockwise to install the stop light switch assembly. NOTICE: The turning torque for installing the stop light switch assembly. HINT: Due to the inverse screw structure, if the stop light switch assembly is turned clockwise, the stop light switch assembly moves in the direction to be pulled out. Stop Light Switch Assembly 0.5 to 2.5 mm (0.020 to 0.098 in.) F043108E12 F043116 3. INSTALL BRAKE PEDAL RETURN SPRING (a) Apply the lithium soap base glycol grease to inner surface of the hole on the brake pedal support subassembly. (b) Install the brake pedal return spring to the brake pedal support sub-assembly. 4. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Install the 4 nuts and brake pedal support subassembly. Torque: 14.2 N*m (145 kgf*cm, 10 ft.*lbf) (b) Connect the stop light switch connector to the stop light switch assembly. BRAKE – BRAKE PEDAL 5. BR–13 INSTALL BRAKE PEDAL SUPPORT REINFORCEMENT (a) Install the brake pedal support reinforcement to the brake pedal support sub-assembly. (b) Temporarily tighten the bolt and nut to the brake pedal support sub-assembly, brake pedal support reinforcement and brake pedal lever. F043115 (c) Install the bolt to the brake pedal support reinforcement. Torque: 34.3 N*m (350 kgf*cm, 25 ft.*lbf) (d) Tighten the bolt and nut. Torque: 34.3 N*m (350 kgf*cm, 25 ft.*lbf) 6. INSTALL PUSH ROD PIN (a) Apply the lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever. (b) Install the push rod pin and clip to the brake pedal lever. 7. INSTALL INSTRUMENT PANEL LOWER LH 8. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 9. INSTALL INSTRUMENT PANEL FINISH PLATE F043151 10. CHECK BRAKE PEDAL HEIGHT HINT: (See page BR-8) 11. CHECK PEDAL FREE PLAY HINT: (See page BR-8) 12. CHECK PEDAL RESERVE DISTANCE HINT: (See page BR-8) 13. CHECK VSC SENSOR SIGNAL HINT: (See page BC-20) BR BRAKE – HYDRAULIC BRAKE BOOSTER BR–25 REMOVAL NOTICE: • When installing, coat the parts indicated by arrows with lithium soap base glycol grease (See page BR13). • As high pressure is applied to the brake actuator tube No. 1, never deform it. • Until the work is over, do not turn the ignition switch to the ON position. • Before starting the work, make sure that the ignition switch is off and depress the brake pedal more than 20 times. HINT: When pressure in the power supply system is released, reaction force becomes light and stroke becomes longer. F051429E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. DRAIN BRAKE FLUID NOTICE: Wash off brake fluid immediately if it comes into contact with a painted surface. 3. REMOVE FRONT DOOR SCUFF PLATE LH 4. REMOVE FRONT FLOOR FOOTREST 5. REMOVE COWL SIDE TRIM BOARD LH 6. REMOVE INSTRUMENT PANEL FINISH PLATE (See page IP-6) 7. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-7) 8. REMOVE STEERING COLUMN HOLE COVER (a) Remove the 4 clips and steering column hole cover. 9. REMOVE PUSH ROD PIN (a) Remove the clip and push rod pin from the clevis. BR BR–26 BRAKE – HYDRAULIC BRAKE BOOSTER 10. REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY (a) Disconnect the 3 connectors from the hydraulic brake booster assembly. F051438E02 To Right Front Wheel BR To Right Rear Wheel To Left Front Wheel (b) Use tags or make a memo to identify the place to reconnect. To Left Rear Wheel F051200E01 (c) Using SST, disconnect the 4 brake lines from the hydraulic brake booster assembly. SST 09023-00101 SST F051171E01 (d) Remove the 4 nuts and pull out the hydraulic brake booster assembly. 11. REMOVE BRAKE BOOSTER GASKET (a) Remove the brake booster gasket from the brake master cylinder. F051420 BRAKE – HYDRAULIC BRAKE BOOSTER BR–27 DISASSEMBLY 1. REMOVE BRAKE ACTUATOR BRACKET NO. 1 (a) Using a hexagon wrench (5 mm), remove the bolt and brake actuator bracket No. 1 from the brake master cylinder. F051421 (b) Using a screwdriver, remove the brake fluid level warning switch connector from the brake actuator bracket No. 1. F051180 2. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir subassembly. Pin Punch F051177E01 (b) Remove the screw and pull out the brake master cylinder reservoir sub-assembly. (c) Remove the master cylinder reservoir filler cap. F051178E02 3. F051181E03 REMOVE MASTER CYLINDER RESERVOIR GROMMET (a) Remove the 3 reservoir grommets from the master cylinder reservoir sub-assembly. BR BR–28 BRAKE – HYDRAULIC BRAKE BOOSTER 4. REMOVE BRAKE ACTUATOR HOSE (a) Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips. 5. REMOVE BRAKE ACTUATOR TUBE NO. 1 (a) Using SST, remove the brake actuator tube No. 1 from the brake master cylinder. SST 09023-00101 6. REMOVE BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY (a) Using a screwdriver, remove the 2 plugs. F051182E02 SST F051183E01 BR F051185E01 (b) Remove the 2 screws and disconnect the wire harnesses from the master cylinder solenoid. F051186E02 (c) Using a screwdriver, remove the clip. F051187 BRAKE – HYDRAULIC BRAKE BOOSTER BR–29 (d) Remove the brake booster with accumulator pump assembly from the brake master cylinder. (e) Remove the 2 brake booster pump collars and the 2 brake booster pump bushes from the brake booster with accumulator pump assembly. F051188 (f) Using a hexagon wrench (4 mm), remove the 2 pins. F051415E03 7. REMOVE BRAKE BOOSTER PUMP BRACKET NO. 2 (a) Using a hexagon wrench (5 mm), remove the 2 bolts and brake booster pump bracket No.2 from the brake master cylinder solenoid. (b) Remove the brake booster pump bush from the brake booster pump bracket No. 2. F051189E02 8. REMOVE BRAKE ACTUATOR BRACKET NO. 3 (a) Remove the bolt and brake actuator bracket No. 3 from the brake master cylinder. 9. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Secure the brake booster with accumulator pump assembly in a vise. (b) Remove the brake booster accumulator assembly. (c) Remove the O-ring from the brake booster accumulator assembly. NOTICE: Ensure no foreign matter enters the pump. (d) Remove the brake booster accumulator pipe and compression spring. F051423 F052314 BR BR–30 BRAKE – HYDRAULIC BRAKE BOOSTER 10. REMOVE MASTER CYLINDER SOLENOID (a) Remove the 6 bolts and master cylinder solenoid. F051195E02 (b) Remove the gasket. F051196 11. REMOVE MASTER CYLINDER PUSH ROD CLEVIS (a) Loosen the lock nut on the rod operating adapter, and remove the push rod clevis and lock nut. BR F051191E02 (b) Loosen the lock nut on the brake master cylinder side, and remove the rod operating adapter and lock nut. 12. REMOVE MASTER CYLINDER BOOT F051192E02 C-ring Pin F051417E02 13. REMOVE PISTON (a) Pressing the piston in with a screwdriver, use a pin or equivalent to push the C-ring from the hole in the master cylinder body then remove it with another screwdriver. (b) Remove the piston, pulling it straight out, not at an angle. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. BRAKE – HYDRAULIC BRAKE BOOSTER BR–31 INSPECTION 1. Red Cable Black Cable INSPECT BRAKE BOOSTER PUMP ASSEMBLY (a) Connect the positive (+) lead from the battery to the red cable of the pump motor, and the negative (-) lead to the black cable. (b) Check brake booster pump motor operation. F051410E01 REASSEMBLY 1. INSTALL PISTON (a) Apply lithium soap base glycol grease to a new piston. (b) Install the piston. (c) Using 2 screwdrivers, install a new snap ring while pressing on the piston. 2. INSTALL MASTER CYLINDER BOOT 3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS (a) Install the brake master cylinder side lock nut and rod operating adapter on the brake master cylinder. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) F051194 F051192E02 (b) Install the lock nut and master cylinder push rod clevis on the rod operating adapter. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) F051191E02 4. F051196 INSTALL MASTER CYLINDER SOLENOID (a) Install a new gasket. NOTICE: Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especially contact surfaces, away from water and dust. BR BR–32 BRAKE – HYDRAULIC BRAKE BOOSTER (b) Install the master cylinder solenoid with 6 new bolts. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) F051195E02 5. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Install the brake booster accumulator pipe and compression spring. NOTICE: Ensure that no foreign matter enters the pump. (b) Install a new O-ring to the brake booster accumulator assembly. (c) Install the brake booster accumulator assembly. Torque: 57 N*m (585 kgf*cm, 42 ft.*lbf) 6. INSTALL BRAKE ACTUATOR BRACKET NO. 3 (a) Install the brake actuator bracket No. 3 to the brake master cylinder with the bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 7. INSTALL BRAKE BOOSTER PUMP BRACKET NO. 2 (a) Install the brake booster pump bush to the brake booster pump bracket No. 2. (b) Using a hexagon wrench (5 mm), install the brake booster pump bracket No. 2 with the 2 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 8. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY (a) Using a hexagon wrench (4 mm), install the 2 pins to the brake master cylinder. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) (b) Install the 2 brake booster pump collars and 2 brake booster pump bushes to the brake booster with accumulator pump assembly. F052314 BR F051423 F051189E02 F051415E03 BRAKE – HYDRAULIC BRAKE BOOSTER BR–33 (c) Install the brake booster with accumulator pump assembly to the brake master cylinder. F051188 (d) Install a new clip. F051199 (e) Install the wire harnesses with the 2 screws. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) BR Red Cable Black Cable F051186E03 (f) Install 2 new plugs. F051185E01 9. SST Fulcrum Length F051184E03 INSTALL BRAKE ACTUATOR TUBE NO. 1 (a) Using SST, install the brake actuator tube No. 1 to the brake master cylinder assembly. SST 09023-00101 Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) NOTICE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). HINT: This torque value is effective when SST is parallel to the torque wrench. BR–34 BRAKE – HYDRAULIC BRAKE BOOSTER 10. INSTALL BRAKE ACTUATOR HOSE (a) Using needle nose pliers, install the brake actuator hose and 2 clips. F051182E02 11. INSTALL MASTER CYLINDER RESERVOIR GROMMET (a) Apply lithium soap base glycol grease to 3 new reservoir grommets. (b) Install the 3 reservoir grommets to the brake master cylinder. HINT: Be careful of the size of each grommet. F051416 12. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Install the brake master cylinder reservoir subassembly with the screw. Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf) (b) Install the master cylinder reservoir filler cap. BR F051178E02 (c) Using a pin punch and hammer, install a new pin to the brake master cylinder reservoir sub-assembly. Pin Punch F051177E01 13. INSTALL BRAKE ACTUATOR BRACKET NO. 1 (a) Install the brake fluid level warning switch connector to the brake actuator bracket No. 1. (b) Using a hexagon wrench (5 mm), install the brake actuator bracket No. 1 to the brake master cylinder with the bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) F051421E02 BRAKE – BRAKE SYSTEM BR–1 BRAKE SYSTEM PRECAUTION NOTICE: • Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent. • It is very important to keep parts and the area clean when repairing the brake system. • It the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. BR BR–2 BRAKE – BRAKE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the likelihood of the cause of the problem. Check each part in order. If necessary, replace these parts. BRAKE SYSTEM Symptom Low pedal or spongy pedal Brake drag BR Brake pull Hard pedal but brake inefficient Suspected Area See page 1. Fluid leaks for brake system - 2. Air in brake system BR-3 3. Piston seals (Worn or damaged) (Front) BR-40 4. Piston seals (Worn or damaged) (Rear) BR-46 5. Brake master cylinder (Faulty) BR-17 1. Brake pedal free play (Minimum) BR-8 2. Parking brake pedal travel (Out of adjustment) PB-1 3. Parking brake wire (Sticking) PB-8 4. Parking brake (Shoe clearance out of adjustment) PB-15 5. Pad (Cracked or distorted) (Front) BR-40 6. Pad (Cracked or distorted) (Rear) BR-46 7. Piston (Stuck) (Front) BR-40 8. Piston (Stuck) (Rear) BR-46 9. Piston (Frozen) (Front) BR-40 10.Piston (Frozen) (Rear) BR-46 11.Tension or return spring (Faulty) PB-15 12.Brake master cylinder (Faulty) BR-17 1. Piston (Stuck) (Front) BR-40 2. Piston (Stuck) (Rear) BR-46 3. Pad (Cracked or distorted) (Front) BR-40 4. Pad (Cracked or distorted) (Rear) BR-46 5. Piston (Frozen) (Front) BR-40 6. Piston (Frozen) (Rear) BR-46 7. Disc (Scored) (Front) BR-40 8. Disc (Scored) (Rear) BR-46 9. Pad (Cracked or distorted) (Front) BR-40 10.Pad (Cracked or distorted) (Rear) BR-46 11.Brake master cylinder (Faulty) BR-17 1. Fluid leaks for brake system - 2. Air in brake system BR-3 3. Pad (Worn) (Front) BR-40 4. Pad (Worn) (Rear) BR-46 5. Pad (Cracked or distorted) (Front) BR-40 6. Pad (Cracked or distorted) (Rear) BR-46 7. Pad (Oily) (Front) BR-40 8. Pad (Oily) (Rear) BR-46 9. Pad (Glazed) (Front) BR-40 10. Pad (Glazed) (Rear) BR-46 11. Disc (Scored) (Front) BR-40 12. Disc (Scored) (Rear) BR-46 13. Brake master cylinder (Faulty) BR-17 BR–3 BRAKE – BRAKE SYSTEM Symptom Noise from brakes Brake warning light lights up*1 (Parking brake pedal released) Brake warning light lights up and skid control buzzer sounds*2 ABS warning light lights up*3 Suspected Area See page 1. Pad (Cracked or distorted) (Front) BR-40 2. Pad (Cracked or distorted) (Rear) BR-46 3. Installation bolt (Loose) BR-46 4. Disc (Scored) (Front) BR-40 5. Disc (Scored) (Rear) BR-46 6. Pad support plate (Loose) BR-46 7. Sliding pin (Worn) BR-46 8. Pad (Dirty) (Front) BR-40 9. Pad (Dirty) (Rear) BR-46 10.Pad (Glazed) (Front) BR-40 11.Pad (Glazed) (Rear) BR-46 12.Tension or return spring (Faulty) PB-15 13.Anti-squeal shim (Damaged) (Front) BR-40 14.Anti-squeal shim (Damaged) (Rear) BR-46 15.Shoe hold-down spring (Damaged) PB-15 1. Brake fluid level BR-3 2. Brake master cylinder power supply system (Faulty) BR-17 Brake master cylinder power supply system (Faulty) BR-17 1. Anti-lock brake system (Faulty) - 2. Brake master cylinder power supply system (Faulty) BR-17 HINT: • *1, *3: The light may stay on for about 60 seconds after the engine starts. It is normal if it goes off after a while. • *2, *3: Depressing the brake pedal repeatedly may turn on the warning light and buzzer. It is normal if the light goes off and the buzzer stops sounding after a few seconds. • *3: While ABS warning light is ON, both VSC warning light and VSC OFF indicator light come on. BR BRAKE – HYDRAULIC BRAKE BOOSTER BR–35 INSTALLATION 1. INSTALL BRAKE BOOSTER GASKET (a) Install a new brake booster gasket on the master cylinder. 2. INSTALL HYDRAULIC BRAKE BOOSTER ASSEMBLY (a) Install the hydraulic brake booster assembly with the 4 nuts. Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf) F051420 To Right Front Wheel To Right Rear Wheel To Left Front Wheel (b) Connect the 4 brake lines to the correct positions of the hydraulic brake booster assembly as shown in the illustration. To Left Rear Wheel BR F051200E01 (c) Using SST, torque the 4 brake lines. SST 09023-00101 Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf) NOTICE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). HINT: This torque value is effective when SST is parallel to the torque wrench. Fulcrum length F051172E01 BR–36 BRAKE – HYDRAULIC BRAKE BOOSTER (d) Connect the 3 connectors to the hydraulic brake booster assembly. F051439E02 BR 3. INSTALL PUSH ROD PIN (a) Install the clip and push rod pin to the clevis. 4. INSTALL STEERING COLUMN HOLE COVER (a) Install the steering column hole cover with the 4 clips. 5. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 6. INSTALL INSTRUMENT PANEL FINISH PLATE 7. INSTALL COWL SIDE TRIM BOARD LH 8. INSTALL FRONT FLOOR FOOTREST 9. INSTALL FRONT DOOR SCUFF PLATE LH F051429E01 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. FILL RESERVOIR WITH BRAKE FLUID HINT: (See page BR-3) 12. BLEED BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY HINT: (See page BR-3) 13. BLEED BRAKE LINE HINT: (See page BR-3) 14. BLEED MASTER CYLINDER SOLENOID HINT: (See page BR-3) BRAKE – HYDRAULIC BRAKE BOOSTER BR–37 15. CHECK BRAKE PEDAL HEIGHT HINT: (See page BR-8) 16. CHECK PEDAL FREE PLAY HINT: (See page BR-8) 17. CHECK PEDAL RESERVE DISTANCE HINT: (See page BR-8) 18. CHECK FLUID LEVEL IN RESERVOIR HINT: (See page BR-17) 19. CHECK FOR BRAKE FLUID LEAKAGE 20. INSPECT BRAKE MASTER CYLINDER OPERATION HINT: (See page BR-17) DISPOSAL 1. A B F051409E01 DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSEMBLY (a) Place the brake booster accumulator assembly in a vise and cover it with cloth. (b) Using a saw, cut the brake booster accumulator body between A and B as shown in the illustration to discharge the gas inside. CAUTION: • Cover with a piece of cloth when working because gas may blow out. • Carefully, not abruptly, cut the assembly. • Wear protective glasses. (c) When the outer body of the brake booster accumulator is cut, gas and liquid discharge. HINT: The gas is colorless, odorless and non-poisonous. BR BRAKE – BRAKE FLUID BR–3 BRAKE FLUID BLEEDING NOTICE: • Wash off brake fluid immediately if it comes into contact with a painted surface. • If the brake pedal is depressed with the reservoir cap removed, then brake fluid will spatter. HINT: • If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. • When bleeding, keep the amount of the fluid between the Min. and Max. lines on the reservoir. 1. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS NO. 116 DOT3 2. BLEED BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY HINT: Perform this step only if the brake booster with accumulator pump assembly is removed and/or installed. (a) Turn the ignition switch off, depress the brake pedal 20 times or more, and release the pressure from the accumulator. (b) Fully depress the brake pedal 10 times. (c) Turn the ignition switch to the ON position and start the brake booster pump. (d) Make sure the pump operates for 8 to 14 seconds. If the pump does not operate as specified, repeat steps (a) to (c) and recheck the operating time. 3. F052299 BLEED BRAKE LINE (a) Front brake line (1) Turn the ignition switch to the ON position and wait until the pump motor has stopped. (2) Connect the vinyl tube to the brake caliper. (3) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. (4) At the point when the fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) (5) Repeat (3) and (4) until all the air in the fluid has been bled out. (6) Repeat the above procedures to bleed the other brake line. BR BR–4 BRAKE – BRAKE FLUID (b) Rear brake line (1) Turn the ignition switch to the ON position and depress the brake pedal. (2) Connect the vinyl tube to the brake caliper. (3) Loosen the bleeder plug and release air. HINT: Brake fluid is sent through the pump, so keep the brake pedal depressed until the air is completely bled out. (4) When the air is completely bled out of the brake fluid through the bleeder plug, tighten the bleeder plug. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) (5) Repeat the above procedures to bleed the other brake line. F052300 4. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Select "ACTIVE TEST" mode on the intelligent tester. (d) Connect the vinyl tube to the rear brake caliper. (e) Loosen the bleeder plug. (f) Select "SRMF & SRMR" to drive the solenoids and bleed air from the rear brake caliper. NOTICE: Do not depress the brake pedal. HINT: • Brake fluid is sent through the pump. • To protect the solenoids, the intelligent tester turns OFF automatically 2 seconds after every solenoid has been turned ON. (g) Repeat step (f) until all the air in the brake fluid is bled out. (h) When the air is completely bled out of the brake fluid through the bleeder plug, tighten the bleeder plug. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) (i) Repeat the above procedures to bleed the other brake line. (j) Turn the ignition switch off. (k) Turn the ignition switch to the ON position. (l) Clear DTC (See page BC-39). Intelligent Tester BR BLEED MASTER CYLINDER SOLENOID HINT: Perform this step only if the master cylinder solenoid is removed and/or installed. DLC3 F051426E01 5. CHECK FLUID LEVEL IN RESERVOIR HINT: (See page BR-17) BRAKE – FRONT BRAKE BR–41 INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) F042679 BR F042680 4. F043106 INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the disc runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page AH-1). If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe. BR–42 BRAKE – FRONT BRAKE REASSEMBLY 1. INSTALL FRONT DISC (a) Aligning the matchmarks, install the front disc. HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout. 2. INSPECT DISC RUNOUT (See page BR-41) 3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG (a) Temporarily tighten the bleeder plug to the disc brake cylinder assembly. (b) Install the breeder plug cap to the breeder plug. 4. INSTALL PISTON SEAL (a) Apply the lithium soap base glycol grease to the 4 new piston seals. (b) Install the 4 piston seals to the disc brake cylinder assembly. 5. INSTALL FRONT DISC BRAKE PISTON (a) Apply the lithium soap base glycol grease to the 4 disc brake pistons. (b) Install the 4 disc brake pistons on the disc brake cylinder assembly. NOTICE: Do not screw the disc brake piston forcedly in the disc brake cylinder assembly. 6. INSTALL CYLINDER BOOT (a) Apply the lithium soap grease glycol grease to the 4 new cylinder boots. (b) Install the 4 cylinder boots on the disc brake cylinder assembly. HINT: Install the cylinder boot securely on the grooves of the disc brake cylinder and piston. BR INSTALLATION 1. F043121 INSTALL DISC BRAKE CYLINDER ASSEMBLY LH (a) Install the disc brake cylinder assembly with 2 bolts. Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) BRAKE – FRONT BRAKE BR–43 (b) Using SST, connect the brake tube to the disc brake cylinder assembly. SST 09023-00101 Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) 2. INSTALL ANTI SQUEAL SHIM KIT FRONT NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad. (a) Install the anti-squeal shims on each brake pads. NOTICE: There should be no oil or grease on the friction surfaces of the brake pads and the front disc. 3. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Install the 2 disc brake pads with anti-squeal shim to the disc brake cylinder assembly. 4. INSTALL FRONT DISC BRAKE ANTIRATTLE W/HOLE PIN (a) Install the 2 anti-rattle w/ hole pins and anti-rattle spring to the disc brake cylinder. HINT: Anti-rattle spring is installed with bottom side of antirattle w/ hole pin. (b) Install the 2 new pin hole clips to the anti-rattle w/ hole pin. NOTICE: When installing the pin hole clip, be sure to install the pin hole clip with the handle facing to the vehicle center. F043120 5. FILL RESERVOIR WITH BRAKE FLUID 6. BLEED BRAKE LINE HINT: (See page BR-3) 7. CHECK FLUID LEVEL IN RESERVOIR 8. CHECK BRAKE FLUID LEAKAGE 9. INSTALL FRONT WHEEL Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) BR BR–5 BRAKE – BRAKE PEDAL BRAKE PEDAL BRAKE COMPONENTS INSTRUMENT PANEL LOWER LH INSTRUMENT PANEL FINISH PLATE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER BR 5.0 (51, 44 in.*lbf) VSC BUZZER CONNECTOR SKID CONTROL ECU ASSEMBLY SKID CONTROL ECU ASSEMBLY SKID CONTROL ECU CONNECTOR 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque C134071E01 BR–6 BRAKE – BRAKE PEDAL CUSHION BRAKE PEDAL RETURN SPRING STOP LIGHT SWITCH ASSEMBLY BRAKE PEDAL SUPPORT SUB-ASSEMBLY STOP LIGHT SWITCH CONNECTOR 14.2 (145, 10) BRAKE PEDAL BUSH 34.3 (350, 25) BRAKE PEDAL SUB-ASSEMBLY BRAKE PEDAL BUSH BRAKE PEDAL SHAFT COLLAR BR COLLAR BRAKE PEDAL SHAFT COLLAR BRAKE PEDAL LINK CLIP E-RING BRAKE PEDAL LINK BRAKE PEDAL LINK PIN 34.3 (350, 25) BRAKE PEDAL PAD COLLAR BRAKE BRAKE PEDAL LEVER PEDAL BUSH BRAKE PEDAL BUSH 34.3 (350, 25) BRAKE PEDAL SUPPORT REINFORCEMENT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Lithium soap base glycol grease C131294E01 BRAKE – REAR BRAKE BR–47 INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scarring. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE (a) Inspect the 4 pad support plates. Make sure the plates have sufficient rebound check for deformation, cracks or wear, rust, dirt or foreign particles. 4. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 18.0 mm (0.709 in.) Minimum thickness: 16.0 mm (0.630 in.) F043130 BR F043131 5. F043187 INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.20 mm (0.0079 in.) (c) If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page AH-1). If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe. BR–48 BRAKE – REAR BRAKE REASSEMBLY BR 1. INSTALL REAR DISC (a) Align the matchmarks and install the rear disc. 2. INSPECT DISC RUNOUT (See page BR-47) 3. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG (a) Temporarily tighten the bleeder plug to the disc brake cylinder assembly rear. (b) Install the bleeder plug cap on the bleeder plug. 4. INSTALL PISTON SEAL (a) Apply the lithium soap base glycol grease to a new piston seal. (b) Install the piston seal on the disc brake cylinder assembly rear. 5. INSTALL REAR DISC BRAKE PISTON (a) Apply the lithium soap base glycol grease to a disc brake piston. (b) Install the disc brake piston on the disc brake cylinder assembly rear. NOTICE: Do not screw the disc brake piston forcedly in the disc brake cylinder assembly rear. 6. INSTALL CYLINDER BOOT (a) Apply the lithium soap base glycol grease to a new cylinder boot. (b) Install the cylinder boot on the disc brake cylinder HINT: Install the cylinder boot securely on the grease of the disc brake cylinder assembly and piston. BRAKE – HYDRAULIC BRAKE BOOSTER BR–13 HYDRAULIC BRAKE BOOSTER BRAKE COMPONENTS INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER INSTRUMENT PANEL FINISH PLATE BR CLIP STEERING COLUMN HOLE COVER FRONT FLOOR FOOTREST COWL SIDE TRIM BOARD LH CLIP FRONT DOOR SCUFF PLATE LH C131297E02 BR–14 BRAKE – HYDRAULIC BRAKE BOOSTER CLIP PUSH ROD PIN BRAKE BOOSTER GASKET HYDRAULIC BRAKE BOOSTER ASSEMBLY BR 14 (145, 10) N*m (kgf*cm, ft.*lbf) : Specified torque 16 (158, 11) *14 (146, 11) Non-reusable part * For use with SST C131298E01 BR–15 BRAKE – HYDRAULIC BRAKE BOOSTER BRAKE ACTUATOR BRACKET NO. 3 MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY 1.7 (17, 15 in.*lbf) BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY MASTER CYLINDER PUSH ROD CLEVIS PIN MASTER CYLINDER RESERVOIR GROMMET LOCK NUT 26 (260, 19) 7.8 (80, 69 in.*lbf) PISTON ROD OPERATING ADAPTER x6 BOLT MASTER CYLINDER BOOT 32 (326, 24) C-RING BRAKE ACTUATOR BRACKET NO. 1 GASKET MASTER CYLINDER SOLENOID 7.8 (80, 69 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Lithium soap base glycol grease C131299E01 BR BR–16 BRAKE – HYDRAULIC BRAKE BOOSTER 57 (585, 42) BRAKE BOOSTER ACCUMULATOR ASSEMBLY O-RING COMPRESSION SPRING BRAKE BOOSTER ACCUMULATOR PIPE BRAKE BOOSTER PUMP ASSEMBLY BRAKE BOOSTER PUMP COLLAR BRAKE BOOSTER PUMP BUSH BRAKE BOOSTER PUMP BRACKET NO. 2 BR 15 (155, 11) *14(143, 10) BRAKE ACTUATOR TUBE NO. 1 PLUG 7.8 (80, 69 in.*lbf) 2.9 (30, 26 in.*lbf) PIN BRAKE BOOSTER PUMP BUSH CLIP BRAKE BOOSTER PUMP BUSH 7.8 (80, 69 in.*lbf) BRAKE ACTUATOR HOSE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * For use with SST C131300E02 BR–17 BRAKE – HYDRAULIC BRAKE BOOSTER ON-VEHICLE INSPECTION Brake Pedal Effort Gauge SST 1. SST INSPECT BRAKE MASTER CYLINDER FLUID PRESSURE CHANGE (a) Inspect the battery voltage. Battery voltage: 11 to 14 V (b) Turn the ignition switch off and depress the brake pedal more than 40 times. HINT: When pressure in the power supply system is released, reaction force becomes light and stroke becomes longer. (c) Install the LSPV gauge (SST) and brake pedal effort gauge, and bleed air. SST 09709-29018 (d) When the booster does not operate: Depress the brake pedal and check fluid pressure. At 245 N (25 kgf, 55 lbf): Front brake pressure Rear brake pressure 2 F043137E02 3,150 kPa (32.1 kgf/cm , 457 psi) or more 0 kPa (0 kgf/cm2, 0 psi) At 343 N (35 kgf, 77 lbf): Front brake pressure 2 4,540 kPa (46.3 kgf/cm , 659 psi) or more Rear brake pressure 0 kPa (0 kgf/cm2, 0 psi) (e) When the booster operates: Depress the brake pedal and check fluid pressure. (1) Turn the ignition switch to the ON position and wait until the pump motor has stopped. (2) Depress the brake pedal and check fluid pressure. At 49 N (5 kgf, 11 lbf): Front brake pressure Rear brake pressure 1,120 to 2,320 kPa 1,220 to 2,420 kPa (11.4 to 23.7 kgf/cm2, 162 to 337 psi) (12.4 to 24.7 kgf/cm2, 177 to 351 psi) At 98 N (10 kgf, 22 lbf): Front brake pressure Rear brake pressure 3,840 to 5,040 kPa 3,990 to 5,190 kPa (39.2 to 51.4 kgf/cm2, 557 to 731 psi) (40.7 to 52.9 kgf/cm2, 579 to 753 psi) At 147 N (15 kgf, 33 lbf): Front brake pressure Rear brake pressure 6,460 to 7,660 kPa 6,660 to 7,860 kPa (65.9 to 78.1 kgf/cm2, 937 to 1,111 psi) (67.9 to 80.1 kgf/cm2, 966 to 1,140 psi) At 196 N (20 kgf, 44 lbf): Front brake pressure Rear brake pressure 8,720 to 9,920 kPa 11,330 to 12,530 kPa (88.9 to 101.2 kgf/cm2, 1,265 to 1,439 psi) (115.5 to 127.8 kgf/cm2, 1,644 to 1,818 psi) BR BR–18 BRAKE – HYDRAULIC BRAKE BOOSTER 2. Intelligent Tester BR DLC3 F051426E01 INSPECT BRAKE MASTER CYLINDER OPERATION (a) Inspect the battery voltage. Battery voltage: 11 to 14 V (b) Turn the ignition switch off and depress the brake pedal more than 20 times. HINT: When pressure in the power supply system is released, reaction force decreases and stroke becomes longer. (c) Check that the brake pedal reaction force decreases. If the pedal reaction force does not decreases, check and replace the brake line and brake master cylinder. (d) Turn the ignition switch to the ON position and check the pump motor operation noise. If the pump motor does not operate, check and replace the wire harness and pump motor (See page BR-25). (e) Connect the intelligent tester to the DLC3. (f) Turn the ignition switch to the ON position. (g) Select "ACTIVE TEST" mode on the intelligent tester. HINT: Please refer to the intelligent tester operator's manual for further details. (h) Jack up and support the vehicle. (i) Release the parking brake lever. (j) Shift the transfer shift lever to the "N" position and check that the rear wheels rotate by hand. (k) Inspect front VSC solenoid (SMCF) operation. (1) Select "SRCF (SMCF)" on the intelligent tester. (2) Turn the "SRCF (SMCF)" ON with the intelligent tester, depress the brake pedal with stable force and check that the pedal cannot be depressed. If the pedal can be depressed, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. (3) Release the brake pedal. (4) When the solenoid is OFF, depress the brake pedal again and check that the brake pedal can be depressed. If the pedal cannot be depressed, replace the brake master cylinder. BRAKE – HYDRAULIC BRAKE BOOSTER BR–19 (l) Inspect front VSC solenoid (SREA) operation. (1) Select "SRCR (SREA)" and "SRCF (SMCF)" on the intelligent tester. (2) Turn the "SRCR (SREA)" and "SRCF (SMCF)" ON simultaneously with the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoids are ON, check that the front wheels do not rotate by hand. If the front wheels rotate, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheels fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheels as slowly as possible. (4) When the solenoids are OFF, turn the "SRCF (SMCF)" ON again, and then depress the brake pedal. Then check the front wheels by rotating them by hand. If the front wheels stop, replace the brake master cylinder. (5) When the "SRCF (SMCF)" is OFF, depress the brake pedal again and check that the brake pedal can be depressed. If the pedal cannot be depressed, replace the brake master cylinder. (m) Inspect front ABS solenoid (SFRH) operation. (1) Select "SFRH" on the intelligent tester. (2) Turn the "SFRH" ON with the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is ON, check the right front wheel by rotating it by hand. If the right front wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. BR BR–20 BR BRAKE – HYDRAULIC BRAKE BOOSTER (4) When the solenoid is OFF, depress the brake pedal again and check that the right front wheel does not rotate by hand. If the right front wheel rotates, replace the brake master cylinder. HINT: When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (n) Inspect front ABS solenoid (SFLH) operation. (1) Select "SFLH" on the intelligent tester. (2) Turn the "SFLH" ON with the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is ON, check the left front wheel by rotating it by hand. If the left front wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoid is OFF, depress the brake pedal again and check that the left front wheel does not rotate by hand. If the left front wheel rotates, replace the brake master cylinder. (o) Inspect front ABS solenoid (SFRR) operation. (1) Select "SFRR" and "SFRH" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SFRR" and "SFRH" ON simultaneously with the intelligent tester. (3) When the solenoids are ON, check that the right front wheel by rotating it by hand. If the right front wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. BRAKE – HYDRAULIC BRAKE BOOSTER BR–21 • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoids are OFF, depress the brake pedal again and check that the right front wheel does not rotate by hand. If the right front wheel rotates, replace the brake master cylinder. (p) Inspect front ABS solenoid (SFLR) operation. (1) Select "SFLR" and "SFLH" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SFLR" and "SFLH" ON simultaneously with the intelligent tester. (3) When the solenoids are ON, check the left front wheel by rotating it by hand. If the left front wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoids are OFF, depress the brake pedal again and check that the left front wheel does not rotate by hand. If the left front wheel rotates, replace the brake master cylinder. (q) Inspect rear VSC solenoid (SREC) operation. (1) Select "SRMF (SREC)" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRMF (SREC)" ON with the intelligent tester. (3) Release the brake pedal when the solenoid is on, and check that the rear wheels do not rotate by hand. If the rear wheels rotate, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. BR BR–22 BR BRAKE – HYDRAULIC BRAKE BOOSTER • When rotating the wheels fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheels as slowly as possible. (4) When the solenoid is OFF, check the rear wheels by rotating them by hand. If the rear wheels stop, replace the brake master cylinder. (r) Inspect rear VSC solenoid (STR) operation. (1) Select "SRMR (STR)" and "SRMF (SREC)" on the intelligent tester. (2) Turn the "SRMR (STR)" and "SRMF (SREC)" ON simultaneously with the intelligent tester. (3) When the solenoids are ON, check that the rear wheels do not rotate by hand. If the rear wheels rotate, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheels fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheels as slowly as possible. (4) When the solenoids are OFF, turn the "SRMF (SREC)" ON again, and check the rear wheels by rotating them by hand. If the rear wheels stop, replace the brake master cylinder. (5) When the "SRMF (SREC)" is OFF, depress the brake pedal again and check that the rear wheels do not rotate by hand. If the rear wheels rotate, replace the brake master cylinder. (s) Inspect rear ABS solenoid (SRRH) operation. (1) Select "SRRH" on the intelligent tester. (2) Turn the "SRRH" ON with the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is ON, check the right rear wheel by rotating it by hand. If the right rear wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. BRAKE – HYDRAULIC BRAKE BOOSTER BR–23 • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoid is OFF, depress the brake pedal again and check that the right rear wheel does not rotate by hand. If the right rear wheel rotates, replace the brake master cylinder. HINT: When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (t) Inspect rear ABS solenoid (SRLH) operation. (1) Select "SRLH" on the intelligent tester. (2) Turn the "SRLH" ON with the intelligent tester, then depress the brake pedal with stable force. (3) When the solenoid is ON, check the left rear wheel by rotating it by hand. If the left rear wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoid is OFF, depress the brake pedal again and check that the left rear wheel does not rotate by hand. If the left rear wheel rotates, replace the brake master cylinder. (u) Inspect rear ABS solenoid (SRRR) operation. (1) Select "SRRR" and "SRRH" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRRR" and "SRRH" ON simultaneously with the intelligent tester. (3) When the solenoids are ON, check the right rear wheel by rotating it by hand. If the right rear wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. BR BR–24 BRAKE – HYDRAULIC BRAKE BOOSTER HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel too fast, the failsafe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoids are OFF, depress the brake pedal again and check that the right rear wheel does not rotate by hand. If the right rear wheel rotates, replace the brake master cylinder. (v) Inspect rear ABS solenoid (SRLR) operation. (1) Select "SRLR"and "SRLH" on the intelligent tester. (2) Depress the brake pedal with stable force, then turn the "SRLR" and "SRLH" ON simultaneously with the intelligent tester. (3) When the solenoids are ON, check the left rear wheel by rotating it by hand. If the left rear wheel stops, replace the brake master cylinder. NOTICE: When operating it continuously, set the interval of more than 20 seconds. HINT: • To protect the solenoids, the intelligent tester turns OFF automatically 2 sec. after every solenoid has been turned ON. • When rotating the wheel too fast, the failsafe function is activated and judgement cannot be made properly. Rotate the wheel as slowly as possible. (4) When the solenoids are OFF, depress the brake pedal again and check that the left rear wheel does not rotate by hand. If the left rear wheel rotates, replace the brake master cylinder. (w) Lower the vehicle. (x) Disconnect the intelligent tester. BR 3. INSPECT BRAKE FLUID LEVEL (a) Turn the ignition switch off, depress the brake pedal 20 times or more (until the pedal reaction feels light and pedal stroke becomes longer), and adjust the fluid level to the MAX level. (b) When the ignition switch is turned to the ON position, brake fluid is sent to the accumulator and the fluid level decreases by approximately 5 mm from the level when the ignition switch is off (normal). BRAKE – REAR BRAKE BR–49 INSTALLATION F043126 F043124 1. INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Apply the lithium soap base glycol grease to a new cylinder hole plug and 2 new cylinder slide bushes. (b) Install the cylinder hole plug and 2 cylinder slide bush to the rear disc brake cylinder mounting. 2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH (a) Install the rear disc brake cylinder mounting with 2 bolts. Torque: 105 N*m (1,071 kgf*cm, 77 ft.*lbf) 3. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE (a) Install the 4 pad support plates on the rear disc brake cylinder mounting. 4. INSTALL REAR DISC BRAKE PAD WEAR INDICATOR PLATE (a) Install the pad wear indicator plate on the inner side disc brake pad. HINT: Install the pad wear indicator facing downward. 5. INSTALL REAR DISC BRAKE ANTI-SQUEL SHIM NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad. (a) Install the anti-squeal shims on each brake pad. NOTICE: There should be no oil or grease on the friction surfaces of the brake pads and the rear disc. 6. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY) (a) Install the 2 disc brake pads with anti-squeal shim to the disc brake cylinder assembly. 7. INSTALL DISC BRAKE CYLINDER ASSEMBLY REAR LH (a) Apply the lithium soap base glycol grease to the sliding part of 2 cylinder slide pins. (b) Install the disc brake cylinder assembly rear with 2 cylinder slide pins. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) BR BR–50 BRAKE – REAR BRAKE 8. CONNECT REAR LH FLEXIBLE HOSE (a) Connect the flexible hose with union bolt and new gasket to the disc brake cylinder assembly rear. Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 9. FILL RESERVOIR WITH BRAKE FLUID 10. BLEED BRAKE LINE HINT: (See page BR-3) F043125 11. CHECK FLUID LEVEL IN RESERVOIR 12. CHECK BRAKE FLUID LEAKAGE 13. INSTALL REAR WHEEL Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) BR BRAKE: FRONT BRAKE: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Brake Section: Brake (front) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q8Y007X Title: BRAKE: FRONT BRAKE: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the 4 cylinder boots from the caliper. 2. REMOVE FRONT DISC BRAKE PISTON (a) Prepare the wooden plate to hold the pistons. (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. BRAKE: FRONT BRAKE: DISASSEMBLY (2007 4Runner) 3. REMOVE PISTON SEAL (a) Using a screwdriver, remove the 4 piston seals from the cylinder. 4. REMOVE FRONT DISC BRAKE BLEEDER PLUG (a) Remove the breeder plug cap and breeder plug from the disc brake cylinder assembly. 5. INSPECT BRAKE CYLINDER AND PISTON 6. INSPECT PAD LINING THICKNESS 7. INSPECT DISC THICKNESS 8. REMOVE FRONT DISC (a) Make matchmarks on the disc and the axle hub. (b) Remove the front disc. BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Brake Section: Brake (front) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q8V007X Title: BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) 4. INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 110 N·m (1,122 kgf·cm, 81 ft·lbf) BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the disc runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout . If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe. AXLE: AXLE SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Axle/Differential Model Year: 2007 Model: 4Runner Doc ID: RM0000016ZS006X Title: AXLE: AXLE SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT FRONT AXLE HUB (a) Remove the front wheel. (b) Remove front disc brake caliper . (c) Remove the front disc. (d) Inspect the axle hub backlash. (1) Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (e) Inspect the axle hub deviation. (1) Using a dial indicator, check the distortion at the surface of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the bearing. 2. INSPECT REAR AXLE HUB & BEARING ASSEMBLY AXLE: AXLE SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) (a) Remove the rear wheel. (b) Remove the rear disc brake caliper . (c) Remove the rear disc. (d) Inspect the axle shaft backlash. (1) Using a dial indicator, check the backlash near the center of the axle shaft. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (e) Inspect the axle shaft deviation. (1) Using a dial indicator, check the distortion at the surface of the axle shaft. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the bearing. BRAKE: FRONT BRAKE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Brake Section: Brake (front) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q8X007X Title: BRAKE: FRONT BRAKE: REMOVAL (2007 4Runner) REMOVAL HINT: Overhaul procedure of the RH side is the same as that of with LH side. 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface. 3. REMOVE FRONT DISC BRAKE ANTIRATTLE W/HOLE PIN (a) Remove the 2 pin hole clips, then remove the 2 antirattle w/ hole pins from disc brake cylinder assembly. (b) Remove the anti-rattle spring from the disc brake pad. 4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Remove the 2 disc brake pads with anti-squeal shim from the disc brake cylinder assembly. 5. REMOVE ANTI SQUEAL SHIM KIT FRONT (a) Remove the 2 anti-squeal shims from each of the disc brake pads. 6. REMOVE DISC BRAKE CYLINDER ASSEMBLY LH (a) Using SST, disconnect the brake tube from the disc brake cylinder assembly. SST: 09023-00101 BRAKE: FRONT BRAKE: REMOVAL (2007 4Runner) HINT: Use a container to each brake fluid as it drains out. (b) Remove the 2 bolts and remove the disc brake cylinder assembly. BRAKE: REAR BRAKE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Brake Section: Brake (rear) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q93006X Title: BRAKE: REAR BRAKE: REMOVAL (2007 4Runner) REMOVAL HINT: Overhaul the RH side by using the same procedures as those for the LH side. 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces. 3. DISCONNECT REAR LH FLEXIBLE HOSE (a) Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder assembly rear. HINT: Use a container to catch brake fluid as it drains out. 4. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH (a) Remove the 2 cylinder slide pins from disc brake cylinder assembly rear. (b) Remove the disc brake cylinder assembly rear from rear disc brake cylinder mounting. 5. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY) BRAKE: REAR BRAKE: REMOVAL (2007 4Runner) (a) Remove the 2 brake pads with anti-squeal shims from rear disc brake cylinder mounting. 6. REMOVE REAR DISC BRAKE ANTI-SQUEL SHIM (a) Remove the 2 anti-squeal shims from each disc brake pads. 7. REMOVE REAR DISC BRAKE PAD WEAR INDICATOR PLATE (a) Remove the pad wear indicator plate from the inner side disc brake pad. 8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the 4 pad support plates from the rear disc brake cylinder mounting. 9. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH (a) Remove the 2 bolts and rear brake cylinder mounting. 10. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Remove the 2 cylinder slide bushes from the rear disc brake cylinder mounting. (b) Remove the cylinder hole plug from the rear disc brake cylinder mounting. BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Brake Section: Brake (front) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q8V007X Title: BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) 4. INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 110 N·m (1,122 kgf·cm, 81 ft·lbf) BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the disc runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout . If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe. BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Brake Section: Brake (front) Model Year: 2007 Model: 4Runner Doc ID: RM000001Q8V007X Title: BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust or scoring. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) 4. INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 110 N·m (1,122 kgf·cm, 81 ft·lbf) BRAKE: FRONT BRAKE: INSPECTION (2007 4Runner) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the disc runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout . If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on a "On-car" brake lathe. BR–44 BRAKE – REAR BRAKE REAR BRAKE BRAKE COMPONENTS 88 (897 65) 11 (112, 8) CYLINDER SLIDE PIN BLEEDER PLUG 88 (897 65) BLEEDER PLUG CAP CYLINDER SLIDE PIN PISTON SEAL REAR FLEXIBLE HOSE PAD SUPPORT PLATE DISC BRAKE PISTON 31 (316, 23) UNION BOLT GASKET DISC BRAKE CYLINDER ASSEMBLY REAR LH BRAKE PAD CYLINDER BOOT ANTI-SQUEAL SHIM 105 (1,071, 77) BR ANTI-SQUEL SHIM PAD WEAR INDICATOR PLATE REAR DISC BRAKE CYLINDER MOUNTING LH CYLINDER SLIDE BUSH PAD SUPPORT PLATE CYLINDER SLIDE BUSH 105 (1,071, 77) CYLINDER HOLE PLUG REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Lithium soap base glycol grease C131296E01 BRAKE – REAR BRAKE BR–45 REMOVAL HINT: Overhaul the RH side by using the same procedures as those for the LH side. 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces. 3. DISCONNECT REAR LH FLEXIBLE HOSE (a) Remove the union bolt and gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder assembly rear. HINT: Use a container to catch brake fluid as it drains out. 4. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR LH (a) Remove the 2 cylinder slide pins from disc brake cylinder assembly rear. (b) Remove the disc brake cylinder assembly rear from rear disc brake cylinder mounting. F043125 5. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY) (a) Remove the 2 brake pads with anti-squeal shims from rear disc brake cylinder mounting. 6. REMOVE REAR DISC BRAKE ANTI-SQUEL SHIM (a) Remove the 2 anti-squeal shims from each disc brake pads. 7. REMOVE REAR DISC BRAKE PAD WEAR INDICATOR PLATE (a) Remove the pad wear indicator plate from the inner side disc brake pad. 8. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE (a) Remove the 4 pad support plates from the rear disc brake cylinder mounting. 9. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH (a) Remove the 2 bolts and rear brake cylinder mounting. F043124 F043126 10. REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Remove the 2 cylinder slide bushes from the rear disc brake cylinder mounting. (b) Remove the cylinder hole plug from the rear disc brake cylinder mounting. BR BR–46 BRAKE – REAR BRAKE DISASSEMBLY 1. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the cylinder boot from disc brake cylinder assembly rear. 2. REMOVE REAR DISC BRAKE PISTON (a) Place a of cloth or equivalent between the piston and the disc brake cylinder assembly rear. (b) Use compressed air to remove the piston from the disc brake cylinder assembly rear. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid. 3. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the disc brake cylinder assembly rear. 4. REMOVE REAR DISC BRAKE BLEEDER PLUG (a) Remove the bleeder plug cap and bleeder plug from disc brake cylinder assembly rear. 5. INSPECT BRAKE CYLINDER AND PISTON (See page BR-46) 6. INSPECT PAD LINING THICKNESS (See page BR-47) 7. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE (See page BR-47) 8. INSPECT DISC THICKNESS (See page BR-47) 9. REMOVE REAR DISC (a) Make matchmarks on the rear disc and the axle hub. (b) Remove the rear disc. F043127 F043128 BR F043129 PB–4 PARKING BRAKE – PARKING BRAKE PEDAL REMOVAL 1. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: (See page IP-6) 2. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY HINT: (See page AC-111) 3. REMOVE AIR BAG SENSOR ASSEMBLY CENTER HINT: (See page RS-428) 4. REMOVE YAWRATE SENSOR HINT: (See page BC-215) 5. REMOVE FLOOR SHIFT ASSEMBLY Type See procedure A750F AT-337 A750E AT-327 6. PB D028115 REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Release the parking brake pedal. (b) Disconnect the parking brake switch connector. (c) Remove the 3 nuts and parking brake control pedal assembly. PARKING BRAKE – PARKING BRAKE PEDAL 7. PB–5 REMOVE PARKING BRAKE CABLE ASSEMBLY NO. 1 (a) Remove the lock nut, adjusting nut, clip and disconnect the parking brake cable assembly No. 1 from the parking brake control pedal assembly. (b) Remove the 2 nuts and 3 bolts from the parking brake cable assembly No. 1. D028116 PB D028118 (c) Remove the lock nut, adjusting nut and parking brake cable assembly No. 1 from the parking brake equalize. D028113 INSTALLATION 1. D028113 INSTALL PARKING BRAKE CABLE ASSEMBLY NO. 1 (a) Install the parking brake cable assembly No. 1, temporary tighten the adjusting nut and lock nut. PB–6 PARKING BRAKE – PARKING BRAKE PEDAL (b) Install the parking brake cable assembly No. 1 with the 2 nuts and 3 bolts. (A) (B) (B) (B) (A) D028118E01 Torque: NUT (A) 6.0 N*m (61 kgf*cm, 53 in.*lbf) BOLT (B) 13 N*m (127 kgf*cm, 9 ft.*lbf) PB (c) Install the parking brake cable assembly No. 1 with the clip, adjusting nut and lock nut. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) (d) Bend the claw. D028116 PB–7 PARKING BRAKE – PARKING BRAKE PEDAL 2. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Install the parking brake control pedal assembly with the 3 nuts. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) (b) Connect the parking brake switch connector. 3. INSTALL FLOOR SHIFT ASSEMBLY Type See procedure A750F AT-341 A750E AT-331 4. INSTALL AIR BAG SENSOR ASSEMBLY CENTER HINT: (See page RS-428) 5. INSTALL YAWRATE SENSOR HINT: (See page BC-216) 6. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY HINT: (See page AC-121) 7. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: (See page IP-12) 8. INSPECT PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) 9. ADJUST PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) D028115 10. INSPECT SRS WARNING LIGHT HINT: (See page BC-23) PB PARKING BRAKE – PARKING BRAKE ASSEMBLY PB–15 INSPECTION 1. INSPECT BRAKE DISC INSIDE DIAMETER (a) Using a brake drum gauge or equivalent, measure the inside diameter of the disk. Standard inside diameter: 210mm (8.27 in.) Maximum inside diameter: 211mm (8.30 in.) 2. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard inside diameter: 4.0mm (0.158 in.) Maximum inside diameter: 1.0mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is severe or uneven wear, replace the brake shoe. 3. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. F006409 BR05332 BR00828 REASSEMBLY 1. BR05332 INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 4.0 mm (0.158 in.) Minimum thickness: 1.0mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is severe or uneven wear, replace the brake shoe. PB PB–16 PARKING BRAKE – PARKING BRAKE ASSEMBLY 2. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. 3. APPLY HIGH TEMPERATURE GREASE (a) Apply the high temperature grease to the shoe attached surface of backing plate (See page PB13). 4. INSTALL PARKING BRAKE SHOE (a) Install the shoe lever and the shim to the rear shoe with a new C-washer. BR00828 (b) Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.25 mm (0.0098 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.6 mm (0.024 in. ) 0.4 mm (0.016 in.) 0.9 mm (0.035 in.) 0.5 mm (0.020 in.) - R000343 (c) Apply the high temperature grease to the adjusting bolt and piece. (d) Install the shoe adjusting screw set and the tension spring to the front and rear shoe. (e) Install the 2 pins, 4 cups and 2 shoe hold-down springs. (f) Connect the parking brake cable to the shoe lever. (g) Install the front and rear parking brake shoe. PB 5. INSTALL PARKING BRAKE SHOE STRUT LH 6. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 7. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (a) Using a needle nose pliers, install the 2 return tension springs. HINT: Install front side spring first, rear side spring next. 8. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. NOTICE: There should be no oil or grease adhering to the friction surface of the shoe lining and disk. F041705 PB–17 PARKING BRAKE – PARKING BRAKE ASSEMBLY RH LH Front Front D028130E02 9. Expand Contract D028131E02 INSTALL REAR DISC 10. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the hole plug, and turn the adjuster and expand the shoes until the disc locks. (c) Contract the shoe adjuster until the disc rotates smoothly. Standard : Return 8 notches (d) Check the shoe has no brake drag. (e) Install the hoke plug. 11. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Install the rear disc brake caliper with the 2 bolts. Torque: 105 N*m (1,071 kgf*cm, 77 ft.*lbf) 12. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 13. INSPECT PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) 14. ADJUST PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) PB PB–1 PARKING BRAKE – PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PROBLEM SYMPTOMS TABLE Use the table below to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. PARKING BRAKE SYSTEM Symptom Brake drag Suspected Area See page 1. Parking brake pedal travel (Out of adjustment) PB-1 2. Parking brake wire (Sticking) PB-8 3. Parking brake shoe clearance (Out of adjustment) PB-15 4. Parking brake shoe lining (Cracked or distorted) PB-15 5. Tension or return spring (Damaged) PB-15 PB PB–2 PARKING BRAKE – PARKING BRAKE SYSTEM ADJUSTMENT D028113 PB 1. REMOVE REAR WHEEL 2. ADJUST PARKING BRAKE SHOE CLEARANCE HINT: (See page PB-15) 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. INSPECT PARKING BRAKE PEDAL TRAVEL (a) Slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel at 294 N (30 kgf, 66 lbf): 5 to 7 clicks 5. ADJUST PARKING BRAKE PEDAL TRAVEL (a) Remove the console rear panel upper. (b) Remove the console panel upper. (c) Remove the rear console box. (d) Confirm that the parking brake pedal is released. (e) Loosen the lock nut and turn the adjusting nut until the parking brake pedal travel is corrected to the specification. (f) Tighten the lock nut. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) (g) Check whether parking brake drags or not. (h) When operating the parking brake pedal, check that the parking brake pedal indicator light comes on. (i) Install the rear console box. (j) Install the console panel upper. (k) Install the console rear panel upper. PB–2 PARKING BRAKE – PARKING BRAKE PEDAL PARKING BRAKE PEDAL PARKING BRAKE BRAKE COMPONENTS PARKING BRAKE SWITCH ASSEMBLY 13 (127, 9) 13 (127, 9) ADJUSTING NUT PB 5.4 (55, 48 in.*lbf) LOCK NUT 13 (127, 9) PARKING BRAKE CABLE ASSEMBLY NO. 1 PARKING PEDAL PAD PARKING BRAKE CONTROL PEDAL ASSEMBLY CLIP N*m (kgf*cm, ft.*lbf) : Specified torque C131301E01 PB–3 PARKING BRAKE – PARKING BRAKE PEDAL 13 (127, 9) PARKING BRAKE CONTROL PEDAL ASSEMBLY ADJUSTING NUT 5.4 (55, 48 in.*lbf) 13 (127, 9) LOCK NUT CONSOLE BOX DUCT NO. 1 PARKING BRAKE CABLE ASSEMBLY NO. 1 6.0 (61, 53 in.*lbf) PB 13 (127, 9) 13 (127, 9) PARKING BRAKE EQUALIZER 12 (122, 9) ADJUSTING NUT 13 (156, 10) 13 (127, 9) LOCK NUT FLOOR SHIFT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque YAWRATE SENSOR C131302E02 PB–8 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE CABLE PARKING BRAKE BRAKE COMPONENTS 8.0 (82, 71 in.*lbf) 13 (127, 9) 13 (127, 9) PARKING BRAKE CABLE ASSEMBLY NO. 2 13 (127, 9) PB CLIP 13 (127, 9) 13 (127, 9) PARKING BRAKE EQUALIZER 8.0 (82, 71 in.*lbf) PARKING BRAKE CABLE ASSEMBLY NO. 3 N*m (kgf*cm, ft.*lbf) : Specified torque C131303E03 PARKING BRAKE – PARKING BRAKE CABLE PB–9 REMOVAL 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Remove the 2 bolts and separate the rear disc brake caliper assembly LH. HINT: Don not disconnect the flexible hose from the brake caliper assembly LH. 3. REMOVE REAR DISC (See page PB-14) 4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-14) 5. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (See page PB-14) 6. REMOVE PARKING BRAKE SHOE STRUT LH 7. REMOVE PARKING BRAKE SHOE (See page PB-14) 8. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 9. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 10. REMOVE CONSOLE UPPER PANEL GARNISH NO. 1 (See page IP-7) 11. REMOVE CONSOLE UPPER PANEL GARNISH NO. 2 12. REMOVE CONSOLE BOX ASSEMBLY REAR (See page IP-9) 13. REMOVE PARKING BRAKE CABLE ASSEMBLY NO. 3 (a) Remove the 2 bolts and disconnect the parking brake cable assembly No. 3 from the backing plate. D028121 PB PB–10 PARKING BRAKE – PARKING BRAKE CABLE (b) Remove the 4 bolts from the parking cable assembly No. 3. D028122 (c) Remove the clip and disconnect the parking brake cable assembly No. 3 from the parking brake equalizer. PB D028123 INSTALLATION 1. D028123 INSTALL PARKING BRAKE CABLE ASSEMBLY NO. 3 (a) Install the parking brake cable assembly no. 3 with the clip to the parking brake equalizer. PARKING BRAKE – PARKING BRAKE CABLE PB–11 (b) Install the parking brake cable assembly No. 3 with the 4 bolts. D028122 Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) (c) Install the parking brake cable assembly No. 3 with the 2 bolts to the backing plate. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) D028121 2. APPLY HIGH TEMPERATURE GREASE (See page PB-16) 3. INSTALL PARKING BRAKE SHOE (See page PB-16) 4. INSTALL PARKING BRAKE SHOE STRUT LH 5. INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING 6. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (See page PB-16) 7. CHECK PARKING BRAKE INSTALLATION (See page PB-16) 8. INSTALL REAR DISC 9. ADJUST PARKING BRAKE SHOE CLEARANCE (See page PB-17) 10. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Install the rear disc brake caliper assembly LH with the 2 bolts. Torque: 105 N*m (1,071 kgf*cm, 77 ft.*lbf) 11. INSTALL REAR WHEEL Torque: 112 N*m (1,137 kgf*cm, 83 ft.*lbf) 12. INSTALL CONSOLE BOX ASSEMBLY REAR PB PB–12 PARKING BRAKE – PARKING BRAKE CABLE 13. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 14. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 15. INSPECT PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) 16. ADJUST PARKING BRAKE PEDAL TRAVEL HINT: (See page PB-1) PB PB–13 PARKING BRAKE – PARKING BRAKE ASSEMBLY PARKING BRAKE ASSEMBLY PARKING BRAKE BRAKE COMPONENTS SHOE HOLD -DOWN SPRING PIN REAR DISC BRAKE CALIPER ASSEMBLY LH 105 (1,071, 83) PARKING BRAKE SHOE RETURN TENSION SPRING SHIM SHOE HOLD-DOWN SPRING C-WASHER PB PARKING BRAKE SHOE STRUT COMPRESSION SPRING PARKING BRAKE SHOE LEVER PARKING BRAKE SHOE PARKING BRAKE SHOE RETURN TENSION SPRING ADJUSTING PIECE ADJUSTING BOLT SHOE ADJUSTING SCREW SET PARKING BRAKE SHOE HOLE PLUG PARKING BRAKE SHOE STRUT LH SHOE HOLD-DOWN SPRING CUP REAR DISC N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Compressor oil ND-OIL 11 or equivalent C131304E01 PB–14 PARKING BRAKE – PARKING BRAKE ASSEMBLY DISASSEMBLY 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH (a) Remove the 2 bolts and separate the rear disc brake caliper assembly LH. HINT: Do not disconnect the flexible hose from the brake caliper. 3. REMOVE REAR DISC (a) Release the parking brake, and remove rear disc. HINT: • Put matchmarks on the disc and remove the axle shaft. • If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. 4. INSPECT BRAKE DISC INSIDE DIAMETER (a) Using a brake drum gauge or equivalent, measure the inside diameter of the disc. Standard inside diameter: 210mm (8.27 in.) Maximum inside diameter: 211mm (8.30 in.) 5. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (a) Using a needle-nose pliers, remove the 2 return tension springs. 6. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (a) Slide out the front shoe and remove the compression spring. 7. REMOVE PARKING BRAKE SHOE STRUT LH 8. REMOVE PARKING BRAKE SHOE (a) Release the cup claw and remove the front and rear parking brake shoe. (b) Disconnect the parking brake cable from the shoe lever. (c) Remove the tension spring and shoe adjuster screw set from the front rear shoe. (d) Remove the 2 shoe hold-down springs, 4 cups and 2 pins. (e) Using a screwdriver, remove the C-washer. (f) Remove the shim and shoe lever from the parking brake shoe. Contract D028126E06 PB F006409 D028127 STEERING COLUMN – STEERING SYSTEM SR–3 ON-VEHICLE INSPECTION 1. Maximum Free Play 30 mm (1.18 in.) INSPECT STEERING WHEEL FREE PLAY (a) Stop the vehicle and align the tires facing straight ahead. (b) Gently turn the steering wheel right and left by hand, and check the steering wheel free play. Maximum free play: 30 mm (1.18 in.) HINT: If the free play exceeds the maximum, check the steering column, steering intermediate shaft, steering sliding yoke, or steering gear. C115520E01 SR SR–4 STEERING COLUMN – STEERING SYSTEM ADJUSTMENT 1. STEERING OFF CENTER ADJUSTMENT PROCEDURE HINT: This is the adjustment procedure for steering off center. (a) Inspect steering wheel off center. (1) Apply masking tape on the top center of the steering wheel and steering column upper cover. (2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/ h), and hold the steering wheel to maintain the course. Steering Wheel Masking Tape Steering Column Upper Cover F016015E08 (3) Draw a line on the masking tape as shown in the illustration. (4) Turn the steering wheel to the center position. HINT: Look at the upper surface of the steering wheel, steering spoke and SRS airbag line to find the center position. Steering Column Upper Cover Marked Line SR Steering Wheel Masking Tape F016016E10 STEERING COLUMN – STEERING SYSTEM SR–5 (5) Draw a new line on the masking tape on the steering wheel as shown in the illustration. (6) Measure the distance between the 2 lines on the masking tape on the steering wheel. (7) Convert the measured distance to steering angle. HINT: • Measured distance 1 mm (0.04 in.) = Steering angle of approximately 1 degree. • Make a note of the steering angle. Steering Column Upper Cover Marked Line Steering Wheel F016017E07 Marked Line R000429E09 F016018E04 (b) Adjust steering angle. (1) Draw a line on the RH and LH tie rod ends and rack ends respectively where it can be easily seen. (2) Using a paper gauge, measure the distance from the RH and LH tie rod ends to the rack end screws. HINT: • Measure both the RH and LH sides. • Make a note of the measured values. (3) Remove the RH and LH boot clips from the rack boots. (4) Loosen the RH and LH lock nuts. (5) Turn the RH and LH rack ends by the same amount (but in different directions) according to the steering angle. HINT: One 360 degree turn of rack end (1.5 mm (0.059 in.) horizontal movement) equals to 12 degrees of steering angle. (6) Tighten the RH and LH lock nuts to the specified torque. Torque: 56 N*m (570 kgf*cm, 41 ft.*lbf) NOTICE: Make sure that the difference in length between the RH and LH tie rod ends and rack end screws is within 1.5 mm (0.059 in.). (7) Install the RH and LH boot clips. SR SR–8 STEERING COLUMN – STEERING COLUMN ASSEMBLY REMOVAL Torx Screw Screw Case 1. PRECAUTION HINT: See page RS-1. 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO. 3 5. REMOVE STEERING WHEEL COVER LOWER NO. 2 6. REMOVE STEERING PAD NOTICE: If the airbag connector is disconnected with the ignition switch being at ON, DTCs will be recorded. (a) Using a "torx" socket wrench ("Torx" socket wrench (T=30)), loosen the 2 "torx" screws until the groove along the screw circumference catches on the screw case. F043322E01 (b) Pull out the steering pad from the steering wheel assembly. NOTICE: When removing the steering pad, take care not to pull the airbag wire harness. (c) Using a screwdriver, release the lock part of each of the airbag connectors and disconnect the 2 airbag connectors. (d) Disconnect the horn ground harness from the steering pad. SR Horn Ground Harness Airbag Connector F043321E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY Correct SR–9 (e) Remove the steering pad. CAUTION: • When storing the steering pad, keep the upper surface of the pad facing upward. • Never disassemble the steering pad. Wrong F043311E01 SST 7. REMOVE STEERING WHEEL ASSEMBLY (a) without Steering pad switch: Disconnect the connector. (b) Remove the steering wheel assembly set nut. (c) Mark matchmarks on the steering wheel assembly and main shaft assembly. (d) Set the SST on the steering wheel assembly. (e) Holding the SST to the monkey spanner and turn the SST, then remove the steering wheel assembly. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) 8. REMOVE FRONT DOOR SCUFF PLATE LH 9. REMOVE FRONT FLOOR FOOT REST Matchmarks F043320E01 10. REMOVE COWL SIDE TRIM BOARD LH 11. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-7) 12. REMOVE INSTRUMENT PANEL LOWER LH 13. REMOVE STEERING COLUMN COVER LWR (a) Remove the 3 screws and steering column cover lower. 14. REMOVE STEERING COLUMN COVER UPR F043298 15. REMOVE SPIRAL CABLE (a) Disconnect the 2 connectors. (b) Remove the 4 screws and spiral cable. H042178 SR SR–10 STEERING COLUMN – STEERING COLUMN ASSEMBLY 16. REMOVE TURN SIGNAL SWITCH ASSEMBLY (a) Disconnect the 3 connectors. (b) Remove the 3 screws and turn signal switch assembly. 17. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 (a) Remove the 4 bolts and engine under cover subassembly No. 1. F043318 18. REMOVE ENGINE UNDER COVER ASSEMBLY REAR (a) Remove the 4 bolts and engine under cover assembly rear. 19. REMOVE STEERING SLIDING YOKE (a) Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2 and steering intermediate shaft assembly. (b) Remove the bolt A and bolt B from the steering sliding yoke. (c) Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2. (d) Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove. A B Matchmarks 20. REMOVE STEERING INTERMEDIATE SHAFT SUBASSEMBLY NO. 2 (a) Mark matchmarks on the power steering gear assembly and steering intermediate shaft subassembly No. 2. (b) Remove the bolt C and intermediate shaft subassembly No. 2 from the power steering gear assembly. C SR Matchmarks F043317E02 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–11 21. REMOVE STEERING COLUMN HOLE COVER (a) Remove the heater to register duct. (b) Remove the 4 clips and steering column hole cover. 22. REMOVE STEERING COLUMN ASSEMBLY (a) Disconnect each of the connectors from the steering column assembly. (b) Disconnect the wire harness from the steering column assembly. (c) Remove the 4 steering column set nuts. (d) Pull out the steering column assembly with the intermediate shaft assembly. Steering Column Hole Cover F043316E01 DISASSEMBLY Matchmarks 1. F043315E01 2. F043310 REMOVE STEERING INTERMEDIATE SHAFT ASSEMBLY (a) Remove the bolt and separate the steering shaft thrust stopper from the steering intermediate shaft assembly. (b) Mark matchmarks on the steering column assembly and steering intermediate shaft. (c) Pull out the intermediate shaft assembly and steering shaft thrust stopper from the steering column assembly. REMOVE STEERING COLUMN BRACKET ASSEMBLY UPPER (w/ Tilt and Telescopic Steering) (a) Remove the inverse nut from the telescopic lever. SR SR–12 STEERING COLUMN – STEERING COLUMN ASSEMBLY (b) Mark the matchmarks on the steering telescopic lever and telescopic lever lock bolt, telescopic lever lock bolt and steering column upper clamp. (c) Remove the steering telescopic lever from the telescopic lever lock bolt. Matchmarks F043309E01 (d) Using a 3 mm (0.12 in.) pin punch, mark the center of the 2 tapered-head bolts. (e) Using a 3 to 4mm (0.12 to 0.16 in.) drill, drill into the 2 bolts. (f) Using a screw extractor, remove the 2 tapered-head bolts, steering column bracket assembly upper, steering column upper clamp and lock wedge. Screw Extractor C063924E01 SR 3. REMOVE STEERING COLUMN BRACKET ASSEMBLY UPPER (w/ Tilt Steering) (a) Using a 3 mm (0.12 in.) pin punch, mark the center of the 2 tapered-head bolts. (b) Using a 3 to 4mm (0.12 to 0.16 in.) drill, drill into the 2 bolts. (c) Using a screw extractor, remove the 2 tapered-head bolts, steering column bracket assembly upper and steering column upper clamp. 4. REMOVE STEERING MAIN SHAFT ASSEMBLY (a) Using SST, remove the 2 tension springs. SST 09921-00010 Screw Extractor C090693E01 SST H041540E01 (b) Remove the 2 bolts and steering column protector. F043308 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–13 (c) Using SST remove the tension spring. SST 09921-00010 (d) Remove the 2 bolts and turn signal bracket. SST F043307E01 (e) Tilt & telescopic steering: Using a screwdriver, remove the steering column No. 1 ring from the steering main shaft. F043306 (f) Using a hexagon wrench (6 mm), remove the 2 tilt steering bolts. (g) Pull out the main shaft with the steering column tube sub-assembly upper from the column tube. SR C090875 (h) Bend the joint of the main shaft at right angles, leaving the cross ball in the No. 2 main shaft subassembly, divide the main shaft into the No. 1 main shaft with the steering column tube sub-assembly upper and No. 2 main shaft sub-assembly. C090846 (i) SST H041541E01 Secure the No. 1 main shaft with the steering column tube sub-assembly upper and SST in a vise. SST 09316-60011 (09316-00051) SR–14 STEERING COLUMN – STEERING COLUMN ASSEMBLY (j) SST Using SST, compress the spring of the steering column tube sub-assembly upper. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04011) NOTICE: Do not overtighten the SST. H041542E01 (k) Using snap ring expander, remove the snap ring and No. 1 main shaft. (l) Remove the compression spring, bearing thrust collar and bearing from the No. 1 main shaft. H041543 SR F004863 5. REMOVE STEERING ENERGY ABSORBING PIN SUB-ASSEMBLY (a) Using pliers, remove the 2 energy absorbing pins. 6. REMOVE STEERING COLUMN ENERGY ABSORBING PLATE 7. REMOVE STEERING ENERGY ABSORBING PLATE GUIDE 8. REMOVE TRANSPONDER KEY AMPLIFIER NOTICE: Take care not to use excessive force to prevent the case from being damaged. (a) Expand the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver. (b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open. F008822 STEERING COLUMN – STEERING COLUMN ASSEMBLY 9. ACC SR–15 REMOVE IGNITION SWITCH LOCK CYLINDER & KEY SET (a) Place the ignition switch lock cylinder assembly at the ACC position. (b) Push down the stop pin with a screwdriver and pull out the ignition switch lock cylinder assembly. C082969E01 10. REMOVE UN-LOCK WARNING SWITCH ASSEMBLY (a) Disconnect the un-lock warning switch assembly connector from the ignition or start switch assembly. (b) Remove the un-lock warning switch assembly toward the rear of the vehicle by pushing up the center part. F043296 11. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY (a) Remove the 2 screws and ignition or starter switch assembly from the steering column bracket assembly upper. SR F043313 12. REMOVE KEY INTER LOCK SOLENOID (a) Remove the 2 screws and key inter lock solenoid from the steering column bracket assembly upper. F043314 SR–16 STEERING COLUMN – STEERING COLUMN ASSEMBLY REASSEMBLY 1. INSTALL KEY INTER LOCK SOLENOID (a) Install the key inter lock solenoid to the steering column bracket assembly upper with 2 screws. 2. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY (a) Install the ignition or starter switch assembly to the steering column bracket assembly upper with 2 screws. 3. INSTALL UN-LOCK WARNING SWITCH ASSEMBLY (a) Install the un-lock warning switch assembly to the steering column bracket assembly upper. (b) Connect the un-lock warning switch assembly connector to the ignition or starter switch assembly. 4. INSTALL IGNITION SWITCH LOCK CYLINDER & KEY SET (a) Make sure that the ignition switch lock cylinder assembly is at the ACC position. (b) Install the ignition switch lock cylinder assembly. 5. INSTALL TRANSPONDER KEY AMPLIFIER NOTICE: Take care not to push the amplifier up with excessive force to prevent it from being damaged. C090812 (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. (b) Push up the transponder key amplifier and connect it to the upper bracket. SR 6. INSPECT STEERING LOCK OPERATION (a) Check that the steering mechanism is activated when removing the key. (b) Check that the steering mechanism is deactivated when inserting the key and turning it to ACC position. 7. INSTALL STEERING ENERGY ABSORBING PLATE GUIDE 8. INSTALL STEERING COLUMN ENERGY ABSORBING PLATE 9. INSTALL STEERING ENERGY ABSORBING PIN SUBASSEMBLY C090697 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–17 10. INSTALL STEERING MAIN SHAFT ASSEMBLY (a) Install the compression spring, bearing thrust collar and bearing to the No. 1 main shaft. (b) Temporarily install the steering column tube subassembly upper to the No. 1 main shaft. C090850 (c) Secure the No. 1 main shaft with the steering column tube sub-assembly upper and SST in a vise. SST 09316-60011 (09316-00051) SST H041541E01 (d) Using SST, compress the spring of the steering column tube sub-assembly upper. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04011) NOTICE: Do not overtighten the SST. SST H041542E01 (e) Using a snap ring expander, install a new snap ring to the main shaft. H041543 (f) C092889 Assemble the No.1 main shaft with the steering column tube sub-assembly upper and No. 2 main shaft sub-assembly. SR SR–18 STEERING COLUMN – STEERING COLUMN ASSEMBLY (g) Using a hexagon wrench (6 mm), install the 2 tilt steering bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (h) Install the main shaft with the steering column tube sub-assembly upper to the column tube. C090875 (i) Tilt & telescopic steering: Install the steering column No. 1 ring to the steering main shaft. F043306 (j) Using SST, install the tension spring. SST 09921-00010 (k) Install the turn signal bracket with the 2 bolts. Torque: 5.7 N*m (58 kgf*cm, 50 in.*lbf) SR SST F043307E01 (l) Install the steering column protector with the 2 bolts. Torque: 6 N*m (60 kgf*cm, 52 in.*lbf) F043308 (m) Using SST, install the 2 tension springs. SST 09921-00010 SST H041540E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–19 11. INSTALL STEERING COLUMN BRACKET ASSEMBLY UPPER (w/ Tilt and Telescopic Steering) (a) Temporarily install the lock wedge, steering column bracket assembly upper and steering column upper clamp with the 2 new tapered-head bolts. (b) Tighten the 2 tapered-head bolts until the bolt heads break off. C090694 F043301 (c) Make the telescopic mechanism most extended condition. (d) After tightening the telescopic lever bolt, perform the loosening procedure at least 5 times to stabilize. Torque: Tighten 20 N*m (204 kgf*cm, 15 ft.*lbf) Loosen 0 N*m (0 kgf*cm, 0 ft.*lbf) (e) Fix the telescopic lever bolt. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) (f) Install the telescopic lever on the position where the telescopic locks. (g) Fix the telescopic lever to the steering column assembly with a inverse nut. Torque: 23 N*m (240 kgf*cm, 17 ft.*lbf) (h) Install the inverse nut on the steering telescopic lever. Torque: 23 N*m (240 kgf*cm, 17 ft.*lbf) F043310 12. INSTALL STEERING COLUMN BRACKET ASSEMBLY UPPER (w/ Tilt Steering) (a) Temporarily install the steering column bracket assembly upper and steering column upper clamp with the 2 new tapered-head bolts. (b) Tighten the 2 tapered-head bolts until the bolt heads break off. C090694 SR SR–20 STEERING COLUMN – STEERING COLUMN ASSEMBLY Matchmarks F043315E01 SR 13. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY (a) Align the matchmarks on the steering column assembly and the steering intermediate shaft assembly. (b) Install the steering intermediate shaft assembly and thrust stopper to the steering column assembly with the bolt. Torque: 36 N*m (360 kgf*cm, 27 ft.*lbf) STEERING COLUMN – STEERING SYSTEM SR–1 STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR STEERING SYSTEM (a) Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering system and result in driving hazards. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (a) The vehicle is equipped with an SRS (Supplemental Restraint System) such as airbags. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing. This may cause a serious accident. Before servicing (including inspection, replacement, removal, and installation of parts), be sure to read the precautionary notices for the Supplemental Restraint System (See page RS-1). SR SR–2 STEERING COLUMN – STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in order. Check each part in order. If necessary, repair or replace the faulty parts. STEERING SYSTEM: Symptom Hard steering Poor return Excessive free play SR Abnormal noise Suspected Area See page 1. Tires (Improperly inflated) TW-1 2. Power steering fluid level (Low) PS-2 3. Drive belt (Loose) PS-2 4. Front wheel alignment (Incorrect) SP-4 5. Steering system joints (Worn) - 6. Suspension arm ball joints (Worn) SP-4 7. Steering column (Binding) - 8. Power steering vane pump PS-7 9. Power steering gear PS-20 1. Tires (Improperly inflated) TW-1 2. Front wheel alignment (Incorrect) SP-4 3. Steering column (Binding) - 4. Power steering gear PS-20 1. Steering system joints (Worn) - 2. Suspension arm ball joints (Worn) SP-4 3. Intermediate shaft, Sliding yoke (Worn) - 4. Front wheel bearing (Worn) SP-4 5. Power steering gear PS-20 1. Power steering fluid level (Low) PS-2 2. Steering system joints (Worn) - 3. Power steering vane pump PS-7 4. Power steering gear PS-20 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–21 INSTALLATION 1. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column assembly with the steering intermediate shaft assembly with the 4 steering column set nuts. Torque: 26 N*m (270 kgf*cm, 20 ft.*lbf) (b) Connect the wire harness to the steering column assembly. (c) Connect each of the connectors to the steering column assembly. 2. INSTALL STEERING COLUMN HOLE COVER (a) Install the steering column hole cover with the 4 clips. (b) Install the heater to register duct to the heater unit. 3. INSTALL STEERING INTERMEDIATE SHAFT SUBASSEMBLY NO. 2 (a) Align the matchmarks on the power steering gear and steering intermediate shaft sub-assembly No. 2. (b) Install the steering intermediate shaft sub-assembly No. 2 to the steering gear box with the bolt C. Torque: Bolt C 36 N*m (360 kgf*cm, 27 ft.*lbf) G021461 A B 4. INSTALL STEERING SLIDING YOKE (a) Align the matchmarks on the steering column and steering sliding yoke. (b) Install the steering sliding yoke to the steering column assembly and slide it upward. (c) Align the matchmarks on the intermediate shaft subassembly No. 2 and steering sliding yoke. (d) Install the sliding yoke to the intermediate shaft subassembly No. 2 with the bolt A and bolt B. Torque: Bolt A, B 36 N*m (360 kgf*cm, 27 ft.*lbf) 5. INSTALL ENGINE UNDER COVER ASSEMBLY REAR (a) Install the engine under cover assembly rear with the 4 bolts. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 6. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 (a) Install the engine under cover sub-assembly No. 1 with the 4 bolts. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) Matchmarks C Matchmarks F043317E02 SR SR–22 STEERING COLUMN – STEERING COLUMN ASSEMBLY 7. INSTALL TURN SIGNAL SWITCH ASSEMBLY (a) Install the turn signal switch assembly with the 3 screws. (b) Connect the 3 connectors to the turn signal switch assembly. 8. INSTALL SPIRAL CABLE (a) Check that the front wheels are facing straight ahead. (b) Turn the spiral cable counterclockwise by hand until it becomes harder to turn. (c) Then rotate the spiral cable clockwise about 2.5 turns to align the mark. HINT: The spiral cable will rotate about 2.5 turns to either left or right of the center. (d) Install the spiral cable with the 4 screws. (e) Connect the 2 connectors to the spiral cable. 9. INSTALL STEERING COLUMN COVER UPR (a) Install the steering column cover upper to the steering column assembly. F043318 H042178 10. INSTALL STEERING COLUMN COVER LWR (a) Install the steering column cover lower to the steering column assembly. (b) Install the 3 screws to the steering column cover upper and lower. SR F043298 11. INSTALL INSTRUMENT PANEL LOWER LH 12. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 13. INSTALL COWL SIDE TRIM BOARD LH 14. INSTALL FRONT FLOOR FOOT REST 15. INSTALL FRONT DOOR SCUFF PLATE LH 16. INSTALL STEERING WHEEL ASSEMBLY (a) Align the matchmarks on the steering wheel and main shaft assembly. (b) Install the steering set nut. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (c) without Steering pad switch: Connect the connector. 17. INSTALL STEERING PAD NOTICE: • Never use airbag parts from another vehicle. When replacing parts, replace with new ones. • Make sure the steering pad is installed to the specified torque. STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–23 • If the steering pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the steering pad with a new one. • When installing the steering pad, take care that the wirings do not interfere with other parts and they are not pinched between other parts. Torx Screw Screw Case F043297E01 (a) Connect the horn ground harness to the steering pad. (b) Connect the 2 airbag connectors. (c) Install the steering pad after confirming that the circumference groove of "torx" screw is caught on the screw case. (d) Using a "torx" socket wrench ("Torx" socket wrench (T=30)), torque the 2 screws. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) 18. INSTALL STEERING WHEEL COVER LOWER NO. 2 19. INSTALL STEERING WHEEL COVER LOWER NO. 3 20. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 21. CONNECT BATTERY NEGATIVE TERMINAL 22. INSPECT SRS WARNING LIGHT HINT: See page RS-1. SR SR–4 STEERING COLUMN – STEERING COLUMN ASSEMBLY STEERING COLUMN ASSEMBLY STEERING COLUMN COMPONENTS STEERING PAD STEERING WHEEL ASSEMBLY 50 (510, 37) STEERING SET NUT STEERING WHEEL COVER LOWER NO. 2 SPIRAL CABLE STEERING WHEEL COVER LOWER NO. 3 8.8 (90, 78 in.*lbf) TURN SIGNAL SWITCH ASSEMBLY TORX SCREW STEERING COLUMN ASSEMBLY STEERING COLUMN COVER UPR STEERING SHAFT THRUST STOPPER SR 26 (270, 20) 36 (360, 26) STEERING COLUMN COVER LWR STEERING INTERMEDIATE SHAFT ASSEMBLY STEERING COLUMN HOLE COVER 36 (360, 26) CLIP STEERING SLIDING YOKE 36 (360, 26) STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY NO. 2 N*m (kgf*cm, ft.*lbf) : Specified torque C131331E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–5 with Tilt Steering Column INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL LOWER LH HEATER TO REGISTER DUCT FRONT FLOOR FOOT REST SR COWL SIDE TRIM BOARD LH FRONT DOOR SCUFF PLATE LH C131332E01 SR–6 STEERING COLUMN – STEERING COLUMN ASSEMBLY UN-LOCK WARNING SWITCH ASSEMBLY IGNITION SWITCH LOCK CYLINDER & KEY SET KEY CYLINDER LIGHT ASSEMBLY 5.7 (58, 50 in.*lbf) TURN SIGNAL BRACKET 20 (204, 15) STEERING COLUMN BRACKET ASSEMBLY UPPER KEY INTER LOCK SOLENOID SNAP RING STEERING COLUMN TUBE SUB-ASSEMBLY COMPRESSION SPRING BEARING TILT STEERING BOLT BEARING THRUST COLLAR IGNITION OR STARTER SWITCH ASSEMBLY 6.0 (60, 52 in.*lbf) STEERING COLUMN PROTECTOR NO. 1 MAIN SHAFT SR TENSION SPRING NO. 2 MAIN SHAFT SUB-ASSEMBLY NO. 1 MAIN SHAFT NO. 2 MAIN SHAFT SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131333E01 SR–7 STEERING COLUMN – STEERING COLUMN ASSEMBLY ENERGY ABSORBING PIN SUB-ASSEMBLY ENERGY ABSORBING GUIDE ENERGY ABSORBING PLATE TENSION SPRING COLUMN TUBE LOCK WEDGE with Tilt & Telescopic with Tilt Steering Column STEERING COLUMN NO. 1 RING STEERING COLUMN UPPER CLAMP TELESCOPIC LEVER with Tilt & Telescopic Steering Column 15 (150, 11) TILT STEERING SUPPORT SUB-ASSEMBLY 23 (240, 17) TAPERED-HEAD BOLT STEERING COLUMN UPPER CLAMP COLUMN TUBE with Tilt Steering Column N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131334E01 SR PS–8 POWER STEERING – VANE PUMP REMOVAL NOTICE: When using a vise, do not overtighten. 1. DRAIN POWER STEERING FLUID (See page PS-2) 2. REMOVE AIR CLEANER ASSEMBLY 3. REMOVE VANE PUMP V BELT (a) Loosen the belt tension by turning the belt tensioner counterclockwise, and remove the belt. 4. SEPARATE OIL RESERVOIR TO PUMP HOSE NO. 1 (a) Loosen the 2 clips and disconnect the 2 vacuum hoses. EM06656 F042719 (b) Loosen the clip and disconnect the hose. PS F042720 5. F042721 SEPARATE PRESSURE FEED TUBE ASSEMBLY (a) Remove the union bolt and a gasket, disconnect the pressure feed tube. POWER STEERING – VANE PUMP 6. PS–9 REMOVE VANE PUMP ASSEMBLY (a) Remove the 2 bolts and nut. (b) Using a "torx" socket (E10), remove the stud bolt. F042722 DISASSEMBLY 1. MEASURE VANE PUMP ROTATING TORQUE (a) Check that the pump rotates smoothly without abnormal noise. (b) Using a torque wrench, check the pump rotating torque. Torque: Rotating torque 0.28 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less PS F004807 2. REMOVE VANE PUMP PULLEY (a) Using SST to stop the pulley rotating, loosen the nut. SST 09960-10010 (09962-01000, 09963-01000) (b) Remove the nut and vane pump pulley from the vane pump shaft. 3. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and suction port union. (b) Remove the O-ring from the suction port union. 4. REMOVE PRESSURE PORT UNION (a) Remove the pressure port union, flow control valve and spring. (b) Remove the O-ring from the pressure port union. 5. REMOVE VANE PUMP REAR HOUSING (a) Remove the 4 bolts and vane pump rear housing. HINT: If the wave washer and side plate are stuck to the vane pump rear housing, lightly tap the vane pump rear housing with a plastic hammer, and remove the wave washer and side plate. F004808 PS–10 POWER STEERING – VANE PUMP (b) Remove the 2 O-rings from the rear housing. 6. REMOVE SIDE PLATE AND WAVE WASHER 7. REMOVE VANE PUMP CAM RING (a) Using a screwdriver, remove the snap ring from the vane pump shaft. (b) Remove the cam ring. 8. REMOVE VANE PUMP ROTOR (a) Remove the vane pump rotor with the 10 vane plates. NOTICE: Be careful not to drop the plate. 9. REMOVE VANE PUMP SHAFT 10. REMOVE STRAIGHT PIN (a) Remove the 2 pins from the vane pump front housing. 11. REMOVE VANE PUMP HOUSING OIL SEAL NOTICE: When using a vise, do not overtighten it. (a) Using a screwdriver with vinyl tape wound around its tip, remove the housing oil seal. NOTICE: Be careful not to damage the vane pump front housing. Oil Seal PS F001511E01 INSPECTION 1. Vane Pump Shaft Bushing Vane Pump Front Housing F001809E02 INSPECT OIL CLEARANCE (a) Using a micrometer and a caliper gauge, measure the oil clearance. Standard clearance: 0.03 to 0.05 mm (0.0012 to 0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the shaft and vane pump front housing. POWER STEERING – VANE PUMP Thickness 2. Height Length N000372E07 PS–11 INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES CLEARANCE (a) Using a micrometer, measure the height, thickness and length of the 10 vane plates. Minimum height: 8.6 mm (0.33858 in.) Minimum thickness: 1.397 mm (0.05500 in.) Minimum length: 14.991 mm (0.59020 in.) (b) Using a feeler gauge, measure the clearance between the vane pump rotor grove and vane plate. Maximum clearance: 0.033 mm (0.00130 in.) If it is more than the maximum, replace the plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4, or None Feeler Gauge R010282E01 HINT: There are 5 vane plate lengths with the following rotor and cam ring marks: Rotor and cam ring mark Vane plate part number Vane plate length mm (in.) None 44345-26010 14.999 - 15.001 (0.59051 - 0.59059) 1 44345-26020 14.997 - 14.999 (0.59043 - 0.59051) 2 44345-26030 14.995 - 14.997 (0.59035 - 0.59043) 3 44345-26040 14.993 - 14.995 (0.59027 - 0.59035) 4 44345-26050 14.991 - 14.993 (0.59020 - 0.59027) Incribed Mark R013897E01 3. W004759 INSPECT FLOW CONTROL VALVE (a) Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. PS PS–12 POWER STEERING – VANE PUMP (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 to 490 kPa (4 to 5 kgf*cm2, 57 to 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A, B, C, D, E or F Compressed Air F004865E01 Inscribed Mark F004866E01 4. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307 in.) If it is not within the specification, replace the spring. 5. INSPECT PRESSURE PORT UNION If the pressure union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the pressure port union. Vernier Caliper PS R008702E02 POWER STEERING – VANE PUMP PS–13 REASSEMBLY NOTICE: When installing, coat the parts indicated by the arrows with power steering fluid (See page PS-6). 1. INSTALL VANE PUMP HOUSING OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using SST, press in the oil seal. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing in the correct direction. 2. INSTALL VANE PUMP SHAFT 3. INSTALL STRAIGHT PIN (a) Using a plastic hammer, tap the 2 new pins to the vane pump front housing. NOTICE: Be careful not to damage the pins. 4. INSTALL VANE PUMP CAM RING (a) Install the cam ring with the inscribed mark facing outward. HINT: Align the holes of the cam ring with the straight pins. 5. INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor with the inscribed mark facing outward. (b) Install a new snap ring to the vane pump shaft. SST Oil Seal W004761E01 Inscribed Mark F004809E01 (c) Install the 10 plates with the round end facing outward. (d) Install a new gasket on the front housing. NOTICE: Be careful of the direction of the gasket. Round End 6. INSTALL VANE PUMP SIDE PLATE REAR (a) Align the holes of the plate and 2 straight pins. 7. INSTALL VANE PUMP REAR HOUSING (a) Install the wave washer so that its protrusions fit into the slots in the side plate. (b) Coat 2 new O-rings with power steering fluid and install them to the rear housing. (c) Install the rear housing with the 4 bolts. Torque: 24 N*m (240 kgf*cm, 17 ft.*lbf) 8. INSTALL PRESSURE PORT UNION (a) Install the spring to the vane pump front housing. (b) Install the flow control valve facing the correct direction (See page PS-3). F004810E01 F001507 PS PS–14 POWER STEERING – VANE PUMP (c) Coat a new O-ring with power steering fluid and install it to the pressure port union. (d) Install the pressure port union. Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf) 9. INSTALL POWER STEERING SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the suction port union. (b) Install the suction port union with the bolt. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 10. INSTALL VANE PUMP PULLEY (a) Install the vane pump pulley and nut to the vane pump shaft. (b) Using SST to stop the pulley rotating, torque a new pulley set nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) SST F004808E01 11. MEASURE VANE PUMP ROTATING TORQUE (a) Check that the pump rotates smoothly without abnormal noise. (b) Using a torque wrench, check the pump rotating torque. Torque: Rotating torque 0.28 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less PS F004807 INSTALLATION 1. F042722 INSTALL VANE PUMP ASSEMBLY (a) Using a "torx" socket (E10), install the vane pump with the stud bolt. Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) (b) Install the 2 bolts and nut. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) POWER STEERING – VANE PUMP PS–15 2. INSTALL VANE PUMP V BELT (a) Loosen the belt tension by turning the belt tensioner counterclockwise, and install the bolt. 3. CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Install the union bolt with a new gasket on each side of the tube. Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 4. CONNECT OIL RESERVOIR TO PUMP HOSE NO. 1 (a) Install the hose with the clip. EM06656 F042721 PS F042720 (b) Install the 2 hoses with the 2 clips. F042719 5. INSTALL AIR CLEANER ASSEMBLY 6. ADD POWER STEERING FLUID (See page PS-2) 7. BLEED POWER STEERING FLUID (See page PS-2) 8. INSPECT POWER STEERING FLUID LEAK (See page PS-2) PS–20 POWER STEERING – POWER STEERING LINK REMOVAL 1. PRECAUTION HINT: See page RS-1. 2. DISCONNECT BATTERY NEGATIVE TERMINAL 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING PAD (See page RS-388) 5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-9) 6. REMOVE STEERING COLUMN COVER LOWER (See page SR-9) 7. REMOVE TURN SIGNAL SWITCH ASSEMBLY (See page SR-10) 8. REMOVE SPIRAL CABLE (See page RS-398) 9. REMOVE FRONT WHEELS 10. REMOVE REAR ENGINE UNDER COVER ASSEMBLY (a) Remove the 6 bolts and rear engine under cover assembly. 11. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 (a) Remove the 4 bolts and engine under cover subassembly No. 1. 12. REMOVE FRONT STABILIZER BAR 13. SEPARATE TIE ROD END SUB-ASSEMBLY LH (a) Remove the cotter pin and nut. (b) Using SST, separate the tie rod end from the steering knuckle arm. SST 09628-62011 PS SST F042735E01 14. SEPARATE TIE ROD END SUB-ASSEMBLY RH HINT: Separate the RH side by the same procedures with the LH side. SST 09628-62011 15. REMOVE STEERING INTERMEDIATE SHAFT SUBASSEMBLY NO. 2 (See page SR-10) 16. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using SST, loosen the flare nut and disconnect the pressure feed tube. SST 09023-12701 SST F042752E01 POWER STEERING – POWER STEERING LINK PS–21 (b) Remove the 2 bolts and separate the pressure feed tube assembly from frame sub-assembly. F042728 17. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (a) Remove the clip and disconnect the return hose. F042723 (b) Using SST, remove the outlet return tube. SST 09023-12701 SST PS F042724E01 F042726 18. REMOVE POWER STEERING LINK ASSEMBLY (a) Remove the 2 bolts, 2 nuts and power steering link assembly. NOTICE: The nut has a detent, so never turn the nut, be sure to turn the bolt. HINT: After the 2 bolts, raise the bolt from the frame, and slide the gear assembly and the bolt as a unit to the position where the bolt can be pulled out, and then remove the bolt. DISASSEMBLY 1. SST F043640E01 FIX POWER STEERING LINK ASSEMBLY (a) Using SST, remove the 2 turn pressure tubes. SST 09023-38201 PS–22 POWER STEERING – POWER STEERING LINK (b) Using the SST, fix the gear assembly between aluminum plates in a vise as shown in the illustration. SST 09612-00012 SST F042800E01 2. REMOVE TIE ROD END SUB-ASSEMBLY LH (a) Place matchmarks on the tie rod end, lock nut and rack end. (b) Loosen the lock nut, remove the tie rod end and lock nut. 3. REMOVE TIE ROD END SUB-ASSEMBLY RH HINT: Remove the RH side by the same procedures with the LH side. 4. REMOVE STEERING RACK BOOT CLAMP LH (a) Using pliers and a screwdriver, loosen the clamp. NOTICE: Be careful not to damage the boot. HINT: Mark the RH and LH boots. 5. REMOVE STEERING RACK BOOT CLAMP RH HINT: Remove the RH side by the same procedures with the LH side. 6. REMOVE STEERING RACK BOOT CLIP LH (a) Using pliers, remove the clip. NOTICE: Be careful not to damage the boot. 7. REMOVE STEERING RACK BOOT CLIP RH HINT: Remove the RH side by the same procedures with the LH side. 8. REMOVE STEERING RACK BOOT LH 9. REMOVE STEERING RACK BOOT RH Matchmarks F006747E01 PS C061334 POWER STEERING – POWER STEERING LINK PS–23 10. REMOVE STEERING RACK END SUB-ASSEMBLY (a) Using a screwdriver and a hammer, stake back the washer. NOTICE: Avoid any impact to the steering rack. ZX09339 SST F043550E01 (b) Using a spanner to hold the steering rack steady, and using SST, remove the rack end. SST 09922-10010 (c) Remove the craw washer. NOTICE: Use SST 09922-10010 in the direction shown in the illustration. (d) Employ the same manner described above to the other side. HINT: Mark the RH and LH rack ends. 11. REMOVE RACK GUIDE (a) Using SST, remove the lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. SST PS F042801E02 (b) Using a hexagon wrench (24 mm), remove the rack guide spring cap. (c) Remove the spring and rack guide. Hexagon Wrench F042802E01 12. REMOVE POWER STEERING CONTROL VALVE (a) Remove the 2 bolts. (b) Pull out the control valve assembly with the control valve housing. (c) Remove the O-ring. (d) Carefully mount the control valve assembly in a soft jaw vise. F043530 PS–24 POWER STEERING – POWER STEERING LINK Vinyl Tape SST (e) Using SST, remove the bearing guide nut. SST 09631-20060 NOTICE: Be careful not to damage the oil seal lip. (f) Remove the O-ring. (g) Remove the dust cover. F043531E01 (h) Using SST and a hammer, drive out the oil seal from the bearing guide nut. SST 09950-60010 (09951-00300), 09950-70010 (09951-07100) (i) Wind vinyl tape to the control valve shaft. SST F041410E01 (j) Vinyl Tape PS F043532E01 Using a plastic hammer, tap out the valve assembly with the bearing guide nut from the control valve housing. NOTICE: Be careful not to damage the oil seal lip. (k) Using a screwdriver, remove the 4 teflon rings from the control valve assembly. NOTICE: Be careful not to damage the grooves for the ring. (l) Using a screw extractor, remove the union seat from the control valve housing. Screw Extractor F043533E01 Oil Seal SST SST Bearing F043534E01 13. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Using SST, press out the bearing and oil seal from the control valve housing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00250) POWER STEERING – POWER STEERING LINK PS–25 14. REMOVE CYLINDER END STOPPER (a) Using SST, remove the stopper. SST 09631-20120 (b) Remove the O-ring from the stopper. SST F043535E02 15. REMOVE STEERING RACK AND OIL SEAL (a) Using SST, press out the steering rack and oil seal. SST 09950-70010 (09951-07200) NOTICE: Take care not to drop the steering rack. (b) Remove the oil seal from the steering rack. Press SST F043562E01 16. REMOVE STEERING RACK PISTON RING (a) Using a screwdriver, remove the teflon ring and Oring from the steering rack. NOTICE: Be careful not to damage the groove for the ring. INSPECTION 1. F043549 ZK08184 INSPECT POWER STEERING RACK (a) Insert a wire into the vent hole of the steering rack by 30 mm (1.18 in.), and ensure that the vent hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. 2. INSPECT TIE ROD END SUB-ASSEMBLY LH (a) Flip the ball joint stud back and forth 5 times as shown in the figure, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 to 4 seconds per 1 turn and take the torque reading on the 5th turn. Torque: Turning 0.29 to 1.96 N*m (2.9 to 20.0 kgf*cm, 2.57 to 17.35 in.*lbf) 3. INSPECT TIE ROD END SUB-ASSEMBLY RH HINT: Inspect the RH side by the same procedures with LH side. PS PS–26 POWER STEERING – POWER STEERING LINK REASSEMBLY 1. INSTALL STEERING RACK PISTON RING (a) Coat a new O-ring with power steering fluid and install it on steering rack. (b) Expand a new teflon ring with your fingers. NOTICE: Be careful not to overexpand the teflon ring. (c) Coat the teflon ring with power steering fluid. C003629 (d) Install the teflon ring to the steering rack, and settle it down with your fingers. N000401 2. Rack Teeth End INSTALL POWER STEERING RACK (a) Coat SST with power steering fluid. (b) Install SST to the rack. SST 09631-00350 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. (c) Install the rack into the rack housing. PS SST W002101E01 SST F005044E01 (d) Coat SST with power steering fluid. SST 09631-00350 (e) Install SST to the steering rack opposite end. (f) Coat a new oil seal lip with power steering fluid, and install the oil seal by pushing it without tilting. NOTICE: • Make sure to install the oil seal facing in the correct direction. • Be careful not to damage the oil seal lip. (g) Remove the SST. SST 09631-00350 POWER STEERING – POWER STEERING LINK 3. PS–27 INSTALL CYLINDER END STOPPER (a) Coat a new O-ring with power steering fluid, and install it to the stopper. (b) Using a wooden block and a hammer, drive in the stopper until it is tightly installed. NOTICE: Be careful not to damage the O-ring. ZX00351 (c) Using SST, torque the stopper. SST 09631-20120 Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf) SST F043535E01 4. SST INSPECT AIR TIGHTNESS (a) Install the SST to the unions of the rack housing. SST 09631-12071 (09633-00010) (b) Apply 53.33 kPa (400 mmHg, 15.75 in Hg) of vacuum for about 30 seconds. (c) Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. PS F043542E01 5. Press SST SST Oil Seal SST INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150) NOTICE: Make sure that the oil seal is installed facing in the correct direction. F001211E01 Press (c) Coat a new bearing with molybdenum disulfide lithium base grease. (d) Using SST, press in the bearing. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150) SST SST Bearing Oil Seal W001753E01 PS–28 POWER STEERING – POWER STEERING LINK 6. INSTALL POWER STEERING CONTROL VALVE (a) Using a plastic hammer and a sliding handle, lightly tap in a new union seat. NOTICE: Before installing the union seat, remove dust sticking to the control valve housing. F043545 (b) Coat the rings with power steering fluid. (c) Expand 4 new rings with your fingers. C003629 (d) Install the rings to the control valve assembly, and settle them down with your fingers. (e) Carefully slide the tapered end of SST over the rings until the ring fits to the steering rack. SST 09631-20081 NOTICE: Be careful not to overexpand the ring. SST PS Z006085E01 Vinyl Tape F041420E01 SST F041421E01 (f) Coat the teflon rings with power steering fluid. (g) To prevent oil seat lip damage, wind vinyl tape on the serrated port of the control valve shaft. (h) Push the valve assembly into the control valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal lip. (i) Coat a new O-ring with power steering fluid, and install it to the bearing guide nut. (j) Coat a new oil seal lip with power steering fluid. (k) Using SST and a hammer, drive in the oil seal. SST 09950-60010 (09951-00390), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing in the correct direction. (l) Lightly mount the control valve assembly between aluminum plates in a vise. (m) To prevent oil seal lip damage, wind vinyl tape on the pinion part of the control valve shaft. POWER STEERING – POWER STEERING LINK SST PS–29 (n) Using SST, torque the guide nut. SST 09631-20060 Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) NOTICE: Be careful not to damage the oil seal lip. Vinyl Tape F043531E01 (o) Using a punch and a hammer, stake the nut. (p) Coat a new O-ring with power steering fluid, and install it to the valve housing. ZX00357 (q) Apply molybdenum disulfide base grease for the needle roller bearing inside the rack housing in the illustrated portion. Volume of grease applied: Approximately 2 g (0.07 oz) (r) Install the control valve assembly with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) Grease Filling PS F041423E01 7. INSTALL RACK GUIDE (a) Install the rack guide and spring. (b) Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Using a hexagon wrench (24 mm), temporarily install the spring cap. 8. ADJUST TOTAL PRELOAD (a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. Hexagon Wrench F042802E01 PS–30 POWER STEERING – POWER STEERING LINK Hexagon Wrench (b) Using a hexagon wrench (24 mm), tighten the rack guide spring cap. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) (c) Return the cap 30°. 30q F043642E01 (d) Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011 (e) Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring is not functioning. SST F043643E01 (f) SST Hexagon Wrench PS F043547E01 Using SST, a torque wrench and a hexagon wrench (24 mm), tighten the cap until the preload is within specification. SST 09616-00011 Torque: Preload in center position (turning) 1.35 to 1.55 N*m (13.77 to 15.81 kgf*cm, 11.94 to 13.71 in.*lbf) NOTICE: Adjustment should be done in the tightening direction of the spring cap. HINT: Adjust the preload so that the turning torque of the control valve shaft, with the steering rack in the center position, is within the specification. (g) Apply sealant to 2 or 3 threads of the lock nut. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (h) Temporarily install the lock nut. (i) SST Fulcrum Length Hexagon Wrench F043644E01 Using a hexagon wrench (24 mm), holding the rack guide spring cap rotating, and using SST, torque the nut. SST 09922-10010 Torque: 65 N*m (660 kgf*cm, 48 ft.*lbf) for use with SST NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). POWER STEERING – POWER STEERING LINK PS–31 (j) Recheck the total preload. Torque: Preload in center position (turning) 1.35 to 1.55 N*m (13.77 to 15.81 kgf*cm, 11.94 to 13.71 in.*lbf) HINT: Adjust the preload so that the tuning torque of the control valve shaft, with the steering rack in the center position, is within the specification. (k) Remove the RH and LH rack ends. SST F043546E01 Fulcrum Length SST SST F043646E01 SST SST Fulcrum Length F043645E01 9. INSTALL STEERING RACK END SUB-ASSEMBLY (a) Install a new claw washer, and temporarily tighten the rack end. HINT: Align the claws of the washer with the steering rack grooves. (b) Using SST to hold the steering rack steady, and using another SST, torque the rack end LH. SST 09922-10010 Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) for use with SST NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 380 mm (14.9 in.). (c) Using SST to hold the rack end LH steady, and using another SST, torque the rack end RH. SST 09922-10010 Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) for use with SST NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 380 mm (14.9 in.). (d) Using a brass bar and a hammer, stake the washer. NOTICE: Avoid any impact to the rack. (e) Employ the same manner described above to the other side. 10. INSTALL STEERING RACK BOOT LH (a) Install the boot. NOTICE: Be careful not to damage or twist the boot. Brass Bar C035928E01 11. INSTALL STEERING RACK BOOT RH HINT: install the RH side by the same procedures with the LH side. PS PS–32 POWER STEERING – POWER STEERING LINK 12. INSTALL STEERING RACK BOOT CLAMP LH (a) Using pliers and a screwdriver, install the clamp. 13. INSTALL STEERING RACK BOOT CLAMP RH HINT: Install the RH side by the same procedures with the LH side. 14. INSTALL STEERING RACK BOOT CLIP LH (a) Using pliers, install the clip. C089469 15. INSTALL STEERING RACK BOOT CLIP RH HINT: Install the RH side by the same procedures with the LH side. 16. INSPECT POWER STEERING GEAR (a) Using SST, check that the rack boot stretches smoothly when the control valve shaft is being rotated. SST 09616-00011 SST F041429E01 (b) Apply MP grease in the illustrated portion. (c) Install the dust cover. Grease Filling PS F041433E01 Fulcrum Length SST F043641E01 17. INSTALL STEERING TURN PRESSURE TUBE (a) Using SST, install the 2 turn pressure tubes. SST 09023-38201 Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) for use with SST HINT: • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). • This torque value is effective in case that SST is parallel to a torque wrench. 18. INSTALL TIE ROD END SUB-ASSEMBLY LH (a) Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. (b) After adjusting toe-in, torque the nut. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) POWER STEERING – POWER STEERING SYSTEM PS–1 POWER STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR STEERING SYSTEM (a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in hazardous driving. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (a) The vehicle is equipped with SRS (Supplemental Restraint System), such as airbags. If service operation is not carried out properly, in a step by step fashion, sudden deployment of the airbags may result in serious injury. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page RS-1). PS PS–2 POWER STEERING – POWER STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. Repair or replace parts as necessary. POWER STEERING SYSTEM Symptom Suspected Area Hard steering Poor return Excessive free play Abnormal noise PS See page 1. Tires (Improperly inflated) TW-1 2. Power steering fluid level (Low) PS-2 3. Front wheel alignment (Incorrect) SP-4 4. Steering arm ball joints (Worn) - 5. Suspension arm ball joints (Worn) SP-4 6. Steering column (Binding) - 7. Power steering vane pump PS-10 8. Power steering gear PS-25 1. Tires (Improperly inflated) TW-1 2. Front wheel alignment (Incorrect) SP-4 3. Steering column (Binding) - 4. Power steering gear PS-25 1. Steering system joints (Worn) - 2. Suspension arm ball joints (Worn) SP-4 3. Intermediate shaft, Sliding yoke (Worn) - 4. Front wheel bearing (Worn) SP-4 5. Power steering gear PS-25 1. Power steering fluid level (Low) PS-2 2. Steering system joints (Worn) - 3. Power steering vane pump PS-10 4. Power steering gear PS-25 ON-VEHICLE INSPECTION 1. INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords, etc. If any defect is found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. Replace the belt if there are any missing ribs. 2. BLEED POWER STEERING SYSTEM (a) Check the fluid level. (b) Jack up the front of the vehicle and support it with stands. (c) Turn the steering wheel. (1) With the engine stopped, turn the wheel slowly from lock to lock several times. (d) Lower the vehicle. (e) Start the engine. (1) Run the engine at idle for a few minutes. F040449 POWER STEERING – POWER STEERING SYSTEM PS–3 (f) Turn the steering wheel. (1) With the engine idling, turn the wheel left or right to the full lock position and keep it there for 2 to 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds.*1 (2) Repeat (*1) several times. (g) Stop the engine. Normal (h) Check for foaming or emulsification. Especially, if the system has to be held twice because of foaming or emulsification, check for fluid leaks in the system. (i) Check the fluid level. Abnormal F040897E06 3. F040898 Noemal Abnormal F040897E07 CHECK FLUID LEVEL (a) Keep the vehicle horizontal. (b) With the engine stopped, check the fluid level in the reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: If the fluid is hot, check that the fluid level is within the HOT range. If the fluid is cold, check that the fluid level is within the COLD range. (c) Start the engine and run at idle. (d) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 to 80°C (167 to 176°F) (e) Check for foaming or emulsification. If foaming or emulsification is identified, bleed the power steering system. PS PS–4 POWER STEERING – POWER STEERING SYSTEM (f) With the engine idling, measure the fluid level in the reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the reservoir. Maximum fluid level rise: About 5 mm (0.20 in.) If a problem is found, bleed the power steering system. (i) Check the fluid level. 5 mm (0.20 in.) or less Engine Idling Engine Stopped R011786E08 4. CHECK STEERING FLUID PRESSURE (a) Disconnect the pressure feed tube assembly (See page PS-8). (b) Connect SST as shown in the illustration. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. (c) Bleed the power steering system. (d) Start the engine and run at idle. (e) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 to 80°C (167 to 176°F) Attachment PS SST IN OUT Pressure Feed Tube Assembly Attachment F004813E01 POWER STEERING – POWER STEERING SYSTEM (f) Oil Reservoir PS Gear Closed PS Vane Pump SST Z015498E06 Open PS Vane Pump SST With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: • Do not keep the valve closed for more than 10 seconds. • Do not allow the fluid temperature to become too high. If not within the specified range, check for fluid leaks and replace parts as necessary. (g) With the engine idling, fully open the valve. (h) Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference in fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. If not within the specified range, check for fluid leaks and replace parts as necessary. Oil Reservoir PS Gear PS–5 Z015499E06 (i) With the engine idling and the valve fully opened, turn the steering wheel left or right to the full lock position. Observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: • Do not keep the steering wheel in the full lock position for more than 10 seconds. • Do not allow the fluid temperature to become too high. If not within the specified range, check for fluid leaks and replace parts as necessary. (j) Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) (k) Connect the pressure feed tube assembly to the vane pump assembly (See page PS-14). (l) Bleed the power steering system. Oil Reservoir Lock Position PS Gear Open PS Vane Pump SST Z015500E06 5. C130081 CHECK STEERING WHEEL ASSEMBLY (a) Center the steering wheel. (b) Remove the steering pad (See page RS-388). (c) Start the engine and run at idle. (d) Measure the steering effort in both directions. Torque: Steering effort (Reference) 6.0 N*m (60 kgf*cm, 53 in.*lbf) or less HINT: Check tire type, pressure and road surface before making your diagnosis. If not within the specified range, check the power steering system (See page PS-1). PS PS–6 POWER STEERING – POWER STEERING SYSTEM (e) Tighten the steering wheel set nut. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (f) Install the steering pad (See page RS-388). PS POWER STEERING – POWER STEERING LINK PS–33 19. INSTALL TIE ROD END SUB-ASSEMBLY RH HINT: Install the RH side by the same procedures with the LH side. INSTALLATION 1. INSTALL POWER STEERING LINK ASSEMBLY (a) Install the power steering link assembly with the 2 bolts and 2 nuts. Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf) NOTICE: The nut has a detent, so never turn the nut, be sure to turn the bolt. HINT: Insert the bolt and slide it with the gear assembly as a unit and then install the bolt on the frame. 2. INSTALL STABILIZER BAR FRONT 3. STABILIZE SUSPENSION 4. CONNECT STEERING GEAR OUTLET RETURN TUBE (a) Using SST, connect the outlet return tube. SST 09023-12701 Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) for use with SST HINT: • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). • This torque value is effective in case that SST is parallel to a torque wrench. F042726 Fulcrum Length SST F043639E01 (b) Install the hose with the clip. F042723 5. F042728 CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Install the pressure feed tube assembly to the frame sub-assembly with the 2 bolts. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) PS PS–34 POWER STEERING – POWER STEERING LINK (b) Using SST, tighten the flare nut and connect the pressure feed tube. SST 09023-12701 Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) for use with SST HINT: • Use a torque wrench with a fulcrum length of 300 mmm (11.81 in.). • This torque value is effective in case that SST is parallel to a torque wrench Fulcrum Length SST F043638E01 6. TIGHTEN STEERING INTERMEDIATE SHAFT SUBASSEMBLY NO. 2 (See page SR-20) 7. CONNECT TIE ROD END SUB-ASSEMBLY LH (a) Connect the tie rod end to the steering knuckle arm. (b) Install the nut and cotter pin. Torque: 91 N*m (928 kgf*cm, 67 ft.*lbf) 8. CONNECT TIE ROD END SUB-ASSEMBLY RH HINT: Install the RH side by the same procedures with the LH side. 9. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 (a) Install the engine under cover sub-assembly No. 1 with the 4 bolts. 10. INSTALL REAR ENGINE UNDER COVER ASSEMBLY (a) Install the rear engine under cover assembly with the 6 bolts. PS 11. INSTALL FRONT WHEELS Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf) 12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 13. INSTALL TURN SIGNAL SWITCH ASSEMBLY (See page SR-21) 14. INSTALL SPIRAL CABLE (See page RS-398) 15. INSTALL STEERING COLUMN COVER LOWER (See page SR-21) 16. CENTER SPIRAL CABLE (See page RS-399) 17. INSTALL STEERING WHEEL ASSEMBLY (See page SR-21) 18. INSPECT STEERING WHEEL CENTER POINT (See page SR-2) 19. INSTALL STEERING PAD (See page RS-388) 20. INSPECT STEERING PAD (See page RS-389) 21. INSPECT SRS WARNING LIGHT (See page RS-389) 22. ADD POWER STEERING FLUID (See page PS-2) 23. BLEED POWER STEERING FLUID (See page PS-2) POWER STEERING – POWER STEERING LINK PS–35 24. CHECK POWER STEERING FLUID LEAKAGE (See page PS-2) 25. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: See page SP-4. PS PS–6 POWER STEERING – VANE PUMP VANE PUMP POWER STEERING STEERING COMPONENTS AIR CLEANER ASSEMBLY VACUUM HOSE 51 (520, 38) UNION BOLT GASKET CLIP PS PRESSURE FEED TUBE ASSEMBLY OIL RESERVOIR TO PUMP HOSE NO. 1 CLIP 22 (224, 16) STUD BOLT VANE PUMP ASSEMBLY 43 (438, 32) VANE PUMP V BELT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C131335E01 PS–7 POWER STEERING – VANE PUMP 83 (850, 61) PRESSURE PORT UNION O-RING FLOW CONTROL VALVE POWER STEERING SUCTION PORT UNION SPRING GASKET O-RING 13 (130, 9) VANE PUMP HOUSING OIL SEAL 44 (449, 32) VANE PUMP HOUSING FRONT VANE PUMP SHAFT VANE PUMP PULLEY VANE PUMP REAR HOUSING VANE PUMP CAM RING STRAIGHT PIN PS SNAP RING 24 (240, 17) O-RING VANE PUMP ROTOR WAVE WASHER X 10 SIDE PLATE VANE PLATE STRAIGHT PIN N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Power steering fluid C131336E01 PS–16 POWER STEERING – POWER STEERING LINK POWER STEERING LINK POWER STEERING STEERING COMPONENTS RETURN HOSE 28 (286, 21) PRESSURE FEED TUBE ASSEMBLY STEERING GEAR OUTLET RETURN TUBE COTTER PIN 41 (449, 32) *42 (428, 31) 91 (928, 67) 41 (428, 32) *42 (428, 31) 100 (1,020, 74) COTTER PIN 91 (928, 67) 70 (714, 52) POWER STEERING LINK ASSEMBLY 70 (714, 52) BUSH PS FRONT STABILIZER BAR BRACKET BUSH BRACKET 40 (408, 30) 40 (408, 30) X6 REAR ENGINE UNDER COVER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque X4 Non-reusable part * For use with SST ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 C131337E01 PS–17 POWER STEERING – POWER STEERING LINK TIE ROD END SUB-ASSEMBLY RH 88 (897, 65) STEERING RACK BOOT CLIP RH STEERING RACK BOOT RH 103 (1,050, 76) *98 (1,000, 72) STEERING RACK END SUB-ASSEMBLY CLAW WASHER STEERING RACK BOOT CLAMP RH 145 (1,479, 107) CYLINDER END STOPPER O-RING BUSHING PS OIL SEAL O-RING TEFLON RING POWER STEERING RACK N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Molybdenum disulfide lithium base grease Power Steering Fluid * For use with SST C131338E01 PS–18 POWER STEERING – POWER STEERING LINK POWER STEERING RACK HOUSING SUB-ASSEMBLY 103 (1,050, 76) *98 (1,000, 72) STEERING RACK END SUB-ASSEMBLY CLAW WASHER STEERING RACK BOOT CLAMP LH PS STEERING RACK BOOT LH STEERING RACK BOOT CLIP LH 88 (897, 65) N*m (kgf*cm, ft.*lbf) : Specified torque TIE ROD END SUB-ASSEMBLY LH Non-reusable part * For use with SST C131569E01 PS–19 POWER STEERING – POWER STEERING LINK 25 (250, 18) *23 (230, 17) TURN PRESSURE TUBE CONTROL VALVE HOUSING 18 (184, 13) 25 (250, 18) *23 (230, 17) DUST COVER 18 (184, 13) O-RING OIL SEAL UNION SEAT O-RING POWER STEERING CONTROL VALVE UPPER OIL SEAL 25 (250, 18) BEARING BEARING GUIDE NUT TEFLON RING POWER STEERING CONTROL VALVE 69 (700, 51) *65 (660, 48) PS LOCK NUT 25 (250, 18) RACK GUIDE SPRING CAP RACK GUIDE SPRING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Molybdenum disulfide lithium base grease RACK HOUSING RACK GUIDE Precoated part Power steering Fluid * For use with SST C131339E01 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–3 PARTS LOCATION ENGINE ROOM R/B - HEATER BLOWER MOTOR RELAY ASSEMBLY (MARKING: HEATER) - COOLER RELAY ASSEMBLY (MARKING: MG CLT) - HEATER FUSE - ECU-B FUSE CONDENSER - HEATER NO. 2 FUSE PRESSURE SWITCH AC THERMISTOR ASSEMBLY COMPRESSOR AND MAGNETIC CLUTCH (AMBIENT TEMPERATURE SENSOR) - MAGNETIC CLUTCH ASSEMBLY - COMPRESSOR LOCK SENSOR C119744E01 AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM COOLER (SOLAR SENSOR) THERMISTOR ASSEMBLY ECM AIR CONDITIONING CONTROL ASSEMBLY AC AIR CONDITIONING AMPLIFIER ASSEMBLY DRIVER SIDE J/B COOLER THERMISTOR - IG1 FUSE (ROOM TEMPERATURE SENSOR) C119745E05 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–5 BLOWER DAMPER SERVO SUB-ASSEMBLY (AIR INLET DAMPER CONTROL SERVO MOTOR) COOLER EXPANSION VALVE COOLER THERMISTOR NO. 1 (EVAPORATOR TEMP. SENSOR) BLOWER MOTOR CONTROL BLOWER WITH FAN MOTOR SUB-ASSEMBLY MODE DAMPER SERVO SUB-ASSEMBLY (AIR OUTLET DAMPER CONTROL SERVO MOTOR) DAMPER SERVO SUB-ASSEMBLY (*1) (AIR MIX DAMPER CONTROL SERVO MOTOR) DAMPER SERVO SUB-ASSEMBLY (AIR MIX DAMPER CONTROL SERVO MOTOR) (*1): Limited grade only HEATER RADIATOR UNIT SUB-ASSEMBLY C119746E01 AC AC–6 AIR CONDITIONING – AIR CONDITIONING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used in steps 2, 5, 6, 7 and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CHECK AND CLEAR DTCS NEXT 3 PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR (GO TO STEP 4) SYMPTOM OCCURS (GO TO STEP 5) 4 SYMPTOM SIMULATION NEXT 5 DTC CHECK (OTHER THAN MULTIPLEX DTC) AC TROUBLE CODE (GO TO STEP 6) NORMAL SYSTEM CODE (GO TO STEP 7) 6 DTC CHART GO TO STEP 8 7 PROBLEM SYMPTOMS TABLE NEXT 8 NEXT ACTUATOR CHECK AIR CONDITIONING – AIR CONDITIONING SYSTEM 9 AC–7 CIRCUIT INSPECTION NEXT 10 TERMINALS OF ECU NEXT 11 IDENTIFICATION OF PROBLEM NEXT 12 REPAIR OR REPLACE NEXT 13 CONFIRMATION TEST NEXT END AC AC–8 AIR CONDITIONING – AIR CONDITIONING SYSTEM PROBLEM SYMPTOMS TABLE If the normal code is displayed during DTC check although the problem still occurs, check the circuits for each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting. AIR CONDITIONING SYSTEM: Symptom Whole functions of the A/C system does not operate. Air Flow Control: No blower operation Air Flow Control: No blower control Temperature Control: No cool air comes out. AC Temperature Control: No warm air comes out. Temperature Control: Output air is warmer or cooler than the set temperature or response is slow. Suspected area See page 1. IG power source circuit AC-92 2. Heater control panel power source circuit AC-86 3. LIN communication circuit AC-97 1. Heater relay circuit AC-88 2. Blower motor circuit AC-78 3. LIN communication circuit AC-97 Blower motor circuit AC-78 1. Volume of refrigerant AC-99 2. Drive belt tension (for 1GR-FE) EM-6 3. Refrigerant pressure AC-99 4. Compressor lock sensor circuit AC-42 5. Compressor circuit AC-82 6. Pressure switch circuit AC-44 7. Air mix control servo motor circuit (Driver side) (*1) AC-73 8. Air mix control servo motor circuit (Passenger side) AC-64 9. Air mix damper position sensor circuit (Driver side) (*1) AC-60 10. Air mix damper position sensor circuit (Passenger side) AC-50 11. Room temp. sensor circuit AC-26 12. Ambient temp. sensor circuit AC-29 13. Vehicle speed signal circuit AC-76 14. LIN communication circuit AC-97 1. Air mix control servo motor circuit (Driver side) (*1) AC-73 2. Air mix control servo motor circuit (Passenger side) AC-64 3. Air mix damper position sensor circuit (Driver side) (*1) AC-60 4. Air mix damper position sensor circuit (Passenger side) AC-50 5. Ambient temp. sensor circuit AC-29 6. Vehicle speed signal circuit AC-76 7. Room temp. sensor circuit AC-26 8. Evaporator temp. sensor circuit AC-32 9. LIN communication circuit AC-97 10. Heater radiator AC-117 1. Room temp. sensor circuit AC-26 2. Ambient temp. sensor circuit AC-29 3. Vehicle speed signal circuit AC-76 4. Solar sensor circuit (Driver side) (*1) AC-47 5. Solar sensor circuit (Passenger side) AC-38 6. Air mix damper position sensor circuit (Driver side) (*1) AC-60 7. Air mix damper position sensor circuit (Passenger side) AC-50 8. Air mix control servo motor circuit (Driver side) (*1) AC-73 9. Air mix control servo motor circuit (Passenger side) AC-64 10. Engine coolant temperature communication circuit AC-35 11. LIN communication circuit AC-97 AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Temperature Control: No temperature control (only Max. cool or Max. warm) No air inlet control No air outlet control Suspected area See page 1. Air mix control servo motor circuit (Driver side) (*1) AC-73 2. Air mix control servo motor circuit (Passenger side) AC-64 3. Air mix damper position sensor circuit (Driver side) (*1) AC-60 4. Air mix damper position sensor circuit (Passenger side) AC-50 5. LIN communication circuit AC-97 1. Air inlet damper control servo motor circuit AC-67 2. Air inlet damper position sensor circuit AC-54 3. LIN communication circuit AC-97 1. Air outlet damper control servo motor circuit AC-70 2. Air outlet damper position sensor circuit AC-57 3. LIN communication circuit AC-97 1. Compressor circuit AC-82 2. LIN communication circuit AC-97 Blinking of A/C indicator Compressor lock sensor circuit AC-42 Set temperature value displayed does not much up with operation of temperature control switch. LIN communication circuit AC-97 Brightness does not change when rheostat volume or light control switch is turned. 1. Illumination light system - 2. Heater control panel - Unable to access the diagnosis mode. LIN communication circuit AC-97 DTC not recorded. Set mode is cleared when IG switch is turned off. 1. Back-up power source circuit AC-95 2. A/C amplifier - Engine idle up does not occur, or is continuous. (*1): Limited grade only AC AC–37 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC Engine Coolant Temperature Communication Circuit 14 DESCRIPTION This circuit converts the resistance of the engine coolant temperature sensor into a pulse signal and transmits to the A/C amplifier. DTC No. Detection Item 14 Trouble Area Open or short in A/C amplifier and ECM circuit • • • ECM Harness or connector between ECM and A/C amplifier assembly A/C amplifier assembly WIRING DIAGRAM ECM 14 THWO E7 Center J/B L-B H J32 J/C E J31 L-B C 3D C 3D L-B 7 A16 TWI A/C Amplifier I033593E01 AC INSPECTION PROCEDURE 1 CHECK DTC (a) Check that DTC P0115 is not output. Result Result Proceed to DTC P0115 is not output. A DTC P0115 is output. B B A GO TO ENGINE CONTROL SYSTEM AC–38 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT ECM (THWO) (a) Remove the ECM with the connectors still connected. (b) Turn the ignition switch ON. THWO A053769E16 5 V/Division “A” “A” GND 0.1 sec./Division (c) Measure the waveform between terminal THWO of the ECM connector and body ground. OK: Pulse generation HINT: • The correct waveform is as shown. • The waveform frequency "A" becomes longer as the engine coolant temperature becomes higher, as shown in the chart. I031455E04 Engine coolant temperature Frequency "A" Below 30°C (86°F) 16 ms Approx. 75°C (167°F) 102 ms 90°C to 100°C (194°F to 212°F) 262 ms NG REPLACE ECM OK AC 3 CHECK HARNESS AND CONNECTOR (ECM - AIR CONDITIONING AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the ECM and the A/C amplifier (See page IN-38). Result Result Proceed to NG A OK (when checking using PROBLEM SYMPTOMS TABLE) B OK (when checking using DTC) B B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPAIR OR REPLACE HARNESS OR CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–39 A REPLACE AIR CONDITIONING AMPLIFIER AC AC–40 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 21 Solar Sensor Circuit (Passenger Side) DESCRIPTION A photodiode in the cooler (solar sensor) thermistor detects solar radiation and sends signals to the A/C amplifier. Resistance of Photodiode High Low Strong Weak Strength of Solar Radiation E107008E01 DTC No. Detection Item 21 Trouble Area • • Open or short in solar sensor circuit • Cooler (solar sensor) thermistor Harness or connector between cooler (solar sensor) thermistor and A/C amplifier A/C amplifier WIRING DIAGRAM AC A/C Amplifier Center J/B P (*1) P (*2) 5 IG1 6 IG1 B 3B P (*1) B 3B P 1 A17 S5 P (*2) A20 Cooler (Solar Sensor) Thermistor V-G (*2) 1 2 5 IG1 V-G (*2) 4 IG1 B-O (*1) 26 (*1) 12 (*2) A16 TSPA (*1) TS (*2) A21 Cooler (Solar Sensor) Thermistor P (*1) B-O (*1) 1 (*1): Limited 2 (*2): SR5 Grade I033596E01 AC–41 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: If the check is performed in a dark place, DTC 21, 24 (solar sensor circuit abnormal) may be output. 1 INSPECT AIR CONDITIONING AMPLIFIER (TS, TSP, S5) (a) Remove the A/C amplifier with the connectors still connected. SR-5 grade: S5 (-) TS (+) I033523E04 (b) Measure the voltage according to the value(s) in the table below. Standard voltage Limited grade: S5 (-) TSPA (+) I033523E05 Tester Connection (Symbols) Condition Specified Condition A17-1 (S5) - A16-26 (TSPA) (*1) Ignition switch ON 0.8 to 4.3 V A17-1 (S5) - A16-12 (TS) (*2) Ignition switch ON 0.8 to 4.3 V *1: Limited *2: SR5 Grade HINT: • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the cooler (solar sensor) thermistor. • Move the light away from the sensor voltage increases • Move the light closer to the sensor voltage decreases OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT COOLER (SOLAR SENSOR) THERMISTOR (a) Remove the cooler (solar sensor) thermistor. SR-5 grade: 2 1 I033907E01 AC AC–42 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the resistance according to the value(s) in the table below. (c) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 1 of the cooler (solar sensor) thermistor. Standard resistance Limited grade: 2 Tester Connection Condition Specified Condition 2-1 Sensor is subject to electric light Except ∞ Ω 2-1 Sensor is covered with a cloth ∞ Ω (No continuity) 1 I033908E01 NOTICE: The connection procedure for using a digital tester such as an electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 2 and positive (+) lead to terminal 1 of the cooler (solar sensor) thermistor. HINT: • As the inspection light is moved away from the sensor, the resistance increases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the cooler (solar sensor) thermistor. NG REPLACE COOLER (SOLAR SENSOR) THERMISTOR OK 3 CHECK HARNESS AND CONNECTOR (COOLER (SOLAR SENSOR) THERMISTOR - A/C AMPLIFIER) AC (a) Check for open and short circuit in the harness and the connector between the cooler (solar sensor) thermistor and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 21 is not output again. Result Result Proceed to DTC 21 is output. A DTC 21 is not output. B B SYSTEM IS OK AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–43 A REPLACE AIR CONDITIONING AMPLIFIER AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–1 AIR CONDITIONING SYSTEM PRECAUTION NOTICE: Because the compressor operates at high voltages, wear electric insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME. ALWAYS WEAR EYE PROTECTION Charging Cylinder AC02810E02 3. AC02811 4. 5. Wrong Okay LO LO HI 6. HI 7. N011084E04 8. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a hospital or see a physician for professional treatment. NEVER HEAT CONTAINER OR EXPOSE IT TO OPEN FLAME BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the compressor may be damaged. Necessary care should be taken to avoid this. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure values are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. If the high pressure valve is opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc. AC AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM 9. AC GENERAL PRECAUTION (a) While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. AC–44 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 22 Compressor Lock Sensor Circuit DESCRIPTION This sensor sends 4 pulses par engine revolution to the A/C amplifier. If the ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the A/C amplifier turns the compressor off, and the indicator flashes at about 1 sec. intervals. DTC No. 22 Detection Item All conditions below are detected for 3 sec. or more. (a) Engine speed: 450 rpm or more. (b) Ratio between engine and compressor speed deviates 20 % or more in comparison with normal operation. Trouble Area • • • • • Cooler compressor assembly Compressor drive belt Compressor lock sensor Harness or connector between compressor lock sensor and A/C amplifier A/C amplifier WIRING DIAGRAM A/C Amplifier W-G 1 2 IM2 W-G 19 A16 LOCK 3 IM2 Y-G 6 A16 SG A2 A/C Lock Sensor (Cooler Compressor Assembly) 2 Y-G I045660E01 AC INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (LOCK) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Turn the A/C switch ON. SG LOCK I033523E06 AC–45 AIR CONDITIONING – AIR CONDITIONING SYSTEM Waveform: 200 mV /Division GND 10 msec./Division I031459E10 (d) Measure the waveform between terminal LOCK (A1619) and terminal SG (A16-6) of the A/C amplifier. OK: Waveform appears as shown in the illustration. Result Result Proceed to NG A OK (Checking from DTC) B OK (When checking from the PROBLEM SYMPTOMS TABLE) C B REPLACE AIR CONDITIONING AMPLIFIER C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A 2 INSPECT COOLER COMPRESSOR ASSEMBLY (a) Disconnect the connector from the cooler compressor assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A2 E005280E16 Tester Connection Condition Specified Condition A2-1 - A2-2 at 20°C (68°F) 165 to 205 Ω NG REPLACE COOLER COMPRESSOR ASSEMBLY AC OK 3 CHECK HARNESS AND CONNECTOR (COOLER COMPRESSOR ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the cooler compressor assembly and the A/C amplifier (See page IN-38). NG OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–46 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 23 Pressure Switch Circuit DESCRIPTION The pressure switch sends appropriate signals to the A/C amplifier when the A/C refrigerant pressure drops too low or rises too high. When the A/C amplifier receives these signals, it outputs signals via the A/ C amplifier to switch OFF the compressor relay and turn OFF the magnetic clutch. DTC No. Detection Item • • 23 Trouble Area • • Open in pressure sensor circuit Abnormal refrigerant pressure below 196 kPa (2.0 kgf/cm2, 28 psi) • • over 3,140 kPa (32.0 kgf/cm2, 455 psi) Pressure switch Harness or connector between pressure switch and A/C amplifier Refrigerant pipe line A/C amplifier WIRING DIAGRAM J1 J/C Y-R D Y-R E 5 IN1 LG-R 1 D Y-R E A/C Amplifier P3 Pressure SW 2 Driver Side J/B IG1 20 1E LG-R 9 A17 PSW I18 Ignition SW 2 1C L-Y 4 IG1 AM1 2 Engine Room R/B B AC ALT 2 AM1 21 1 2 2 2 W-L 2 B Battery I045661E02 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–47 INSPECTION PROCEDURE 1 INSPECT REFRIGERANT PRESSURE (a) Set the manifold gauge (See page AC-99). (b) Read the manifold gauge pressure when these conditions are established. Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Engine running at 1,500 rpm • Blower speed control switch at "HI" position • Temperature control dial at "COOL" position • Air conditioning switch ON • Fully open doors Standard: Pressure on high pressure side: 1.37 to 1.57 MPa (13.9 to 16.0 kgf*cm2, 198 to 228 psi) HINT: If the refrigerant pressure is below 196 kPa (2.0 kgf*cm2, 28 psi), the refrigerant amount in the air conditioning cycle may have decreased significantly for reasons such as a gas leakage. NG REPAIR OR REPLACE AIR CONDITIONING CYCLE OK 2 CHECK AIR CONDITIONING OPERATION I040669 AC (a) Disconnect the pressure switch connector. (b) Connect terminals 1 and 2 of the connector of the pressure switch on the vehicle wire harness side using a service wire. (c) Start the engine. (d) Turn the air conditioning switch on and check that the magnetic clutch is turned on. (e) Check that the magnetic clutch is turned off when disconnecting terminals 1 and 2 (that are connected in the prior step). OK: Terminals 1 and 2 connected: the compressor is operated Terminals 1 and 2 disconnected: the compressor is not operated NG Go to step 3 AC–48 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK REPLACE PRESSURE SWITCH 3 CHECK HARNESS AND CONNECTOR (PRESSURE SWITCH - AIR CONDITIONING AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the pressure switch and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 23 is not output again. Result Result Proceed to DTC 23 is output. A DTC 23 is not output. (Checking from the DTC) B DTC 23 is not output. (Checking from the PROBLEM SYMPTOMS TABLE) C AC B SYSTEM IS OK C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A REPLACE AIR CONDITIONING AMPLIFIER AC–49 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 24 Solar Sensor Circuit (Driver Side) DESCRIPTION A photodiode in the solar sensor detects solar radiation and sends signals to the A/C amplifier. Resistance of Photodiode High Low Strong Weak Strength of Solar Radiation E107008E01 HINT: This DTC is indicated only for limited grade (right/left independent temperature control system). DTC No. 24 Detection Item Trouble Area • • Open or short in solar sensor circuit circuit • Cooler (Solar sensor) thermistor Harness or connector between cooler (solar sensor) thermistor and A/C amplifier A/C amplifier WIRING DIAGRAM Limited grade: A/C Amplifier Center J/B P 5 IG1 B 3B P B 3B P AC 1 A17 S5 A21 A/C Solar Sensor R 1 3 6 IG1 R 12 A16 TSDR I033594E01 INSPECTION PROCEDURE HINT: If the check is performed in a dark place, DTC 21, 24 (solar sensor circuit abnormal) may be output. AC–50 1 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT AIR CONDITIONING AMPLIFIER (TS, S5) (a) Remove the A/C amplifier with the connectors still connected. (b) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TSDR (+) I033523E07 Tester Connection (Symbols) Condition Specified Condition A17-1 (S5) - A16-12 (TSDR) Ignition switch ON 0.8 to 4.3 V HINT: • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the cooler (solar sensor) thermistor. • Move the light away from the sensor voltage increases • Move the light closer to the sensor voltage decreases OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT COOLER (SOLAR SENSOR) THERMISTOR (a) Remove the cooler (solar sensor) thermistor. (b) Measure the resistance according to the value(s) in the table below. (c) Connect the positive (+) lead from the ohmmeter to terminal 3 and the negative (-) lead to terminal 1 of the cooler (solar sensor) thermistor. Standard resistance AC 3 1 I033908E02 Tester Connection Condition Specified Condition 3-1 Sensor is subject to electric light Except ∞ Ω 3-1 Sensor is covered with a cloth ∞ Ω (No continuity) NOTICE: The connection procedure for using a digital tester such as an electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 3 and positive (+) lead to terminal 1 of the cooler (solar sensor) thermistor. HINT: • As the inspection light is moved away from the sensor, the resistance increases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the cooler (solar sensor) thermistor. AC–51 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPLACE COOLER (SOLAR SENSOR) THERMISTOR OK 3 CHECK HARNESS AND CONNECTOR (COOLER (SOLAR SENSOR) - AIR CONDITIONING AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the cooler (solar sensor) thermistor and the air conditioning amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 24 is not output again. Result Result Proceed to DTC 24 is output. A DTC 24 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–52 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC Air Mix Damper Position Sensor Circuit (Passenger Side) 31 DESCRIPTION This sensor detects the position of the air mix damper and sends the appropriate signals to the A/C amplifier. The position sensor is built into the damper servo sub-assembly (air mix control servo motor). Voltage (V) 4 1 0 100% Damper opening angle E109300E01 DTC No. Detection Item Trouble Area • 31 Open or short in air mix damper position sensor circuit • • AC Damper servo sub-assembly (Air mix damper position sensor) Harness or connector between damper servo subassembly (air mix damper position sensor) and A/C amplifier A/C amplifier WIRING DIAGRAM Damper Servo Sub-assembly (Air Mix Damper Position Sensor) 2 2 A28 A26 (*1) (*2) 3 A/C Amplifier Center J/B P B 3B B 3B P 1 A17 S5 3 A28 A26 (*1) (*2) (*1): Limited 1 1 A28 A26 (*1) (*2) Y-G L-W (*1) L-O (*2) 6 A16 SG 23 (*1) 25 (*2) A16 TPPA (*1) TP (*2) (*2): SR5 Grade I033598E01 AC–53 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TP, TPDR, SG) (a) Remove the A/C amplifier with the connectors still connected. SR-5 grade: SG (-) TP (+) I033523E08 (b) Turn the ignition switch ON. (c) Change the set temperature to activate the air mix damper. (d) Measure the voltage according to the value(s) in the table below. Standard voltage: SR-5 grade Limited grade: SG (-) TPPA (+) Tester Connection (Symbols) Condition Specified Condition A16-25 (TP) - A16-6 (SG) Ignition switch ON MAX. HOT position 0.5 to 1.8 V A16-25 (TP) - A16-6 (SG) Ignition switch ON MAX. COLD position 3.5 to 5.5 V Tester Connection (Symbols) Condition Specified Condition A16-23 (TPPA) - A16-6 (SG) Ignition switch ON MAX. HOT position 0.5 to 1.8 V A16-23 (TPPA) - A16-6 (SG) Ignition switch ON MAX. COLD position 3.5 to 5.5 V I033523E09 Limited grade HINT: As the set temperature increases, the voltage decreases gradually without interruption. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT DAMPER SERVO SUB-ASSEMBLY (a) Remove the damper servo sub-assembly. AC AC–54 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Disconnect the connector from the damper servo subassembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Always 4.2 to 7.8 kΩ I030157 (d) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 3-2 MAX. COLD position 3.4 to 6.2 kΩ 3-2 MAX. HOT position 0.8 to 1.6 kΩ MAX. COLD MAX. HOT I033526E02 Resistance (kΩ) 3.4 to 6.2 Arm position (e) As the damper servo sub-assembly moves from COLD side to HOT side, the resistance decreases gradually without interruption. HINT: For details regarding operation of the servo motor (See page AC-67). NG 0.8 to 1.6 MAX. COOL MAX. HOT REPLACE DAMPER SERVO SUBASSEMBLY I030161E01 AC OK 3 CHECK HARNESS AND CONNECTOR (AIR MIX DAMPER POSITION SENSOR - A/C AMPLIFIER) (a) Check for open and short in the harness and the connector between the damper servo sub-assembly (air mix damper position sensor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 31 is not output again. AC–55 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to DTC 31 is output. A DTC 31 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–56 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 32 Air Inlet Damper Position Sensor Circuit DESCRIPTION This sensor detects the position of the air inlet damper and sends appropriate signals to the A/C amplifier. The position sensor is built into the blower damper servo sub-assembly (air inlet damper control servo motor). Voltage (V) 4 1 0 100% Damper opening angle E109300E01 DTC No. Detection Item Trouble Area • 32 Open or short in air inlet damper position sensor circuit • • AC Blower damper servo sub-assembly (Air inlet damper position sensor) Harness or connector between blower damper servo sub-assembly (air inlet damper position sensor) and A/C amplifier A/C amplifier WIRING DIAGRAM A25 Blower Damper Servo Sub-assembly (Air Inlet Damper Position Sensor) P 1 B 3B B 3B Y-G 3 A/C Amplifier Center J/B 2 P-B P 1 A17 S5 6 A16 SG 16 A16 TPI I033597E01 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–57 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TPI, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Change the set RECIRCULATION/FRESH to activate the blower damper. (d) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TPI (+) I033523E10 Tester Connection (Symbols) Condition Specified Condition A16-16 (TPI) - A16-6 (SG) Ignition switch ON RECIRCULATION position 3.5 to 4.5 V A16-16 (TPI) - A16-6 (SG) Ignition switch ON FRESH position 0.5 to 1.8 V HINT: As the blower damper is moved from RECIRCULATION side to FRESH side, the voltage decreases gradually without interruption. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Remove the blower damper servo sub-assembly. (b) Disconnect the connector from the blower damper servo sub-assembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance I030157 Tester Connection Condition Specified Condition 1-2 Always 4.2 to 7.8 kΩ AC AC–58 AIR CONDITIONING – AIR CONDITIONING SYSTEM (d) Measure the resistance according to the value(s) in the table below. Standard resistance RECIRCULATION Tester Connection Condition Specified Condition 3-2 RECIRCULATION position 0.8 to 1.6 kΩ 3-2 FRESH position 3.4 to 6.2 kΩ FRESH I033528E01 (e) As the blower damper servo sub-assembly moves from FRESH side to RECIRCULATION side, the resistance decreases gradually without interruption. HINT: For details regarding operation of the servo motor (See page AC-70). Resistance (kΩ) 3.4 to 6.2 0.8 to 1.6 RECIRCULATION NG FRESH REPLACE BLOWER DAMPER SERVO SUBASSEMBLY I030159E02 OK 3 CHECK HARNESS AND CONNECTOR (AIR INLET DAMPER POSITION SENSOR - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the blower damper servo subassembly (air inlet damper position sensor) and the A/C amplifier (See page IN-38). AC NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 32 is not output again. Result Result Proceed to DTC 32 is output. A DTC 32 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER SYSTEM IS OK AC–59 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 33 Air Outlet Damper Position Sensor Circuit DESCRIPTION This sensor detects the position of the air outlet damper and sends appropriate signals to the A/C amplifier. The position sensor is built into the mode damper servo sub-assembly (air outlet servo motor). Voltage (V) 4 1 0 100% Damper opening angle E109300E01 DTC No. Detection Item Trouble Area • Open or short in air outlet damper position sensor circuit 33 • • Mode damper servo sub-assembly (Air outlet damper position sensor) Harness or connector between mode damper servo sub-assembly (air outlet damper position sensor) and A/C amplifier A/C amplifier WIRING DIAGRAM A29 Mode Damper Servo Sub-assembly (Air Outlet Damper Position Sensor) P 2 Center J/B B 3B B 3B Y-G 3 1 LG-R AC A/C Amplifier P 1 A17 S5 6 A16 SG 17 A16 TPO I033597E02 AC–60 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TPO, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Change the set air flow mode to activate the mode damper servo sub-assembly. (d) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TPO (+) I033523E11 Tester Connection (Symbols) Condition Specified Condition A16-17 (TPO) - A16-6 (SG) Ignition switch ON FACE position 3.5 to 4.5 V A16-17 (TPO) - A16-6 (SG) Ignition switch ON DEF position 0.5 to 1.5 V HINT: As the mode damper is moved from FACE side to DEF side, the voltage decreases gradually without interruption. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT MODE DAMPER SERVO SUB-ASSEMBLY (a) Remove the mode damper servo sub-assembly. (b) Disconnect the connector from the mode damper servo sub-assembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance AC Tester Connection Condition Specified Condition 1-2 Always 4.2 to 7.8 kΩ I030157 (d) Measure the resistance according to the value(s) in the table below. Standard resistance FACE DEF I034386E01 Tester Connection Condition Specified Condition 3-2 FACE position 0.8 to 1.6 kΩ 3-2 DEF position 3.4 to 6.2 kΩ AC–61 AIR CONDITIONING – AIR CONDITIONING SYSTEM Resistance (kΩ) 3.4 to 6.2 Arm position (e) As the mode damper servo sub-assembly moves from DEF side to FACE side, the resistance decreases gradually without interruption. HINT: For details regarding operation of the servo motor (See page AC-73). NG 0.8 to 1.6 DEF FACE REPLACE MODE DAMPER SERVO SUBASSEMBLY I030161E15 OK 3 CHECK HARNESS AND CONNECTOR (AIR OUTLET DAMPER POSITION SENSOR - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the mode damper servo subassembly (air outlet damper position sensor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 33 is not output again. Result Result Proceed to DTC 33 is output. A DTC 33 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER SYSTEM IS OK AC AC–62 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 36 Air Mix Damper Position Sensor Circuit (Driver Side DESCRIPTION This sensor detects the position of the air mix damper and sends the appropriate signals to the A/C amplifier. The position sensor is built into the damper servo sub-assembly (air mix damper control servo motor). Voltage (V) 4 1 0 100% Damper opening angle E109300E01 HINT: This DTC is indicated only for limited grade (right/left independent temperature control system). DTC No. Detection Item Trouble Area • 36 AC Short to ground or power source circuit in air mix damper position sensor circuit • • Damper servo sub-assembly (Air mix damper position sensor) Harness or connector between damper servo subassembly (air mix damper position sensor) and A/C amplifier A/C amplifier AC–63 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Limited grade: A/C Amplifier Center J/B P B 3B 1 A27 Damper Servo Sub-assembly (Air Mix Damper Position Sensor) B 3B P 6 Y-G 3 1 A17 S5 A16 SG 2 25 L-O A16 TPDR I033597E03 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TPDR, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Change the set temperature to activate the air mix damper. (d) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TPDR (+) I033523E12 Tester Connection (Symbols) Condition Specified Condition A16-25 (TPDR) - A16-6 (SG) Ignition switch ON MAX. COLD position 3.5 to 4.5 V A16-25 (TPDR) - A16-6 (SG) Ignition switch ON MAX. HOT position 0.5 to 1.8 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–64 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT DAMPER SERVO SUB-ASSEMBLY (a) Remove the damper servo sub-assembly. (b) Disconnect the connector from the damper servo subassembly. (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Always 4.2 to 7.8 kΩ I030157 (d) Measure the resistance according to the value(s) in the table below. Standard resistance MAX. HOT Tester Connection Condition Specified Condition 3-2 MAX. COLD position 3.4 to 6.2 kΩ 3-2 MAX. HOT position 0.8 to 1.6 kΩ MAX. COLD I033527E01 Resistance (kΩ) 3.4 to 6.2 Arm position AC (e) As the damper servo sub-assembly moves from COLD side to HOT side, the resistance decreases gradually without interruption. HINT: For details regarding operation of the servo motor (See page AC-76). NG 0.8 to 1.6 MAX. COOL MAX. HOT REPLACE DAMPER SERVO SUBASSEMBLY I030161E16 OK 3 CHECK HARNESS AND CONNECTOR (AIR MIX DAMPER POSITION SENSOR - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the damper servo sub-assembly (air mix damper position sensor) and the A/C amplifier (See page IN-38). NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR AC–65 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 36 is not output again. Result Result Proceed to DTC 36 is output. A DTC 36 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–66 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC Air Mix Damper Control Servo Motor Circuit (Passenger Side) 41 DESCRIPTION This damper servo sub-assembly (air mix damper control servo motor) is controlled by the A/C amplifier and moves the air mix damper to the desired position. DTC No. Detection Item Trouble Area • Air mix damper position sensor value does not change even if A/C amplifier operates air mix servo motor. 41 • • Damper servo sub-assembly (Air mix damper control servo motor) Harness or connector between A/C amplifier and damper servo sub-assembly (air mix damper control servo motor) A/C amplifier WIRING DIAGRAM Damper Servo Sub-assembly (Air Mix Damper Control Servo Motor) 5 5 A28 A26 (*1) (*2) L-Y (*1) V-R (*2) 24 (*1) 23 (*2) AMCPA (*1) A17 AMC (*2) L-R (*1) V-W (*2) 16 (*1) 14 (*2) AMHPA (*1) A17 AMH (*2) M 4 4 A28 A26 (*1) (*2) (*1): Limited A/C Amplifier (*2): SR5 Grade I033600E01 AC INSPECTION PROCEDURE 1 PERFORM ACTUATOR CHECK (a) Operate the A/C control panel to enter the actuator check mode (See page AC-24). (b) Press the DEF switch to enter the step operation. (c) Check the air flow temperature by hand. Display Code Air Mix Damper Operation 0 COLD side (0 % open) 1 COLD side (0 % open) 2 COLD side (0 % open) 3 COLD/HOT (50 % open) 4 COLD/HOT (50 % open) 5 COLD/HOT (50 % open) 6 HOT side (100 % open) 7 HOT side (100 % open) 8 HOT side (100 % open) 9 HOT side (100 % open) AC–67 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT DAMPER SERVO SUB-ASSEMBLY (a) Remove the damper servo sub-assembly. I030157 (b) Connect the battery positive (+) lead to terminal 4 and the battery negative (-) lead to terminal 5, then check that the lever turns to "COLD" side smoothly. (c) Connect the battery positive (+) lead to terminal 5 and the battery negative (-) lead to terminal 4, then check that the lever turns to "HOT" side smoothly. OK: Motor operates smoothly. MAX. COLD MAX. HOT I033526E02 NG REPLACE DAMPER SERVO SUBASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (DAMPER SERVO SUB-ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the damper servo sub-assembly (air mix damper control servo motor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 41 is not output again. Result Result Proceed to DTC 41 is output. A DTC 41 is not output. B AC AC–68 AIR CONDITIONING – AIR CONDITIONING SYSTEM B A REPLACE AIR CONDITIONING AMPLIFIER AC SYSTEM IS OK AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM TERMINALS OF ECU 1. Air conditioning amplifier A17 A16 I033903E01 AC Symbols (Terminals No.) Wiring Color IG - GND (A16-1 - A16-5) Condition Y-R - W-B Ignition switch: ON 10 to 14 V +B - GND (A16-2 - A16-5) W-R - W-B Always 10 to 14 V BLW - GND (A16-3 - A16-5) LG-B - W-B Ignition switch: ON Blower motor: Operating LIN1 (A16-4) L-B GND - Body ground (A16-5 - Body ground) W-B - Body ground Always Below 1.0 Ω SG - Body ground (A16-6 - Body ground) Y-G - Body ground Always Below 1.0 Ω TWI - GND (A16-7 - A16-5) L-B - W-B Ignition switch: ON SPD - GND (A16-8 - A16-5) V-R - W-B Ignition switch: ON Turn propeller shaft slowly TSDR - S5 (A16-12 - A17-1) (*1) R - P (*1) Ignition switch: ON, Solar sensor subject to electric light 4.0 to 5.5 V TSDR - S5 (A16-12 - A17-1) (*1) R - P (*1) Ignition switch: ON, Solar sensor covered by a cloth Below 1.0 V TS - S5 (A16-12 - A17-1) (*2) V-G - P (*2) Ignition switch: ON, Solar sensor subject to electric light 4.0 to 5.5 V TS - S5 (A16-12 - A17-1) (*2) V-G - P (*2) Ignition switch: ON, Solar sensor covered by a cloth Below 1.0 V TR - SG (A16-15 - A16-6) V-Y - Y-G Ignition switch: ON, Room temp.: 25°C (77°F) 1.35 to 1.75 V TR - SG (A16-15 - A16-6) V-Y - Y-G Ignition switch: ON, Room temp.: 40°C (104°F) 0.85 to 1.25 V TPI - SG (A16-16 - A16-6) P-B - Y-G Ignition switch: ON Set air intake: RECIRCULATION 3.5 to 4.5 V TPI - SG (A16-16 - A16-6) P-B - Y-G Ignition switch: ON Set air intake: FRESH 0.5 to 1.8 V TPO - SG (A16-17 - A16-6) LG-R - Y-G Ignition switch: ON, Set air flow: FACE 3.5 to 4.5 V TPO - SG (A16-17 - A16-6) LG-R - Y-G Ignition switch: ON, Set air flow: DEF 0.5 to 1.8 V ACT - GND (A16-18 - A16-5) BR-W - W-B Start engine Blower speed: LO Magnetic clutch: Engaged 10 to 14 V ACT - GND (A16-18 - A16-5) BR-W - W-B Start engine Blower speed: LO Magnetic clutch: Not engaged Below 1.0 V LOCK - GND (A16-19 - A16-5) W-G - W-B Heater control panel communication circuit Engine running: Idle speed A/C system: Operate speed Specification Pulse generation (See waveform 1) - Pulse generation (See waveform 2) 0 - 4.5 to 5.5 V (Voltage is generated intermittently) Pulse generation (See waveform 3) AC–11 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminals No.) Wiring Color HR - GND (A16-21 - A16-5) Condition Specification L - W-B Ignition switch: ON, Blower switch: ON Below 1.0 V HR - GND (A16-21 - A16-5) L - W-B Ignition switch: ON, Blower switch: OFF 10 to 14 V TAM - SG (A16-22 - A16-6) GR - Y-G Ignition switch: ON, Ambient temp.: 25°C (77°F) 1.35 to 1.75 V TAM - SG (A16-22 - A16-6) GR - Y-G Ignition switch: ON, Ambient temp.: 40°C (104°F) 0.85 to 1.25 V TPPA - SG (A16-23 - A16-6) (*1) L-W - Y-G Ignition switch: ON Set passenger side temp.: Max. COLD 3.5 to 4.5 V TPPA - SG (A16-23 - A16-6) (*1) L-W - Y-G Ignition switch: ON Set passenger side temp.: Max. HOT 0.5 to 1.5 V TE - SG (A16-24 - A16-6) G - Y-G Ignition switch: ON Evaporator temp.: 0°C (32°F) 2.0 to 2.4 V TE - SG (A16-24 - A16-6) G - Y-G Ignition switch: ON Evaporator temp.: 15°C (59°F) 1.4 to 1.8 V TPDR - SG (A16-25 - A16-6) (*1) L-O - Y-G Ignition switch: ON Set (driver side *1) temp.: Max. COLD 3.5 to 4.5 V TPDR - SG (A16-25 - A16-6) (*1) L-O - Y-G Ignition switch: ON Set (driver side *1) temp.: Max. HOT 0.5 to 1.5 V TP - SG (A16-25 - A16-6) (*2) L-O - Y-G Ignition switch: ON Set (driver side *1) temp.: Max. COLD 3.5 to 4.5 V TP - SG (A16-25 - A16-6) (*2) L-O - Y-G Ignition switch: ON Set (driver side *1) temp.: Max. HOT 0.5 to 1.5 V TSPA - S5 (A16-26 - A17-1) (*1) B-O - P Ignition switch: ON, Solar sensor subject to electric light 4.0 to 5.5 V TSPA - S5 (A16-26 - A17-1) (*1) B-O - P Ignition switch: ON, Solar sensor covered by a cloth Below 1.0 V S5 - SG A17-1 - A16-6) P - Y-G Ignition switch: ON 4.5 to 5.5 V AOF - GND (A17-3 - A16-5) LG-R - W-B Ignition switch: ON, Set air flow: FACE 10 to 14 V AOF - GND (A17-3 - A16-5) LG-R - W-B Ignition switch: ON, Set air flow: Except FACE AOD - GND A17-4 - A16-5) LG - W-B Ignition switch: ON, Set air flow: DEF AOD - GND A17-4 - A16-5) LG - W-B Ignition switch: ON, Set air flow: Except DEF AIR - GND (A17-5 - A16-5) P-L - W-B Ignition switch: ON Set air intake: RECIRCULATION AIR - GND (A17-5 - A16-5) P-L - W-B Ignition switch: ON, Set air intake: FRESH Below 1.0 V AIF - GND (A17-6 - A16-5) P-G - W-B Ignition switch: ON, Set air intake: FRESH 10 to 14 V AIF - GND (A17-6 - A16-5) P-G - W-B Ignition switch: ON Set air intake: RECIRCULATION Below 1.0 V AC1 - GND (A17-7 - A16-5) GR-G - W-B Start engine Blower speed: LO Magnetic clutch: Engaged Below 1.0 V AC1 - GND (A17-7 - A16-5) GR-G - W-B Start engine Blower speed: LO Magnetic clutch: Not engaged 10 to 14 V PSW - GND (A17-9 - A16-5) LG-R - W-B Start engine Operate A/C system Refrigerant pressure: Abnormal pressure (More than 3,140 kPa and less than 196 kPa) PSW - GND (A17-9 - A16-5) LG-R - W-B Start engine Operate A/C system Refrigerant pressure: Normal pressure (Less than 3,140 kPa and less than 196 kPa) Below 1.0 V 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V 10 to 14 V AC AC–12 Symbols (Terminals No.) AIR CONDITIONING – AIR CONDITIONING SYSTEM Wiring Color Condition MGC - GND (A17-10 - A16-5) BR-Y - W-B Engine running: Idle speed A/C system: Operate Magnetic clutch: Not engaged MGC - GND (A17-10 - A16-5) BR-Y - W-B Engine running: Idle speed A/C system: Operate Magnetic clutch: Engaged AMHDR - GND (A17-14 - A16-5) (*1) V-W - W-B Ignition switch: ON Set (driver side *1) temp.: Max. HOT AMHDR - GND (A17-14 - A16-5) (*1) V-W - W-B Ignition switch: ON Set (driver side *1) temp.: Max. COLD AMH - GND (A17-14 - A16-5) (*2) V-W - W-B Ignition switch: ON Set (driver side *1) temp.: Max. HOT AMH - GND (A17-14 - A16-5) (*2) V-W - W-B Ignition switch: ON Set (driver side *1) temp.: Max. COLD AMHPA - GND (A17-16 - A16-5) (*1) L-R - W-B Ignition switch: ON Set passenger temp.: Max. HOT AMHPA - GND (A17-16 - A16-5) (*1) L-R - W-B Ignition switch: ON Set passenger side temp.: Max. COLD DMOT (A17-19) BR-B DMIN (A17-20) W-L Specification 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V Multiplex communication circuit - Multiplex communication circuit - AMCDR - GND (A17-23 - A16-5) (*1) V-R - W-B Ignition switch: ON Set (driver side *1) temp.: Max. COLD AMCDR - GND (A17-23 - A16-5) (*1) V-R - W-B Ignition switch: ON Set (driver side *1) temp.: Max. HOT AMC - GND (A17-23 - A16-5) (*2) V-R - W-B Ignition switch: ON Set (driver side *1) temp.: Max. COLD AMC - GND (A17-23 - A16-5) (*2) V-R - W-B Ignition switch: ON Set (driver side *1) temp.: Max. HOT AMCPA - GND (A17-24 - A16-5) (*1) L-Y - W-B Ignition switch: ON Set passenger temp.: Max. COLD AMCPA - GND (A17-24 - A16-5) (*1) L-Y - W-B Ignition switch: ON Set passenger side temp.: Max. HOT AC 2. 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V 10 to 14 V Below 1.0 V (*1): Limited grade (*2): SR-5 grade Air conditioning control assembly: D3 I033905E01 Symbols (Terminals No.) Wiring Color B - GND (D3-1 - D3-7) R - W-B IG+ - GND (D3 -2 - D3-7) Condition Specification Always 10 to 14 V Y-R - W-B Ignition switch: ON 10 to 14 V IG+ - GND (D3 -2 - D3-7) Y-R - W-B Ignition switch: Except ON ACC - GND (D3-8 - D3-7) GR - W-B Ignition switch: ACC Below 1.0 V 10 to 14 V AC–13 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminals No.) Wiring Color ACC - GND (D3-8 - D3-7) GR - W-B GND - Body ground (D3-7 - Body ground) W-B - Body ground LIN-B (D3-14) L-B Condition Ignition switch: Except ACC Below 1.0 V Always Below 1.0 V A/C amplifier communication circuit 3. E4 Specification E5 - ECM E6 E7 E8 I030693E19 Symbols (Terminals No.) Wiring Color Condition E1 - Body ground (E6-1 - Body ground) W-B - Body ground (*3) BR - Body ground (*4) THWO - Body ground (E7-14 - Body ground) L-B - Body ground ACT - Body ground (E7-25 - Body ground) BR-W - Body ground Start engine Blower speed: LO Magnetic clutch: Engaged 10 to 14 V ACT - Body ground (E7-25 - Body ground) BR-W - Body ground Start engine Blower speed: LO Magnetic clutch: Not engaged Below 1.0 V AC1 - Body ground (E7-24 - Body ground) GR-G - Body ground Start engine Blower speed: LO Magnetic clutch: Engaged 10 to 14 V AC1 - Body ground (E7-24 - Body ground) GR-G - Body ground Start engine Blower speed: LO Magnetic clutch: Not engaged Below 1.0 V Always Specification Below 1.0 V Engine running: Idle speed Pulse generation (See waveform 2) (*3): 2UZ-FE (*4): 1GR-FE 2 V/Division 500 msec./Division (a) Oscilloscope waveform 1: Terminal to be measured: BLW of A/C amplifier Setting for measurement: 2 V/DIV, 500 msec./DIV Condition: Ignition switch ON I031456E21 5 V/Division GND 0.1 sec./Division I031455E03 (b) Oscilloscope waveform 2: Terminal to be measured: TWI of A/C amplifier and TWHO of ECM Setting for measurement: 5 V/DIV, 0.1 sec./DIV Condition: Ignition switch ON AC AC–14 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Oscilloscope waveform 3: Terminal to be measured: MGC of A/C amplifier and ECM Setting for measurement: 200 mV/DIV, 10 msec./ DIV Condition: Ignition switch ON 200 mV /Division GND 10 msec./Division CG SG I031459E09 DIAGNOSIS SYSTEM CANH 1. SIL CANL BAT E106867E04 AC CHECK DLC3 (a) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 1576-4 format. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. Symbol (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 3 MΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF 3 MΩ or higher AC–69 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 42 Air Inlet Damper Control Servo Motor Circuit DESCRIPTION The blower damper servo sub-assembly (air inlet damper control servo motor) is controlled by the A/C amplifier and moves the air inlet damper to the desired position. DTC No. Detection Item Trouble Area • Air inlet damper position sensor value does not change even if A/C amplifier operates air inlet control servo motor. 42 • • Blower damper servo sub-assembly (Air inlet damper control servo motor) Harness or connector between blower damper servo sub-assembly (air inlet damper control servo motor) and A/C amplifier A/C amplifier WIRING DIAGRAM A/C Amplifier 5 A17 AIR P-L 4 A25 Blower Damper Servo Sub-assembly (Air Inlet Damper Control Servo Motor) M 6 P-G A17 AIF 5 I033599E01 AC INSPECTION PROCEDURE 1 PERFORM ACTUATOR CHECK (a) Remove the glove compartment to see and check the recirculation damper operation. (1) Operate the A/C control panel to enter the actuator check mode (See page AC-24). (2) Press the DEF switch to enter the step operation. (3) Press the DEF switch in order, and visually check the recirculation damper operation. Display Code Recirculation damper position 0 RECIRCULATION 1 RECIRCULATION 2 FRESH/RECIRCULATION 3 FRESH/RECIRCULATION 4 FRESH 5 FRESH 6 FRESH 7 FRESH AC–70 AIR CONDITIONING – AIR CONDITIONING SYSTEM Display Code Recirculation damper position 8 FRESH 9 FRESH OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT BLOWER DAMPER SERVO SUB-ASSEMBLY (a) Remove the blower damper servo sub-assembly. I030157 RECIRCULATION FRESH I033528E01 AC (b) Connect the battery positive (+) lead to terminal 4 and the battery negative (-) lead to terminal 5, then check that the lever turns to "RECIRCULATION" side smoothly. (c) Connect the battery positive (+) lead to terminal 5 and the battery negative (-) lead to terminal 4, then check that the lever turns to "FRESH" side smoothly. OK: Motor operates smoothly. NG REPLACE BLOWER DAMPER SERVO SUBASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (BLOWER DAMPER SERVO SUB-ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the blower damper servo subassembly (air inlet damper control servo motor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 42 is not output again. AC–71 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to DTC 42 is output. A DTC 42 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–72 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 43 Air Outlet Damper Control Servo Motor Circuit DESCRIPTION This circuit turns the servo motor and changes each mode damper position by the signals from the A/C amplifier. When the AUTO switch is on, the A/C amplifier changes the mode automatically between (FACE), (BI-LEVEL) and (FOOT) according to the temperature setting. DTC No. Detection Item Trouble Area • Air outlet damper position sensor value does not change even if A/C amplifier operates air outlet damper control servo motor. 43 • • Mode damper servo sub-assembly (Air outlet damper control servo motor) Harness or connector between A/C amplifier and mode damper servo sub-assembly (air outlet damper control servo motor) A/C amplifier WIRING DIAGRAM A/C Amplifier 4 A17 AOD LG 4 A29 Mode Damper Servo Sub-assembly (Air Outlet Damper Control Servo Motor) M 3 LG-R A17 AOF 5 I033599E02 AC INSPECTION PROCEDURE 1 PERFORM ACTUATOR CHECK (a) Warm up the engine. (b) Operate the A/C control panel to enter the actuator check mode (See page AC-24). (c) Press the DEF switch to enter the step operation. (d) Press the DEF switch, and check the air flow by hand. Display Code Air Mix Damper Operation 0 FACE 1 FACE 2 B/L 3 B/L 4 FOOT 5 FOOT 6 FOOT 7 FOOT 8 FOOT/DEF AIR CONDITIONING – AIR CONDITIONING SYSTEM Display Code Air Mix Damper Operation 9 DEF OK AC–73 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT MODE DAMPER SERVO SUB-ASSEMBLY (a) Remove the mode damper servo sub-assembly. I030157 (b) Connect the battery positive (+) lead to terminal 4 and the battery negative (-) lead to terminal 5, then check that the lever turns to "DEF" position smoothly. (c) Connect the battery positive (+) lead to terminal 5 and the battery negative (-) lead to terminal 4, then check that the lever turns to "FACE" position smoothly. OK: Motor operates smoothly. FACE DEF I034386E01 NG REPLACE MODE DAMPER SERVO SUBASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (MODE DAMPER SERVO SUB-ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the mode damper servo subassembly (air outlet damper control servo motor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 43 is not output again. AC AC–74 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to DTC 43 is output. A DTC 43 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER AC SYSTEM IS OK AC–99 AIR CONDITIONING – REFRIGERANT REFRIGERANT ON-VEHICLE INSPECTION 1. Sight Glass I033456E01 Item INSPECT REFRIGERANT VOLUME (a) Check the sight glass on the liquid tube subassembly. Test conditions: • Engine is running at 1,500 rpm. • Blower speed control switch is at HI. • A/C switch is ON. • Temperature control switch is at MAX. COOL. • Doors are fully open. Symptom Amount of Refrigerant Corrective Procedures (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear Bubbles visible Insufficient* 2 No bubbles visible Empty, insufficient or too much Refer to items 3 and 4 Empty or nearly empty 3 No temperature difference between compressor inlet and outlet (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear Considerable temperature difference between compressor inlet and outlet Correct or too much Refer to items 5 and 6 Immediately after A/C is turned OFF, refrigerant becomes clear Too much (1) Drain or discharge refrigerant (2) Bleed air and supply proper amount of purified refrigerant Immediately after A/C is turned OFF, refrigerant foams and then becomes clear Correct 1 4 5 6 - HINT: : If the ambient temperature is higher than usual but cooling is sufficient, bubbles in the sight glass are permissible. * 2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET (a) This method uses a manifold gauge set to locate problem areas. Read the manifold gauge pressure when the following conditions are established. Test conditions: • Temperature at the air inlet is 30 to 35°C (86 to 95°F). • Engine is running at 1,500 rpm. • All doors are fully open. • Blower speed control switch is at HI. • Temperature control switch is at MAX. COOL. • A/C switch is ON. Gauge readings (Reference) AC AC–100 AIR CONDITIONING – REFRIGERANT Pressure on low-pressure side MPa (kgf/cm2) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.80) 0.3 (3.0) 0.27 (2.75) 0.2 (2.0) 1.2 (12.23) Blower LO Zone 0.22 (2.24) 0.2 (2.03) 1.25 (12.74) 0.14 (1.42) 0.5 (5.0) Pressure on highpressure side 1.32 (13.46) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) MPa (kgf/cm2) I030081E04 (1) Normally functioning refrigeration system Gauge reading AC Pressure side Refrigerant volume Low 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High 1.37 to 1.57 MPa (14 to 16 kgf/cm2) (2) The A/C system periodically changes between normal and improper function due to moisture in the refrigeration system. E050573E01 I022117 Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low - pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing temporary stop of cycle. However, when melted, normal state is restored - Drier is oversaturated - Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation 1. Replace cooler drier 2. Remove moisture from cycle by repeatedly evacuating air 3. Supply appropriate volume of new refrigerant AC–101 AIR CONDITIONING – REFRIGERANT (3) The A/C system does not function effectively due to insufficient cooling. I022118 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high-pressure sides - Cooling performance insufficient Gas leakage from refrigeration system - Insufficient refrigerant - Refrigerant leakage 1. Check for gas leakage and repair if necessary 2. Supply appropriate volume of new refrigerant 3. If indicated pressure value is close to 0 when connected to gauge, create vacuum after inspecting and repairing the location of leakage (4) The A/C system does not function effectively due to poor circulation of the refrigerant. AC I022119 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high-pressure sides - Frost exists on piping from condenser to A/C unit Refrigerant flow obstructed by dirt in condenser Condenser clogged Replace condenser (5) The A/C system does not function intermittently because the refrigerant does not circulate. I022120 AC–102 AIR CONDITIONING – REFRIGERANT Symptoms Probable Cause Diagnosis Corrective Actions - Vacuum indicated on lowpressure side, and extremely low pressure indicated on highpressure side - Frost or condensation seen on piping on both sides of condenser or expansion valve - Refrigerant flow obstructed by moisture or dirt in refrigeration system - Refrigerant flow obstructed by gas leakage from expansion valve Refrigerant does not circulate 1. Check expansion valve 2. Clean expansion valve by blowing air 3. Replace condenser 4. Evacuate air and charge appropriate volume of new refrigerant 5. For gas leakage from expansion valve, replace expansion valve (6) The A/C system does not function effectively due to overcharged refrigerant or insufficient cooling of the condenser. I022121 Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides - Excessive refrigerant - Cooling performance of condenser insufficient - Condenser is dirty - Condenser fan motor is malfunctioning - Excessive refrigerant 1. Clean condenser 2. Check condenser fan motor operation 3. If 1 and 2 are normal, check the amount of refrigerant and supply appropriate volume of refrigerant (7) The A/C system does not function due to air in the refrigeration system. CAUTION: The low-pressure piping may be very hot and cause serious burns. AC HINT: These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging I022122E03 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure extremely high on both low and high-pressure sides - The low-pressure piping is too hot to touch Air in refrigeration system - Air in refrigeration system - Vacuum purging insufficient 1. Check if compressor oil is dirty or insufficient 2. Evacuate air and charge new refrigerant AC–103 AIR CONDITIONING – REFRIGERANT (8) The A/C system does not function effectively due to an expansion valve malfunction. I022123 Symptoms Probable Cause Diagnosis Corrective Actions -Pressure extremely high on both low and high-pressure sides -Frost or condensation on piping on low-pressure side Problem with expansion valve - Excessive refrigerant in low pressure piping - Expansion valve too wide open Replace expansion valve (9) The A/C system does not function due to a defective compressor. I022124 Symptoms Probable Cause Diagnosis Corrective Actions -Pressure extremely high on both low and high-pressure sides -Pressure extremely low on highpressure side Internal leakage in compressor - Compression failure - Leakage from damaged valve or broken sliding parts Repair or replace compressor AC AC–75 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 46 Air Mix Damper Control Servo Motor Circuit (Driver Side) DESCRIPTION The damper servo sub-assembly (air mix damper control servo motor) is controlled by the A/C amplifier and moves the air mix damper to the desired position. HINT: This DTC is displayed for only limited grade (right/left independent temperature control system). DTC No. Detection Item Trouble Area • Air mix damper position sensor value does not change even if A/C amplifier operates air mix control servomotor servo motor. 46 • • Damper servo sub-assembly (Air mix damper control servo motor) Harness or connector between damper servo subassembly (air mix control servo motor) and A/C amplifier A/C amplifier WIRING DIAGRAM Limited grade: A/C Amplifier V-R 4 A27 Damper Servo Sub-assembly (Air Mix Damper Control Servo Motor) M V-W 5 23 A17 AMCDR 14 A17 AMHDR AC I033599E03 INSPECTION PROCEDURE 1 PERFORM ACTUATOR CHECK (a) Operate the A/C control panel to enter the actuator check mode (See page AC-24). (b) Press the DEF switch to enter the step operation. (c) Check the air flow temperature by hand. Display Code Air Mix Damper Operation 0 COLD side (0 % open) 1 COLD side (0 % open) 2 COLD side (0 % open) 3 COLD/HOT (50 % open) 4 COLD/HOT (50 % open) 5 COLD/HOT (50 % open) 6 COLD/HOT (50 % open) 7 HOT side (100 % open) AC–76 AIR CONDITIONING – AIR CONDITIONING SYSTEM Display Code Air Mix Damper Operation 8 HOT side (100 % open) 9 HOT side (100 % open) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT DAMPER SERVO SUB-ASSEMBLY (a) Remove the damper servo sub-assembly. I030157 (b) Connect the battery positive (+) lead to terminal 4 and the battery negative (-) lead to terminal 5, then check that the lever turns to "COLD" side smoothly. (c) Connect the battery positive (+) lead to terminal 5 and the battery negative (-) lead to terminal 4, then check that the lever turns to "HOT" side smoothly. OK: Motor operates smoothly. MAX. HOT MAX. COLD I033527E01 AC NG REPLACE DAMPER SERVO SUBASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (DAMPER SERVO SUB-ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short in the harness and the connector between the damper servo sub-assembly (air mix damper control servo motor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 46 is not output again. AC–77 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to DTC 46 is output. A DTC 46 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–78 AIR CONDITIONING – AIR CONDITIONING SYSTEM Vehicle Speed Signal Circuit DESCRIPTION This A/C amplifier monitors the vehicle speed through signals sent from the speed sensor. The A/C amplifier uses these signals to receive the ambient temperature sensor signal. WIRING DIAGRAM A/C Amplifier Combination Meter Assembly Driver Side J/B 5 C9 V-R 1 1G Center J/B 11 B V-R 1K 3D B 3D V-R 8 A16 SPD I033607E01 AC INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (SPD) (a) Remove the A/C amplifier with the connectors still connected. (b) Shift the shift lever to neutral. (c) Lift up the vehicle. (d) Turn the ignition switch ON. SPD I033523E13 AIR CONDITIONING – AIR CONDITIONING SYSTEM (e) Measure the voltage between terminal SPD of the A/C amplifier connector and body ground when the wheel is turned slowly. Standard: Voltage is generated intermittently is as shown in the illustration. 10 to 14 V 0 AC–79 Turn the wheel NG Go to step 2 E116248E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the combination meter assembly and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE COMBINATION METER ASSEMBLY AC AC–80 AIR CONDITIONING – AIR CONDITIONING SYSTEM Blower Motor Circuit DESCRIPTION The blower motor is operated by signals from the A/C amplifier. Blower motor speed signals are transmitted by changes in the Duty Ratio. Blower Level HI M2 M1 LO 0 89 67 100 30 43 SI Duty (%) Duty Ratio = ON OFF AC A A+B 㨄 100 (%) A B 1 Cycle E107334E02 Duty Ratio The duty ratio is the ratio of the blower motor ON time (A) to the total of the blower motor ON and OFF time (A + B). The blower motor controller controls the blower motor speed. AC–81 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM A/C Amplifier B3 Blower Motor Control G-Y 3 +B SI 2 Center J/B J24 J/C 4 VM GND 3 A16 BLW LG-B W-B 1 A W-B B 3F B 3F W-B A B2 Blower with Fan Motor Sub-assembly W-L 1 B-Y 2 M Engine Room R/B HEATER No. 2 G-Y 2 2 2 1 A14 IC4 From Heater Blower Motor Relay From Heater Blower Motor Relay A J37 J/C II IK I033605E01 INSPECTION PROCEDURE 1 PERFORM ACTUATOR CHECK (a) Operate the A/C control panel to enter the actuator check mode (See page AC-24). (b) Press the blower switch and change it to the step operation. (c) Check the air flow temperature by hand. Display Code Air Mix Damper Operation 0 0 (No blower) 1 1 (LO) 2 17 (Medium) 3 17 (Medium) 4 17 (Medium) 5 17 (Medium) 6 17 (Medium) 7 17 (Medium) 8 17 (Medium) 9 31 (HI) OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–82 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT FUSE (HTR NO. 2) (a) Remove the HTR No. 2 fuse from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room R/B: Tester Item Condition Specified Condition HTR No. 2 fuse Always Below 1 Ω NG REPLACE FUSE (HTR NO. 2) HTR No. 2 Fuse F043247E02 OK 3 INSPECT BLOWER WITH FAN MOTOR SUB-ASSEMBLY 1 (a) Remove the blower with fan motor sub-assembly. (b) Connect the battery positive (+) lead to terminal 2 and the battery negative (-) lead to terminal 1. OK: Blower motor operates smoothly. 2 NG AC REPLACE BLOWER WITH FAN MOTOR SUBASSEMBLY I031426E01 OK 4 CHECK HARNESS AND CONNECTOR (HEATER BLOWER MOTOR RELAY - BLOWER MOTOR CONTROL) (a) Check for open and short circuit in the harness and the connector between the blower motor relay and the blower motor control (See page IN-38). NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 5 AC–83 CHECK HARNESS AND CONNECTOR (BLOWER MOTOR CONTROL - BODY GROUND) (a) Check for open and short circuit in the harness and the connector between the blower motor control and body ground (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 INSPECT AIR CONDITIONING AMPLIFIER (BLW) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Set the blower speed to LO. BLW I033523E14 1 V/ Division (d) Measure the waveform between terminal A16-3 (BLW) of the A/C amplifier and body ground. OK: Waveform appears as shown in the illustration. HINT: Waveform varies with the blower level. NG 500 μsec./Division REPLACE AIR CONDITIONING AMPLIFIER I031456E22 OK 7 CHECK HARNESS AND CONNECTOR (BLOWER MOTOR CONTROL - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the blower motor control and the A/C amplifier (See page IN-38). NG OK REPLACE BLOWER MOTOR CONTROL REPLACE AIR CONDITIONING AMPLIFIER AC AC–84 AIR CONDITIONING – AIR CONDITIONING SYSTEM Compressor Circuit DESCRIPTION The A/C amplifier outputs the magnetic clutch ON signal from AC1 terminal to the ECM. When the ECM receives this signal, it sends a signal from ACT terminal and the A/C amplifier switches the A/C magnetic clutch relay ON. This turns the A/C magnetic clutch on. WIRING DIAGRAM A/C Amplifier ECM 25 E7 BR-W 2 IK1 BR-W 18 A16 ACT 24 AC1 E7 GR-G 1 IK1 GR-G 7 A17 AC1 A17 IC4 BR-Y 10 A17 MGC ACT Engine Room R/B MG CLT Relay Y-R 2 Y-R 2 1 5 2 3 2 2 BR-Y L-B C J1 J/C D1 IC4 C L-B Y-R AC E E 3 IM1 J1 J/C 3 A2 Magnetic Clutch Assembly (Cooler Compressor Assembly) L-B From IG1 Fuse I045662E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch on. AC–85 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Check the A/C magnetic clutch input signal using DATA LIST. ENGINE: Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note A/C SIG A/C signal / ON or OFF A/C switch pushed: ON A/C switch released: OFF - NG Go to step 8 OK 2 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch on. (c) Check the A/C magnetic clutch operation permission signal using DATA LIST. ENGINE: Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note A/C MAG CLUTCH A/C magnetic clutch / ON or OFF A/C switch ON: ON A/C switch OFF: OFF - NG REPLACE ECM OK 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch on. (c) Check the A/C magnetic clutch operation using ACTIVE TEST. AIR CONDITIONER: Item Test Details / Display (Range) Diagnostic Note A/C MAG CLUTCH magnetic clutch relay / OFF, ON Operating sound can be heard NG Go to step 5 OK 4 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER (ACT TERMINAL) - ECM (ACT TERMINAL)) (a) Check for open and short circuit in the harness and the connector between the A/C amplifier and the ECM (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR AC AC–86 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 5 INSPECT COOLER RELAY ASSEMBLY (MG CLT RELAY) 2 1 3 5 3 1 2 (a) Remove the cooler relay assembly (MG CLT relay) from the engine room J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 Battery voltage is applied between terminals 1 and 2 Below 1 Ω 5 Z018060E01 NG REPLACE COOLER RELAY ASSEMBLY (MG CLT RELAY) OK 6 INSPECT MAGNETIC CLUTCH ASSEMBLY (a) Disconnect the connector from the cooler compressor assembly. (b) Connect the battery positive (+) lead to terminal 3, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock. AC NG REPLACE MAGNETIC CLUTCH ASSEMBLY E005280E17 OK 7 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER (MGC TERMINAL) - BODY GROUND) (a) Check for open and short circuit in the harness and the connector between the A/C amplifier and body ground (See page IN-38). NG OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–87 AIR CONDITIONING – AIR CONDITIONING SYSTEM 8 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER (AC1 TERMINAL) - ECM (AC1 TERMINAL)) (a) Check for open and short circuit in the harness and the connector between the A/C amplifier and the ECM (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 9 INSPECT AIR CONDITIONING AMPLIFIER (AC1) (a) Remove the A/C amplifier with the connectors still connected. (b) Start the engine and push AUTO switch. (c) Measure the voltage according to the value(s) in the table below. Standard voltage AC1 I033523E15 Tester Connection (Symbols) Condition Specified Condition A17-7 (AC1) - Body ground A/C switch: OFF 3.7 to 4.5 V A17-7 (AC1) - Body ground A/C switch: ON 1.3 to 2.6 V NG REPLACE AIR CONDITIONING AMPLIFIER OK REPLACE ECM AC AC–88 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Control Panel Power Source Circuit DESCRIPTION This circuit is a power supply for the air conditioning control assembly (heater control panel). WIRING DIAGRAM D3 A/C Control Assembly Driver Side J/B IG1 2 J7 J/C 8 1C 1J A 4 2 W-L AM1 AM1 2 H A Y-R A 2 Y-R IG+ C2 IC4 ALT 1 2 2 2 Short Pin 1 DOME R 1 2 2 2 2 W 2 1 2 B Center J/B R AC J25 J/C Engine Room R/B 2 IG1 A H Y-R Y-R I18 Ignition SW L-Y J20 J/C J7 J/C B D J8 J/C D H H R R W-B A A 3C B 3F 3C B 3F B 3F R 1 W-B 7 B GND W-B A A J37 J/C J24 J/C Battery II IK I045744E02 AC–89 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the connector from the air conditioning control panel assembly. (b) Measure the voltage according to the value(s) in the table below. Standard voltage B IG+ B052311E03 Tester Connection (Symbols) Condition Specified Condition D3-1 (B) - Body ground Always 10 to 14 V D3-2 (IG+) - Body ground Ignition switch ON 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BODY GROUND) (a) Disconnect the connector from the air conditioning control panel assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance GND Tester Connection (Symbols) Condition Specified Condition D3-7 (GND) - Body ground Always Below 1 Ω B052311E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–90 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Relay Circuit DESCRIPTION The heater relay is switched on by signals from the A/C amplifier. It supplies power to the blower motor. WIRING DIAGRAM A/C Amplifier Driver Side J/B J1 J/C Y-R Y-R E E IG1 20 1E 2 1C From Ignition Switch Engine Room R/B To Blower Motor Control Y-R R HTR No. 2 2 2 2 1 Heater Blower Motor Relay 2 1 2 2 5 3 4 B-Y 2 2 A11 IC4 L To Blower Motor Control B-Y 2 21 A16 HR L W-B HTR 2 2 1 B 2 B J3 J/C B W-B AC Battery EB I045743E01 AC–91 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK FUSE (HTR) (a) Remove the HTR fuse from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room R/B: Tester Item Condition Specified Condition HTR fuse Always Below 1 Ω NG REPLACE FUSE (HTR) HTR Fuse F043247E03 OK 2 INSPECT HEATER BLOWER MOTOR RELAY (a) Remove the heater blower motor relay from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 3-5 Always 10 kΩ or higher 3-5 When battery voltage applied to terminals 1 and 2 Below 1 Ω 3-4 Always Below 1 Ω 3-4 When battery voltage applied to terminals 1 and 2 10 kΩ or higher E032993 NG OK REPLACE HEATER BLOWER MOTOR RELAY AC AC–92 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (HEATER BLOWER MOTOR RELAY - BATTERY) (a) Remove the heater blower motor relay assembly from the engine room R/B. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Engine Room J/B: Tester Connection Condition 1 - Body ground Ignition switch ON 10 to 14 V 5 - Body ground Always 10 to 14 V NG Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR I033590E01 OK 4 CHECK HARNESS AND CONNECTOR (HEATER BLOWER MOTOR RELAY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room J/B: AC Tester Connection Condition Specified Condition 4 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR I033590E01 OK 5 CHECK HARNESS AND CONNECTOR (HEATER BLOWER MOTOR RELAY - AIR CONDITIONING AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the heater blower motor relay and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–93 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–94 AIR CONDITIONING – AIR CONDITIONING SYSTEM IG Power Source Circuit DESCRIPTION The main power source is supplied to the A/C amplifier when the ignition switch ON. The power source is used for operating the A/C amplifier and servo motor, etc. WIRING DIAGRAM A/C Amplifier Driver Side J/B L-Y IG1 2 1C J7 J/C 8 1J Y-R A Y-R A H J25 J/C Y-R H A Y-R A 1 A16 IG Engine Room R/B I18 Ignition SW ALT AM1 W-L 4 IG1 J20 J/C 2 AM1 2 B 12 2 1 2 2 B 2 Center J/B W-B B 3F B 3F B 3F 5 A16 GND W-B W-B A AC A J37 J/C J24 J/C Battery II IK I045742E02 AC–95 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (IG1) (a) Remove the IG1 fuse from the driver side J/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Driver Side J/B: IG1 Fuse NG Tester Item Condition Specified Condition IG1 fuse Always Below 1 Ω REPLACE FUSE (IG1) F043250E01 OK 2 INSPECT AIR CONDITIONING AMPLIFIER (IG+ - GND) GND (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage IG Tester Connection (Symbols) Condition Specified Condition A16-1 (IG) - A16-5 (GND) Ignition switch ON 10 to 14 V I033523E17 NG Go to step 3 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–96 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the connector from the A/C amplifier. (b) Measure the voltage according to the value(s) in the table below. Standard voltage IG I033524E04 Tester Connection (Symbols) Condition Specified Condition A16-1 (IG) - Body ground Ignition switch OFF Below 1 V A16-1 (IG) - Body ground Ignition switch ON 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance GND AC Tester Connection Condition Specified Condition A16-5 (GND) - Body ground Always Below 1 Ω NG I033524E02 OK REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS OR CONNECTOR AC–97 AIR CONDITIONING – AIR CONDITIONING SYSTEM Back-up Power Source Circuit DESCRIPTION The back-up power source circuit for the A/C amplifier is shown below. Power is supplied even when turning the engine switch off and is used for diagnostic trouble code memory, etc. WIRING DIAGRAM 4 1B A/C Amplifier Center J/B Driver Side J/B 4 1L W-R B 3E B 3E W-R 2 A16 +B Engine Room R/B ECU-B W-R 2 B 2 1 2 Short Pin 1 2 2 W 2 Battery AC I033601E01 AC–98 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-B) (a) Remove the ECU-B fuse from the engine room R/B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Engine Room R/B: NG Tester Item Condition Specified Condition ECU-B fuse Always Below 1 Ω REPLACE FUSE (ECU-B) ECU-B Fuse F043247E04 OK 2 CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the connector from the A/C amplifier. (b) Measure the voltage according to the value(s) in the table below. Standard voltage AC +B I033524E03 Tester Connection (Symbols) Condition Specified Condition A16-2 (+B) - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–15 DTC CHECK / CLEAR 1. DTC CHECK (SENSOR CHECK) (a) Start the engine and warm it up. (b) Perform the indicator check (See page AC-16). HINT: After the indicator check is completed, the system enters the DTC check mode automatically. (c) Push the "R/F" switch to perform the actuator check. (1) SR-5 grade: SR-5 grade: I033520E01 Limited grade: I034050E01 (2) Limited grade: NOTICE: • In the sensor check mode, which is automatically transferred from the indicator check mode, troubleshooting may be partially performed. Be sure to perform the actuator check, and then the sensor check again. • If the check is performed in a dark place, DTC 21, 24 may be displayed. HINT: When there are no problems, DTC 00 is output. (d) If the steps are difficult to read because they change automatically, push the "FRONT DEF" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "FRONT DEF" switch is pushed. I033518E01 DTC I033518E02 (e) Read the code displayed on the panel. (Trouble codes are output on the temperature display.) HINT: Refer to the DTC chart (Diagnostic Trouble Code chart) for details of the codes. • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the actuator check mode. • This illustration shows the switch design of MZgrade models. This design differs slightly from that of MS-grade models. AC AC–16 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. CLEARING DTC (a) There are two ways to cancel a DTC. (1) During the sensor check, press the "FRONT DEF" switch and "REAR DEF" switch at the same time. I033518E03 (2) Pull the ECU-B fuse in the engine room J/B for 20 seconds or longer to clear the DTC memory. Engine Room J/B: ECU-B Fuse F043247E01 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–99 LIN Communication Circuit DESCRIPTION This circuit is a communication line between the air conditioning control assembly (heater control panel) and the A/C amplifier. WIRING DIAGRAM D3 A/C Control Assembly LIN-B A/C Amplifier 14 L-B 4 A16 LIN1 AC H016798E03 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (A/C CONTROL ASSEMBLY - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the air conditioning control assembly and A/C amplifier (See page IN-38). NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR AC–100 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM REPLACE AIR CONDITIONING CONTROL ASSEMBLY (a) Replace the air conditioning control assembly with a normal one and check that the condition returns to normal. OK: Same problem does not occur. NG OK END AC REPLACE AIR CONDITIONING AMPLIFIER AC–104 AIR CONDITIONING – REFRIGERANT REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a) Start up the engine. (b) Turn the A/C switch on. (c) Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. (d) Stop the engine. (e) Using SST, discharge the refrigerant gas. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. CHARGE REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC-134a (R134a). Standard: 600 +- 30 g (21.16 +- 1.06 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Amount to be charged Charge 100 g (3.53 oz.) Mean value in proper range AC +-30 g (+-1.06 oz.) Overcharged Point where bubbles disappear High Pressure Refrigerant Amount Sub-cool System I037365E06 NOTICE: • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. AIR CONDITIONING – REFRIGERANT AC–105 • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass. Check for Leakage Gas Leak Detector I042222E10 3. WARM UP ENGINE (a) Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant. NOTICE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor. 4. INSPECT LEAKAGE OF REFRIGERANT (a) After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector. (b) Perform the operation under the following conditions: • Stop the engine. • Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas). • Repeat the test 2 or 3 times. • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf*cm2 57 to 85 psi) (c) Using a gas leak detector, check the refrigerant line for leakage. (d) If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (e) Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. AC AC–106 AIR CONDITIONING – REFRIGERANT LINE REFRIGERANT LINE HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS 2UZ-FE: COOLER REFRIGERANT LIQUID PIPE C DISCHARGE HOSE SUB-ASSEMBLY COOLER REFRIGERANT SUCTION PIPE C 7.8 (80, 69 in.*lbf) 9.8 (100, 87 in.*lbf) AC 9.8 (100, 87 in.*lbf) 5.4 (55, 47 in.*lbf) 7.8 (80, 69 in.*lbf) 5.4 (55, 47 in.*lbf) AIR CONDITIONING TUBE ASSEMBLY SUCTION HOSE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C119699E01 AC–107 AIR CONDITIONING – REFRIGERANT LINE 1GR-FE: SUCTION PIPE SUB-ASSEMBLY 5.4 (55, 47 in.*lbf) COOLER REFRIGERANT LIQUID PIPE A 9.8 (100, 87 in.*lbf) 5.4 (55, 47 in.*lbf) DISCHARGE HOSE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) AC 5.4 (55, 47 in.*lbf) 7.8 (79, 68 in.*lbf) 5.4 (55, 47 in.*lbf) AIR CONDITIONING TUBE ASSEMBLY SUCTION HOSE SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C119700E01 AIR CONDITIONING – AIR CONDITIONING UNIT AC–111 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-103) 2. DISCONNECT COOLER REFRIGERANT SUCTION PIPE C (a) Install SST on the piping clamp. HINT: Make sure the direction of the piping clamp claw and SST by seeing the illustration shown on the caution label. (b) Push down SST and release the clamp lock. NOTICE: Be careful not to deform the tube when pushing SST. (c) Pull SST slightly and push the release lever, and then remove the piping clamp with SST. SST 09870-00015 Pull Push SST Release Lever I003839E01 Disconnect the tube using hand (d) Disconnect the air conditioning tube assembly. NOTICE: • Do not use tools like screwdriver to remove the tube. • Cap the open fittings immediately to keep moisture or dirt out of the system. Screw Driver 3. I006919E09 DISCONNECT COOLER REFRIGERANT LIQUID PIPE C HINT: Disconnection of the cooler refrigerant liquid pipe C is same as the cooler refrigerant suction pipe C. SST 09870-00025 4. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT) (a) Using pliers, grip the claws of the clip and slide the clip and disconnect the heater water outlet hose A (from the heater unit). 5. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT) 6. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assembly (See page IP-6). 7. REMOVE ECM • See page ES-434 for 1GR-FE. • See page ES-510 for 2UZ-FE. 8. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See page AC-148) I033459 AC AC–112 AIR CONDITIONING – AIR CONDITIONING UNIT 9. 2 Claws REMOVE SIDE DEFROSTER NOZZLE DUCT NO. 1 (a) Remove the 2 clips. (b) Release the 2 claw fittings and remove the side defroster nozzle duct No. 1. I033460E01 10. REMOVE SIDE DEFROSTER NOZZLE DUCT NO. 2 (a) Remove the 2 clips. (b) Release the 2 claw fittings and remove the side defroster nozzle duct No. 2. 2 Claws I033461E01 11. REMOVE HEATER TO REGISTER DUCT NO. 1 (a) Remove the screw. (b) Release the 2 pin fittings and remove the heater to register duct No. 1. 2 Pins I033462E01 AC 12. REMOVE HEATER TO REGISTER DUCT NO. 3 (a) Remove the screw. (b) Release the 2 pin fittings and remove the heater to register duct No. 3. 2 Pins I033463E01 13. REMOVE AIR DUCT REAR NO. 1 (a) Release the 6 claw fittings and 3 clamps and remove the air duct rear No. 2. 6 Claws 3 Clamps I033465E01 AIR CONDITIONING – AIR CONDITIONING UNIT AC–113 14. REMOVE AIR DUCT REAR NO. 2 (a) Release the 6 claw fittings and 3 clamps and remove the air duct rear No. 1. 6 Claws 3 Clamps I033464E01 15. DISCONNECT CONSOLE BOX DUCT NO. 1 (a) Remove the clip and disconnect the console box duct No. 1. I033466 16. REMOVE AIR DUCT NO. 1 (a) Release the 3 claw fittings and remove the air duct No. 1. 3 Claws I033477E01 17. REMOVE AIR DUCT NO. 2 (a) Release the 3 claw fittings and remove the air duct No. 2. 3 Claws I033478E01 18. REMOVE INSTRUMENT PANEL BRACE MOUNTING BRACKET NO. 1 (a) Remove the bolt, nut and instrument panel brace mounting bracket No. 1. I033467 AC AC–114 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Remove the bolt, nut and instrument panel brace mounting bracket No. 1. I033468 19. DISCONNECT STEERING COLUMN ASSEMBLY (a) Release the 3 clamps and disconnect the connector. 3 Clamps I033469E01 (b) Remove the 4 nuts and disconnect the steering column assembly. 20. REMOVE INSTRUMENT PANEL REINFORCEMENT (a) Remove the 6 bolts and 8 nuts. I033470 AC I033471 (b) Release the 27 clamps. AIR CONDITIONING – AIR CONDITIONING UNIT AC–115 (c) Disconnect the connectors. 27 Clamps I033472E01 (d) Remove the 5 bolts. AC I033473 (e) Remove the 7 bolts and instrument panel reinforcement. I033474 AC–116 AIR CONDITIONING – AIR CONDITIONING UNIT 21. REMOVE HEATER TO REGISTER DUCT CENTER (a) Release the 4 claw fittings and remove the heater to register duct center. 4 Claws I033475E01 22. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER (a) Release the 4 claw fittings and remove the defroster nozzle assembly lower. 4 Claws I033476E01 23. REMOVE AIR CONDITIONING UNIT ASSEMBLY (a) Disconnect the connectors. (b) Remove the 2 nut and air conditioner unit assembly. I033479 AC 24. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY (a) Remove the 2 screws and air conditioning radiator assembly. I033480 DISASSEMBLY 1. I033484 REMOVE MODE DAMPER SERVO SUB-ASSEMBLY (a) Remove the 3 screws and mode damper servo subassembly. AIR CONDITIONING – AIR CONDITIONING UNIT AC–117 2. REMOVE DAMPER SERVO SUB-ASSEMBLY (INDEPENDENCE TEMPERATURE CONTROL) (a) Remove the 3 screws and damper servo subassembly. 3. REMOVE DAMPER SERVO SUB-ASSEMBLY (a) Remove the 3 screws and damper servo subassembly. 4. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Remove the screw, clamp and heater radiator unit sub-assembly. 5. REMOVE COOLER UNIT DRAIN HOSE NO. 1 6. REMOVE AIR CONDITIONING TUBE ASSEMBLY (a) Remove the screw. (b) Release the claw fitting and remove the cover. I033486 I033485 I034326 Claw I033481E01 (c) Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and air conditioning tube assembly. (d) Remove the 2 O-rings from the air conditioning tube assembly. I034327 AC AC–118 AIR CONDITIONING – AIR CONDITIONING UNIT 7. REMOVE COOLER EXPANSION VALVE (a) Remove the cooler expansion valve from the cooler evaporator sub-assembly No.1. 8. REMOVE COOLING UNIT PACKING NO. 1 (a) Remove the cooling unit packing No. 1. 9. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO. 1 (a) Remove the 4 screws and air duct sub-assembly. I034328 I034368 I034329 AC (b) Remove the 8 screws and separate the heater case. (c) Remove the cooler evaporator sub-assembly No. 1. I033488 (d) Remove the 2 O-rings from the cooler evaporator sub-assembly No. 1. I033489 AIR CONDITIONING – AIR CONDITIONING UNIT AC–119 10. REMOVE COOLER THERMISTOR NO. 1 (a) Remove the cooler thermistor No. 1 from the cooler evaporator sub-assembly No. 1. 11. REMOVE COVER PLATE C119714 AC AC–120 AIR CONDITIONING – AIR CONDITIONING UNIT REASSEMBLY 1. INSTALL COVER PLATE 2. INSTALL COOLER THERMISTOR NO. 1 (a) Install the cooler thermistor No. 1 to the evaporator as shown in the illustration. (b) Check that the thermistor sticks to the evaporator surface as shown in the illustration (A: Thermistor, B: Evaporator). NOTICE: If reusing the evaporator, DO NOT insert the thermistor to the position that it had been inserted before. Insert it to between the position C shown in the illustration. 3. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO. 1 (a) Sufficiently apply compressor oil to the 2 new Orings and fitting surface of the cooler expansion valve. Compressor oil: ND-OIL8 or equivalent (b) Install the 2 O-rings on the cooler evaporator subassembly No. 1. (B) (C) (A) 50 (1.97) 74.5 (2.93) 100.5 (3.96) 255.4 (10.06) mm (in.) C119715E01 AC I033489 (c) Install the cooler evaporator sub-assembly No. 1 on the heater case. (d) Install the heater case with the 8 screws. I033488 AIR CONDITIONING – AIR CONDITIONING UNIT AC–121 (e) Install the air duct sub-assembly with the 4 screws. I034329 4. INSTALL COOLING UNIT PACKING NO. 1 (a) Install the cooling unit packing No. 1. HINT: Securely attach so that the gap in the cooling unit packing No. 1 will not be mode. 5. INSTALL COOLER EXPANSION VALVE (a) Install the cooler expansion valve from cooler evaporator sub-assembly No. 1. 6. INSTALL AIR CONDITIONING TUBE ASSEMBLY (a) Sufficiently apply compressor oil to the 2 new Orings and fitting surface of the air conditioning tube assembly. Compressor oil: ND-OIL8 or equivalent (b) Install the 2 O-rings on the air conditioning tube assembly. (c) Using a hexagon wrench 4.0 mm (0.15 in.), install the air conditioning tube assembly with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 ft.*lbf) I034368 I034328 I034327 AC AC–122 AIR CONDITIONING – AIR CONDITIONING UNIT INSTALLATION 1. INSTALL AIR CONDITIONING UNIT ASSEMBLY (a) Install the air conditioner unit assembly with the 2 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Connect the connectors. 2. INSTALL INSTRUMENT PANEL REINFORCEMENT (a) Install the instrument panel reinforcement with the 7 bolts. I033479 I033474 (b) Install the 5 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) CAUTION: Tighten the bolts in the following order shown in the illustration to install the air conditioner unit assembly. AC (3) (1) (2) (4) (5) I033473E01 (c) Install the 27 clamps. AIR CONDITIONING – AIR CONDITIONING UNIT AC–123 (d) Connect the connectors. 27 Clamps I033472E01 (e) Install the 6 bolts and 8 nuts. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) AC I033471 3. I033470 INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column assembly with the 4 nuts. Torque: 26 N*m (265 kgf*cm, 19 in.*lbf) AC–124 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Install the 3 clamps and connect the connectors. 4. INSTALL ECM • See page ES-434 for 1GR-FE. • See page ES-510 for 2UZ-FE. 5. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the instructions for installation of the instrument panel safety pad sub-assembly (See page IP-12). 6. INSTALL COOLER REFRIGERANT LIQUID PIPE C (a) Lubricate new O-ring with compressor oil and install them on the hose. Compressor oil: ND-OIL 8 or equivalent (b) Install the cooler refrigerant liquid pipe C and piping clamp. HINT: After connection, check the fitting for the claw of the piping clamp. 7. INSTALL COOLER REFRIGERANT SUCTION PIPE C (a) Lubricate a new O-ring with compressor oil and install it to the pipe. Compressor oil: ND-OIL 8 or equivalent (b) Install the cooler refrigerant suction pipe C and piping clamp. HINT: After connection, check the fitting for the claw of the piping clamp. 8. CHARGE REFRIGERANT (See page AC-103) 9. WARM UP ENGINE (See page AC-104) 3 Clamps I033469E01 Connect Wrong Gap I006878E01 AC 10. INSPECT LEAKAGE OF REFRIGERANT (See page AC-104) AC–128 AIR CONDITIONING – BLOWER UNIT REASSEMBLY 1. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY 2. INSTALL BLOWER MOTOR CONTROL 3. INSTALL BLOWER DAMPER SERVO MOTOR SUBASSEMBLY 4. INSTALL AIR FILTER COVER PLATE 5. INSTALL CLEAN AIR FILTER 6. INSTALL CLEAN AIR FILTER SUB-ASSEMBLY INSTALLATION 1. INSTALL BLOWER ASSEMBLY (a) Install the blower assembly with the claw fitting. (b) Install the bolt, 2 screws and nut. Torque: Bolt 9.8 N*m (100 kgf*cm, 87 in.*lbf) Nut 5.4 N*m (55 kgf*cm, 48 in.*lbf) I034332E01 (c) Install the 7 clamps and connect the connectors. AC 7 Clamps 2. INSTALL AIR DUCT NO. 2 3. INSTALL INSTRUMENT PANEL REGISTER ASSEMBLY NO. 2 4. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO. 2 5. INSTALL GLOVE COMPARTMENT DOOR SUBASSEMBLY 6. INSTALL GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 7. INSTALL INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 8. INSTALL COWL SIDE TRIM BOARD RH 9. INSTALL CONSOLE BOX ASSEMBLY REAR I034331E01 10. INSTALL CONSOLE UPPER PANEL GARNISH NO. 2 11. INSTALL CONSOLE UPPER PANEL GARNISH NO. 1 12. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 13. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY AC–132 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) INSTALLATION 1. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor and magnetic clutch with the 4 bolts. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) (b) Connect the connector. 2. INSTALL SUCTION HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the suction hose sub-assembly. I034406 (d) Install the suction hose sub-assembly on the compressor and the magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 3. I034405 INSTALL DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the discharge hose subassembly. (d) Install the discharge hose sub-assembly on the compressor and magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) AC I034404 4. INSTALL FAN AND GENERATOR V BELT 5. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 6. CHARGE REFRIGERANT (See page AC-103) 7. WARM UP ENGINE (See page AC-104) 8. INSPECT LEAKAGE OF REFRIGERANT (See page AC-104) AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) AC–135 DISASSEMBLY 1. REMOVE MAGNETIC CLUTCH ASSEMBLY (a) Place the compressor and magnetic clutch in a vise. (b) Using SST, remove the bolt, magnetic clutch hub and magnetic clutch washer. SST 09960-10010 (09962-01000, 09963-00500) I033497 (c) Using a snap ring expander, remove the snap ring and magnetic clutch rotor. (d) Remove the screw and disconnect the connector. E037091 (e) Using a snap ring expander, remove the snap ring and magnetic clutch starter. 2. REMOVE COOLER COMPRESSOR BRACKET 3. REMOVE COOLER COMPRESSOR ASSEMBLY AC E050116 INSPECTION 1. I033499 INSPECT MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the magnetic clutch hub. (b) Connect the battery positive lead to terminal 1 of the magnetic clutch connector and the negative lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance. Standard clearance: 0.35 to 0.60 mm (0.013 to 0.023 in.) If the measured value is out of the standard range, remove the magnetic clutch hub and adjust it with the magnetic clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnetic clutch washers. AC–136 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) 2. INSPECT COMPRESSOR OIL (a) When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE: • When checking the compressor oil level, observe the precautions on the cooler removal/installation. • Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. • If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage. • Be sure to use ND-OIL8 for compressor oil. REASSEMBLY 1. INSTALL MAGNETIC CLUTCH ASSEMBLY (a) Fit the parts shown in the illustration and install the magnetic clutch starter. AC I032460 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. (c) Install the screw and connect the connector. I032461 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) AC–137 (d) Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up. (e) Install the magnetic clutch washer and magnetic clutch hub. NOTICE: Do not change the combination of the magnetic clutch washers used before disassembly. I031582 (f) Using SST, install the magnetic clutch hub and magnetic clutch washer with the bolt. SST 09960-10010 (09962-01000, 09963-00500) Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) I033498 INSTALLATION I033928 1. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor and magnetic clutch and stay, compressor with the 3 bolts. Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf) (b) Install the nut. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) (c) Connect the connector. 2. INSTALL SUCTION HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL8 or equivalent (c) Install the O-ring on the suction hose sub-assembly. (d) Install the suction hose sub-assembly on the compressor and magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 3. I033927 INSTALL DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the hose. (b) Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL8 or equivalent (c) Install an O-ring on the discharge hose subassembly. AC AC–138 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) (d) Install the discharge hose sub-assembly on the compressor and magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) I033926 AC 4. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY (See page EM-6) 5. INSTALL FAN AND GENERATOR V BELT 6. CHARGE REFRIGERANT (See page AC-103) 7. WARM UP ENGINE (See page AC-104) 8. INSPECT LEAKAGE OF REFRIGERANT (See page AC-104) AC–140 AIR CONDITIONING – CONDENSER REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-103) 2. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the cooler refrigerant discharge hose sub-assembly from the cooler condenser assembly. (b) Remove the O-ring from the cooler refrigerant discharge hose sub-assembly. NOTICE: Seat the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 3. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY (a) Remove the bolt and disconnect the air conditioning tube assembly from the cooler condenser assembly. (b) Remove the O-ring from the air conditioning tube assembly. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 4. REMOVE COOLER CONDENSER CUSHION NO. 2 (a) Remove the nut and cooler condenser bracket No. 1. I033500 I033501 AC I033507 (b) Remove the 4 bolts, nut and cooler condenser cushion No. 2. I033924 AIR CONDITIONING – CONDENSER AC–141 5. REMOVE COOLER CONDENSER CUSHION NO. 1 (a) Remove the 4 bolts and cooler condenser cushion No. 1. 6. REMOVE COOLER CONDENSER CORE (a) Remove the cooler condenser core. I033925 I033505E01 DISASSEMBLY 1. REMOVE COOLER DRYER (a) Using a hexagon wrench 14 mm (0.55 in.), remove the cap and filter from the modulator. 14 mm (0.55 in.) Hexagon Wrench Modulator I032993E03 (b) Remove the O-ring from the cap. I032475 (c) Using needle nose pliers, remove the cooler dryer. I032994 AC AC–142 AIR CONDITIONING – CONDENSER REASSEMBLY 1. INSTALL COOLER DRYER (a) Using needle nose pliers, install the cooler dryer. I032994 (b) Install a new O-ring on the cap. (c) Sufficiently apply compressor oil to the fitting surfaces of the O-ring and the cap. Compressor oil: ND-OIL 8 or equivalent E055408 (d) Using a hexagon wrench 14 mm (0.55 in.), install the cap to the cooler condenser assembly. Torque: 2.9 N*m (30 kgf*cm, 25 in.*lbf) 14 mm (0.55 in.) Hexagon Wrench Modulator I032993E03 AC INSTALLATION 1. INSTALL COOLER CONDENSER CUSHION NO. 1 (a) Install the cooler condenser cushion No. 1 with the 4 bolts. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 2. INSTALL COOLER CONDENSER CUSHION NO. 2 (a) Install the cooler condenser cushion No. 2 with the 4 bolts and nut. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) I033925 I033924 AIR CONDITIONING – CONDENSER AC–143 (b) Install the cooler condenser bracket No. 1 with the nut. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 3. I033507 INSTALL AIR CONDITIONING TUBE ASSEMBLY (a) Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assembly. (b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the air conditioning tube assembly. (d) Connect the air conditioning tube assembly on the cooler condenser assembly with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 4. I033501 INSTALL DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assembly. (b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent (c) Install the O-ring on the discharge hose subassembly. (d) Connect the discharge hose sub-assembly on the cooler condenser assembly with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) I033500 5. CHARGE REFRIGERANT (See page AC-103) 6. WARM UP ENGINE (See page AC-104) 7. INSPECT LEAKAGE OF REFRIGERANT (See page AC-104) AC AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC–145 REASSEMBLY 1. INSTALL COOLER CONTROL SWITCH BULB (INDEPENDENCE TEMPERATURE CONTROL) 2. INSTALL COOLER CONTROL SWITCH BULB (EXCEPT INDEPENDENCE TEMPERATURE CONTROL) AC AC–146 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY INSTALLATION 1. AC INSTALL AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–17 CHECK MODE PROCEDURE 1. LIST OF OPERATION METHODS (a) By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnostic check mode. AC AC–18 AIR CONDITIONING – AIR CONDITIONING SYSTEM AUTO and Recirculation / Fresh switches are not pressed at the same time. Turn the ignition switch ON while pressing AUTO and Recirculation / Fresh switches. Indicator Check (continuous operation) OFF DTC Check (sensor check) (continuous operation) Actuator Check (continuous operation) R/F OFF AUTO DEF DEF OFF DTC Check (sensor check) (step operation) R/F AUTO AC R/F Actuator Check (step operation) OFF AUTO DEF DEF Cancel the check mode and start A/C control. : Indicates switch operation R/F: Recirculation / Fresh select switch DEF: Front defroster switch E106866E20 2. INDICATOR CHECK (a) Turn the ignition switch off. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–19 (b) Turn the ignition switch on while pressing the A/C control "AUTO" switch and "R/F" switch simultaneously. (1) SR-5 grade: SR-5 grade: I033520E01 (2) Limited grade: Limited grade: I034050E01 1 Sec. 1 Sec. ON OFF SR-5 grade: 3. Limited grade: I033909E01 (c) The indicator check is automatically performed when panel diagnosis is activated. Check that the indicators light up and go off at 1 second intervals 4 times in succession. HINT: • The sensor check automatically starts when the indicator check is completed. • Press the "OFF" switch to cancel the check mode. • If a navigation system is installed, the indicator will blink and the buzzer will sound. DTC CHECK (SENSOR CHECK) (a) Start the engine and warm it up. (b) Perform the indicator check. HINT: After the indicator check is completed, the system enters the DTC check mode automatically. (c) Push the "R/F" switch to perform the actuator check. NOTICE: • In the sensor check mode, which is automatically transferred from the indicator check mode, troubleshooting may be partially performed. Be sure to perform the actuator check, and then the sensor check again. • If the check is performed in a dark place, DTC 21, 24 may be displayed. HINT: When there are no problems, DTC 00 is output. AC AC–20 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC I033518E04 4. (d) If the steps are difficult to read because they change automatically, push the "FRONT DEF" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "FRONT DEF" switch is pushed. (e) Read the code displayed on the panel. HINT: Refer to the DTC chart (Diagnostic Trouble Code chart) for details of the codes (See page AC-21). • Push the "OFF" switch to finish panel diagnosis. • Push the "R/F" switch to enter the actuator check mode. ACTUATOR CHECK (a) Start the engine and warm it up. (b) Perform the indicator check. (c) Push the "R/F" switch to perform the actuator check. HINT: Be sure to perform the actuator check after starting the engine. I033520E02 1 Sec. (d) As the actuator check is repeated from steps 1 to 10 at 1 second intervals, check the temperature and air flow visually and by hand. HINT: • The display blinks at 1 second intervals in the step operation. • Push the "OFF" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. 1 Sec. ON AC OFF Display Code I033517E01 Conditions Step No. Display Code Blower Level Air Flow Vent Air Inlet Damper Magnetic clutch Air Mix Damper 1 0 0 FACE RECIRCULATION OFF "COLD" side (Fully closed) 2 1 1 FACE RECIRCULATION OFF "COLD" side (Fully closed) AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–21 Conditions Step No. Display Code Blower Level Air Flow Vent Air Inlet Damper Magnetic clutch Air Mix Damper 3 2 17 B/L FRESH/ RECIRCULATION ON "COLD" side (Fully closed) 4 3 17 B/L FRESH/ RECIRCULATION ON "COLD"/ "HOT" (50 % open) 5 4 17 FOOT FRESH ON "COLD"/ "HOT" (50 % open) 6 5 17 FOOT FRESH ON "COLD"/ "HOT" (50 % open) 7 6 17 FOOT FRESH ON "HOT" side (Fully opened) 8 7 17 FOOT/ DEF FRESH ON "HOT" side (Fully opened) 9 8 17 FOOT/ DEF FRESH ON "HOT" side (Fully opened) 10 9 31 DEF FRESH ON "HOT" side (Fully opened) I033518E01 (e) If the steps are difficult to read because they change automatically, push the "FRONT DEF" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "FRONT DEF" switch is pushed. HINT: • Push the "OFF" switch to finish the panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. AC AC–108 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS SIDE DEFROSTER NOZZLE DUCT NO. 2 DEFROSTER NOZZLE ASSEMBLY LOWER SIDE DEFROSTER NOZZLE DUCT NO. 1 AC HEATER TO REGISTER DUCT NO. 3 HEATER TO REGISTER DUCT CENTER HEATER TO REGISTER DUCT NO. 1 C119702E01 AC–109 AIR CONDITIONING – AIR CONDITIONING UNIT INSTRUMENT PANEL REINFORCEMENT INSTRUMENT PANEL BRACE MOUNTING BRACKET NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET NO. 1 AIR CONDITIONING RADIATOR ASSEMBLY 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) BLOWER ASSEMBLY 5.4 (55, 48 in.*lbf) AIR DUCT NO. 2 9.8 (100, 87 in.*lbf) AC 5.4 (55, 48 in.*lbf) 9.8 (100, 87 in.*lbf) AIR DUCT NO. 1 AIR DUCT REAR NO. 1 AIR DUCT REAR NO. 2 CONSOLE BOX DUCT NO. 1 N*m (kgf*cm, ft.*lbf) : Specified torque C119701E01 AC–110 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING TUBE ASSEMBLY COOLING UNIT PACKING NO. 1 COOLER EXPANSION VALVE 3.5 (35, 30 in.*lbf) O-RING O-RING COOLER EVAPORATOR SUB-ASSEMBLY NO. 1 Except Independence Temperature Control: COVER PLATE COOLER THERMISTOR NO. 1 DAMPER SERVO SUB-ASSEMBLY AC Independence Temperature Control: DAMPER SERVO SUB-ASSEMBLY COOLER UNIT DRAIN HOSE NO. 1 MODE DAMPER SERVO SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque HEATER RADIATOR UNIT SUB-ASSEMBLY Non-reusable part Compressor oil ND-OIL 8 or equivalent C119703E01 AC–22 AIR CONDITIONING – AIR CONDITIONING SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator, and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / ENGINE / DATA LIST. (e) Check the value(s) by referring to the table below. ENGINE Item Measurement Item / (Range) Display Normal Condition Diagnostic Note A/C SIG A/C signal / ON or OFF ON: A/C ON OFF: A/C OFF - A/C MAG CLUTCH A/C magnetic clutch relay / OFF, ON ON: A/C magnetic clutch ON OFF: A/C magnetic clutch OFF - 2. AC ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, VSVs, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Turn the tester on. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / AIR CONDITIONER / ACTIVE TEST. (e) Perform the ACTIVE TEST by referring to the table below. AIR CONDITIONER Item Test Details / Display (Range) Diagnostic Note A/C MAG CLUTCH (Magnetic clutch relay) Magnetic clutch relay / OFF, ON - AC–23 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSTIC TROUBLE CODE CHART If malfunction code is displayed during the DTC check (sensor check), check the circuit listed for that code in the table below (Proceed to the page given for that circuit). DTC No. Detection Item Trouble Area Memory *5 See page 11 *1 Room Temperature Sensor Circuit 1. Cooler thermistor (Room temp. sensor) 2. A/C amplifier 3. Harness or connector between cooler thermistor (room temp. sensor) and A/C amplifier Memorized (8.5 min. or more) AC-26 12 *2 Ambient Temperature Sensor Circuit 1. Thermistor assembly (Ambient temp. sensor) 2. Harness or connector between thermistor assembly (ambient temp. sensor) and A/C amplifier 3. A/C amplifier Memorized (8.5 min. or more) AC-29 13 Evaporator Temperature Sensor Circuit 1. Cooler thermistor No. 1 (Evaporator temp. sensor) 2. Harness or connector between cooler thermistor No. 1 (evaporator temp. sensor) and A/C amplifier 3. A/C amplifier Memorized (8.5 min. or more) AC-32 14 Engine Coolant Temperature Communication Circuit 1. Harness or connector between ECM and A/C amplifier 2. ECM 3. A/C amplifier - AC-35 Solar Sensor Circuit (Passenger Side) 1. Cooler (solar sensor) thermistor 2. Harness or connector between cooler (solar sensor) thermistor and A/ C amplifier 3. A/C amplifier Memorized (8.5 min. or more) (only when circuit is shorted) AC-38 Compressor Lock Sensor Circuit 1. Compressor drive belt 2. Compressor lock sensor 3. Cooler compressor assembly 4. Harness or connector between compressor lock sensor and A/C amplifier 5. A/C amplifier - AC-42 Pressure Switch Circuit 1. Pressure switch 2. A/C amplifier 3. Refrigerant pipe line 4. Harness or connector between pressure switch and A/C amplifier - AC-44 Solar Sensor Circuit (Driver Side) 1. Cooler (Solar sensor) thermistor 2. Harness or connector between cooler (solar sensor) thermistor and A/ C amplifier 3. A/C amplifier Memorized (8.5 min. or more) (only when circuit is shorted) AC-47 21 *3 22 *4 23 24 *3*6 AC AC–24 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. Detection Item Trouble Area 31 Air Mix Damper Position Sensor Circuit (Passenger Side) 1. Damper servo subassembly (Air mix damper position sensor) 2. A/C amplifier 3. Harness or connector between damper servo sub-assembly (air mix damper position sensor) and A/C amplifier Memorized (1 min. or more) AC-50 32 Air Inlet Damper Position Sensor Circuit 1. Blower damper servo sub-assembly (Air inlet damper position sensor) 2. A/C amplifier 3. Harness or connector between blower damper servo sub-assembly (air inlet damper position sensor) and A/C amplifier Memorized (1 min. or more) AC-54 33 Air Outlet Damper Position Sensor Circuit 1. Mode damper servo sub-assembly (Air outlet damper position sensor) 2. A/C amplifier 3. Harness or connector between mode damper servo sub-assembly (air outlet damper position sensor) and A/C amplifier Memorized (1 min. or more) AC-57 36 *6 Air Mix Damper Position Sensor Circuit (Driver Side 1. Damper servo subassembly (Air mix damper position sensor) 2. A/C amplifier 3. Harness or connector between damper servo sub-assembly (air mix damper position sensor) and A/C amplifier Memorized (1 min. or more) AC-60 41 Air Mix Damper Control Servo Motor Circuit (Passenger Side) 1. Damper servo subassembly (Air mix damper control servo motor) 2. Harness or connector between damper servo sub-assembly (air mix damper control servo motor) and A/C amplifier 3. A/C amplifier Memorized (15 sec.) AC-64 42 Air Inlet Damper Control Servo Motor Circuit 1. Blower damper servo sub-assembly (Air inlet damper control servo motor) 2. Harness or connector between blower damper servo sub-assembly (Air inlet damper control servo motor) and A/C amplifier 3. A/C amplifier Memorized (15 sec.) AC-67 43 Air Outlet Damper Control Servo Motor Circuit 1. Mode damper servo sub-assembly (Air outlet damper control servo motor) 2. Harness or connector between mode damper servo sub-assembly (air outlet damper control servo motor) and A/C amplifier 3. A/C amplifier Memorized (15 sec.) AC-70 AC Memory *5 See page AC–25 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. 46 *6 Detection Item Trouble Area Air Mix Damper Control Servo Motor Circuit (Driver Side) 1. Damper servo subassembly (Air mix damper control servo motor) 2. Harness or connector between damper servo sub-assembly (air mix damper control servo motor) and A/C amplifier 3. A/C amplifier Memory *5 Memorized (15 sec.) See page AC-73 HINT: • *1: If the room temp. is approx. -18.6°C (-3.7°F) or lower, trouble code 11 may be output even though the system is normal. • *2: If the ambient temp. is approx. -52.9°C (-61.4°F) or lower, a malfunction code may be output even though the system is normal. • *3: If the check is performed in a dark place, DTC 21, 24 (solar sensor circuit) could be displayed. • *4: Compressor lock (DTC 22) is indicated only for a existing malfunction. To confirm DTC 22, perform the following steps. (1) With the engine ON, enter the DTC check mode. (2) Press the R/F switch to enter actuator check mode, and set the operation to Step No. 3. (3) Press the AUTO switch to return to DTC check mode. (4) The DTC is displayed after approx. 3 sec. • *5: The A/C amplifier memorizes the DTC of the respective malfunction which occurred within the period of the time indicated in the brackets. • *6: DTC 24, 36 and 46 are indicated only for limited grade (right/left independent temperature control system). AC AC–124 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS 9.8 (100, 87 in.*lbf) BLOWER ASSEMBLY 5.4 (55, 48 in.*lbf) BLOWER DAMPER SERVO SUB-ASSEMBLY AC AIR REFINER ELEMENT BLOWER MOTOR CONTROL AIR FILTER COVER PLATE AIR FILTER SUB-ASSEMBLY BLOWER WITH FAN MOTOR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C138859E01 AIR CONDITIONING – BLOWER UNIT AC–125 REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 2. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 3. REMOVE CONSOLE UPPER PANEL GARNISH NO. 1 (See page IP-7) 4. REMOVE CONSOLE UPPER PANEL GARNISH NO. 2 5. REMOVE CONSOLE BOX ASSEMBLY REAR (See page IP-9) 6. REMOVE COWL SIDE TRIM BOARD RH (See page IP9) 7. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2 (See page IP-9) 8. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 9. REMOVE GLOVE COMPARTMENT DOOR SUBASSEMBLY (See page IP-9) 10. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO. 2 (See page IP-9) 11. REMOVE INSTRUMENT PANEL REGISTER ASSEMBLY NO. 2 (See page IP-10) 12. REMOVE AIR DUCT NO. 2 (a) Remove the 4 bolts and disconnect the Instrument panel safety pad sub-assembly. (b) Remove the 3 claw fittings and remove the air duct No. 2. 3 Claws I034330E01 13. REMOVE BLOWER ASSEMBLY (a) Release the 7 clamps and disconnect the connectors. 7 Clamps I034331E01 AC AC–126 AIR CONDITIONING – BLOWER UNIT (b) Remove the bolt and 2 screws and nut. (c) Release the claw fitting and remove the blower assembly. I034332E02 DISASSEMBLY 2 Claws 1. REMOVE CLEAN AIR FILTER SUB-ASSEMBLY (a) Release the 2 claw fittings and remove the air filter sub-assembly. 2. REMOVE CLEAN AIR FILTER (a) Remove the air refiner element from the air filter cover plate. 3. REMOVE AIR FILTER COVER PLATE 4. REMOVE BLOWER DAMPER SERVO SUBASSEMBLY (a) Remove the 3 screws and blower damper servo sub-assembly. 5. REMOVE BLOWER MOTOR CONTROL (a) Remove the 2 screws and blower motor control. I034189E01 I034190 AC I033494 I033495 AIR CONDITIONING – BLOWER UNIT 6. AC–127 REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY (a) Remove the 3 screws and blower with fan motor sub-assembly. I033496 AC AC–26 AIR CONDITIONING – AIR CONDITIONING SYSTEM ACTUATOR CHECK 1. ACTUATOR CHECK (a) Start the engine and warm it up. (b) Perform the indicator check (See page AC-16). (c) Push the "R/F" switch to perform the actuator check. HINT: Be sure to perform the actuator check after starting the engine. I033520E02 1 Sec. (d) As the actuator check is repeated from steps 1 to 10 at 1 second intervals, check the temperature and air flow visually and by hand. HINT: • The display blinks at 1 second intervals in the step operation. • As an example, the illustration shows that display code 21 is output. • Push the "OFF" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. 1 Sec. ON OFF Display Code AC I033517E01 Conditions Step No. Display Code Blower Level Air Flow Vent Air Inlet Damper Magnetic clutch Air Mix Damper 1 0 0 FACE RECIRCULATION OFF "COLD" side (Fully closed) 2 1 1 FACE RECIRCULATION OFF "COLD" side (Fully closed) 3 2 17 B/L FRESH/ RECIRCULATION ON "COLD" side (Fully closed) 4 3 17 B/L FRESH/ RECIRCULATION ON "COLD"/ "HOT" (50 % open) 5 4 17 FOOT FRESH ON "COLD"/ "HOT" (50 % open) 6 5 17 FOOT FRESH ON "COLD"/ "HOT" (50 % open) 7 6 17 FOOT FRESH ON "HOT" side (Fully opened) AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–27 Conditions Step No. Display Code Blower Level Air Flow Vent Air Inlet Damper Magnetic clutch Air Mix Damper 8 7 17 FOOT/ DEF FRESH ON "HOT" side (Fully opened) 9 8 17 FOOT/ DEF FRESH ON "HOT" side (Fully opened) 10 9 31 DEF FRESH ON "HOT" side (Fully opened) (e) If the steps are difficult to read because they change automatically, push the "FRONT DEF" switch to display the steps one at a time so that they can be read easily. The items are displayed step by step each time the "FRONT DEF" switch is pushed. HINT: • Push the "OFF" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. I033518E01 AC AC–128 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS MAGNETIC CLUTCH ASSEMBLY AC COOLER COMPRESSOR ASSEMBLY SNAP RING 18 (183, 13) MAGNETIC CLUTCH WASHER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C119706E01 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) AC–129 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-103) 2. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO. 1 3. REMOVE FAN AND GENERATOR V BELT 4. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the nut and disconnect the discharge hose sub-assembly from the compressor and magnetic clutch. (b) Remove the O-ring from the discharge hose subassembly. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matters from entering. 5. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Remove the nut and disconnect the suction hose sub-assembly from the compressor and magnetic clutch. (b) Remove the O-ring from the suction hose subassembly. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matters from entering. 6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (a) Disconnect the connector. (b) Remove the 4 bolts and the compressor and magnetic clutch. I034404 I034405 I034406 DISASSEMBLY 1. I034407 REMOVE MAGNETIC CLUTCH ASSEMBLY (a) Place the compressor and magnetic clutch in a vise. (b) Using SST, remove the bolt, the magnetic clutch hub and the magnetic clutch washer. SST 09960-10010 (09962-01000, 09963-00500) AC AC–130 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) (c) Using a snap ring expander, remove the snap ring and the magnetic clutch rotor. (d) Remove the screw and disconnect the connector. I034346 (e) Using a snap ring expander, remove the snap ring and the magnetic clutch starter. 2. REMOVE COOLER COMPRESSOR ASSEMBLY I034347 INSPECTION 1. INSPECT MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the magnetic clutch hub. (b) Connect the battery positive lead to terminal 1 of magnetic clutch connector and the negative lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance. Standard clearance: 0.35 to 0.60 mm (0.013 to 0.023 in.) If the measured value is outside the standard range, remove the magnetic clutch hub and adjust it with the magnetic clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnetic clutch washers. 2. INSPECT COMPRESSOR OIL (a) When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE: • When checking the compressor oil level, observe the precautions on the cooler removal/installation. I034409 AC AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 1GR-FE) AC–131 • Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes excessive, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. • If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage. • Be sure to use ND-OIL8 for compressor oil. REASSEMBLY 1. INSTALL MAGNETIC CLUTCH ASSEMBLY (a) Fit the parts shown in the illustration and install the magnetic clutch starter. E065508 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. (c) Install the screw and connect the connector. I032461 (d) Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up. (e) Install the magnetic clutch washer and the magnetic clutch hub. NOTICE: Do not change the combination of the magnetic clutch washers used before disassembly. I031582 (f) I034408 Using SST, install the magnetic clutch hub and magnetic clutch washer with the bolt. SST 09960-10010 (09962-01000, 09963-00500) Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) AC AC–28 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 11 Room Temperature Sensor Circuit DESCRIPTION This sensor detects the temperature inside the cabin and sends appropriate signals to the A/C amplifier. DTC No. 11 Detection Item Trouble Area • • Open or short in room temperature sensor circuit • Cooler thermistor (Room temperature sensor) Harness or connector between cooler thermistor (room temperature sensor) and A/C amplifier A/C amplifier WIRING DIAGRAM A/C Amplifier A19 Cooler Thermistor (Room Temp. Sensor) Y-G 6 A16 SC V-Y 15 A16 TR 2 1 AC I045740E01 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TR, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TR (+) I033523E01 Tester Connection (Symbols) Condition Specified Condition A16-15 (TR) - A16-6 (SG) Ignition switch ON at 25°C (77°F) 1.8 to 2.2 V A16-15 (TR) - A16-6 (SG) Ignition switch ON at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. AIR CONDITIONING – AIR CONDITIONING SYSTEM OK AC–29 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) (a) Remove the cooler thermistor (room temp. sensor). I030111 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Resistance (kΩ) 4.0 3.5 Tester Connection Condition Specified Condition 3.0 A19-1 - A19-2 10°C (50°F) 3.00 to 3.73 kΩ A19-1 - A19-2 15°C (59°F) 2.45 to 2.88 kΩ A19-1 - A19-2 20°C (68°F) 1.95 to 2.30 kΩ 2.0 A19-1 - A19-2 25°C (77°F) 1.60 to 1.80 kΩ 1.5 A19-1 - A19-2 30°C (86°F) 1.28 to 1.47 kΩ 1.0 A19-1 - A19-2 35°C (95°F) 1.00 to 1.22 kΩ 0.5 A19-1 - A19-2 40°C (104°F) 0.80 to 1.00 kΩ A19-1 - A19-2 45°C (113°F) 0.65 to 0.85 kΩ A19-1 - A19-2 50°C (122°F) 0.50 to 0.70 kΩ A19-1 - A19-2 55°C (131°F) 0.44 to 0.60 kΩ A19-1 - A19-2 60°C (140°F) 0.36 to 0.50 kΩ 2.5 0.0 10 50 20 68 30 40 86 104 Temperature 50 60 (°C) 122 140 (°F) I041430E08 NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring the sensor temperature, it must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG OK REPLACE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) AC AC–30 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (COOLER THERMISTOR (ROOM TEMPERATURE SENSOR) - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the cooler thermistor (room temp. sensor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 11 is not output again. Result Result Proceed to DTC 11 is output. A DTC 11 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER AC SYSTEM IS OK AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) AC–133 COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS MAGNETIC CLUTCH ASSEMBLY AC COOLER COMPRESSOR ASSEMBLY SNAP RING 18 (183, 13) MAGNETIC CLUTCH WASHER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C138860E01 AC–134 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH (for 2UZ-FE) REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-103) 2. REMOVE FAN AND GENERATOR V BELT 3. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the nut and disconnect the discharge hose sub-assembly from the compressor and magnetic clutch. (b) Remove the O-ring from the discharge hose subassembly. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 4. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Remove the nut and disconnect the cooler refrigerant suction hose sub-assembly from the compressor and magnetic clutch. (b) Remove the O-ring from the cooler refrigerant suction hose sub-assembly. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (a) Disconnect the connector. (b) Remove the nut. (c) Remove the 3 bolts, stay, compressor and magnetic clutch. I033926 I033927 AC I033928 AC–31 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 12 Ambient Temperature Sensor Circuit DESCRIPTION This sensor detects the temperature outside the cabin and sends appropriate signals to the A/C amplifier. DTC No. Detection Item Trouble Area • 12 Open or short in ambient temperature sensor circuit Thermistor assembly (Ambient temperature sensor) Harness or connector between thermistor assembly (ambient temperature sensor) and A/C amplifier A/C amplifier • • WIRING DIAGRAM A/C Amplifier GR A1 Thermistor Assembly (Ambient Temp. Sensor) A13 IC4 GR 22 A16 TAM 1 2 Y-G 5 IC3 Y-G 6 A16 SG AC I045741E01 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TAM, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TAM (+) I033523E02 Tester Connection (Symbols) Condition Specified Condition A16-22 (TAM) - A16-6 (SG) Ignition switch ON at 25°C (77°F) 1.4 to 1.8 V A16-22 (TAM) - A16-6 (SG) Ignition switch ON at 40°C (104°F) 0.9 to 1.3 V AC–32 AIR CONDITIONING – AIR CONDITIONING SYSTEM HINT: As the temperature increases, the voltage decreases. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT THERMISTOR ASSEMBLY (AMBIENT TEMPERATURE SENSOR) (a) Remove the thermistor assembly (ambient temp. sensor). I030155 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Resistance (kΩ) 4.0 Tester Connection 3.5 3.0 2.5 AC Condition Specified Condition A1-1 - A1-2 10°C (50°F) 3.00 to 3.73 kΩ A1-1 - A1-2 15°C (59°F) 2.45 to 2.88 kΩ A1-1 - A1-2 20°C (68°F) 1.95 to 2.30 kΩ 2.0 A1-1 - A1-2 25°C (77°F) 1.60 to 1.80 kΩ 1.5 A1-1 - A1-2 30°C (86°F) 1.28 to 1.47 kΩ 1.0 A1-1 - A1-2 35°C (95°F) 1.00 to 1.22 kΩ 0.5 A1-1 - A1-2 40°C (104°F) 0.80 to 1.00 kΩ 0.0 10 50 A1-1 - A1-2 45°C (113°F) 0.65 to 0.85 kΩ 20 68 30 40 86 104 Temperature 50 60 (°C) 122 140 (°F) A1-1 - A1-2 50°C (122°F) 0.50 to 0.70 kΩ A1-1 - A1-2 55°C (131°F) 0.44 to 0.60 kΩ A1-1 - A1-2 60°C (140°F) 0.36 to 0.50 kΩ I041430E08 NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring the sensor temperature, it must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG OK REPLACE THERMISTOR ASSEMBLY AC–33 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 CHECK HARNESS AND CONNECTOR (THERMISTOR ASSEMBLY (AMBIENT TEMP. SENSOR) - A/C AMPLIFIER) (a) Check for open and short circuit in the harness and the connector between the thermistor assembly (ambient temp. sensor) and the A/C amplifier (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 12 is not output again. Result Result Proceed to DTC 12 is output. A DTC 12 is not output. B B SYSTEM IS OK A REPLACE AIR CONDITIONING AMPLIFIER AC AC–138 AIR CONDITIONING – CONDENSER CONDENSER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS 5.4 (55, 47 in.*lbf) O-RING DISCHARGE HOSE SUB-ASSEMBLY 5.4 (55, 47 in.*lbf) 5.4 (55, 47 in.*lbf) AIR CONDITIONING TUBE ASSEMBLY 5.4 (55, 47 in.*lbf) O-RING COOLER CONDENSER CUSHION NO. 1 5.4 (55, 47 in.*lbf) COOLER CONDENSER CUSHION NO. 1 5.4 (55, 47 in.*lbf) 5.4 (55, 47 in.*lbf) AC 5.4 (55, 47 in.*lbf) COOLER DRYER COOLER CONDENSER CUSHION NO. 2 O-RING COOLER CONDENSER CORE 5.4 (55, 47 in.*lbf) 2.9 (30, 25 in.*lbf) CAP COOLER CONDENSER CUSHION NO. 2 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Compressor oil ND-OIL 8 or equivalent C134077E01 AIR CONDITIONING – CONDENSER AC–139 ON-VEHICLE INSPECTION 1. INSPECT COOLER CONDENSER ASSEMBLY (a) If a fin of the cooler condenser assembly is dirty, clean it with water and dry it with compressor air. NOTICE: Do not damage the fin of the condenser assembly. (b) If a fin of the condenser assembly is bent, make it straight using a screwdriver or pliers. 2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check pipe joints for gas leakage. (b) If gas leakage is detected in a joint, check the torque of the joint. AC AC–34 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC 13 Evaporator Temperature Sensor Circuit DESCRIPTION This sensor detects the temperature inside the cooling unit and sends appropriate signals to the A/C amplifier. DTC No. Detection Item Trouble Area • 13 Open or short in evaporator temperature sensor circuit Cooler thermistor No. 1 ( Evaporator temperature sensor) Harness or connector between cooler thermistor No. 1 (evaporator temperature sensor) and A/C amplifier A/C amplifier • • WIRING DIAGRAM A/C Amplifier A18 Cooler Thermistor NO. 1 (Evaporator Temp. Sensor) G 24 A16 TE Y-G 6 A16 SG 1 2 AC I045740E02 INSPECTION PROCEDURE 1 INSPECT AIR CONDITIONING AMPLIFIER (TE, SG) (a) Remove the A/C amplifier with the connectors still connected. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage SG (-) TE (+) Tester Connection (Symbols) Condition Specified Condition A16-24 (TE) - A16-6 (SG) Ignition switch ON at 0°C (32°F) 2.0 to 2.4 V A16-24 (TE) - A16-6 (SG) Ignition switch ON at 15°C (59°F) 1.4 to 1.8 V I033523E03 AC–35 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT COOLER THERMISTOR NO. 1 (EVAPORATOR TEMPERATURE SENSOR) (a) Remove the cooler thermistor No. 1 (evaporator temp. sensor). + E050650E04 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Resistance (kΩ) 10.0 9.0 Tester Connection Condition Specified Condition 8.0 A18-1 - A18-2 -10°C (14°F) 7.30 to 9.10 kΩ 7.0 A18-1 - A18-2 -5°C (23°F) 5.65 to 6.95 kΩ 6.0 A18-1 - A18-2 0°C (32°F) 4.40 to 5.35 kΩ 5.0 A18-1 - A18-2 5°C (41°F) 3.40 to 4.15 kΩ 4.0 A18-1 - A18-2 10°C (50°F) 2.70 to 3.25 kΩ 3.0 A18-1 - A18-2 15°C (59°F) 2.14 to 2.58 kΩ A18-1 - A18-2 20°C (68°F) 1.71 to 2.05 kΩ A18-1 - A18-2 25°C (77°F) 1.38 to 1.64 kΩ A18-1 - A18-2 30°C (86°F) 1.11 to 1.32 kΩ 2.0 1.0 0.0 -10 14 0 32 Temperature 10 50 20 68 30 (°C) 86 (°F) I041431E03 NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring the sensor temperature, it must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG REPLACE COOLER THERMISTOR NO. 1 (EVAPORATOR TEMPERATURE SENSOR) OK 3 CHECK HARNESS AND CONNECTOR (COOLER THERMISTOR NO. 1 - A/C AMPLIFIER) (a) Check for open and short in the harness and the connector between the cooler thermistor No. 1 (evaporator temp. sensor) and the A/C amplifier (See page IN-38). AC AC–36 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK DTC (a) Start up the DTC check mode. (b) Check that DTC 13 is not output again. Result Result Proceed to DTC 13 is output. A DTC 13 is not output. B B A REPLACE AIR CONDITIONING AMPLIFIER AC SYSTEM IS OK AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC–143 AIR CONDITIONING CONTROL ASSEMBLY HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS AIR CONDITIONING CONTROL ASSEMBLY - COOLER CONTROL SWITCH BULB C119745E03 AC AC–144 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY REMOVAL 1. 4 Claws REMOVE AIR CONDITIONING CONTROL ASSEMBLY (a) Remove the screw. (b) Release the 4 claw fittings. (c) Disconnect the connector and remove the air conditioning control assembly. I033457E01 DISASSEMBLY 1. REMOVE COOLER CONTROL SWITCH BULB (EXCEPT INDEPENDENCE TEMPERATURE CONTROL) (a) Remove the 8 cooler control switch bulbs from the air conditioning control assembly. 2. REMOVE COOLER CONTROL SWITCH BULB (INDEPENDENCE TEMPERATURE CONTROL) (a) Remove the 9 cooler control switch bulbs from the air conditioning control assembly. I033458E01 I033448E01 AC AC–148 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER REMOVAL I033506 AC 1. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-7) 3. REMOVE CONSOLE UPPER PANEL GARNISH NO. 1 (See page IP-7) 4. REMOVE CONSOLE UPPER PANEL GARNISH NO. 2 5. REMOVE CONSOLE BOX ASSEMBLY REAR 6. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (See page AC-144) 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER (See page IP-8) 8. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect the connectors. (b) Remove the 3 screws and air conditioning amplifier assembly. AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC–149 INSTALLATION 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER 3. INSTALL AIR CONDITIONING CONTROL ASSEMBLY 4. INSTALL CONSOLE BOX ASSEMBLY REAR 5. INSTALL CONSOLE UPPER PANEL GARNISH NO. 2 6. INSTALL CONSOLE UPPER PANEL GARNISH NO. 1 7. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 8. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY AC AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC–145 AIR CONDITIONING AMPLIFIER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS AIR CONDITIONING CONTROL ASSEMBLY AC AIR CONDITIONING AMPLIFIER ASSEMBLY C119745E04 AC–146 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER G G G C C G G G C C C AC INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER B B AIR CONDITIONING CONTROL ASSEMBLY B120190E05 AC–147 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER CONSOLE UPPER PANEL GARNISH NO. 1 CONSOLE UPPER PANEL GARNISH NO. 2 B B CONSOLE UPPER REAR PANEL SUB-ASSEMBLY CONSOLE PANEL SUB-ASSEMBLY UPPER B B B B B B CONSOLE BOX ASSEMBLY REAR AC B120191E07 RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM PARTS LOCATION COMBINATION METER ASSEMBLY: AIR CONDITIONING CONTROL ASSEMBLY: 2#55'0)'4 #+4$#) ' RSCA OFF INDICATOR (*1) 1(( 10 SRS WARNING LIGHT PASSENGER AIRBAG ON/OFF INDICATOR CURTAIN SHIELD AIRBAG ASSEMBLY LH (*1) FRONT AIRBAG SENSOR LH FRONT AIRBAG SENSOR RH CURTAIN SHIELD AIRBAG ASSEMBLY RH (*1) RS CURTAIN SHIELD AIRBAG CUTOFF SWITCH (*1) SPIRAL CABLE STEERING PAD C *1: WITH SIDE AND CURTAIN SHIELD AIRBAG C123756E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–15 OCCUPANT CLASSIFICATION ECU CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT SIDE AIRBAG ASSEMBLY RH (*1) SIDE AIRBAG SENSOR RH (*1) SEAT POSITION SENSOR REAR AIRBAG SENSOR RH (*1) SIDE AIRBAG SENSOR LH (*1) RS FRONT SEAT OUTER BELT ASSEMBLY LH FRONT SEAT SIDE AIRBAG ASSEMBLY LH (*1) FRONT SEAT INNER BELT ASSEMBLY LH FRONT SEAT OUTER BELT ASSEMBLY RH REAR AIRBAG SENSOR LH (*1) *1: WITH SIDE AND CURTAIN SHIELD AIRBAG C C123757E01 RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SYSTEM DIAGRAM Front Airbag Sensor LH Steering Pad (Driver Side Squib) Front Airbag Sensor RH Front Passenger Airbag Assembly (Front Passenger Side Squib) Side Airbag Sensor LH (*1) Front Seat Side Airbag Assembly LH (Side Squib LH) (*1) Side Airbag Sensor RH (*1) Rear Airbag Sensor LH (*1) Rear Airbag Sensor RH (*1) Seat Position Airbag Sensor Front Seat Side Airbag Assembly RH (Side Squib RH) (*1) Center Airbag Sensor Assembly Curtain Shield Airbag Assembly LH (Curtain Shield Squib LH) (*1) Curtain Shield Airbag Assembly RH (Curtain Shield Squib RH) (*1) Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) Front Seat Inner Belt Assembly LH (Seat Belt Buckle Switch LH) Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) RS Curtain Shield Airbag Cutoff Switch (*1) Combination Meter Assembly (RSCA OFF Indicator) Combination Meter Assembly (SRS Warning Light) Occupant Classification ECU ECM DLC3 *1: with Side and Curtain Shield Airbag C123758E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–17 SYSTEM DESCRIPTION 1. 2. GENERAL (a) In conjunction with impact absorbing structure for a frontal collision, the SRS (Supplemental Restraint System) driver airbag and front passenger airbag were designed to supplement seat belts in the event of a frontal collision in order to help reduce shock to the head, chest and knee of the driver. This system is a 3-sensor type airbag system to detect the impact during a frontal collision using the center airbag sensor assembly and front airbag sensors. It also operates the airbag system and seat belt pretensioner. (b) In order to detect the extent of the collision during the initial stages of the collision in further detail, the front airbag sensors have been changed from mechanical type to electrical type deceleration sensors. Accordingly, the deployment of the driver airbag and front passenger airbag is controlled in two stages according to the severity of the impact. (c) In conjunction with impact absorbing structure for a side collision, the front seat airbag and curtain shield airbag were designed to help reduce shock to the driver, front passenger, and rear outer passengers in the event of a side collision or rollover. (d) RSCA (Roll Sensing of Curtain Shield Airbags) is used in order to deploy the curtain shield airbags and the seat belt pretensioner for the driver and front passenger, in the event that the vehicle rolls over. (e) The curtain shield airbag that helps reduce shock to the front and rear seat occupants with a single curtain shield airbag has been adopted. In conjunction with this system, the side airbag sensors have been installed at the bottom of the center pillars and the rear airbag sensors have been installed at the bottom of the rear pillars respectively. (f) In this system, a front side collision is detected by the side airbag sensors in order to deploy the side airbags. A rear side collision is detected by the rear airbag sensors and the center airbag sensor assembly in order to deploy the side airbags and curtain shield airbags. (g) The center airbag sensor assembly sends the airbag deployment signal to the body ECU via a discrete line to operate collision door lock release control. CONSTRUCTION AND OPERATION (a) FRONT AIRBAG SENSOR (1) The front airbag sensors are installed on the right and left radiator supports respectively. RS RS–18 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) The front airbag sensor consists of the deceleration sensor. (3) The deceleration sensor is built into the front airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a frontal collision. Accordingly, the extent of the initial collision can be detected in detail. (b) SIDE AIRBAG SENSOR (1) The side airbag sensors are installed on the bottom of the right and left center pillars respectively. (2) The side airbag sensor consists of the deceleration sensor and ignition control circuit. (3) The deceleration sensor is built into the side airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a front side collision. Accordingly, the extent of the initial collision can be detected in detail. (c) REAR AIRBAG SENSOR (1) The rear airbag sensors are installed on the right and left rear pillars respectively. (2) The rear airbag sensor consists of the deceleration sensor and ignition control circuit. (3) The deceleration sensor is built into the rear airbag sensor, and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a rear side collision. Accordingly, the extent of the initial collision can be detected in detail. (d) CENTER AIRBAG SENSOR ASSEMBLY (1) General • The center airbag sensor assembly is installed on the center floor under the console box. • The center airbag sensor assembly consists of the deceleration sensor, safing sensor, electronic safing sensor, ignition control circuit and diagnostic circuit. • The center airbag sensor assembly receives signals from the deceleration sensor and safing sensor built into the center airbag sensor assembly and front airbag sensor. Then the center airbag sensor assembly determines whether or not the driver airbag, front passenger airbag, and front seat belt pretensioners should be activated, and diagnoses system malfunctions. • The center airbag sensor assembly causes the front seat airbag and the curtain shield airbag assemblies to deploy when receiving signals from the side airbag sensor. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) (3) (4) (5) RS–19 • The center airbag sensor assembly receives signals from the deceleration sensor and the electronic safing sensor built into the center airbag sensor assembly and the rear airbag sensor, and determines whether or not the side airbag and curtain shield airbag assemblies should be activated, and diagnoses system malfunctions. • The center airbag sensor assembly sends the airbag deployment signal to the ECM through BEAN to operate fuel pump control. • The center airbag sensor assembly sends the airbag deployment signal to the body ECU through a discrete line to operate collision door lock release control. Deceleration sensor and ignition control circuit • The deceleration sensor is built into the center airbag sensor assembly. • The ignition control circuit performs calculations based on the signal output from the deceleration sensors of the center airbag sensor assembly and front airbag sensor. If the calculated values are greater than the specified values, it activates ignition operation. Safing sensor • The safing sensor is built into the center airbag sensor assembly. During a frontal collision, the sensor turns on and outputs an ON signal to the center airbag sensor assembly if a deceleration rate greater than the specified value is applied to the safing sensor. Electronic safing sensor • The electronic safing sensor is built into the center airbag sensor assembly. During a side collision, the sensor turns on and outputs an ON signal to the center airbag sensor assembly if a deceleration rate greater than the specified value is applied to the electronic safing sensor. Backup power source • The backup power source consists of a power supply capacitor and a DC-DC converter. If the power system does not function during a collision, the power supply capacitor discharges and supplies electric power to the system. The DC-DC converter operates as a boosting transformer when the battery voltage falls below a predetermined level. RS RS–20 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (6) Diagnostic circuit • This circuit constantly diagnoses system malfunctions. When a malfunction is detected, it lights up the SRS warning light on the combination meter assembly to inform the driver. (7) Memory circuit • When a malfunction is detected in the diagnostic circuit, it is coded and stored in the memory circuit. (e) SRS WARNING LIGHT (1) The SRS warning light is located on the combination meter assembly. It comes on to inform the driver of system trouble when a malfunction is detected in self-diagnosis of the center airbag sensor assembly. Under normal operating conditions, when the ignition switch is turned to the ON position, it comes on for approximately 6 seconds and then goes off. RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS–21 DEPLOYMENT CONDITION When the vehicle collides and the shock is greater than the specified value, the SRS is activated automatically. The center airbag sensor assembly includes the safing sensor and deceleration sensor. The safing sensor was designed to be turned on at a smaller deceleration rate than the deceleration sensor. (a) The center airbag sensor assembly determines whether or not ignition is necessary based on signals from the deceleration sensor and the front airbag sensor (*1). If the safing sensor and deceleration sensor turn on simultaneously, current flows to the squibs to deploy the SRS as shown in the illustration below. Center Airbag Sensor Assembly Steering Pad Safing Sensor ON AND Deceleration Sensor ON Front Passenger Airbag Assembly Front Seat Outer Belt Assembly Center Airbag Sensor Assembly Steering Pad Safing Sensor ON AND Deceleration Sensor ON Front Passenger Airbag Assembly Front Seat Outer Belt Assembly AND Front Airbag Sensor (*1) C C109526E12 HINT: *1: In case of a front collision, the ignition signal could be output with the deceleration sensor ON signal even without a signal from the front airbag sensor. RS RS–22 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) The center airbag sensor assembly determines whether or not ignition is necessary based on signals from the side airbag sensor. If the safing sensor and side airbag sensor turn on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below. Center Airbag Sensor Assembly Safing Sensor Front Seat Side Airbag Assembly AND Curtain Shield Airbag Assembly Side Airbag Sensor C C109527E03 (c) The center airbag sensor assembly determines whether or not ignition is necessary based on signals from the rear airbag sensor. If the safing sensor and rear airbag sensor turn on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below (*1). Front Seat Side Airbag Assembly Deployment RS Safing Sensor OR Center Airbag Sensor Assembly Curtain Shield Airbag Assembly AND Rear Airbag Sensor (*1) C C109528E03 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–23 HINT: *1: If the front seat side airbag assembly deploys, the curtain shield airbag assembly will also deploy, regardless of whether the signal is output from the rear airbag sensor. (d) The vehicle is equipped with the function to activate the SRS in case of vehicle rollover. A circuit to detect vehicle rollover is built into the center airbag sensor assembly. When the conditions for vehicle rollover are met, the SRS is activated as shown in the illustration below. Center Airbag Sensor Assembly Safing Sensor ON Curtain Shield Airbag Assembly AND Front Seat Outer Belt Assembly Rollover Circuit ON H045342E01 RS RS–24 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used in steps 2, 4, 6, 8 and 9. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check for DTC output. DTC IS OUTPUT: CHECK MULTIPLEX COMMUNICATION CIRCUIT DTC IS NOT OUTPUT: Go to step 3 3 WARNING LIGHT CHECK NEXT 4 CHECK DTC (Present and Past DTCs) DTC IS OUTPUT (INCLUDING NORMAL SYSTEM CODE): Go to step 5 DTC IS NOT OUTPUT: PROBLEM SYMPTOMS TABLE RS 5 DTC CHART NEXT 6 CIRCUIT INSPECTION NEXT 7 NEXT REPAIR SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8 RS–25 CLEAR DTC (Present and Past DTCs) NEXT 9 CHECK DTC (Present and Past DTCs) DTC IS NOT OUTPUT: Go to step 10 DTC IS OUTPUT: Go to step 5 10 CONFIRMATION TEST NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–69 B0105/53 Short in Front Passenger Side Squib Circuit DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0105/53 is recorded when a short circuit is detected in the front passenger side squib circuit. DTC No. DTC Detecting Condition • B0105/53 • • Short circuit between P+ wire harness and P- wire harness of front passenger side squib Front passenger side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM Center Airbag Sensor Assembly A35 Front Passenger Side Squib 1 2 10 A32 P+ 11 A32 P- RS C128524E22 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). RS–70 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) D C Front Passenger Side Squib Center Airbag Sensor Assembly Connector "C" A35 SST DLC3 CG C B0105/53 TC C111755E06 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0105/53 is not output. HINT: Codes other than DTC B0105/53 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS–71 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB CIRCUIT) Instrument Panel Wire A D C Front Passenger Side Squib B Center Airbag Sensor Assembly Connector "C" (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A35-1 (P+) - A35-2 (P-) Always 1 MΩ or higher NG A35 REPAIR OR REPLACE INSTRUMENT PANEL WIRE P+ PC C114767E16 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Center Airbag Side Squib Sensor Assembly DLC3 CG C DTC B0105/53 TC C110398E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–72 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0106/54 Open in Front Passenger Side Squib Circuit DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0106/54 is recorded when an open circuit is detected in the front passenger side squib circuit. DTC No. DTC Detecting Condition • B0106/54 • • Open circuit in P+ wire harness or P- wire harness of front passenger side squib Front passenger side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-66. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) D C RS Front Passenger Side Squib Center Airbag Sensor Assembly Connector “C” A35 SST DLC3 CG C DTC B0106/54 TC C111756E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–73 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0106/54 is not output. HINT: Codes other than DTC B0106/54 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C Front Passenger Side Squib B Center Airbag Sensor Assembly Tester connection Condition Specified condition A35-1 (P+) - A35-2 (P-) Always Below 1 Ω NG Connector "C" REPAIR OR REPLACE INSTRUMENT PANEL WIRE A35 P+ RS PC C114767E16 OK RS–74 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Center Airbag Side Squib Sensor Assembly DLC3 CG C DTC B0106/54 TC C110400E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–1 AIRBAG SYSTEM PRECAUTION CAUTION: • The vehicle is equipped with a Supplemental Restraint System (SRS). It consists of a driver airbag, front passenger airbag, side airbag, curtain shield airbag, and front seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures indicated in the repair manual. • Wait at least 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery before starting the operation. (The SRS is equipped with a backup power source, so that if work is started within 90 seconds after disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed). • Do not expose the steering pad, front passenger airbag assembly, center airbag sensor assembly, front airbag sensor, front seat inner belt assembly, seat position sensor, occupant classification ECU, front seat side airbag assembly, side airbag sensor, curtain shield airbag assembly, rear airbag sensor, or front seat outer belt assembly directly to hot air or flames. NOTICE: • Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect DTCs before disconnecting the battery. • Even in the case of a minor collision when the SRS does not deploy, the steering pad, front passenger airbag assembly, center airbag sensor assembly, front airbag sensor, front seat inner belt assembly, seat position sensor, occupant classification ECU, front seat side airbag assembly, side airbag sensor, curtain shield airbag assembly, rear airbag sensor, and front seat outer belt assembly should be inspected. • Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the repair. • Never use SRS parts from another vehicle. When replacing parts, replace them with new ones. RS RS–2 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • Never disassemble or repair any of the following parts in order to reuse them. If any of these parts have been dropped, or a defect is found (e.g. cracks, dents or any other defects) in any of the housings, brackets or connectors, then replace the part with a new one. (a)Steering Pad (b)Front Passenger Airbag Assembly (c)Front Seat Side Airbag Assembly (d)Curtain Shield Airbag Assembly (e)Center Airbag Sensor Assembly (f) Front Airbag Sensor (g)Front Seat Inner Belt Assembly (h)Seat Position Sensor (i) Occupant Classification ECU (j) Side Airbag Sensor (k)Rear Airbag Sensor (l) Front Seat Outer Belt Assembly • Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. • Information labels are attached near the SRS components. Follow the instructions in the caution. • After work on the SRS is completed, perform the SRS warning light check (See page RS-28). • When the negative (-) terminal cable is disconnected from the battery, the memory will be cleared. Because of this, be sure to make a record of the contents memorized in each system before starting work. When work is finished, adjust each system as it was before. Never attempt to avoid erasing vehicle system memories by using a backup power supply from outside the vehicle. • If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. HINT: In the airbag system, the center airbag sensor assembly, front airbag sensors LH and RH, side airbag sensors LH and RH, rear airbag sensors LH and RH are collectively referred to as the airbag sensors. 1. HANDLING PRECAUTIONS FOR AIRBAG SENSORS (a) Before starting the following operations, wait for at least 90 seconds after disconnecting the negative () terminal cable from the battery: (1) Replacement of the airbag sensors (2) Adjustment of the front/rear doors of a vehicle equipped with a side airbag and curtain shield airbag (fitting adjustment). (b) When connecting or disconnecting the airbag sensor connectors, ensure that each sensor is installed in the vehicle. (c) Do not use the airbag sensors which have been dropped during the operation or transportation. (d) Do not disassemble the airbag sensors. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. RS–3 INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) When the airbag has not deployed, confirm the DTCs by checking the SRS warning light. If there is any malfunction in the SRS airbag system, perform troubleshooting. (b) When any of the airbags have deployed, replace the airbag sensors and check the installation condition. RS RS–4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS SRS CONNECTORS (a) SRS connectors are located as shown in the following illustration. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 35 15 Occupant Classification ECU Curtain Shield Airbag Assembly RH (Curtain Shield Squib RH) (*1) 33 16 RS–5 36 34 9 Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) 31 Rear Airbag Sensor RH 10 32 7 Front Seat Side Airbag Assembly RH (Side Squib RH) (*1) 29 Side Airbag Sensor RH 8 30 5 13 6 Front Airbag Sensor RH Front Passenger Airbag Assembly (Front Passenger Side Squib) 21 14 22 3 Curtain Shield Airbag Cutoff Switch (*1) 25 4 Center Airbag Sensor Assembly 26 1 23 3 2 Combination Meter Assembly 24 Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) 27 4 5 28 13 6 Front Airbag Sensor LH 14 Spiral Cable 19 18 7 RS 17 Side Airbag Sensor LH Steering Pad (Driver Side Squib) 20 Front Seat Side Airbag Assembly LH (Side Squib LH) (*1) 29 8 9 30 Rear Airbag Sensor LH 11 *1: with Side and Curtain Shield Airbag Seat Position Sensor/Front Seat Inner Belt Assembly LH Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) 31 10 32 33 12 34 Curtain Shield Airbag Assembly LH (Curtain Shield Squib LH) (*1) C123754E01 RS–6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM No. Connector type (1) Terminal Twin-Lock Mechanism Connectors 2, 4, 6, 8, 10, 12, 15, 16, 17, 18, 19, 20, 21, 27, 28, 35 (2) Activation Prevention Mechanism Connectors 2, 4, 22, 24, 26, 28, 30, 32 (3) Electrical Connection Check Mechanism Connectors 1, 2, 3, 4 (4) Half Connection Prevention Mechanism Connectors 6, 8, 10, 18, 20, 25, 27 (5) Connector Lock Mechanism Connectors 23, 29, 31 Spacer Housing Female Male Z005953E02 RS Application (b) All connectors in the SRS, except the seat position airbag sensor connector, are colored yellow to distinguish them from other connectors. These connectors have special functions, and are specially designed for the SRS. All SRS connectors use durable gold-plated terminals, and are placed in the locations shown on the previous page to ensure high reliability. (1) Terminal twin-lock mechanism: All connectors with a terminal twin-lock mechanism have a two-piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. RS–7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) Activation prevention mechanism: All connectors with an activation prevention mechanism contain a short spring plate. When these connectors are disconnected, the short spring plate creates a short circuit by automatically connecting the positive (+) and negative (-) terminals of the squib. ●When Connector is Connected ●When Connector is Disconnected Short Spring Plate Short Spring Plate Housing Terminal Housing Squib Connectors Short Spring Plate Contacting Male Terminal Short Spring Plate ON Squib Closed Circuit H045309E03 RS RS–8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) Electrical connection check mechanism: This mechanism electrically checks that the connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. Disconnection Detection Pin Center Airbag Sensor Assembly H041646E06 ٨Half Connection ٨Complete Connection Terminal for Diagnosis Terminal for Diagnosis Disconnection Detection PIN H001315E02 (4) Half connection prevention mechanism: If the connector is not completely connected, the connector is disconnected due to the spring operation so that no continuity exists. RS Locking Part Stopper Locking Arm Spring Slider Stopper Rebounded by Slider (Spring) H040180E02 RS–9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (5) Connector lock mechanism: Locking the connector lock button connects the connector securely. Lock Button Claw Groove H040181E04 4. Lock Button (Yellow part) DISCONNECTION OF CONNECTORS FOR STEERING PAD, CURTAIN SHIELD AIRBAG ASSEMBLY, AND FRONT SEAT OUTER BELT ASSEMBLY HINT: Tape up the screwdriver tip before use. (a) Release the lock button (yellow part) of the connector using a screwdriver (Procedure A). (b) Insert the screwdriver tip between the connector and the base, and then raise the connector (Procedure B). Lock Button (Yellow part) Tape RS Mark C C123672E01 5. CONNECTION OF CONNECTORS FOR STEERING PAD, CURTAIN SHIELD AIRBAG ASSEMBLY, AND FRONT SEAT OUTER BELT ASSEMBLY (a) Connect the connector. RS–10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) Push down securely on the lock button (yellow part) of the connector. (When locking, a click sound can be heard.) Lock Button (Yellow Part) H043151E08 6. Slider DISCONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG ASSEMBLY (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider RS Disconnection is completed H001586E07 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7. RS–11 CONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG ASSEMBLY (a) Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) Slider Slider Connection is completed H043731E05 8. Slider HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. DISCONNECTION OF CONNECTOR FOR FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. RS Slider Disconnection is completed H001584E03 RS–12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9. CONNECTION OF CONNECTOR FOR FRONT SEAT SIDE AIRBAG ASSEMBLY (a) Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will side. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H043169E02 Outer RS H002763E02 10. DISCONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR, SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) While holding both the sides of the outer connector locking sleeve, slide the outer in the direction shown by the arrow. (b) When the connector lock is released, the connectors are disconnected. HINT: Be sure to hold both outer flank sides. Holding the top and bottom will make disconnection difficult. Connector lock is released Disconnection is completed H002764E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–13 11. CONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR, SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) Connect the connector as shown in the illustration (When locking, make sure that the outer returns to its original position and a click sound can be heard). HINT: When connecting, the outer will slide. Be sure not to hold the outer while connecting, as it may result in an insecure fit. Outer Outer Connection is completed H002768E02 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–75 Short to GND in Front Passenger Side Squib Circuit B0107/51 DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0107/51 is recorded when a short to ground is detected in the front passenger side squib circuit. DTC No. DTC Detecting Condition • B0107/51 • • Short circuit in front passenger side squib wire harness (to ground) Front passenger side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-66. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–76 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) D C Front Passenger Center Airbag Side Squib Sensor Assembly Connector “C” A35 SST DLC3 CG C B0107/51 TC C111757E05 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0107/51 is not output. HINT: Codes other than DTC B0107/51 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS–77 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C Front Passenger Side Squib B Center Airbag Sensor Assembly Tester connection Condition Specified condition A35-1 (P+) - Body ground Always 1 MΩ or higher A35-2 (P-) - Body ground Always 1 MΩ or higher Connector "C" NG A35 REPAIR OR REPLACE INSTRUMENT PANEL WIRE P+ PC C114767E16 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Center Airbag Side Squib Sensor Assembly DLC3 CG C DTC B0107/51 TC C110402E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–78 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Short to B+ in Front Passenger Side Squib Circuit B0108/52 DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0108/52 is recorded when a short to B+ is detected in the front passenger side squib circuit. DTC No. DTC Detecting Condition • B0108/52 • • Short circuit in front passenger side squib wire harness (to B+) Front passenger side squib malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-66. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) D C Front Passenger Center Airbag Side Squib Sensor Assembly Connector “C” A35 SST DLC3 CG C RS–79 B0108/52 TC C111758E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0108/52 is not output. HINT: Codes other than DTC B0108/52 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS RS–80 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB CIRCUIT) Instrument Panel Wire A D C Front Passenger Side Squib B Center Airbag Sensor Assembly (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition Connector "C" A35-1 (P+) - Body ground Ignition switch ON Below 1 V A35 A35-2 (P-) - Body ground Ignition switch ON Below 1 V P+ NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE PC C114767E16 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY RS DC Front Passenger Center Airbag Side Squib Sensor Assembly DLC3 CG C DTC B0108/52 TC C110404E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–81 OK USE SIMULATION METHOD TO CHECK RS RS–82 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0110/43 Short in Side Squib RH Circuit DESCRIPTION The side squib RH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly RH (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0110/43 is recorded when a short circuit is detected in the side squib RH circuit. DTC No. DTC Detecting Condition • B0110/43 • • Short circuit between SFR+ wire harness and SFRwire harness of side squib RH Side squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat side airbag assembly RH (Side squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM Center Airbag Sensor Assembly S27 Side Squib RH 1 RS 2 5 A33 SFR+ 6 A33 SFR- C128524E23 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–83 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (SIDE SQUIB RH) D C Side Squib RH Center Airbag Sensor Assembly Connector “C” SST S27 1 2 DLC3 CG C DTC B0110/43 TC C110405E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly RH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat side airbag assembly RH (side squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0110/43 is not output. HINT: Codes other than DTC B0110/43 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT ASSEMBLY RH Go to step 2 RS RS–84 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (SIDE SQUIB RH CIRCUIT) Floor Wire A D C Side Squib RH B Center Airbag Sensor Assembly Connector “C” Tester connection Condition Specified condition S27-1 (SFR+) - S27-2 (SFR-) Always 1 MΩ or higher NG S27 SFR+ (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance 1 2 REPAIR OR REPLACE FLOOR WIRE SFR- C C110406E23 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Side Squib RH Sensor Assembly RS DLC3 CG C DTC B0110/43 TC C110407E01 (a) Connect the connectors to the front seat side airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–85 B0111/44 Open in Side Squib RH Circuit DESCRIPTION The side squib RH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly RH (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0111/44 is recorded when an open circuit is detected in the side squib RH circuit. DTC No. DTC Detecting Condition • B0111/44 Open circuit in SFR+ wire harness or SFR- wire harness of side squib RH Side squib RH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Front seat side airbag assembly RH (Side squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-79. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (SIDE SQUIB RH) D C Side Squib RH Center Airbag Sensor Assembly Connector “C” SST S27 1 2 DLC3 CG C DTC B0111/44 TC C110408E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly RH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat side airbag assembly RH (side squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–86 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0111/44 is not output. HINT: Codes other than DTC B0111/44 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY RH 2 CHECK FLOOR WIRE (SIDE SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A D C Side Squib RH B Center Airbag Sensor Assembly Tester connection Condition Specified condition S27-1 (SFR+) - S27-2 (SFR-) Always Below 1 Ω NG Connector “C” REPAIR OR REPLACE FLOOR WIRE S27 SFR+ 1 2 SFR- C C110406E23 OK RS 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Side Squib RH Sensor Assembly DLC3 CG C DTC B0111/44 TC C110409E01 (a) Connect the connectors to the front seat side airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–87 REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–88 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0112/41 Short to GND in Side Squib RH Circuit DESCRIPTION The side squib RH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly RH (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0112/41 is recorded when a short to ground is detected in the side squib RH circuit. DTC No. DTC Detecting Condition • B0112/41 • • Short circuit in side squib RH wire harness (to ground) Side squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat side airbag assembly RH (Side squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-79. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (SIDE SQUIB RH) D C Side Squib RH RS Center Airbag Sensor Assembly Connector “C” SST S27 1 2 DLC3 CG C DTC B0112/41 TC C110410E06 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly RH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat side airbag assembly RH (side squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–89 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0112/41 is not output. HINT: Codes other than DTC B0112/41 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY RH 2 CHECK FLOOR WIRE (SIDE SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A D C Side Squib RH B Center Airbag Sensor Assembly Connector “C” Tester connection Condition Specified condition S27-1 (SFR+) - Body ground Always 1 MΩ or higher S27-2 (SFR-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE S27 SFR+ 1 2 SFR- C C110406E23 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Side Squib RH DLC3 CG C Center Airbag Sensor Assembly DTC B0112/41 TC C110411E01 (a) Connect the connectors to the front seat side airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not related to this check. RS RS–90 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–91 B0113/42 Short to B+ in Side Squib RH Circuit DESCRIPTION The side squib RH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly RH (side squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0113/42 is recorded when a short to B+ is detected in the side squib RH circuit. DTC No. DTC Detecting Condition B0113/42 • • • Short circuit in side squib RH wire harness (to B+) Side squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat side airbag assembly RH (Side squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-79. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (SIDE SQUIB RH) D C Side Squib RH Center Airbag Sensor Assembly Connector “C” SST S27 1 2 DLC3 CG C DTC B0113/42 TC C110412E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly RH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat side airbag assembly RH (side squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–92 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0113/42 is not output. HINT: Codes other than DTC B0113/42 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY RH 2 CHECK FLOOR WIRE (SIDE SQUIB RH CIRCUIT) Floor Wire A D C Side Squib RH B Center Airbag Sensor Assembly Connector “C” S27 SFR+ 1 2 (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition S27-1 (SFR+) - Body ground Ignition switch ON Below 1 V S27-2 (SFR-) - Body ground Ignition switch ON Below 1 V SFR- C C110406E23 NG REPAIR OR REPLACE FLOOR WIRE OK RS 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Side Squib RH Sensor Assembly DLC3 CG C DTC B0113/42 TC C110413E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front seat side airbag assembly RH and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0113/42 is not output. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–93 HINT: Codes other than code B0113/42 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–94 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0115/47 Short in Side Squib LH Circuit DESCRIPTION The side squib LH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly LH (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0115/47 is recorded when a short circuit is detected in the side squib LH circuit. DTC No. DTC Detecting Condition • B0115/47 • • Short circuit between SFL+ wire harness and SFLwire harness of side squib LH Side squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat side airbag assembly LH (Side squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM Center Airbag Sensor Assembly S26 Side Squib LH 1 RS 2 12 A30 SFL+ 11 A30 SFL- C128524E24 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–95 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (SIDE SQUIB LH) D C Side Squib LH Center Airbag Sensor Assembly Connector “C” SST S26 1 2 DLC3 CG C DTC B0115/47 TC C110414E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly LH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat side airbag assembly LH (side squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0115/47 is not output. HINT: Codes other than DTC B0115/47 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT ASSEMBLY LH Go to step 2 RS RS–96 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SIDE SQUIB LH CIRCUIT) A D C Side Squib LH B Floor Wire No. 2 Center Airbag Sensor Assembly Connector “C” Tester connection Condition Specified condition S26-1 (SFL+) - S26-2 (SFL-) Always 1 MΩ or higher NG S26 SFL+ (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance 1 2 REPAIR OR REPLACE FLOOR WIRE NO. 2 SFL- C C110415E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Side Squib LH Center Airbag Sensor Assembly RS DLC3 CG C DTC B0115/47 TC C110416E01 (a) Connect the connectors to the front seat side airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–97 B0116/48 Open in Side Squib LH Circuit DESCRIPTION The side squib LH circuit consists of the center airbag sensor assembly and the front seat side assembly LH (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0116/48 is recorded when an open circuit is detected in the side squib LH circuit. DTC No. DTC Detecting Condition • B0116/48 Open circuit in SFL+ wire harness or SFL- wire harness of side squib LH Side squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Front seat side airbag assembly LH (Side squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-91. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (SIDE SQUIB LH) D C Side Squib LH Center Airbag Sensor Assembly Connector “C” SST S26 1 2 DLC3 CG C DTC B0116/48 TC C110417E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly LH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat side airbag assembly LH (side squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–98 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0116/48 is not output. HINT: Codes other than DTC B0116/48 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (SIDE SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance A D C Side Squib LH B Floor Wire No. 2 Center Airbag Sensor Assembly Tester connection Condition Specified condition S26-1 (SFL+) - S26-2 (SFL-) Always Below 1 Ω NG Connector “C” REPAIR OR REPLACE FLOOR WIRE NO. 2 S26 SFL+ 1 2 SFL- C C110415E17 OK RS 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Side Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0116/48 TC C110418E01 (a) Connect the connectors to the front seat side airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not related to this check. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–99 REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM PROBLEM SYMPTOMS TABLE AIRBAG SYSTEM Symptom RS Suspected Area When the ignition switch is turned to the ON position, the SRS warning light sometimes remains on even after approximately 6 seconds. SRS Warning Light Remains ON The SRS warning light always comes on even when no DTC is output. SRS Warning Light Remains ON When the ignition switch is turned to the ON position, the SRS warning light does not come on. SRS Warning Light does not Come ON Although the SRS warning light operates normally, a DTC or a normal system code is not displayed. TC and CG Terminal Circuit Although terminals TC and CG are not connected, a DTC or normal system code is displayed. TC and CG Terminal Circuit See page RS-275 RS-275 RS-282 RS-284 RS-284 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–27 TERMINALS OF ECU 1. A30 CENTER AIRBAG SENSOR ASSEMBLY (with Side and Curtain Shield Airbag) A33 A32 2 1 6 5 4 3 2 1 4 3 B A B A B A 2 1 12 11 10 9 8 7 6 5 17 16 15 14 13 12 11 10 9 8 7 12 11 10 9 8 7 6 5 4 3 20 19 18 17 16 15 14 13 28 27 26 25 24 23 22 21 20 19 18 20 19 18 17 16 15 14 13 C C111710E08 Terminal No. Terminal Symbol Terminal Description A - Half Connection Detection Mechanism B - Half Connection Detection Mechanism A30-1 CSL- Rear Airbag Sensor LH A30-2 LBE- Front Seat Inner Belt Assembly LH (Seat Belt Buckle Switch LH) A30-3 LSP- Seat Position Sensor A30-4 LSP+ Seat Position Sensor A30-7 PL- Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) A30-8 PL+ Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) A30-9 ICL+ Curtain Shield Airbag Assembly LH (Curtain Shield Squib LH) A30-10 ICL- Curtain Shield Airbag Assembly LH (Curtain Shield Squib LH) A30-11 SFL- Front Seat Side Airbag Assembly (Side Squib LH) A30-12 SFL+ Front Seat Side Airbag Assembly (Side Squib LH) A30-13 ESCL Rear Airbag Sensor LH A30-14 VUCL Rear Airbag Sensor LH A30-15 CSL+ Rear Airbag Sensor LH A30-16 VUPL Side Airbag Sensor LH A30-17 SSL+ Side Airbag Sensor LH A30-18 ESL Side Airbag Sensor LH A30-19 LBE+ Front Seat Inner Belt Assembly LH (Seat Belt Buckle Switch LH) A30-20 SSL- Side Airbag Sensor LH A32-1 P-AB Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) A32-2 PBEW A32-3 LA Combination Meter Assembly (SRS Warning Light) A32-5 IG2 IGN Fuse Passenger Seat Belt Warning Light RS RS–28 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Terminal No. RS Terminal Symbol Terminal Description Combination Meter Assembly (RSCA OFF Indicator) A32-6 RMIL A32-7 P2- Front Passenger Airbag Assembly (Passenger Side Squib 2nd Step) A32-8 P2+ Front Passenger Airbag Assembly (Passenger Side Squib 2nd Step) A32-9 +SR Front Airbag Sensor RH A32-10 P+ Front Passenger Airbag Assembly (Passenger Side Squib) A32-11 P- Front Passenger Airbag Assembly (Passenger Side Squib) A32-12 SIL DLC3 A32-13 D- Steering Pad (Driver Side Squib) A32-14 D+ Steering Pad (Driver Side Squib) A32-15 +SL Front Airbag Sensor LH A32-16 D2+ Steering Pad (Driver Side Squib 2nd Step) A32-17 D2- Steering Pad (Driver Side Squib 2nd Step) A32-19 TC DLC3 A32-20 -SR Front Airbag Sensor RH A32-21 RMSW A32-23 GSW2 ECM A32-25 PAON Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) A32-26 -SL Front Airbag Sensor LH A32-27 E1 Ground A32-28 E2 Ground A33-1 FSR+ Occupant Classification ECU A33-2 FSR- Occupant Classification ECU A33-4 CSR- Rear Airbag Sensor RH A33-5 SFR+ Front Seat Side Airbag Assembly (Side Squib RH) A33-6 SFR- Front Seat Side Airbag Assembly (Side Squib RH) A33-7 ICR- Curtain Shield Airbag Assembly RH (Curtain Shield Squib RH) A33-8 ICR+ Curtain Shield Airbag Assembly RH (Curtain Shield Squib RH A33-9 PR+ Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) A33-10 PR- Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) A33-13 SSR- Side Airbag Sensor RH A33-15 ESR Side Airbag Sensor RH A33-16 SSR+ Side Airbag Sensor RH A33-17 VUPR Side Airbag Sensor RH A33-18 CSR+ Rear Airbag Sensor RH A33-19 VUCR Rear Airbag Sensor RH A33-20 ESCR Rear Airbag Sensor RH Combination Meter Assembly (RSCA OFF Indicator) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. A31 CENTER AIRBAG SENSOR ASSEMBLY (without Side and Curtain Shield Airbag) A32 A34 6 5 4 3 2 1 B A 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 7 B A RS–29 B A 6 5 4 3 2 1 12 11 10 9 8 7 28 27 26 25 24 23 22 21 20 19 18 12 11 10 9 8 7 C C111711E05 Terminal No. Terminal Symbol Terminal Description A - Half Connection Detection Mechanism B - Half Connection Detection Mechanism A31-1 PL- Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) A31-2 PL+ Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) A31-3 LSP+ Seat Position Sensor A31-7 LBE- Front Seat Inner Belt Assembly LH (Seat Belt Buckle Switch LH) A31-8 LSP- Seat Position Sensor A31-11 LBE+ Front Seat Inner Belt Assembly LH (Seat Belt Buckle Switch LH) A32-1 P-AB Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) A32-2 PBEW A32-3 LA Combination Meter Assembly (SRS Warning Light) A32-5 IG2 IGN Fuse A32-7 P2- Front Passenger Airbag Assembly (Passenger Side Squib 2nd Step) A32-8 P2+ Front Passenger Airbag Assembly (Passenger Side Squib 2nd Step) A32-9 +SR Front Airbag Sensor RH A32-10 P+ Front Passenger Airbag Assembly (Passenger Side Squib) A32-11 P- Front Passenger Airbag Assembly (Passenger Side Squib) A32-12 SIL DLC3 A32-13 D- Steering Pad (Driver Side Squib) A32-14 D+ Steering Pad (Driver Side Squib) A32-15 +SL Front Airbag Sensor LH A32-16 D2+ Steering Pad (Driver Side Squib 2nd Step) A32-17 D2- Steering Pad (Driver Side Squib 2nd Step) A32-19 TC DLC3 A32-20 -SR Front Airbag Sensor RH Passenger Seat Belt Warning Light RS RS–100 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0117/45 Short to GND in Side Squib LH Circuit DESCRIPTION The side squib LH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly LH (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0117/45 is recorded when a short to ground is detected in the side squib LH circuit. DTC No. DTC Detecting Condition • B0117/45 Short circuit in side squib LH wire harness (to ground) Side squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Front seat side airbag assembly LH (Side squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-91. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (SIDE SQUIB LH) D C Side Squib LH Center Airbag Sensor Assembly RS Connector “C” SST S26 1 2 DLC3 CG C DTC B0117/45 TC C110419E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly LH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat siassembly LH (side squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–101 OK: DTC B0117/45 is not output. HINT: Codes other than DTC B0117/45 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (SIDE SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance A D C Side Squib LH B Floor Wire No. 2 Center Airbag Sensor Assembly Connector “C” Tester connection Condition Specified condition S26-1 (SFL+) - Body ground Always 1 MΩ or higher S26-2 (SFL-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 S26 SFL+ 1 2 SFL- C C110415E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Side Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0117/45 TC C110421E01 (a) Connect the connectors to the front seat side airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not related to this check. RS RS–102 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–103 B0118/46 Short to B+ in Side Squib LH Circuit DESCRIPTION The side squib LH circuit consists of the center airbag sensor assembly and the front seat side airbag assembly LH (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0118/46 is recorded when a short to B+ is detected in the side squib LH circuit. DTC No. DTC Detecting Condition • • • B0118/46 Short circuit in side squib LH wire harness (to B+) Side squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat side airbag assembly LH (Side squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-91. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (SIDE SQUIB LH) D C Side Squib LH Center Airbag Sensor Assembly Connector “C” SST S26 1 2 DLC3 CG C DTC B0118/46 TC C110420E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat side airbag assembly LH. (d) Connect the black wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat side airbag assembly LH (side squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–104 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0118/46 is not output. HINT: Codes other than DTC B0118/46 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (SIDE SQUIB LH CIRCUIT) A D C Side Squib LH B Floor Wire No. 2 Center Airbag Sensor Assembly Connector “C” S26 SFL+ 1 2 SFL- C C110415E17 (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition S26-1 (SFL+) - Body ground Ignition switch ON Below 1 V S26-2 (SFL-) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK RS 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Side Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0118/46 TC C110422E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front seat side airbag assembly LH and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0118/46 is not output. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–105 HINT: Codes other than code B0118/46 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–287 OCCUPANT CLASSIFICATION SYSTEM PRECAUTION 1. INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) Perform the zero point calibration and sensitivity check if any of the following conditions occur. • The occupant classification ECU is replaced. • Accessories (seatback tray and seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON/OFF indicator ("OFF") comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. NOTICE: When an accident vehicle is brought into the workshop for repair, check the flatness of the body side that is equipped with the passenger seat. If the flatness is not within +- 3.0 mm (0.118 in.), adjust it to the specified range. RS RS–288 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PARTS LOCATION COMBINATION METER ASSEMBLY: AIR CONDITIONING CONTROL ASSEMBLY: 2#55'0)'4 #+4$#) ' SRS WARNING LIGHT 1(( 10 PASSENGER AIRBAG ON/OFF INDICATOR OCCUPANT CLASSIFICATION ECU RS CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY RH C C123749E01 RS–106 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0126/27 Seat Belt Buckle Switch LH Circuit Malfunction DTC B0127/27 Seat Belt Buckle Switch LH Malfunction DESCRIPTION The seat belt buckle switch LH circuit consists of the center airbag sensor assembly and the front seat inner belt assembly LH (seat belt buckle switch LH). DTC B0126/27 or B0127/27 is recorded when a malfunction is detected in the seat belt buckle switch LH circuit. DTC No. DTC Detecting Condition • B0126/27 B0127/27 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the driver side seat belt buckle switch circuit for 2 seconds. Front seat inner belt assembly LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat inner belt assembly LH (Seat belt buckle switch LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM Center Airbag Sensor Assembly B12 Seat Belt Buckle Switch LH 19 11 A30 A31 LBE+ (*1) (*2) 1 RS Buckle SW 2 7 A30 A31 LBE(*1) (*2) 3 *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag H046330E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–107 INSPECTION PROCEDURE 1 CHECK DTC Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly DLC3 DTC B0126/B0127/27 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B0126, B0127 or 27 is not output. HINT: Codes other than code B0126, B0127 or 27 may be output at this time, but they are not related to this check. NG CG C Go to step 2 TC C110423E15 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the front seat inner belt assembly LH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–108 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No.2 D A C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector “B” A30 (*1) Connector “C” LBELBE+ B12 1 2 3 4 LBE- LBE+ *1: with Side and Curtain Shield Airbag LBE+ Service Wire A31 (*2) *2: without Side and Curtain Shield Airbag Service Wire C C123781E01 OK RS LBE- (a) Disconnect the connectors from the center airbag sensor assembly and the front seat inner belt assembly LH. (b) with Side airbag: Using a service wire, connect A30-19 (LBE+) and A30-2 (LBE-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) without Side airbag: Using a service wire, connect A31-11 (LBE+) and A31-7 (LBE-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition B12-1 (LBE+) - B12-3 (LBE-) Always Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–109 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No.2 D A C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly (a) Disconnect the service wire from connector "B". (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition B12-1 (LBE+) - Body ground Ignition switch ON Below 1 V B12-3 (LBE-) - Body ground Ignition switch ON Below 1 V Connector “C” NG B12 LBE+ REPAIR OR REPLACE FLOOR WIRE NO. 2 1 2 3 4 LBEC C111660E29 OK 5 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Floor Wire No.2 D A C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Connector “C” LBEC 1 2 3 4 C111660E29 OK Tester connection Condition Specified condition B12-1 (LBE+) - Body ground Always 1 MΩ or higher B12-3 (LBE-) - Body ground Always 1 MΩ or higher NG B12 LBE+ (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–110 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT) Floor Wire No.2 D A C B Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly (a) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition B12-1 (LBE+) - B12-3 (LBE-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector “C” B12 LBE+ LBEC 1 2 3 4 C111660E29 OK 7 CHECK FRONT SEAT INNER BELT ASSEMBLY LH RS Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly DLC3 CG C DTC B0126/B0127/27 TC C110423E15 (a) Connect the connectors to the front seat inner belt assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0126, B0127 or 27 is not output. HINT: Codes other than code B0126, B0127 or 27 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8 RS–111 REPLACE FRONT SEAT INNER BELT ASSEMBLY LH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the front seat inner belt assembly LH (See page SB-6). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 CHECK CENTER AIRBAG SENSOR ASSEMBLY Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly DLC3 CG C DTC B0126/B0127/27 TC C110423E15 OK END (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (c) Clear the DTCs stored in memory (See page RS-35). (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Check the DTCs (See page RS-35). OK: DTC B0126/27 is output. HINT: Codes other than code B0126/27 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–112 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0130/63 Short in Front Pretensioner Squib RH Circuit DESCRIPTION The front pretensioner squib RH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly RH (front pretensioner squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0130/63 is recorded when a short circuit is detected in the front pretensioner squib RH circuit. DTC No. DTC Detecting Condition • B0130/63 • • Trouble Area • Short circuit between PR+ wire harness and PRwire harness of front pretensioner squib RH Front pretensioner squib RH malfunction Center airbag sensor assembly malfunction • • Front seat outer belt assembly RH (Front pretensioner squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM Center Airbag Sensor Assembly P17 Front Pretensioner Squib RH 1 2 RS 5 9 A33 A34 PR+ (*1) (*2) 10 6 A33 A34 PR(*1) (*2) *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag H044107E05 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–113 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PRETENSIONER SQUIB RH) D C Front Pretensioner Squib RH Center Airbag Sensor Assembly Connector “C” P17 SST DLC3 CG DTC B0130/63 TC C C111724E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat outer belt assembly RH (front pretensioner squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0130/63 is not output. HINT: Codes other than DTC B0130/63 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the floor wire. RS RS–114 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (d) Check that the floor wire connector (on the front seat outer belt assembly RH side) is not damaged. OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 3 CHECK FLOOR WIRE (FRONT PRETENSIONER SQUIB RH CIRCUIT) Floor Wire A D C B Center Airbag Front Pretensioner Sensor Assembly Squib RH P17 C RS PR- C111725E15 OK Tester connection Condition Specified condition P17-1 (PR+) - P17-2 (PR) Always 1 MΩ or higher NG Connector “C” PR+ (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–115 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Front Pretensioner Sensor Assembly Squib RH DLC3 CG C DTC B0130/63 TC C110427E01 (a) Connect the connectors to the front seat outer belt assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–116 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0131/64 Open in Front Pretensioner Squib RH Circuit DESCRIPTION The front pretensioner squib RH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly RH (front pretensioner squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0131/64 is recorded when an open circuit is detected in the front pretensioner squib RH circuit. DTC No. DTC Detecting Condition • B0131/64 Open circuit in PR+ wire harness or PR- wire harness of front pretensioner squib RH Front pretensioner squib RH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Front seat outer belt assembly RH (Front pretensioner squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-109. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 RS CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PRETENSIONER SQUIB RH) D C Center Airbag Front Pretensioner Sensor Assembly Squib RH Connector “C” P17 SST DLC3 CG C DTC B0131/64 TC C111726E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat outer belt assembly RH (front pretensioner squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–117 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0131/64 is not output. HINT: Codes other than DTC B0131/64 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH 2 CHECK FLOOR WIRE (FRONT PRETENSIONER SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A B Center Airbag Front Pretensioner Sensor Assembly Squib RH D C Tester connection Condition Specified condition P17-1 (PR+) - P17-2 (PR) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE Connector “C” P17 PR+ PR- RS C C111725E15 OK RS–118 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Center Airbag Front Pretensioner Sensor Assembly Squib RH DLC3 CG C DTC B0131/64 TC C110429E01 (a) Connect the connectors to the front seat outer belt assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–119 Short to GND in Front Pretensioner Squib RH Circuit B0132/61 DESCRIPTION The front pretensioner squib RH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly RH (front pretensioner squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0132/61 is recorded when a short to ground is detected in the front pretensioner squib RH circuit. DTC No. DTC Detecting Condition • B0132/61 • • Short circuit in front pretensioner squib RH wire harness (to ground) Front pretensioner squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat outer belt assembly RH (Front pretensioner squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-109. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–120 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PRETENSIONER SQUIB RH) D C Center Airbag Front Pretensioner Sensor Assembly Squib RH Connector “C” P17 SST DLC3 CG C DTC B0132/61 TC C111727E05 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat outer belt assembly RH (front pretensioner squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0132/61 is not output. HINT: Codes other than DTC B0132/61 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH Go to step 2 RS–121 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK FLOOR WIRE (FRONT PRETENSIONER SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A B Center Airbag Front Pretensioner Sensor Assembly Squib RH D C Tester connection Condition Specified condition P17-1 (PR+) - Body ground Always 1 MΩ or higher P17-2 (PR-) - Body ground Always 1 MΩ or higher NG Connector “C” REPAIR OR REPLACE FLOOR WIRE P17 PR+ C PR- C111725E15 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Pretensioner Squib RH DLC3 CG C Center Airbag Sensor Assembly DTC B0132/61 TC C110431E01 (a) Connect the connectors to the front seat outer belt assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–122 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Short to B+ in Front Pretensioner Squib RH Circuit B0133/62 DESCRIPTION The front pretensioner squib RH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly RH (front pretensioner squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0133/62 is recorded when a short to B+ is detected in the front pretensioner squib RH circuit. DTC No. DTC Detecting Condition • B0133/62 • • Short circuit in front pretensioner squib RH wire harness (to B+) Front pretensioner squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat outer belt assembly RH (Front pretensioner squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-109. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–123 CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PRETENSIONER SQUIB RH) D C Center Airbag Front Pretensioner Sensor Assembly Squib RH Connector “C” P17 SST DLC3 CG C DTC B0133/62 TC C111728E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the front seat outer belt assembly RH (front pretensioner squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0133/62 is not output. HINT: Codes other than DTC B0133/62 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH Go to step 2 RS RS–124 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (FRONT PRETENSIONER SQUIB RH CIRCUIT) Floor Wire A B Center Airbag Front Pretensioner Sensor Assembly Squib RH D C Connector “C” (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition P17-1 (PR+) - Body ground Ignition switch ON Below 1 V P17-2 (PR-) - Body ground Ignition switch ON Below 1 V P17 NG PR+ C REPAIR OR REPLACE FLOOR WIRE PR- C111725E15 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY RS DC Center Airbag Front Pretensioner Sensor Assembly Squib RH DLC3 CG C DTC B0133/62 TC C110433E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front seat outer belt assembly and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–125 OK USE SIMULATION METHOD TO CHECK RS RS–126 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0135/73 Short in Front Pretensioner Squib LH Circuit DESCRIPTION The front pretensioner squib LH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly LH (front pretensioner squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0135/73 is recorded when a short circuit is detected in the front pretensioner squib LH circuit. DTC No. DTC Detecting Condition • B0135/73 • • Short circuit between PL+ wire harness and PLwire harness of front pretensioner squib LH Front pretensioner squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat outer belt assembly LH (Front pretensioner squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM Center Airbag Sensor Assembly P16 Front Pretensioner Squib LH 1 2 RS 2 8 A30 A31 PL+ (*1) (*2) 1 7 A30 A31 PL(*1) (*2) *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag H044104E06 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–127 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (FRONT PRETENSIONER SQUIB LH) D C Front Pretensioner Squib RH Center Airbag Sensor Assembly Connector "C" P16 SST DLC3 CG DTC B0135/73 TC C C109513E11 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat outer belt assembly LH (front pretensioner squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0135/73 is not output. HINT: Codes other than DTC B0135/73 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the floor wire No. 2. RS RS–128 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (d) Check that the floor wire No. 2 connector (on the front seat outer belt assembly LH side) is not damaged. OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 3 CHECK FLOOR WIRE NO. 2 (FRONT PRETENSIONER SQUIB LH) (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire No. 2 A D C B Front Pretensioner Squib LH Center Airbag Sensor Assembly P16 C RS PL- C111703E19 OK Condition Specified condition P16-1 (PL+) - P16-2 (PL) Always 1 MΩ or higher NG Connector “C” PL+ Tester connection REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–129 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Pretensioner Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0135/73 TC C110436E01 (a) Connect the connectors to the front seat outer belt assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0135/73 is not output. HINT: Codes other than DTC B0135/73 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–130 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0136/74 Open in Front Pretensioner Squib LH Circuit DESCRIPTION The front pretensioner squib LH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly LH (front pretensioner squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0136/74 is recorded when an open circuit is detected in the front pretensioner squib LH circuit. DTC No. DTC Detecting Condition • B0136/74 Open circuit in PL+ wire harness or PL- wire harness of front pretensioner squib LH Front pretensioner squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Front seat outer belt assembly LH (Front pretensioner squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-123. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (FRONT PRETENSIONER SQUIB LH) D C Front Pretensioner Squib LH Center Airbag Sensor Assembly RS Connector “C” P16 SST DLC3 CG C DTC B0136/74 TC C111729E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat outer belt assembly LH (front pretensioner squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–131 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B0136/74 is not output. HINT: Codes other than DTC B0136/74 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (FRONT PRETENSIONER SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire No. 2 A D C B Front Pretensioner Squib LH Center Airbag Sensor Assembly Tester connection Condition Specified condition P16-1 (PL+) - P16-2 (PL) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector “C” P16 PL+ PL- RS C C111703E19 OK RS–132 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Pretensioner Squib LH DLC3 CG C Center Airbag Sensor Assembly DTC B0136/74 TC C110438E01 (a) Connect the connectors to the front seat outer belt assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0136/74 is not output. HINT: Codes other than DTC B0136/74 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–133 Short to GND in Front Pretensioner Squib LH Circuit B0137/71 DESCRIPTION The front pretensioner squib LH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly LH (front pretensioner squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0137/71 is recorded when a short to ground is detected in the front pretensioner squib LH circuit. DTC No. DTC Detecting Condition • B0137/71 • • Short circuit in front pretensioner squib LH wire harness (to ground) Front pretensioner squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat outer belt assembly LH (Front pretensioner squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-123. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–134 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (FRONT PRETENSIONER SQUIB LH) D C Front Pretensioner Squib LH Center Airbag Sensor Assembly Connector “C” P16 SST DLC3 CG C DTC B0137/71 TC C111730E05 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat outer belt assembly LH (front pretensioner squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0135/73 is not output. HINT: Codes other than DTC B0135/73 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH Go to step 2 RS–135 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK FLOOR WIRE NO. 2 (FRONT PRETENSIONER SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire No. 2 A D C B Front Pretensioner Squib LH Center Airbag Sensor Assembly Tester connection Condition Specified condition P16-1 (PL+) - Body ground Always 1 MΩ or higher P16-2 (PL-) - Body ground Always 1 MΩ or higher NG Connector “C” REPAIR OR REPLACE FLOOR WIRE NO. 2 P16 PL+ C PL- C111703E19 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Pretensioner Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0137/71 TC C110440E01 (a) Connect the connectors to the front seat outer belt assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0137/71 is not output. HINT: Codes other than DTC B0137/71 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–30 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Terminal No. Terminal Symbol A32-23 GSW2 ECM Terminal Description A32-25 PAON Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) A32-26 -SL Front Airbag Sensor LH A32-27 E1 Ground A32-28 E2 Ground A34-3 FSR+ Occupant Classification ECU A34-5 PR+ Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) A34-6 PR- Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) A34-10 FSR- Occupant Classification ECU DIAGNOSIS SYSTEM CG SG 1. SIL CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E98 Symbols (Terminal No.) RS Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V HINT: If the display shows a communication error message when connecting the cable of the intelligent tester to the DLC3, turning the ignition switch to the ON position and operating the intelligent tester, there is a problem on the vehicle side or tool side. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. Vibrate Slightly Shake Slightly Vibrate Slightly 3. D025083E02 RS–31 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be simulated. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned to the ON position). (1) Slightly vibrate the part of the sensor considered to be the problem with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. FUNCTION OF SRS WARNING LIGHT (a) Primary check. (1) Turn the ignition switch to the LOCK position. After 2 seconds or more, turn the ignition switch to the ON position. The SRS warning light comes on for approximately 6 seconds and the diagnosis of the SRS airbag system (including the seat belt pretensioner and front passenger occupant classification system) is performed. HINT: If trouble is detected during the primary check, the SRS warning light remains on even after the primary check period (for approximately 6 seconds) has elapsed. (b) Constant check. (1) After the primary check, the center airbag sensor assembly constantly monitors the airbag system for trouble. HINT: If trouble is detected during the constant check, the center airbag sensor assembly functions as follows: • The SRS warning light comes on. RS RS–32 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • The SRS warning light goes off, and then comes on. This blinking pattern indicates a source voltage drop. The SRS warning light goes off 10 seconds after the source voltage returns to normal. (c) Review. (1) When the airbag system is normal: The SRS warning light comes on only for the primary check period (for approximately 6 seconds after the ignition switch is turned to the ON position). (2) When the airbag system has trouble: • The SRS warning light remains on even after the primary check period has elapsed. • The SRS warning light goes off after the primary check, but comes on again during the constant check. • The SRS warning light does not come on when turning the Ignition switch from the LOCK to the ON position. HINT: The center airbag sensor assembly keeps the SRS warning light on if the airbag has been deployed. 4. RS C093955E02 5. Condition Vacant SRS WARNING LIGHT CHECK (a) Turn the ignition switch to the ON position, and check that the SRS warning light comes on for approximately 6 seconds (primary check). (b) Check that the SRS warning light goes off approximately 6 seconds after the ignition switch is turned to the ON position (constant check). HINT: When any of the following symptoms occur, refer to the "Problem Symptoms Table" (See page RS-24). • The SRS warning light comes on occasionally, after the primary check period has elapsed. • The SRS warning light comes on, but a DTC is not output. • When the ignition switch is turned to ON position, the SRS warning light does not come on. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check (1) Turn the ignition switch to the ON position. (2) The passenger airbag ON/OFF indicator comes on for approximately 4 seconds, then goes off for approximately 2 seconds. (3) Approximately 6 seconds after the ignition switch is turned to the ON position, the passenger airbag ON/OFF indicator will be ON/ OFF depending on the conditions listed below. "ON" indicator "OFF" indicator OFF OFF RS–33 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Condition "ON" indicator "OFF" indicator ON OFF Adult is seated. Child is seated. OFF ON Child restraint system is set. OFF ON Front passenger occupant classification failure OFF ON HINT: • The passenger airbag ON/OFF indicator is based on the timing chart below in order to check the indicator light circuit. ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) 2 sec. 4 sec. 2 sec. ON OFF Passenger Airbag ON/OFF Indicator (”OFF”) 4 sec. ON OFF ON/OFF condition depends on the front passenger detection results. H043700E01 • When the front passenger occupant classification system has trouble, both the SRS warning light and the passenger airbag ON/OFF indicator come on. In this case, check the DTCs in the "AIRBAG SYSTEM" first. Then troubleshoot the occupant classification system if DTC B1150/23 is detected, and troubleshoot the passenger airbag ON/OFF indicator if DTC B1152/28 is detected. 6. H045951 PASSENGER AIRBAG ON/OFF INDICATOR CHECK (a) Turn the ignition switch to the ON position. (b) Check that the passenger airbag ON/OFF indicator ("ON" and "OFF") comes on for approximately 4 seconds, then goes off for approximately 2 seconds. HINT: Refer to the table in the previous step regarding the passenger airbag ON/ OFF indicator when the ignition switch is turned to the ON position and approximately 6 seconds pass. RS RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7. RS ACTIVATION PREVENTION MECHANISM (a) FUNCTION OF ACTIVATION PREVENTION MECHANISM (1) An activation prevention mechanism is built into the connector (on the center airbag sensor assembly side) of the airbag system squib circuit to prevent accidental airbag activation. (2) This mechanism closes the circuit when the connector is disconnected by bringing the short spring into contact with the terminals and shutting off external electricity to prevent accidental airbag activation. (b) RELEASE METHOD OF ACTIVATION PREVENTION MECHANISM (1) To release the activation prevention mechanism, insert a piece of paper with the same thickness as the male terminal (approximately 0.5 mm (0.020 in.)) between the terminals and the short spring to break the connection. (2) Refer to the illustrations on the next 2 pages for connectors used in the activation prevention mechanism and its release method. CAUTION: Never release the activation prevention mechanism on the squib connector even when inspecting with the squib disconnected. NOTICE: • Do not release the activation prevention mechanism unless specially directed by the troubleshooting procedure. • To prevent the terminal and the short spring from becoming damaged, always use a piece of paper with the same thickness as the male terminal. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 35 15 Occupant Classification ECU Curtain Shield Airbag Assembly RH (Curtain Shield Squib RH) (*1) 33 16 RS–35 36 34 9 Front Seat Outer Belt Assembly RH (Front Pretensioner Squib RH) 31 Rear Airbag Sensor RH 10 32 7 Front Seat Side Airbag Assembly RH (Side Squib RH) (*1) 29 Side Airbag Sensor RH 8 30 5 13 6 Front Airbag Sensor RH Front Passenger Airbag Assembly (Front Passenger Side Squib) 21 14 22 3 Curtain Shield Airbag Cutoff Switch (*1) 25 4 Center Airbag Sensor Assembly 26 1 23 3 2 Combination Meter Assembly 24 Air Conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) 27 4 5 28 13 6 Front Airbag Sensor LH 14 Spiral Cable 19 18 7 RS 17 Side Airbag Sensor LH Steering Pad (Driver Side Squib) 20 Front Seat Side Airbag Assembly LH (Side Squib LH) (*1) 29 8 9 30 Rear Airbag Sensor LH 11 *1: with Side and Curtain Shield Airbag Seat Position Sensor/Front Seat Inner Belt Assembly LH Front Seat Outer Belt Assembly LH (Front Pretensioner Squib LH) 31 10 32 33 12 34 Curtain Shield Airbag Assembly LH (Curtain Shield Squib LH) (*1) C123754E01 RS–36 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM without Side and Curtain Shield Airbag: Center Airbag Sensor Assembly 4 2 After Release Before Release 4 Paper Paper Short Spring Short Spring Short Spring Short Spring Short Spring with Side and Curtain Shield Airbag: Center Airbag Sensor Assembly 4 2 After Release Before Release 4 Paper Paper Short Spring Short Spring Short Spring Short Spring After Release Before Release Connector 18 Short Spring Short Spring Short Spring Paper Paper RS Short Spring After Release Before Release Connector 30 Short Spring Short Spring Paper Paper Short Spring C111742E05 RS–136 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Short to B+ in Front Pretensioner Squib LH Circuit B0138/72 DESCRIPTION The front pretensioner squib LH circuit consists of the center airbag sensor assembly and the front seat outer belt assembly LH (front pretensioner squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0138/72 is recorded when a short to B+ is detected in the front pretensioner squib LH circuit. DTC No. DTC Detecting Condition • B0138/72 • • Short circuit in front pretensioner squib LH wire harness (to B+) Front pretensioner squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front seat outer belt assembly LH (Front pretensioner squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-123. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–137 CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (FRONT PRETENSIONER SQUIB LH) D C Front Pretensioner Squib LH Center Airbag Sensor Assembly Connector “C” P16 SST DLC3 CG C DTC B0138/72 TC C111731E05 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the front seat outer belt assembly LH (front pretensioner squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0138/72 is not output. HINT: Codes other than DTC B0138/72 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH Go to step 2 RS RS–138 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (FRONT PRETENSIONER SQUIB LH CIRCUIT) Floor Wire No. 2 A D C B Front Pretensioner Squib LH Center Airbag Sensor Assembly Connector “C” P16 PL+ C (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition P16-1 (PL+) - Body ground Ignition switch ON Below 1 V P16-2 (PL-) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO. 2 PL- C111703E19 OK 3 RS CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Pretensioner Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B0138/72 TC C110442E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front seat outer belt assembly LH and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0138/72 is not output. HINT: Codes other than DTC B0138/72 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–139 OK USE SIMULATION METHOD TO CHECK RS RS–140 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1100/31 Center Airbag Sensor Assembly Malfunction DESCRIPTION The center airbag sensor assembly circuit consists of the center airbag sensor assembly, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when a malfunction is detected in the center airbag sensor assembly circuit. DTC No. DTC Detecting Condition • • • • • • • B1100/31 Short in front airbag sensor RH circuit (to ground) Short in front airbag sensor RH circuit (to B+) Short in front airbag sensor RH circuit Short in front airbag sensor LH circuit (to ground) Short in front airbag sensor LH circuit (to B+) Short in front airbag sensor LH circuit Center airbag sensor assembly malfunction Trouble Area • • • Center airbag sensor assembly Engine room main wire Instrument panel wire HINT: When a trouble code is displayed simultaneously with B1100/31, repair the malfunction indicated by this code (except B1100/31) first. WIRING DIAGRAM A15 Front Airbag Sensor RH +SR -SR RS 2 1 Center Airbag Sensor Assembly 2 IN2 1 IN2 9 A32 +SR 20 A32 -SR A14 Front Airbag Sensor LH +SL 2 -SL C 1 2 IC1 1 IC1 15 A32 +SL 26 A32 -SL C111743E09 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–141 INSPECTION PROCEDURE 1 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT TO GROUND) F A E DC Front Airbag Sensor RH B Center Airbag Sensor Assembly Connector “E” A15 -SR +SR C C123608E35 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front airbag sensor RH and the center airbag sensor assembly. (d) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A15-2 (+SR) - Body ground Always 1 MΩ or higher A15-1 (-SR) - Body ground Always 1 MΩ or higher NG Go to step 8 OK 2 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT TO B+) F A E Front Airbag Sensor RH DC B Center Airbag Sensor Assembly Connector “E” (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A15-2 (+SR) - Body ground Ignition switch ON Below 1 V A15-1 (-SR) - Body ground Ignition switch ON Below 1 V A15 -SR C NG +SR C123608E35 OK Go to step 9 RS RS–142 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT) F A E DC Front Airbag Sensor RH B Center Airbag Sensor Assembly Connector “E” Tester connection Condition Specified condition A15-2 (+SR) - A15-1 (SR) Always 1 MΩ or higher NG A15 -SR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance Go to step 10 +SR C C123608E35 OK 4 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (SHORT TO GROUND) F A E Front Airbag Sensor LH RS (a) Disconnect the connector from the front airbag sensor LH. (b) Measure the resistance according to the value(s) in the table below. Resistance DC B Center Airbag Sensor Assembly Connector “E” A14 -SL C Condition Specified condition A14-2 (+SL) - Body ground Always 1 MΩ or higher A14-1 (-SL) - Body ground Always 1 MΩ or higher NG +SL C123608E36 OK Tester connection Go to step 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–143 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (SHORT TO B+) F A E DC Front Airbag Sensor LH B Center Airbag Sensor Assembly Connector “E” (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A14-2 (+SL) - Body ground Always Below 1 V A14-1 (-SL) - Body ground Always Below 1 V A14 -SL NG +SL C Go to step 12 C123608E36 OK 6 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (SHORT) F A E Front Airbag Sensor LH DC B Center Airbag Sensor Assembly Connector “E” C +SL C123608E36 OK Tester connection Condition Specified condition A14-2 (+SL) - A14-1 (SL) Always 1 MΩ or higher NG A14 -SL (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance RS Go to step 13 RS–144 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DTC B1100/31 DLC3 CG TC H041086E06 (a) Connect the connectors to the center airbag sensor assembly, front airbag sensors RH and LH. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1100/31 is not output. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK 8 CHECK ENGINE ROOM MAIN WIRE (SHORT TO GROUND) Instrument Panel Wire RS A F E Front Airbag Sensor RH D C B Center Airbag Sensor Assembly Engine Room Main Wire (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A15-2 (+SR) - Body ground Always 1 MΩ or higher A15-1 (-SR) - Body ground Always 1 MΩ or higher NG Connector “E” A15 -SR C +SR C123609E26 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 RS–145 CHECK ENGINE ROOM MAIN WIRE (SHORT TO B+) Instrument Panel Wire A F E Front Airbag Sensor RH D C B Center Airbag Sensor Assembly Engine Room Main Wire Connector “E” (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the engine room main wire connector from the instrument panel wire. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A15-2 (+SR) - Body ground Ignition switch ON Below 1 V A15-1 (-SR) - Body ground Ignition switch ON Below 1 V A15 -SR C NG +SR REPAIR OR REPLACE ENGINE ROOM MAIN WIRE C123609E26 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–146 10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK ENGINE ROOM MAIN WIRE (SHORT) Instrument Panel Wire A F E Front Airbag Sensor RH D C B Center Airbag Sensor Assembly (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A15-2 (+SR) - A15-1 (SR) Always 1 MΩ or higher NG Engine Room Main Wire Connector “E” A15 -SR C +SR C123609E26 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 11 RS–147 CHECK ENGINE ROOM MAIN WIRE (SHORT TO GROUND) Instrument Panel Wire A F E Front Airbag Sensor LH D C B Center Airbag Sensor Assembly Engine Room Main Wire (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A14-2 (+SL) - Body ground Always 1 MΩ or higher A14-1 (-SL) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE Connector “E” A14 -SL C +SL C123609E27 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–148 12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK ENGINE ROOM MAIN WIRE (SHORT TO B+) Instrument Panel Wire A F E Front Airbag Sensor LH D C B Center Airbag Sensor Assembly Engine Room Main Wire Connector “E” (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the engine room main wire connector from the instrument panel wire. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A14-2 (+SL) - Body ground Ignition switch ON Below 1 V A14-1 (-SL) - Body ground Ignition switch ON Below 1 V A14 -SL C NG +SL C123609E27 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13 RS–149 CHECK ENGINE ROOM MAIN WIRE (SHORT) Instrument Panel Wire A F E Front Airbag Sensor LH D C B Center Airbag Sensor Assembly (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A14-2 (+SL) - A14-1 (SL) Always 1 MΩ or higher NG Engine Room Main Wire REPAIR OR REPLACE ENGINE ROOM MAIN WIRE Connector “E” A14 -SL C +SL C123609E27 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–386 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD STEERING PAD SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS “TORX” SCREW “TORX” SCREW 8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf) STEERING COLUMN COVER UPPER STEERING WHEEL ASSEMBLY SPIRAL CABLE RS STEERING WHEEL COVER LOWER NO.3 STEERING WHEEL COVER LOWER NO.2 STEERING COLUMN COVER LOWER STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque C C131315E03 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–387 ON-VEHICLE INSPECTION 1. INSPECT STEERING PAD (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). (b) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. 2. H042163 INSPECT STEERING PAD (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28 ). (b) With the steering pad removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad or steering wheel assembly with a new one: • Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. • Cracks or other damage to the connectors. • Deformation of the steering wheel assembly. • Deformation of the horn button contact plate of the steering pad. • There should be no interference between the steering pad and steering wheel assembly, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel assembly. CAUTION: Be sure to follow the correct removal and installation procedures. Horn Button Contact Plate C123766E01 RS RS–150 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Half Connection in Center Airbag Sensor Assembly Connectors B1135/24 DESCRIPTION The center airbag sensor assembly connector has a mechanism that electrically detects half connection. The center airbag sensor assembly monitors the voltage applied to the disconnection detection pins and detects half connection. DTC B1135/24 is recorded when the center airbag sensor assembly detects an open circuit in the electrical connection check mechanism of the airbag sensor connector or in the airbag sensor circuit. DTC No. DTC Detecting Condition • B1135/24 • Malfunction of electrical connection check mechanism of center airbag sensor assembly connector Center airbag sensor assembly malfunction Trouble Area • • Electrical connection check mechanism Center airbag sensor assembly INSPECTION PROCEDURE 1 CHECK CENTER AIRBAG SENSOR ASSEMBLY CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check the connection of the center airbag sensor assembly connectors. OK: The connectors are connected. HINT: When the connectors are not firmly connected, disconnect them once and reconnect them securely. NEXT RS 2 CHECK CENTER AIRBAG SENSOR ASSEMBLY Center Airbag Sensor Assembly DLC3 CG C DTC B1135/24 TC C110445E01 (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (c) Clear the DTCs stored in memory (See page RS-35). (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Check the DTCs (See page RS-35). OK: DTC B1135/24 is not output. HINT: Codes other than code B1135/24 may be output at this time, but they are not related to this check. NG Go to step 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–151 OK END 3 PERFORM VISUAL CHECK OF DISCONNECTION DETECTION PIN without Side and Curtain Shield Airbag: Disconnection Detection Pin with Side and Curtain Shield Airbag: (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the center airbag sensor assembly. (d) Check the disconnection detection pin of the connector. HINT: Compare one connector with the other 2 connectors. OK: No deformation is identified. NG REPAIR OR REPLACE CENTER AIRBAG SENSOR ASSEMBLY CONNECTOR Disconnection Detection Pin C C111732E05 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–152 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1140/32 Side Airbag Sensor Assembly RH Circuit Malfunction DESCRIPTION The side airbag sensor assembly RH circuit consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1140/32 is recorded when a malfunction in the side airbag sensor assembly RH circuit is detected. DTC No. DTC Detecting Condition • B1140/32 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the side airbag sensor assembly RH circuit for 2 seconds. Side airbag sensor assembly RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Side airbag sensor assembly RH Center airbag sensor assembly Floor wire WIRING DIAGRAM S17 Side Airbag Sensor Assembly RH ESR RS VUPR SSR- SSR+ 1 Center Airbag Sensor Assembly 15 A33 ESR 17 A33 VUPR 4 2 13 A33 SSR- 16 A33 SSR+ 3 H043054E25 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–153 INSPECTION PROCEDURE 1 CHECK DTC Center Airbag Side Airbag Sensor Assembly Sensor Assembly RH DLC3 DTC B1140/32 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not related to this check. NG CG C Go to step 2 TC C110446E02 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor assembly RH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–154 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire D A C B Center airbag Sensor Assembly Side Airbag Sensor Assembly RH Connector “C” Connector “B” A33 S17 VUPR Tester connection Condition Specified condition S17-4 (VUPR) - S17-1 (ESR) Always Below 1 Ω ESR VUPR ESR Service Wire C C110451E08 Floor Wire D A C B Side Airbag Sensor Assembly RH RS (a) Disconnect the connectors from the center airbag sensor assembly and the side airbag sensor assembly RH. (b) Using a service wire, connect A33-17 (VUPR) and A3315 (ESR) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance Center Airbag Sensor Assembly Connector “C” Connector “B” S17 A33 SSR+ SSR- Service Wire C C110450E08 OK Tester connection Condition Specified condition S17-3 (SSR+) - S17-2 (SSR-) Always Below 1 Ω NG SSR- SSR+ (d) Using a service wire, connect A33-16 (SSR+) and A3313 (SSR-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE RS–155 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK FLOOR WIRE (SHORT TO B+) Floor Wire A D C B Side Airbag Sensor Assembly RH Center Airbag Sensor Assembly (a) Disconnect the service wire from connector "B". (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition S17-4 (VUPR) - Body ground Ignition switch ON Below 1 V Connector “C” S17-1 (ESR) - Body ground Ignition switch ON Below 1 V S17 S17-3 (SSR+) - Body ground Ignition switch ON Below 1 V S17-2 (SSR-) - Body ground Ignition switch ON Below 1 V SSR+ SSR- VUPR ESR C NG REPAIR OR REPLACE FLOOR WIRE C109481E15 OK 5 CHECK FLOOR WIRE (SHORT TO GROUND) Floor Wire A D C B Side Airbag Sensor Assembly RH Center Airbag Sensor Assembly Connector “C” S17 SSR+ VUPR C SSR- Tester connection Condition Specified condition S17-4 (VUPR) - Body ground Always 1 MΩ or higher S17-1 (ESR) - Body ground Always 1 MΩ or higher S17-3 (SSR+) - Body ground Always 1 MΩ or higher S17-2 (SSR-) - Body ground Always 1 MΩ or higher NG ESR C109481E15 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE RS RS–156 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Floor Wire A D C B Side Airbag Sensor Assembly RH Center Airbag Sensor Assembly Tester connection Condition Specified condition S17-4 (VUPR) - S17-1 (ESR) Always 1 MΩ or Higher S17-3 (SSR+) - S17-2 (SSR-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE Connector “C” S17 SSR+ VUPR SSR- ESR C C109481E15 OK 7 CHECK SIDE AIRBAG SENSOR ASSEMBLY RH RS Center Airbag Side Airbag Sensor Assembly Sensor Assembly LH DTC B1140/32 DLC3 DTC B1141/33 CG C TC (a) Connect the connector to the center airbag sensor assembly. (b) Interchange the side airbag sensor assembly RH with LH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (See page RS-35). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (See page RS-35). Result C110449E02 NG:A Proceed To Display (DTC Output) NG: A DTC B1140/32 is output. NG: B DTC B1141/33 is output. OK DTC B1140/32 and B1141/33 are not output. REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B RS–157 REPLACE SIDE AIRBAG SENSOR ASSEMBLY RH OK USE SIMULATION METHOD TO CHECK RS RS–158 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1141/33 Side Airbag Sensor Assembly LH Circuit Malfunction DESCRIPTION The side airbag sensor assembly LH circuit consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1141/33 is recorded when a malfunction in the side airbag sensor assembly LH circuit is detected. DTC No. DTC Detecting Condition • B1141/33 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the side airbag sensor assembly RH circuit for 2 seconds. Side airbag sensor assembly LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Side airbag sensor assembly LH Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM S16 Side Airbag Sensor Assembly LH ESL RS VUPL SSL- SSL+ 1 Center Airbag Sensor Assembly 18 A30 ESL 16 A30 VUPL 4 2 20 A30 SSL- 17 A30 SSL+ 3 H043054E26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–159 INSPECTION PROCEDURE 1 CHECK DTC Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly DLC3 DTC B1141/33 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not related to this check. NG CG C Go to step 2 TC C110453E02 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the side airbag sensor assembly LH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–160 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 D A C B Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly Connector “C” Connector “B” S16 VUPL C Specified condition S16-4 (VUPL) - S16-1 (ESL) Always Below 1 Ω VUPL C110448E09 Floor Wire No. 2 D A C B Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly RS Connector “C” Connector “B” S16 A30 SSL- SSL- (d) Using a service wire, connect A30-17 (SSL+) and A3020 (SSL-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition S16-3 (SSL+) - S16-2 (SSL-) Always Below 1 Ω NG SSL+ Service Wire C110447E09 OK Condition ESL ESL C Tester connection A30 Service Wire SSL+ (a) Disconnect the connectors from the center airbag sensor assembly and the front airbag sensor assembly LH. (b) Using a service wire, connect A30-16 (VUPL) and A3018 (ESL) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–161 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Floor Wire No. 2 A D C B Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly (a) Disconnect the service wire from connector "B". (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition S16-4 (VUPL) - Body ground Always Below 1 V Connector “C” S16-1 (ESL) - Body ground Always Below 1 V S16 S16-3 (SSL+) - Body ground Always Below 1 V S16-2 (SSL-) - Body ground Always Below 1 V SSL+ SSL- VUPL ESL NG C REPAIR OR REPLACE FLOOR WIRE NO. 2 C109479E18 OK 5 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Floor Wire No. 2 A D C B Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly Connector “C” S16 SSL+ VUPL C SSL- Tester connection Condition Specified condition S16-4 (VUPL) - Body ground Always 1 MΩ or higher S16-1 (ESL) - Body ground Always 1 MΩ or higher S16-3 (SSL+) - Body ground Always 1 MΩ or higher S16-2 (SSL-) - Body ground Always 1 MΩ or higher NG ESL C109479E18 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–162 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT) Floor Wire No. 2 A D C B Side Airbag Sensor Assembly LH Center Airbag Sensor Assembly (a) Measure the resistance according to the value(s) in the table below. Standard Tester connection Condition Specified condition S16-4 (VUPL) - S16-1 (ESL) Always 1 MΩ or Higher S16-3 (SSL+) - S16-2 (SSL-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector “C” S16 SSL+ VUPL SSLESL C C109479E18 OK 7 RS CHECK SIDE AIRBAG SENSOR ASSEMBLY LH Side Airbag Sensor Assembly RH Center Airbag Sensor Assembly DTC B1140/32 DLC3 DTC B1141/33 CG C TC (a) Connect the connector to the center airbag sensor assembly. (b) Interchange the side airbag sensor assembly RH with LH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (See page RS-35). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (See page RS-35). Result C110452E02 NG:A Proceed To Display (DTC Output) NG: A DTC B1140/32 is output. NG: B DTC B1141/33 is output. OK DTC B1140/32 and B1141/33 are not output. REPLACE SIDE AIRBAG SENSOR ASSEMBLY LH SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B RS–163 REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–164 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1148/36 Front Airbag Sensor RH Circuit Malfunction DESCRIPTION The front airbag sensor RH circuit consists of the diagnosis circuit and the frontal deceleration sensor, etc. If the center airbag sensor assembly receives signals from the frontal deceleration sensor, it judges whether or not the SRS should be activated. DTC B1148/36 is recorded when a malfunction is detected in the front airbag sensor RH circuit. DTC No. DTC Detecting Condition • B1148/36 • • Open circuit in +SR wire harness or -SR wire harness of front airbag sensor RH circuit Front airbag sensor RH sensor malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Front airbag sensor RH Center airbag sensor assembly Engine room main wire Instrument panel wire WIRING DIAGRAM A15 Front Airbag Sensor RH +SR -SR RS 2 1 Center Airbag Sensor Assembly 2 IN2 9 A32 +SR 1 IN2 20 A32 -SR H002750E36 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–165 INSPECTION PROCEDURE 1 CHECK FRONT AIRBAG SENSOR RH DC Front Airbag Sensor RH DLC3 CG C Center Airbag Sensor Assembly DTC B1148/36 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1148/36 is not output. HINT: Codes other than code B1148/36 may be output at this time, but they are not related to this check. NG TC Go to step 2 C110454E01 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the front airbag sensor RH. OK: The connectors are connected. NG OK CONNECTOR CONNECTORS, THEN GO TO STEP 1 RS RS–166 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR RH CIRCUIT (OPEN) A F E D C Front Airbag Sensor RH B Center Airbag Sensor Assembly Connector “E” Connector “B” A15 A32 (a) Disconnect the connectors from the center airbag sensor assembly and the front airbag sensor RH. (b) Using a service wire, connect A32-9 (+SR) and A32-20 (SR) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A15-2 (+SR) - A15-1 (SR) Always Below 1 Ω +SR NG +SR -SR Go to step 5 -SR Service Wire C C123610E06 OK 4 RS CHECK FRONT AIRBAG SENSOR RH DC Front Airbag Sensor LH Center Airbag Sensor Assembly DTC B1148/36 DLC3 DTC B1149/37 C CG TC (a) Disconnect the service wire from connector "B". (b) Connect the connector to the center airbag sensor assembly. (c) Interchange the front airbag sensor RH with LH, and connect the connectors to them. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). Result C110456E02 NG:A Proceed To Display (DTC Output) NG: A DTC B1148/36 is output. NG: B DTC B1149/37 is output. OK DTC B1148/36 and B1149/37 are not output. REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B RS–167 REPLACE FRONT AIRBAG SENSOR RH OK USE SIMULATION METHOD TO CHECK 5 CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire F A E Front Airbag Sensor RH D C B Center Airbag Sensor Assembly Engine Room Main Wire Connector “C” +SR IN2 A32 Tester connection Condition Specified condition IN2-1 (+SR) - IN2-2 (-SR) Always Below 1 Ω NG Connector “B” -SR (a) Disconnect the instrument panel wire connector from the engine room main wire. HINT: The service wire has already been inserted into connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE INSTRUMENT PANEL WIRE +SR -SR Service Wire C C110457E07 OK RS REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS–168 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1149/37 Front Airbag Sensor LH Circuit Malfunction DESCRIPTION The front airbag sensor LH circuit consists of the diagnosis circuit and the frontal deceleration sensor, etc. If the center airbag sensor assembly receives signals from the frontal deceleration sensor, it judges whether or not the SRS should be activated. DTC B1149/37 is recorded when a malfunction is detected in the front airbag sensor LH circuit. DTC No. DTC Detecting Condition • B1149/37 • • Open circuit in +SL wire harness or -SL wire harness of front airbag sensor LH circuit Front airbag sensor LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Front airbag sensor LH Center airbag sensor assembly Engine room main wire Instrument panel wire WIRING DIAGRAM A14 Front Airbag Sensor LH +SL -SL RS 2 1 Center Airbag Sensor Assembly 2 IC1 15 A32 +SL 1 IC1 26 A32 -SL H002750E37 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–169 INSPECTION PROCEDURE 1 CHECK FRONT AIRBAG SENSOR LH DC Front Airbag Sensor LH DLC3 Center Airbag Sensor Assembly DTC B1149/37 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1149/37 is not output. HINT: Codes other than code B1149/37 may be output at this time, but they are not related to this check. NG CG C Go to step 2 TC C110458E01 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the front airbag sensor LH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP1 RS RS–170 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR LH CIRCUIT (OPEN) A F E D C Front Airbag Sensor LH B Center Airbag Sensor Assembly Connector “E” Connector “B” A32 A14 +SL (a) Disconnect the connectors from the center airbag sensor assembly and the front airbag sensor LH. (b) Using a service wire, connect A32-15 (+SL) and A32-26 (-SL) of connector "B". HINT: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A14-2 (+SL) - A14-1 (SL) Always Below 1 Ω NG Go to step 5 +SL -SL Service Wire C -SL C123611E05 OK 4 RS CHECK FRONT AIRBAG SENSOR LH DC Front Airbag Sensor RH Center Airbag Sensor Assembly DTC B1148/36 DLC3 DTC B1149/37 CG C TC (a) Disconnect the service wire from connector "B". (b) Connect the connector to the center airbag sensor assembly. (c) Interchange the side airbag sensor RH with LH and connect the connectors to them. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). Result C110456E01 NG:A Proceed To Display (DTC Output) NG: A DTC B1148/36 is output. NG: B DTC B1149/37 is output. OK DTC B1148/36 and B1149/37 are not output. REPLACE FRONT AIRBAG SENSOR LH RS–171 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK 5 CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire F A E Front Airbag Sensor LH D C B Center Airbag Sensor Assembly Engine Room Main Wire Connector “C” Connector “B” IC1 A32 -SL (a) Disconnect the instrument panel wire connector from the engine room main wire. HINT: The service wire has already been inserted into connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition IC1-2 (+SL) - IC1-1 (-SL) Always Below 1 Ω NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE +SL +SL SST -SL C C110460E06 OK REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–172 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1150/23 Occupant Classification System Malfunction DESCRIPTION The occupant classification system circuit consists of the center airbag sensor assembly and the occupant classification ECU. If the center airbag sensor assembly receives signals from the occupant classification ECU, it determines whether or not the front passenger airbag assembly and the front seat airbag assembly RH should be operated. DTC B1150/23 is recorded when a malfunction is detected in the occupant classification system circuit. DTC No. DTC Detecting Condition • B1150/23 • • The center airbag sensor assembly receives a line short signal, open signal, short to ground signal or B+ short signal in the occupant classification system circuit for 2 seconds. Occupant classification ECU malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Occupant classification ECU Center airbag sensor assembly Floor wire Seat wire No. 1 WIRING DIAGRAM Occupant Classification ECU Center Airbag Sensor Assembly 8 FSR+ O3 1 Bl1 3 1 A33 A34 FSR+ (*1) (*2) 4 O3 4 Bl1 2 10 A33 A34 FSR(*1) (*2) RS FSR- *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag C116312E02 INSPECTION PROCEDURE 1 CHECK DTC (OCCUPANT CLASSIFICATION ECU) (a) Turn the ignition switch to the ON position, and wait for at least 10 seconds. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–173 (b) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-300). OK: DTC is not output. NG GO TO OCCUPANT CLASSIFICATION SYSTEM OK 2 CHECK DTC (CENTER AIRBAG SENSOR ASSEMBLY) DC Occupant Classification ECU DLC3 Center Airbag Sensor Assembly DTC B1150/23 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1150/23 is not output. HINT: Codes other than code B1150/23 may be output at this time, but they are not related to this check. NG CG C Go to step 3 TC C110461E01 OK USE SIMULATION METHOD TO CHECK 3 RS CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the occupant classification ECU. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS–174 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT TO GROUND) F (a) Disconnect the connectors from the center airbag sensor assembly and the occupant classification ECU. (b) Measure the resistance according to the value(s) in the table below. Resistance A E DC Occupant Classification ECU B Center Airbag Sensor Assembly Tester connection Condition Specified condition O3-8 (FSR+) - Body ground Always 1 MΩ or higher O3-4 (FSR-) - Body ground Always 1 MΩ or higher NG Go to step 8 Connector “E” O3 FSR- FSR+ C C110462E30 OK 5 RS CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT TO B+) F E DC Occupant Classification ECU A B Center Airbag Sensor Assembly (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition O3-8 (FSR+) - Body ground Ignition switch ON Below 1 V O3-4 (FSR-) - Body ground Ignition switch ON Below 1 V NG Connector “E” O3 FSR- FSR+ C C110462E30 OK Go to step 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 RS–175 CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT) F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition O3-8 (FSR+) - O3-4 (FSR-) Always 1 MΩ or higher NG Go to step 10 Connector “E” O3 FSR- FSR+ C C110462E30 OK RS RS–176 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (OPEN) A E D C B Center Airbag Sensor Assembly Occupant Classification ECU Connector “B” F A33 (*1) Connector “E” FSR- O3 Service Wire FSR- FSR+ A34 (*2) FSR+ *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag FSRC RS Service Wire C111721E12 OK Tester connection Condition Specified condition O3-8 (FSR+) - O3-4 (FSR-) Always Below 1 Ω NG 1 2 3 4 5 6 7 8 9 101112 FSR+ (a) with Side and curtain shield airbag: Using a service wire, connect A33-1 (FSR+) and A33-2 (FSR-) of connector "B". (b) without Side and curtain shield airbag: Using a service wire, connect A34-3 (FSR+) and A34-10 (FSR-) of connector "B". (c) Measure the resistance according to the value(s) in the table below. Resistance Go to step 11 RS–177 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8 CHECK FLOOR WIRE (SHORT TO GROUND) (a) Disconnect the floor wire connector from the seat wire No. 1. (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire Tester connection Condition Specified condition Bl1-1 (FSR+) - Body ground Always 1 MΩ or higher Bl1-4 (FSR-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector “C” Bl1 FSR+ FSRC C110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–178 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (SHORT TO B+) Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the floor wire connector from the seat wire No. 1. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Floor Wire Connector “C” Bl1 FSR+ C110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS Condition Specified condition Ignition switch ON Below 1 V Bl1-4 (FSR-) - Body ground Ignition switch ON Below 1 V NG FSRC Tester connection Bl1-1 (FSR+) - Body ground REPAIR OR REPLACE FLOOR WIRE RS–179 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 CHECK FLOOR WIRE (SHORT) (a) Disconnect the floor wire connector from the seat wire No. 1. (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Tester connection Condition Specified condition Bl1-1 (FSR+) -Bl1-4 (FSR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Floor Wire Connector “C” Bl1 FSR+ FSRC C110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–180 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Seat Wire No. 1 Floor Wire F A E D C B Occupant Classification ECU Center Airbag Sensor Assembly (a) Disconnect the floor wire connector from the seat wire No. 1. HINT: The service wire has already been inserted into connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance Connector “B” A33 (*1) Connector “C” FSR+ Bl1 FSR+ A34 (*2) FSR+ FSR*1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag FSRC Service Wire C111722E08 OK RS Condition Specified condition Always Below 1 Ω NG Service Wire FSR- Tester connection Bl1-1 (FSR+) - Bl1-4 (FSR-) REPAIR OR REPLACE SEAT WIRE NO. 1 REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1152/28 RS–181 Passenger Airbag ON/OFF Indicator Circuit Malfunction DESCRIPTION The passenger airbag ON/OFF indicator light circuit consists of the center airbag sensor assembly and passenger airbag ON/OFF indicator. This circuit indicates the operation condition of the front passenger airbag assembly, the front seat airbag assembly RH and front seat belt pretensioner RH. DTC B1152/28 is recorded when a malfunction is detected in the passenger airbag ON/OFF indicator circuit. DTC No. DTC Detecting Condition • B1152/28 • • The center airbag sensor assembly receives a line short signal, open signal, short to ground signal or B+ short signal in the passenger airbag ON/OFF indicator circuit for 2 seconds. Passenger airbag ON/OFF indicator malfunction Center airbag sensor assembly malfunction Trouble Area • • • Air conditioning control assembly (Passenger airbag ON/OFF indicator) Center airbag sensor assembly Instrument panel wire RS RS–182 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM D3 Air Conditioning Control Assembly PAON P-AB Center Airbag Sensor Assembly 25 A32 PAON 13 1 A32 P-AB 6 J20 J/C J25 J/C IG+ 2 A GND 7 B 3F Center J/B A I18 Ignition SW 2 AM1 H J7 J/C H A A Driver Side J/B 2 1C IG1 4 IG1 8 1J Engine Room R/B AM1 2 B 3F 2 2 ALT 1 2 1 2 27 A32 E1 2 28 A32 E2 A J24 J/C RS Battery II IJ IH H045967E01 INSPECTION PROCEDURE 1 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CONDITION (a) Turn the ignition switch to the ON position. (b) Check the passenger airbag ON/OFF indicator operation. HINT: Refer to the normal condition of the passenger airbag ON/OFF indicator (See page RS-28). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–183 ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) 2 sec. 4 sec. 2 sec. ON OFF Passenger Airbag ON/OFF Indicator (”OFF”) 4 sec. ON OFF ON/OFF condition depends on the front passenger detection results. H043700E01 Result ON/OFF Indicator Illumination Proceed to Always ON A OFF B B Go to step 10 A 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the air conditioning control assembly. OK: The connectors are connected. NG CONNECT CONNECTORS OK 3 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the air conditioning control assembly. (b) Check that the connectors (on the center airbag sensor assembly side and the air conditioning control assembly side) are not damaged. RS RS–184 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The connectors are not deformed or damaged. NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE OK 4 CHECK PASSENGER AIRBAG ON/OFF INDICATOR H045951 (a) Connect the connector to the air conditioning control assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Check the passenger airbag ON/OFF indicator operation. OK: The passenger airbag ON/OFF indicator ("ON" and "OFF") does not come on. NG Go to step 6 OK 5 RS CHECK CENTER AIRBAG SENSOR ASSEMBLY Passenger Airbag ON/OFF Indicator DLC3 Center Airbag Sensor Assembly DTC B1152/28 CG TC C C110466E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1152/28 is not output. HINT: Codes other than code B1152/28 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 RS–185 CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Connector “B” Connector “C” P-AB A32 P-AB D3 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the air conditioning control assembly. (d) Using a service wire, connect A32-1 (P-AB) and A32-25 (PAON) of connector "B". (e) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition D3-6 (P-AB) - D3-13 (PAON) Always Below 1 Ω NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE PAON Service Wire PAON C123759E01 OK 7 CHECK INSTRUMENT PANEL WIRE (SHORT) (a) Disconnect the SST from connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Connector “C” P-AB D3 PAON C123760E01 OK Tester connection Condition Specified condition D3-6 (P-AB) - D3-13 (PAON) Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–186 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Tester connection Condition Specified condition D3-6 (P-AB) - Body ground Always 1 MΩ or higher D3-13 (PAON) - Body ground Always 1 MΩ or higher NG Connector “C” P-AB REPAIR OR REPLACE INSTRUMENT PANEL WIRE D3 PAON C123760E01 OK 9 CHECK INSTRUMENT PANEL WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Instrument Panel Wire RS D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Tester connection Condition Specified condition D3-6 (P-AB) - Body ground Ignition switch ON Below 1 V D3-13 (PAON) - Body ground Ignition switch ON Below 1 V Connector “C” P-AB NG D3 PAON C123760E01 REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–187 OK REPLACE AIR CONDITIONING CONTROL ASSEMBLY 10 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the air conditioning control assembly. OK: The connectors are connected. NG CONNECT CONNECTORS OK 11 CHECK CONNECTORS (a) Disconnect the connectors from the center airbag sensor assembly and the air conditioning control assembly. (b) Check that the connectors (on the center airbag sensor assembly side and the air conditioning control assembly side) are not damaged. OK: The connectors are not deformed or damaged. NG OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–188 12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Connector “B” Connector “C” P-AB (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the telltale light assembly. (d) Using a service wire, connect A32-1 (P-AB) and A32-25 (PAON) of connector "B". (e) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition D3-6 (P-AB) - D3-13 (PAON) Always Below 1 Ω A32 P-AB D3 NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE PAON Service Wire PAON C123759E01 OK 13 CHECK INSTRUMENT PANEL WIRE (SHORT) (a) Disconnect the service wire from connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire RS D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Connector “C” P-AB D3 PAON C123760E01 OK Tester connection Condition Specified condition D3-6 (P-AB) - D3-13 (PAON) Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 14 RS–189 CHECK INSTRUMENT PANEL WIRE (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Tester connection Condition Specified condition D3-6 (P-AB) - Body ground Always 1 MΩ or higher D3-13 (PAON) - Body ground Always 1 MΩ or higher NG Connector “C” P-AB REPAIR OR REPLACE INSTRUMENT PANEL WIRE D3 PAON C123760E01 OK 15 CHECK INSTRUMENT PANEL WIRE (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Instrument Panel Wire D A C Air Conditioning Control Assembly B Center Airbag Sensor Assembly Tester connection Condition Specified condition D3-6 (P-AB) - Body ground Ignition switch ON Below 1 V D3-13 (PAON) - Body ground Ignition switch ON Below 1 V Connector “C” P-AB NG D3 PAON C123760E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–190 16 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK AIR CONDITIONING CONTROL ASSEMBLY (POWER SOURCE) Air Conditioning Control Assembly Side: (a) Turn the ignition switch to the ON position. (b) Measure the voltage and resistance according to the value(s) in the table below. Voltage and Resistance D3 IG+ GND Tester connection Condition Specified condition D3-2 (IG+) - Body ground Ignition switch ON 10 to 14 V D3-7 (GND) - Body ground Always 1 MΩ or higher H045953E01 NG REPAIR OR REPLACE WIRE HARNESS (AIR CONDITIONING CONTROL ASSEMBLY BATTERY) OR BATTERY OK 17 CHECK PASSENGER AIRBAG ON/OFF INDICATOR A32 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the telltale light assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Check the passenger airbag ON/OFF indicator condition. Result P-AB PAON H040065E24 RS Tester connection Condition Passenger airbag ON/ OFF indicator condition A32-25 (PAON) - Body ground Ignition switch ON "ON" comes on A32-1 (P-AB) - Body ground Ignition switch ON "OFF" comes on NG OK REPLACE AIR CONDITIONING CONTROL ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 18 RS–191 CHECK CENTER AIRBAG SENSOR ASSEMBLY Passenger Airbag ON/OFF Indicator DLC3 Center Airbag Sensor Assembly DTC B1152/28 CG TC C C110466E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1152/28 is not output. HINT: Codes other than code B1152/28 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–192 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1153/25 Seat Position Airbag Sensor Circuit Malfunction DESCRIPTION The seat position airbag sensor circuit consists of the center airbag sensor assembly and the seat position airbag sensor. DTC B1153/25 is recorded when a malfunction is detected in the seat position airbag sensor circuit. DTC No. DTC Detecting Condition B1153/25 When one of the following conditions is met: • The center airbag sensor assembly detects a line short signal, open signal, short to ground signal, or short to B+ signal in the seat position airbag sensor circuit. • Seat position airbag sensor malfunction • Center airbag sensor assembly malfunction Trouble Area • • • • Seat position airbag sensor Center airbag sensor assembly Front seat inner belt assembly LH Floor wire No. 2 WIRING DIAGRAM 6 1 B12 3 4 A31 A30 LSP+ (*2) (*1) 2 5 B12 8 3 A31 A30 LSP- RS (*2) (*1) Front Seat Inner Belt Assembly LH Center Airbag Sensor Assembly Seat Position Airbag Sensor *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag C C145320E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–193 INSPECTION PROCEDURE 1 CHECK DTC A F DC Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 CG DTC B1153/25 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1153/25 is not output. HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. NG Go to step 2 TC C C145326E01 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTORS RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly, seat position airbag sensor and front seat inner belt assembly LH. OK: The connectors are properly connected. HINT: If the connectors are not connected securely, reconnect the connectors and proceed to the next inspection. (d) Disconnect the connectors from the center airbag sensor assembly, seat position airbag sensor and front seat inner belt assembly LH. (e) Check that the terminals of the connectors are not damaged. OK: The terminals are not deformed or damaged. RS–194 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPLACE WIRE HARNESS OK 3 CHECK SEAT POSITION AIRBAG SENSOR CIRCUIT (OPEN) F A E DC B Seat Position Airbag Sensor Center Airbag Sensor Assembly Connector E (*1) LSP- LSP+ Service Wire Connector B A31 (*2) LSP+ RS LSPService Wire C C145329E01 OK Tester Connection Condition Specified Condition 1-2 Always Below 1 Ω HINT: *1: with Side and curtain shield airbag *2: without Side and curtain shield airbag Connector B A30 (a) Using a service wire, connect terminals LSP+ and LSPof connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (b) Measure the resistance between the terminals of connector E according to the value(s) in the table below. Standard resistance NG Go to step 10 RS–195 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK SEAT POSITION AIRBAG SENSOR CIRCUIT (SHORT TO GROUND) (a) Disconnect the service wire from connector B. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A F E DC Seat Position Airbag Sensor B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition 1 - Body ground Always 1MΩ or higher 2 - Body ground Always 1MΩ or higher NG Go to step 11 Connector E C C145330E01 OK 5 CHECK SEAT POSITION AIRBAG SENSOR CIRCUIT (SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance E DC Seat Position Airbag Sensor Specified Condition Always 1MΩ or higher NG Center Airbag Sensor Assembly C145330E01 OK Condition 1-2 B Connector E C Tester Connection A F Go to step 12 RS RS–196 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK SEAT POSITION AIRBAG SENSOR CIRCUIT (SHORT TO B+) (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard voltage A F E DC Seat Position Airbag Sensor B Center Airbag Sensor Assembly Tester Connection Condition Specified Condition 1 - Body ground Ignition switch ON Below 1 V 2 - Body ground Ignition switch ON Below 1 V NG Go to step 13 Connector E C C145330E01 OK 7 RS CHECK SEAT POSITION AIRBAG SENSOR A F DC Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 CG C DTC B1153/25 TC C145326E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the seat position airbag sensor and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1153/25 is not output. HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. NG Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–197 OK USE SIMULATION METHOD TO CHECK 8 REPLACE SEAT POSITION AIRBAG SENSOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat position airbag sensor. (See page RS443). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 CHECK CENTER AIRBAG SENSOR ASSEMBLY A F DC Seat Position Airbag Sensor Center Airbag Sensor Assembly DLC3 DTC B1153/25 (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (c) Clear the DTCs stored in memory (See page RS-35). (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Check the DTCs (See page RS-35). OK: DTC B1153/25 is not output. HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. NG CG C TC C145326E01 OK END REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–198 10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Front Seat Inner Belt Assembly LH Floor Wire No. 2 F A E D C B Seat Position Airbag Sensor Center Airbag Sensor Assembly Connector C LSP+ A30 Tester Connection Condition Specified Condition B12-2 (LSP+) - B12-4 (LSP-) Always Below 1 Ω HINT: *1: with Side and curtain shield airbag *2: without Side and curtain shield airbag Connector B LSP+ (a) Disconnect the front seat inner belt assembly LH connector from the floor wire No. 2 connector. HINT: The service wire has already been inserted into connector B. (b) Measure the resistance of connector C according to the value(s) in the table below. Standard resistance NG REPLACE FLOOR WIRE NO. 2 LSP- (*1) B12 LSPService Wire Connector B A31 (*2) LSP+ Service Wire RS C LSPC145333E01 OK REPLACE FRONT SEAT INNER BELT ASSEMBLY LH RS–199 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 11 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) Front Seat Inner Belt Assembly LH Floor Wire No. 2 A F E DC B Seat Position Airbag Sensor Center Airbag Sensor Assembly (a) Disconnect the front seat inner belt assembly LH connector from the floor wire No. 2 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition B12-2 (LSP+) - Body ground Always 1MΩ or higher B12-4 (LSP-) - Body ground Always 1MΩ or higher NG Connector C REPLACE FLOOR WIRE NO. 2 B12 LSP+ LSPC C145334E01 OK REPLACE FRONT SEAT INNER BELT ASSEMBLY LH RS RS–200 12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT) Front Seat Inner Belt Assembly LH Floor Wire No. 2 A F E DC B Seat Position Airbag Sensor Center Airbag Sensor Assembly (a) Disconnect the front seat inner belt assembly LH connector from the floor wire No. 2 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition B12-2 (LSP+) - B12-4 (LSP-) Always 1MΩ or higher NG REPLACE FLOOR WIRE NO. 2 Connector C B12 LSP+ LSPC C145334E01 OK REPLACE FRONT SEAT INNER BELT ASSEMBLY LH RS RS–201 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) Front Seat Inner Belt Assembly LH Floor Wire No. 2 A F E DC B Seat Position Airbag Sensor Center Airbag Sensor Assembly Connector C B12 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the front seat inner belt assembly LH connector from the floor wire No. 2 connector. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition B12-2 (LSP+) - Body ground Ignition switch ON Below 1 V B12-4 (LSP-) - Body ground Ignition switch ON Below 1 V LSP+ NG REPLACE FLOOR WIRE NO. 2 LSPC C145334E01 OK REPLACE FRONT SEAT INNER BELT ASSEMBLY LH RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–37 DTC CHECK / CLEAR 1. CG 1 2 3 4 5 6 7 8 9 10 111213 141516 TC A082779E07 Normal System Code (w/o Past Trouble Code) 0.25 sec. ON OFF 0.25 sec. Normal System Code (w/ Past Trouble Code) 0.75 sec. ON OFF 0.25 sec. Trouble Code (Example Codes 11 and 31) 0.5 sec. 2.5 sec. 4.0 sec. ON OFF 1.5 sec. 0.5 sec. DTC 11 Repeat DTC 31 H013050E02 DTC CHECK (USING SST CHECK WIRE) (a) Check the DTCs (Present trouble code). (1) Turn the ignition switch ON, and wait for approximately 60 seconds. (2) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (b) Check the DTCs (Past trouble code). (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (2) Turn the ignition switch ON, and wait for approximately 60 seconds. (c) Read the DTCs. (1) Read the blinking patterns of the DTCs. As examples, the blinking patterns for the normal system code and trouble codes 11 and 31 are shown in the illustration. • Normal system code indication (without past trouble code) The light blinks twice per second. • Normal system code indication (with past trouble code) When the past trouble code is stored in the center airbag sensor assembly, the light blinks only once per second. • Trouble code indication The first two blinkings indicate the first DTC. The second blinking occurs after a 1.5second pause. If there are more than 1 code, there will be a 2.5second pause between each code. After all codes are shown, there will be a 4.0-second pause, and they all will be repeated. HINT: • If 2 or more malfunctions are found, the indication begins with the smaller numbered code. • If DTCs are indicated without connecting the terminals, proceed to the "TC and CG Terminal Circuit" (See page RS-284). RS RS–38 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. RS DTC CLEAR (USING SST CHECK WIRE) (a) Clear the DTCs. (1) When the ignition switch is turned off, the DTCs are cleared. HINT: Depending on the DTC, the code may not be cleared by turning off the ignition switch. In this case, proceed to the next procedure. (2) Using SST, connect terminals TC and CG of the DLC3, and then turn the ignition switch to the ON position. SST 09843-18040 (3) Disconnect terminal TC of the DLC3 within 3 to 10 seconds after the DTCs are output, and check if the SRS warning light comes on after 3 seconds. (4) Within 2 to 4 seconds after the SRS warning light comes on, connect terminals TC and CG of the DLC3. (5) The SRS warning light should go off within 2 to 4 seconds after connecting terminals TC and CG of the DLC3. Then, disconnect terminal TC within 2 to 4 seconds after the SRS warning light goes off. (6) The SRS warning light comes on again within 2 to 4 seconds after disconnecting terminal TC. Then, reconnect terminals TC and CG of the DLC3 within 2 to 4 seconds after the SRS warning light comes on. RS–39 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (7) Check if the SRS warning light goes off within 2 to 4 seconds after connecting terminals TC and CG of the DLC3. Also check if the normal system code is output within 1 second after the SRS warning light goes off. If DTCs are not cleared, repeat this procedure until the codes are cleared. ON Ignition Switch LOCK Open DLC3 (TC and CG) Short SRS Warning Light (*) 0.5 sec. 0.5 sec. 0.25 sec. 0.25 sec. ON OFF T1: 0 to ∞ sec. 1.5 sec. T2: approx. 6 sec. T3: 3 to 5 sec. T1 T4: 3 to 10 sec. T2 T3 T4 T5 T6 T5 T6 T5 T6 T5 T7 T5: 2 to 4 sec. T6: 1 to 5 sec. T7: within 1 sec. *: The past trouble code in the illustration shows DTC 21 as an example. C C109537E02 3. Intelligent Tester A066288E01 DTC CHECK (a) Check the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (b) Clear the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. RS RS–40 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK MODE PROCEDURE Intelligent Tester 1. A066288E01 RS CHECK MODE (SIGNAL CHECK): DTC CHECK (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Select the "SIGNAL CHECK", and proceed checking using the intelligent tester. NOTICE: Select the "SIGNAL CHECK" from the "DTC CHECK" screen displayed on the intelligent tester to clear the output DTCs (both present and past). HINT: • DTCs can be detected more sensitively in check mode than in normal diagnosis mode. • Perform check mode inspection when a malfunction in each squib circuit is suspected even after the normal system code is output through normal diagnosis mode inspection. RS–202 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1154/38 Rear Airbag Sensor RH Circuit Malfunction DESCRIPTION The rear airbag sensor RH circuit consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1154/38 is recorded when a malfunction in the rear airbag sensor RH circuit is detected. DTC No. DTC Detecting Condition • B1154/38 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the rear airbag sensor RH circuit for 2 seconds. Rear airbag sensor RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Rear airbag sensor RH Center airbag sensor assembly Floor wire WIRING DIAGRAM Center airbag Sensor assembly S19 Rear Airbag Sensor RH ESCR 1 VUCR 4 20 A33 ESCR 19 A33 VUCR RS CSR- 2 CSR+ 3 4 A33 CSR- 18 A33 CSR+ H043054E27 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–203 INSPECTION PROCEDURE 1 CHECK DTC Rear Airbag Sensor RH DLC3 Center Airbag Sensor Assembly DTC B1154/38 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1154/38 is not output. HINT: Codes other than code B1154/38 may be output at this time, but they are not related to this check. NG CG C Go to step 2 TC C111661E01 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the rear airbag sensor RH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–204 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire A D C B Rear Airbag Sensor RH Center Airbag Sensor Assembly Connector “C” Connector “B” S19 A33 (a) Disconnect the connectors from the center airbag sensor assembly and the rear airbag sensor RH. (b) Using a service wire, connect A33-19 (VUCR) and A3320 (ESCR) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition S19-4 (VUCR) - S19-1 (ESCR) Always Below 1 Ω ESCR Service Wire VUCR VUCR ESCR C C111713E08 Floor Wire A D C B Center Airbag Sensor Assembly Rear Airbag Sensor RH RS Connector “C” Connector “B” S19 A33 Service Wire C CSR- CSR+ C111714E08 OK Tester connection Condition Specified condition S19-3 (CSR+) - S19-2 (CSR-) Always Below 1 Ω NG CSR- CSR+ (d) Using a service wire, connect A33-18 (CSR+) and A33-4 (CSR-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE RS–205 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK FLOOR WIRE (SHORT TO B+) Floor Wire D A C Rear Airbag Sensor RH B Center Airbag Sensor Assembly Connector “C” S19 CSR+ CSR- VUCR ESCR C (a) Disconnect the service wire from connector "B". (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition S19-4 (VUCR) - Body ground Ignition switch ON Below 1 V S19-1 (ESCR) - Body ground Ignition switch ON Below 1 V S19-3 (CSR+) - Body ground Ignition switch ON Below 1 V S19-2 (CSR-) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE C109485E16 OK 5 CHECK FLOOR WIRE (SHORT TO GROUND) Floor Wire D A C Rear Airbag Sensor RH B Center Airbag Sensor Assembly Connector “C” CSR+ VUCR C S19 CSR- ESCR C109485E16 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition S19-4 (VUCR) - Body ground Always 1 MΩ or higher S19-1 (ESCR) - Body ground Always 1 MΩ or higher S19-3 (CSR+) - Body ground Always 1 MΩ or higher S19-2 (CSR-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE RS RS–206 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard Floor Wire D A C Rear Airbag Sensor RH B Center Airbag Sensor Assembly Tester connection Condition Specified condition S19-4 (VUCR) - S19-1 (ESCR) Always 1 MΩ or higher S19-3 (CSR+) - S19-2 (CSR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector “C” CSR+ VUCR S19 CSR- ESCR C C109485E16 OK 7 CHECK REAR AIRBAG SENSOR RH RS Rear Airbag Sensor LH Center Airbag Sensor Assembly DLC3 DTC B1154/38 CG TC (a) Connect the connector to the center airbag sensor assembly. (b) Interchange the rear airbag sensor LH with RH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (See page RS-35). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (See page RS-35). Result DTC B1155/39 C C111662E01 NG:A Proceed To Display (DTC Output) NG: A DTC B1154/38 is output. NG: B DTC B1155/39 is output. OK DTC B1154/38 and B1155/39 are not output. REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B RS–207 REPLACE REAR AIRBAG SENSOR RH OK USE SIMULATION METHOD TO CHECK RS RS–208 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1155/39 Rear Airbag Sensor LH Circuit Malfunction DESCRIPTION The rear airbag sensor LH circuit consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the center airbag sensor assembly receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1155/39 is recorded when a malfunction in the rear airbag sensor LH circuit is detected. DTC No. DTC Detecting Condition • B1155/39 • • The center airbag sensor assembly receives a line short circuit signal, an open circuit signal,, a short circuit to ground signal or a short circuit to B+ signal in the rear airbag sensor LH circuit for 2 seconds. Rear airbag sensor LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Rear airbag sensor LH Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM S18 Rear Airbag Sensor LH ESCL VUCL Center Airbag Sensor Assembly 1 4 13 A30 ESCL 14 A30 VUCL RS CSL- CSL+ 2 3 1 A30 CSL- 15 A30 CSL+ H043054E28 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–209 INSPECTION PROCEDURE 1 CHECK DTC Rear Airbag Sensor LH DLC3 Center Airbag Sensor Assembly DTC B1155/39 (a) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (b) Clear the DTCs stored in memory (See page RS-35). (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Check the DTCs (See page RS-35). OK: DTC B1155/39 is not output. HINT: Codes other than code B1155/39 may be output at this time, but they are not related to this check. NG C CG Go to step 2 TC C111663E01 OK USE SIMULATION METHOD TO CHECK 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and the rear airbag sensor LH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–210 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (OPEN) Floor Wire No. 2 D A C B Rear Airbag Sensor LH Center Airbag Sensor Assembly Connector “C” Connector “B” S18 A30 (a) Disconnect the connectors from the center airbag sensor assembly and the rear airbag sensor LH. (b) Using a service wire, connect A30-14 (VUCL) and A3013 (ESCL) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition S18-4 (VUCL) - S18-1 (ESCL) Always Below 1 Ω ESCL VUCL ESCL Service Wire VUCL C C111715E12 Floor Wire No. 2 D A C B Rear Airbag Sensor LH Center Airbag Sensor Assembly RS Connector “C” Connector “B” S18 A30 CSL- CSL+ CSL- OK CSL+ Tester connection Condition Specified condition S18-3 (CSL+) S18-2 (CSL-) Always Below 1 Ω NG Service Wire C (d) Using a service wire, connect A30-15 (CSL+) and A30-1 (CSL-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Resistance C111716E12 REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–211 CHECK FLOOR WIRE NO. 2 (SHORT TO B+) (a) Disconnect SST from connector "B". (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Floor Wire No. 2 A D C B Rear Airbag Sensor LH Center Airbag Sensor Assembly Connector “C” S18 CSL+ CSL- VUCL ESCL Tester connection Condition Specified condition S18-4 (VUCL) - Body ground Ignition switch ON Below 1 V S18-1 (ESCL) - Body ground Ignition switch ON Below 1 V S18-3 (CSL+) - Body ground Ignition switch ON Below 1 V S18-2 (CSL-) - Body ground Ignition switch ON Below 1 V NG C REPAIR OR REPLACE FLOOR WIRE NO. 2 C109483E16 OK 5 CHECK FLOOR WIRE NO. 2 (SHORT TO GROUND) (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire No. 2 A D C B Rear Airbag Sensor LH Center Airbag Sensor Assembly Connector “C” S18 C CSL+ CSL- VUCL ESCL Condition Specified condition Always 1 MΩ or higher S18-1 (ESCL) - Body ground Always 1 MΩ or higher S18-3 (CSL+) - Body ground Always 1 MΩ or higher S18-2 (CSL-) - Body ground Always 1 MΩ or higher NG C109483E16 OK Tester connection S18-4 (VUCL) - Body ground REPAIR OR REPLACE FLOOR WIRE NO. 2 RS RS–212 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE NO. 2 (SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard Floor Wire No. 2 A D C B Rear Airbag Sensor LH Center Airbag Sensor Assembly Tester connection Condition Specified condition S18-4 (VUCL) - S18-1 (ESCL) Always 1 MΩ or Higher S18-3 (CSL+) - S18-2 (CSL-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO. 2 Connector “C” S18 CSL+ CSL- VUCL ESCL C C109483E16 OK 7 RS CHECK REAR AIRBAG SENSOR LH Rear Airbag Sensor RH (a) Connect the connector to the center airbag sensor assembly. (b) Interchange the rear airbag sensor LH with RH and connect the connectors to them. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Clear the DTCs stored in memory (See page RS-35). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (See page RS-35). Result Center Airbag Sensor Assembly DLC3 DTC B1154/38 CG C TC DTC B1155/39 Proceed to C111664E01 NG: A NG: B OK NG:A Display (DTC output) DTC B1154/38 is output. DTC B1155/39 is output. DTC B1154/38 and B1155/39 are not output. REPLACE REAR AIRBAG SENSOR LH SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG:B RS–213 REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–397 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS “TORX” SCREW “TORX” SCREW 8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf) STEERING COLUMN COVER UPPER STEERING WHEEL ASSEMBLY SPIRAL CABLE 50 (510, 37) STEERING WHEEL COVER LOWER NO. 3 RS STEERING WHEEL COVER LOWER NO. 2 STEERING COLUMN COVER LOWER STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque C C131315E02 RS–398 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE REMOVAL H042177 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO. 3 (See page RS-387) 5. REMOVE STEERING WHEEL COVER LOWER NO. 2 (See page RS-388) 6. REMOVE STEERING PAD (See page RS-388) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-9) 8. REMOVE STEERING COLUMN COVER LOWER (a) Remove the 3 screws and steering column cover lower. 9. REMOVE STEERING COLUMN COVER UPPER (a) Remove the steering column cover upper. 10. REMOVE SPIRAL CABLE (a) Disconnect the connectors from the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Disengage the 4 claws and remove the spiral cable. RS H042178 RS–214 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1160/83 Short in Curtain Shield Squib RH Circuit DESCRIPTION The curtain shield squib RH circuit consists of the center airbag sensor assembly and the curtain airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1160/83 is recorded when a short circuit is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition • B1160/83 • • Short circuit between ICR+ wire harness and ICRwire harness of curtain shield squib RH Curtain shield squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Curtain shield airbag assembly RH (Curtain shield squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM Center Airbag Sensor Assembly C17 Curtain Shield Squib RH 1 RS 2 8 A33 ICR+ 7 A33 ICR- C128524E25 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent test. (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–215 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (CURTAIN SHIELD SQUIB RH) D C Curtain Shield Squib RH Center Airbag Sensor Assembly Connector “C” C17 DLC3 CG SST DTC B1630/83 TC C C111665E07 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the curtain shield airbag assembly RH (Curtain shield squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1160/83 is not output. HINT: Codes other than DTC B1160/83 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the floor wire. RS RS–216 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (d) Check that the floor wire connector (on the curtain shield airbag assembly RH side) is not damaged. OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 3 CHECK FLOOR WIRE (CURTAIN SHIELD SQUIB RH CIRCUIT) Floor Wire D C Curtain Shield Squib RH A B Center Airbag Sensor Assembly ICR- C17 C RS C111666E27 OK Tester connection Condition Specified condition C17-1 (ICR+) - C17-2 (ICR-) Always 1 MΩ or higher NG Connector “C” ICR+ (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–217 CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Curtain Shield Sensor Assembly Squib RH DLC3 CG C DTC B1160/83 TC C111667E01 (a) Connect the connectors to the curtain shield airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1160/83 is not output. HINT: Codes other than DTC B1160/83 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–218 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1161/84 Open in Curtain Shield Squib RH Circuit DESCRIPTION The curtain shield squib RH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1161/84 is recorded when an open circuit is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition • B1161/84 Open circuit in ICR+ wire harness or ICR- wire harness of curtain shield squib RH Curtain shield squib RH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Curtain shield airbag assembly RH (Curtain shield squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-211. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (CURTAIN SHIELD SQUIB RH) D C Curtain Shield Squib RH RS Center Airbag Sensor Assembly Connector “C” C17 DLC3 CG C SST DTC B1631/84 TC C111674E06 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the curtain shield airbag assembly RH (Curtain shield squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–219 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B1161/84 is not output. HINT: Codes other than DTC B1161/84 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH 2 CHECK FLOOR WIRE (CURTAIN SHIELD SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A D C Curtain Shield Squib RH B Center Airbag Sensor Assembly Tester connection Condition Specified condition C17-1 (ICR+) - C17-2 (ICR-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE Connector “C” ICR+ ICR- C17 RS C C111666E27 OK RS–220 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY D C Center Airbag Curtain Shield Sensor Assembly Squib RH DLC3 CG C DTC B1161/84 TC C111673E01 (a) Connect the connectors to the curtain shield airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1161/84 is not output. HINT: Codes other than DTC B1161/84 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–221 Short to GND in Curtain Shield Squib RH Circuit B1162/81 DESCRIPTION The curtain shield squib RH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1162/81 is recorded when a short to ground is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition • B1162/81 • • Short circuit in curtain shield squib RH wire harness (to ground) Curtain shield squib RH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Curtain shield airbag assembly RH (Curtain shield squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-211. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–222 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (CURTAIN SHIELD SQUIB RH) D C Curtain Shield Squib RH Center Airbag Sensor Assembly Connector “C” C17 DLC3 CG C SST DTC B1632/81 TC C111675E06 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the curtain shield airbag assembly RH (Curtain shield squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1162/81 is not output. HINT: Codes other than DTC B1162/81 may be output at this time, but they are not related to this check. NG OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH Go to step 2 RS–223 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK FLOOR WIRE (CURTAIN SHIELD SQUIB RH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Floor Wire A D C Curtain Shield Squib RH B Center Airbag Sensor Assembly Tester connection Condition Specified condition C17-1 (ICR+) - Body ground Always 1 MΩ or higher C17-2 (ICR-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector “C” ICR+ ICR- C17 C C111666E27 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib RH DLC3 CG C Center Airbag Sensor Assembly DTC B1162/81 TC C111676E01 (a) Connect the connectors to the curtain shield airbag assembly RH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1162/81 is not output. HINT: Codes other than DTC B1162/81 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–224 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1163/82 Short to B+ in Curtain Shield Squib RH Circuit DESCRIPTION The curtain shield squib RH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1163/82 is recorded when a short to B+ is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition • B1163/82 Short circuit in curtain shield squib RH wire harness (to B+) Curtain shield squib RH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Curtain shield airbag assembly RH (Curtain shield squib RH) Center airbag sensor assembly Floor wire WIRING DIAGRAM See page RS-211. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (CURTAIN SHIELD SQUIB RH) D C Curtain Shield Squib RH RS Center Airbag Sensor Assembly Connector “C” C17 DLC3 CG C SST DTC B1633/82 TC C111679E06 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire. CAUTION: Never connect a tester to the curtain shield airbag assembly RH (Curtain shield squib RH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS–225 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B1163/82 is not output. HINT: Codes other than DTC B1163/82 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH 2 CHECK FLOOR WIRE (CURTAIN SHIELD SQUIB RH CIRCUIT) Floor Wire A D C Curtain Shield Squib RH B Center Airbag Sensor Assembly Connector “C” ICR+ ICR- (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition C17-1 (ICR+) - Body ground Ignition switch ON Below 1 V C17-2 (ICR-) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE C17 RS C C111666E27 OK RS–226 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib RH DLC3 CG C Center Airbag Sensor Assembly DTC B1163/82 TC C111678E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the curtain shield airbag assembly RH and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1163/82 is not output. HINT: Codes other than code B1163/82 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–227 B1165/87 Short in Curtain Shield Squib LH Circuit DESCRIPTION The curtain shield squib LH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1165/87 is recorded when a short circuit is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition • B1165/87 • • Short circuit between ICL+ wire harness and ICLwire harness of curtain shield squib LH Curtain shield squib LH malfunction Center airbag sensor assembly malfunction Trouble Area • • • Curtain shield airbag assembly LH (Curtain shield squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM Center Airbag Sensor Assembly C16 Curtain Shield Squib LH 1 2 9 A30 ICL+ 10 A30 ICL- RS C128524E26 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). RS–228 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (CURTAIN SHIELD SQUIB LH) D C Curtain Shield Squib LH Center Airbag Sensor Assembly Connector “C” C16 DLC3 CG SST DTC B1165/87 TC C C111681E07 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the curtain shield airbag assembly LH (curtain shield squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1165/87 is not output. HINT: Codes other than DTC B1165/87 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the floor wire No. 2. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–229 (d) Check that the floor wire No. 2 connector (on the curtain shield airbag assembly LH side) is not damaged. OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO. 2 OK 3 CHECK FLOOR WIRE NO. 2 (CURTAIN SHIELD SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance A D C Curtain Shield Squib LH B Center Airbag Sensor Assembly Floor Wire No. 2 Tester connection Condition Specified condition C16-1 (ICL+) - Body ground Always 1 MΩ or higher C16-2 (ICL-) - Body ground Always 1 MΩ or higher Connector “C” NG ICL+ REPAIR OR REPLACE FLOOR WIRE NO. 2 ICL- C16 C C111682E21 OK RS RS–230 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B1165/87 TC C111683E01 (a) Connect the connectors to the curtain shield airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1165/87 is not output. HINT: Codes other than DTC B1165/87 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–231 B1166/88 Open in Curtain Shield Squib LH Circuit DESCRIPTION The curtain shield squib LH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1166/88 is recorded when an open circuit is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition • B1166/88 Open circuit in ICL+ wire harness or ICL- wire harness of curtain shield squib LH Curtain shield squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Curtain shield airbag assembly LH (Curtain shield squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-224. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (CURTAIN SHIELD SQUIB LH) D C Curtain Shield Squib LH Center Airbag Sensor Assembly Connector “C” C16 SST DLC3 CG C DTC B1166/88 TC C111684E07 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the curtain shield airbag assembly LH (curtain shield squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–232 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B1166/88 is not output. HINT: Codes other than DTC B1166/88 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (CURTAIN SHIELD SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance A D C Curtain Shield Squib LH B Center Airbag Sensor Assembly Tester connection Condition Specified condition C16-1 (ICL+) - C16-2 (ICL-) Always Below 1 Ω Floor Wire No. 2 NG Connector “C” ICL+ ICL- C16 RS C C111682E21 OK REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–233 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B1166/88 TC C111685E01 (a) Connect the connectors to the curtain shield airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1166/88 is not output. HINT: Codes other than DTC B1166/88 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS RS–234 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1167/85 Short to GND in Curtain Shield Squib LH Circuit DESCRIPTION The curtain shield squib LH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1167/85 is recorded when a short to ground is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition • B1167/85 Short circuit in curtain shield squib LH wire harness (to ground) Curtain shield squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Curtain shield airbag assembly LH (Curtain Shield Squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-224. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (CURTAIN SHIELD SQUIB LH) D C Curtain Shield Squib LH Center Airbag Sensor Assembly RS Connector “C” C16 SST DLC3 CG C DTC B1167/85 TC C111686E07 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the curtain shield airbag assembly LH (curtain shield squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–235 OK: DTC B1167/85 is not output. HINT: Codes other than DTC B1167/85 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (CURTAIN SHIELD SQUIB LH CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance A D C Curtain Shield Squib LH B Center Airbag Sensor Assembly Floor Wire No. 2 Condition Specified condition C16-1 (ICL+) - Body ground Always 1 MΩ or higher C16-2 (ICL-) - Body ground Always 1 MΩ or higher NG Connector “C” ICL+ Tester connection REPAIR OR REPLACE FLOOR WIRE NO. 2 ICL- C16 RS C C111682E21 OK RS–236 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B1167/85 TC C111687E01 (a) Connect the connectors to the curtain shield airbag assembly LH and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1167/85 is not output. HINT: Codes other than code B1167/85 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–237 B1168/86 Short to B+ in Curtain Shield Squib LH Circuit DESCRIPTION The curtain shield squib LH circuit consists of the center airbag sensor assembly and the curtain shield airbag assembly LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1168/86 is recorded when a short to B+ is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition • B1168/86 Short circuit in curtain shield squib LH wire harness (to B+) Curtain shield squib LH malfunction Center airbag sensor assembly malfunction • • Trouble Area • • • Curtain shield airbag assembly LH (Curtain shield squib LH) Center airbag sensor assembly Floor wire No. 2 WIRING DIAGRAM See page RS-224. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (CURTAIN SHIELD SQUIB LH) D C Curtain Shield Squib LH Center Airbag Sensor Assembly Connector “C” C16 SST DLC3 CG C DTC B1168/86 TC C111688E08 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag assembly LH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the floor wire No. 2. CAUTION: Never connect a tester to the curtain shield airbag assembly LH (curtain shield squib LH) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). RS RS–238 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: DTC B1168/86 is not output. HINT: Codes other than DTC B1168/86 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH 2 CHECK FLOOR WIRE NO. 2 (CURTAIN SHIELD SQUIB LH CIRCUIT) A D C Curtain Shield Squib LH B Center Airbag Sensor Assembly Floor Wire No. 2 Connector “C” ICL+ RS C111682E21 OK Tester connection Condition Specified condition C16-1 (ICL+) - Body ground Ignition switch ON Below 1 V C16-2 (ICL-) - Body ground Ignition switch ON Below 1 V NG ICL- C16 C (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage REPAIR OR REPLACE FLOOR WIRE NO. 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–239 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Curtain Shield Squib LH Center Airbag Sensor Assembly DLC3 CG C DTC B1168/86 TC C111689E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the curtain shield airbag assembly LH and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1168/86 is not output. HINT: Codes other than code B1168/86 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–41 DIAGNOSTIC TROUBLE CODE CHART AIRBAG SYSTEM DTC Code B0100/13 B0101/14 B0102/11 B0103/12 B0105/53 B0106/54 B0107/51 Detection Item Check Mode SRS Warning Light See page Short in Driver Side Squib Circuit 1. Steering pad (Driver side squib) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire Trouble Area *2 ON RS-46 Open in Driver Side Squib Circuit 1. Steering pad (Driver side squib) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-51 Short to GND in Driver Side Squib Circuit 1. Steering pad (Driver side squib) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-56 Short to B+ in Driver Side Squib Circuit 1. Steering pad (Driver side squib) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-61 Short in Front Passenger Side Squib Circuit 1. Front passenger airbag assembly (Front passenger side squib) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-66 Open in Front Passenger Side Squib Circuit 1. Front passenger airbag assembly (Front passenger side squib) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-69 Short to GND in Front Passenger Side Squib Circuit 1. Front passenger airbag assembly (Front passenger side squib) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-72 RS RS–42 DTC Code B0108/52 B0110/43 B0111/44 B0112/41 RS B0113/42 B0115/47 B0116/48 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Detection Item Check Mode SRS Warning Light See page Short to B+ in Front Passenger Side Squib Circuit 1. Front passenger airbag assembly (Front passenger side squib) 2. Center airbag sensor assembly 3. Instrument panel wire Trouble Area *2 ON RS-75 Short in Side Squib RH Circuit 1. Front seat side airbag assembly RH (Side squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-79 Open in Side Squib RH Circuit 1. Front seat side airbag assembly RH (Side squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-82 Short to GND in Side Squib RH Circuit 1. Front seat side airbag assembly RH (Side squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-85 Short to B+ in Side Squib RH Circuit 1. Front seat side airbag assembly RH (Side squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-88 Short in Side Squib LH Circuit 1. Front seat side airbag assembly LH (Side squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-91 Open in Side Squib LH Circuit 1. Front seat side airbag assembly LH (Side squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-94 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Code B0117/45 B0118/46 B0126/27 B0127/27 B0130/63 B0131/64 B0132/61 Detection Item Trouble Area RS–43 Check Mode SRS Warning Light See page Short to GND in Side Squib LH Circuit 1. Front seat side airbag assembly LH (Side squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-97 Short to B+ in Side Squib LH Circuit 1. Front seat side airbag assembly LH (Side squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-100 Seat Belt Buckle Switch LH Circuit Malfunction 1. Front seat inner belt assembly LH (Seat belt buckle switch LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 ON RS-103 Seat Belt Buckle Switch LH Malfunction 1. Front seat inner belt assembly LH (Seat belt buckle switch LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 ON RS-103 Short in Front Pretensioner Squib RH Circuit 1. Front seat outer belt assembly RH (Front pretensioner squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-109 Open in Front Pretensioner Squib RH Circuit 1. Front seat outer belt assembly RH (Front pretensioner squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-113 Short to GND in Front Pretensioner Squib RH Circuit 1. Front seat outer belt assembly RH (Front pretensioner squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-116 RS RS–44 DTC Code Check Mode SRS Warning Light See page Short to B+ in Front Pretensioner Squib RH Circuit 1. Front seat outer belt assembly RH (Front pretensioner squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-119 Short in Front Pretensioner Squib LH Circuit 1. Front seat outer belt assembly LH (Front pretensioner squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-123 Open in Front Pretensioner Squib LH Circuit 1. Front seat outer belt assembly LH (Front pretensioner squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-127 Short to GND in Front Pretensioner Squib LH Circuit 1. Front seat outer belt assembly LH (Front pretensioner squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-130 Short to B+ in Front Pretensioner Squib LH Circuit 1. Front seat outer belt assembly LH (Front pretensioner squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-133 B1100/31 Center Airbag Sensor Assembly Malfunction 1. Center airbag sensor assembly 2. Engine room main wire 3. Instrument panel wire *1 ON RS-137 B1135/24 Half Connection in Center Airbag Sensor Assembly Connectors 1. Electrical connection check mechanism 2. Center airbag sensor assembly *1 ON RS-147 Side Airbag Sensor Assembly RH Circuit Malfunction 1. Side airbag sensor RH 2. Center airbag sensor assembly 3. Floor wire *1 Blink RS-149 B0133/62 B0135/73 B0136/74 B0137/71 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B0138/72 B1140/32 Detection Item Trouble Area SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Code Trouble Area Check Mode SRS Warning Light See page Side Airbag Sensor Assembly LH Circuit Malfunction 1. Side airbag sensor LH 2. Center airbag sensor assembly 3. Floor wire No. 2 *1 Blink RS-155 Front Airbag Sensor RH Circuit Malfunction 1. Front airbag sensor RH 2. Center airbag sensor assembly 3. Engine room main wire 4. Instrument panel wire *1 ON RS-161 Front Airbag Sensor LH Circuit Malfunction 1. Front airbag sensor LH 2. Center airbag sensor assembly 3. Engine room main wire 4. Instrument panel wire *1 ON RS-165 B1150/23 Occupant Classification System Malfunction 1. Occupant classification ECU 2. Center airbag sensor 3. Floor wire 4. Front seat wire No. 1 *1 ON RS-169 B1152/28 Passenger Airbag ON/OFF Indicator Circuit Malfunction 1. Air conditioning control assembly 2. Center airbag sensor 3. Instrument panel wire *1 ON RS-178 Seat Position Airbag Sensor Circuit Malfunction 1. Seat position airbag sensor 2. Center airbag sensor assembly 3. Front seat inner belt assembly LH 4. Floor wire No. 2 *1 ON RS-189 Rear Airbag Sensor RH Circuit Malfunction 1. Rear airbag sensor RH 2. Center airbag sensor assembly 3. Floor wire *1 Blink RS-199 Rear Airbag Sensor LH Circuit Malfunction 1. Rear airbag sensor LH 2. Center airbag sensor assembly 3. Floor wire No. 2 *1 Blink RS-205 Short in Curtain Shield Squib RH Circuit 1. Curtain shield airbag assembly RH (Curtain shield squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-211 B1141/33 B1148/36 B1149/37 B1153/25 B1154/38 B1155/39 B1160/83 Detection Item RS–45 RS RS–46 DTC Code B1161/84 B1162/81 B1163/82 B1165/87 B1166/88 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Detection Item Check Mode SRS Warning Light See page Open in Curtain Shield Squib RH Circuit 1. Curtain shield airbag assembly RH (Curtain shield squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-215 Short to GND in Curtain Shield Squib RH Circuit 1. Curtain shield airbag assembly RH (Curtain shield squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-218 Short to B+ in Curtain Shield Squib RH Circuit 1. Curtain shield airbag assembly RH (Curtain shield squib RH) 2. Center airbag sensor assembly 3. Floor wire *2 Blink RS-221 Short in Curtain Shield Squib LH Circuit 1. Curtain shield airbag assembly LH (Curtain shield squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-224 Open in Curtain Shield Squib LH Circuit 1. Curtain shield airbag assembly LH (Curtain shield squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-228 Short to GND in Curtain Shield Squib LH Circuit 1. Curtain shield airbag assembly LH (Curtain shield squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-231 Short to B+ in Curtain Shield Squib LH Circuit 1. Curtain shield airbag assembly LH (Curtain shield squib LH) 2. Center airbag sensor assembly 3. Floor wire No. 2 *2 Blink RS-234 RS B1167/85 B1168/86 Trouble Area SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC Code B1180/17 B1181/18 B1182/19 B1183/22 B1185/57 B1186/58 Detection Item Trouble Area RS–47 Check Mode SRS Warning Light See page Short in Driver Side Squib 2nd Step Circuit 1. Steering pad (Driver side squib 2nd step) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-237 Open in Driver Side Squib 2nd Step Circuit 1. Steering pad (Driver side squib 2nd step) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-242 Short to GND in Driver Side Squib 2nd Step Circuit 1. Steering pad (Driver side squib 2nd step) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-247 Short to B+ in Driver Side Squib 2nd Step Circuit 1. Steering pad (Driver side squib 2nd step) 2. Spiral cable 3. Center airbag sensor assembly 4. Instrument panel wire *2 ON RS-252 Short in Front Passenger Side Squib 2nd Step Circuit 1. Front passenger airbag assembly (Front passenger side squib 2nd step) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-257 Open in Front Passenger Side Squib 2nd Step Circuit 1. Front passenger airbag assembly (Front passenger side squib 2nd step) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-260 RS RS–48 DTC Code B1187/55 B1188/56 B1628/29 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Detection Item Trouble Area Check Mode SRS Warning Light See page Short to GND in Front Passenger Side Squib 2nd Step Circuit 1. Front passenger airbag assembly (Front passenger side squib 2nd step) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-263 Short to B+ in Front Passenger Side Squib 2nd Step Circuit 1. Front passenger airbag assembly (Front passenger side squib 2nd step) 2. Center airbag sensor assembly 3. Instrument panel wire *2 ON RS-266 Roll Over Cut Off Indicator Malfunction 1. Combination meter assembly 2. Center airbag sensor assembly 3. Instrument panel wire *1 Blink RS-270 RS–240 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1180/17 Short in Driver Side Squib 2nd Step Circuit DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1180/17 is recorded when a short circuit is detected in the driver side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1180/17 • • • Short circuit between D2+ wire harness and D2wire harness of driver side squib 2nd step Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib 2nd step) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM Center Airbag Sensor Assembly Driver Side Squib 2nd Step 4 RS 3 16 A32 D2+ 17 A32 D2- A36 Spiral Cable H001451E48 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–241 • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) Spiral Cable F E DC Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector E SST Color: Black DLC3 CG DTC B1180/17 TC C C111690E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1180/17 is not output. HINT: Codes other than DTC B1180/17 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE STEERING PAD 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the spiral cable. (d) Check that the spiral cable connector (on the steering pad side) is not damaged. RS RS–242 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPLACE SPIRAL CABLE OK 3 CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT Driver Side Squib 2nd Step A F E DC Spiral Cable B Center Airbag Sensor Assembly Connector E (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition D2+ - D2- Always 1 MΩ or higher NG D2- Go to step 5 D2+ Color: Black C C111719E01 OK RS 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY F E DC Spiral Cable Center Airbag Sensor Assembly Driver Side Squib 2nd Step DLC3 CG DTC B1180/17 TC H042137E02 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1180/17 is not output. HINT: Codes other than DTC B1180/17 may be output at this time, but they are not related to this check. RS–243 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK 5 CHECK INSTRUMENT PANEL WIRE (a) Disconnect the cowl wire connector from the spiral cable. HINT: The activation prevention mechanism of connector "B" has already been released. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Driver Side Squib 2nd Step Tester connection Condition Specified condition A36-4 (D2+) - A36-3 (D2) Always 1 MΩ or higher NG Connector “C” REPAIR OR REPLACE INSTRUMENT PANEL WIRE A36 D2+ D2C C110388E32 OK RS RS–244 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK SPIRAL CABLE Instrument Panel Wire Driver Side Squib 2nd Step A F E D C Spiral Cable B Center Airbag Sensor Assembly (a) Release the activation prevention mechanism built into connector "D" (See page RS-28). (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition D2+ - D2- Always 1 MΩ or higher NG Connector E D2- D2+ Color: Black C C111718E01 OK USE SIMULATION METHOD TO CHECK RS REPLACE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–245 B1181/18 Open in Driver Side Squib 2nd Step Circuit DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1181/18 is recorded when an open circuit is detected in the driver side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1181/18 • • • Open circuit in D2+ wire harness or D2- wire harness of driver side squib 2nd step Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib 2nd step) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-237. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–246 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) Spiral Cable DC F E Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector E SST Color: Black DLC3 CG DTC B1181/18 TC C C111691E01 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1181/18 is not output. HINT: Codes other than DTC B1181/18 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS–247 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Driver Side Squib 2nd Step A F E DC B Spiral Cable Tester connection Condition Specified condition D2+ - D2- Always Below 1 Ω Center Airbag Sensor Assembly NG Go to step 4 Connector E D2- D2+ Color: Black C C111719E03 OK 3 CENTER AIRBAG SENSOR ASSEMBLY Spiral Cable FE DC Driver Side Squib 2nd Step DLC3 CG Center Airbag Sensor Assembly DTC B1181/18 TC H042140E02 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1181/18 is not output. HINT: Codes other than DTC B1181/18 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–248 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (a) Disconnect the cowl wire connector from the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A F E D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib 2nd Step Tester connection Condition Specified condition A36-4 (D2+) - A36-3 (D2) Always Below 1 Ω NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector “C” A36 D2+ D2C C110388E32 OK 5 CHECK SPIRAL CABLE Instrument Panel Wire Driver Side Squib 2nd Step RS A F E D C Spiral Cable Center Airbag Sensor Assembly D2+ Color: Black C Tester connection Condition Specified condition D2+ - D2- Always Below 1 Ω B Connector E D2- (a) Measure the resistance according to the value(s) in the table below. Resistance C111718E01 NG REPLACE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–249 OK USE SIMULATION METHOD TO CHECK RS SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–401 FRONT PASSENGER AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS HEATER TO REGISTER DUCT NO. 2 DEFROSTER NOZZLE ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY 20 (200, 14) RS INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C131316E01 RS–402 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. INSPECT FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). (b) With the front passenger airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the instrument panel with a new one: Cuts, minute cracks or marked discoloration on the instrument panel around the front passenger airbag assembly. 2. C131324 INSPECT FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) With the front passenger airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front passenger airbag assembly, instrument panel or instrument panel reinforcement with a new one: • Cuts, minute cracks or marked discoloration on the front passenger airbag assembly. • Cracks or other damage to the connectors. • Deformation or cracks on the instrument panel or instrument panel reinforcement. HINT: There should be no interference between the instrument panel and the front passenger airbag assembly. CAUTION: Be sure to follow the correct removal and installation procedures. RS C123767 RS–250 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Short to GND in Driver Side Squib 2nd Step Circuit B1182/19 DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1182/19 is recorded when a short to ground is detected in the driver side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1182/19 • • • Short circuit in driver side squib 2nd step wire harness (to ground) Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib 2nd step) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-237. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–251 CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) DC F E Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector E SST Color: Black DLC3 CG DTC B1182/19 TC C C111692E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1182/19 is not output. HINT: Codes other than DTC B1182/19 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS RS–252 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Driver Side Squib 2nd Step A F E DC B Spiral Cable Center Airbag Sensor Assembly Tester connection Condition Specified condition D2+ - Body ground Always 1 MΩ or higher D2- - Body ground Always 1 MΩ or higher NG Go to step 4 Connector E D2- D2+ Color: Black C C111719E01 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Spiral Cable RS FE DC Driver Side Squib 2nd Step DLC3 CG Center Airbag Sensor Assembly DTC B1182/19 TC H042142E02 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1182/19 is not output. HINT: Codes other than DTC B1182/19 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–253 CHECK INSTRUMENT PANEL WIRE (a) Disconnect the cowl wire connector from the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A F E D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib 2nd Step Tester connection Condition Specified condition A36-4 (D2+) - Body ground Always 1 MΩ or higher A36-3 (D2-) - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector “C” A36 D2+ D2C C110388E32 OK 5 CHECK SPIRAL CABLE Instrument Panel Wire Driver Side Squib 2nd Step A F E D C Spiral Cable B Center Airbag Sensor Assembly (a) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition D2+ - Body ground Always 1 MΩ or higher D2- - Body ground Always 1 MΩ or higher NG Connector E D2- D2+ Color: Black C C111718E01 REPLACE SPIRAL CABLE RS RS–254 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK USE SIMULATION METHOD TO CHECK RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–255 Short to B+ in Driver Side Squib 2nd Step Circuit B1183/22 DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1183/22 is recorded when a short to B+ is detected in the driver side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1183/22 • • • Short circuit in driver side squib 2nd step wire harness (to B+) Driver side squib 2nd step malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib 2nd step) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-237. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–256 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) Spiral Cable DC F E Driver Side Squib 2nd Step Center Airbag Sensor Assembly Connector E SST Color: Black DLC3 CG DTC B1183/22 TC C C111693E01 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1183/22 is not output. HINT: Codes other than DTC B1183/22 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS–257 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT Driver Side Squib 2nd Step A F E DC B Spiral Cable Center Airbag Sensor Assembly Connector E (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition D2+ - Body ground Ignition switch ON Below 1 V D2- - Body ground Ignition switch ON Below 1 V NG D2- Go to step 4 D2+ Color: Black C C111719E01 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Spiral Cable FE DC Driver Side Squib 2nd Step DLC3 CG Center Airbag Sensor Assembly DTC B1183/22 TC H042144E02 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the steering pad and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1183/22 is not output. HINT: Codes other than DTC B1183/22 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–258 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK USE SIMULATION METHOD TO CHECK 4 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Driver Side Squib 2nd Step Connector “C” A36 D2C110388E32 OK RS Tester connection Condition Specified condition A36-4 (D2+) - Body ground Ignition switch ON Below 1 V A36-3 (D2-) - Body ground Ignition switch ON Below 1 V NG D2+ C (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the cowl wire connector from the spiral cable. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–259 CHECK SPIRAL CABLE Instrument Panel Wire Driver Side Squib 2nd Step A F E D C Spiral Cable B Center Airbag Sensor Assembly (a) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition D2+ - Body ground Ignition switch ON Below 1 V D2- - Body ground Ignition switch ON Below 1 V NG REPLACE SPIRAL CABLE Connector E D2- D2+ Color: Black C C111718E01 OK USE SIMULATION METHOD TO CHECK RS RS–260 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1185/57 Short in Front Passenger Side Squib 2nd Step Circuit DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1185/57 is recorded when a short circuit is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1185/57 • • Short circuit between P2+ wire harness and P2wire harness of front passenger side squib 2nd step Passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM Center Airbag Sensor Assembly A35 Front Passenger Side Squib 2nd Step 3 8 A32 P2+ RS 4 7 A32 P2- C128524E27 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–261 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) D C Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector “C” A35 SST DLC3 CG C DTC B1185/57 TC C111759E03 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1185/57 is not output. HINT: Codes other than DTC B1185/57 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS RS–262 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB 2ND STEP CIRCUIT) Instrument Panel Wire A D C Front Passenger Side Squib 2nd Step B Center Airbag Sensor Assembly (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A35-3 (P2+) - A35-4 (P2) Always 1 MΩ or higher Connector “C” NG A35 REPAIR OR REPLACE INSTRUMENT PANEL WIRE P2- P2+ C C114767E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY RS DC Front Passenger Side Squib 2nd Step DLC3 CG C Center Airbag Sensor Assembly DTC B1185/57 TC C111695E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1185/57 is not output. HINT: Codes other than DTC B1185/57 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–263 Open in Front Passenger Side Squib 2nd Step Circuit B1186/58 DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1186/58 is recorded when an open circuit is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1186/58 • • Open circuit in P2+ wire harness or P2- wire harness of front passenger side squib 2nd step Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-257. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–264 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) D C Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector “C” A35 SST DLC3 CG C DTC B1186/58 TC C114764E03 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the Instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1186/58 is not output. HINT: Codes other than DTC B1186/58 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS–265 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB 2ND STEP CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C Front Passenger Side Squib 2nd Step B Center Airbag Sensor Assembly Tester connection Condition Specified condition A35-3 (P2+) - A35-4 (P2) Always Below 1 Ω NG Connector “C” REPAIR OR REPLACE INSTRUMENT PANEL WIRE A35 P2- P2+ C C114767E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Side Squib 2nd Step DLC3 CG C Center Airbag Sensor Assembly DTC B1186/58 TC C111697E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1186/58 is not output. HINT: Codes other than DTC B1186/58 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–266 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Short to GND in Front Passenger Side Squib 2nd Step Circuit B1187/55 DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1187/55 is recorded when a short to ground is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1187/55 • • Short circuit in front passenger side squib 2nd step wire harness (to ground) Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-257. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) D C Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector “C” A35 SST DLC3 CG C RS–267 DTC B1187/55 TC C114765E02 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1187/55 is not output. HINT: Codes other than DTC B1187/55 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS RS–268 2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB 2ND STEP CIRCUIT) (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C Front Passenger Side Squib 2nd Step B Center Airbag Sensor Assembly Tester connection Condition Specified condition A35-3 (P2+) - Body ground Always 1 MΩ or higher A35-4 (P2-) - Body ground Always 1 MΩ or higher Connector “C” NG A35 REPAIR OR REPLACE INSTRUMENT PANEL WIRE P2- P2+ C C114767E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY RS DC Front Passenger Side Squib 2nd Step DLC3 CG C Center Airbag Sensor Assembly DTC B1187/55 TC C111699E01 (a) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B1187/55 is not output. HINT: Codes other than DTC B1187/55 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–269 Short to B+ in Front Passenger Side Squib 2nd Step Circuit B1188/56 DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor assembly and the front passenger airbag assembly. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1188/56 is recorded when a short to B+ is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detecting Condition • B1188/56 • • Short circuit in front passenger side squib 2nd step wire harness (to B+) Front passenger side squib 2nd step malfunction Center airbag sensor assembly malfunction Trouble Area • • • Front passenger airbag assembly (Front passenger side squib 2nd step) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-257. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–270 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) D C Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector “C” A35 SST DLC3 CG C DTC B1188/56 TC C114766E02 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag assembly. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire. CAUTION: Never connect a tester to the front passenger airbag assembly (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1188/56 is not output. HINT: Codes other than DTC B1188/56 may be output at this time, but they are not related to this check. NG OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY Go to step 2 RS–271 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB 2ND STEP CIRCUIT) Instrument Panel Wire A D C B Front Passenger Side Squib 2nd Step Center Airbag Sensor Assembly Connector “C” A35 (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A35-3 (P2+) - Body ground Ignition switch ON Below 1 V A35-4 (P2-) - Body ground Ignition switch ON Below 1 V NG P2- REPAIR OR REPLACE INSTRUMENT PANEL WIRE P2+ C C114767E17 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY DC Front Passenger Side Squib 2nd Step DLC3 CG C Center Airbag Sensor Assembly DTC B1188/56 TC C111701E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the front passenger airbag assembly and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B1188/56 is not output. HINT: Codes other than DTC B1188/56 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–272 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK USE SIMULATION METHOD TO CHECK RS RS–273 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1628/29 Roll Over Cut Off Indicator Malfunction DESCRIPTION The RSCA OFF switch is a mechanism that operates both right and left side of the curtain shield airbag assembly and the front seat outer belt assembly when the center airbag sensor assembly detects a rollover. The RSCA OFF indicator is installed in the combination meter assembly. If the RSCA OFF switch is operated, the indicator comes on to inform the driver that the roll-over detection system is not working. The initial setting of the roll-over detection system is on. It automatically operates every time the ignition switch is turned on. DTC No. DTC Detecting Condition • B1628/29 • • The center airbag sensor assembly receives an open signal or short to ground in the RSCA OFF indicator circuit. RSCA OFF indicator malfunction Center airbag sensor assembly malfunction Trouble Area • • • Combination meter assembly (RSCA OFF indicator) Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM Center Airbag Sensor Assembly Combination Meter Assembly 15 C10 10 C8 6 A32 RMIL RSCA OFF Driver Side J/B GAUGE 4 1G I18 Ignition SW 6 1D RS 6 IG2 AM2 7 Engine Room R/B AM2 2 1 2 2 Battery H046338E01 RS–274 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK RSCA OFF INDICATOR CONDITION (a) Turn the ignition switch to the ON position, and push the RSCA OFF switch for 2 seconds. (b) Check the RSCA OFF indicator condition according to the table below. Result Proceed to Condition A RSCA OFF indicator dose not come on (remains off) when the RSCA OFF switch is operated. B RSCA OFF indicator remains on when the RSCA OFF switch is not operated. B Go to step 6 A 2 CHECK COMBINATION METER ASSEMBLY (SOURCE VOLTAGE) Combination Meter Assembly: C8 H044462E01 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Remove the combination meter assembly (See page ME-59). (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition C8-10 - Body ground Ignition switch ON 10 to 14 V NG OK GO TO METER / GAUGE SYSTEM RS–275 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 CHECK INSTRUMENT PANEL WIRE (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the center airbag sensor assembly. (d) Measure the resistance according to the value(s) in the table below. Resistance Center Airbag Sensor Assembly Side: RMIL A32 Combination Meter Assembly (Left Side of Vehicle) Connector Front View: Tester connection Condition Specified condition A32-6 (RMIL) - C8-10 Always Below 1 Ω NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE C8-10 C123782E01 OK 4 CHECK INSTRUMENT PANEL WIRE (SHORT TO B+) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C8-10 I033110E02 OK (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition C8-10 - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–276 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY Airbag Sensor Assembly Center Combination Meter Assembly DTC B1628/29 DLC3 CG TC A133750E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the center airbag sensor assembly. (d) Install the combination meter assembly (See page ME61). (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B1628/29 is not output. HINT: Codes other than code B1628/29 may be output at this time, but they are not related to this check. If the DTC B1628/29 is output after the center airbag sensor assembly is replaced, there may be trouble in the combination meter assembly (RSCA OFF indicator). If RSCA OFF indicator remains off when DTC B1628/29 is output, there may be trouble in the combination meter assembly (RSCA OFF indicator). NG RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK 6 CHECK RSCA OFF INDICATOR OPERATION (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Check the RSCA OFF indicator condition. OK: The RSCA OFF indicator does not come on. RS–277 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY NG 7 CHECK INSTRUMENT PANEL WIRE (SHORT TO GROUND) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C8-10 I033110E02 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Remove the combination meter assembly (See page ME-59). (d) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition C8-10 - Body ground Always 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE OK REPLACE COMBINATION METER ASSEMBLY RS RS–278 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light Remains ON DESCRIPTION The SRS warning light is located on the combination meter assembly. When the SRS is normal, the SRS warning light comes on for approximately 6 seconds after the ignition switch is turned from the LOCK position to ON position, and then goes off automatically. If there is a malfunction in the SRS, the SRS warning light comes on to inform the driver of a problem. When terminals TC and CG of the DLC3 are connected, the DTC is displayed by blinking of the SRS warning light. The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the center airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the voltage of the SRS to normal voltage. A malfunction in this circuit is not recorded in the center airbag sensor assembly. The SRS warning light automatically goes off when the source voltage returns to normal. The signal to illuminate the SRS warning light is transmitted from the center airbag sensor assembly to the combination meter assembly through the multiplex communication system. WIRING DIAGRAM Center Airbag Sensor Assembly Combination Meter Assembly 3 2 C10 RS 15 C10 A32 LA GAUGE SRS 5 A32 IG2 I18 Ignition Switch 27 A32 E1 13 C10 AM2 28 A32 E2 Battery C123761E01 RS–279 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK SRS WARNING LIGHT OPERATION (a) Check the SRS warning light operation approximately 6 seconds after the ignition switch is turned to the ON position. Result SRS Warning Light Illumination Proceed to Remains on after it goes off A Remains on B B Go to step 6 A 2 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG CHECK AND REPLACE BATTERY OR CHARGING SYSTEM OK 3 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connector is properly connected to the center airbag sensor assembly. OK: The connector is properly connected. NG OK CONNECT CONNECTOR RS RS–280 4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK WIRE HARNESS (SOURCE VOLTAGE OF CENTER AIRBAG SENSOR ASSEMBLY) IG2 A32 E2 E1 H040065E25 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Operate all components of the electrical system (defogger, wipers, headlight, heater blower, etc.). (e) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition A32-5 (IG2) - Body ground Ignition switch ON 10 to 14 V (f) Turn the ignition switch to the LOCK position. (g) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition A32-27 (E1) - Body ground Always Below 1 Ω A32-28 (E2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) OK 5 RS CHECK SRS WARNING LIGHT (a) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Check the SRS warning light condition. OK: After the primary check period, SRS warning light goes off for approximately 10 seconds, and remains on. HINT: The primary check period shows approximately 6 seconds after the ignition switch is turned to the ON position. NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY GO TO METER / GAUGE SYSTEM RS–281 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG CHECK AND REPLACE BATTERY OR CHARGING SYSTEM OK 7 CHECK CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor assembly and combination meter assembly. OK: The connectors are properly connected. NG CONNECT CONNECTORS OK 8 CHECK WIRE HARNESS (SOURCE VOLTAGE OF CENTER AIRBAG SENSOR ASSEMBLY) IG2 A32 E2 E1 H040065E25 (a) Disconnect the connectors from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Operate all components of the electrical system (defogger, wipers, headlight, heater blower, etc.). (e) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition A32-5 (IG2) - Body ground Ignition switch ON 10 to 14 V (f) Turn the ignition switch to the LOCK position. (g) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition A32-27 (E1) - Body ground Always Below 1 Ω A32-28 (E2) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) RS RS–282 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 9 CHECK WIRE HARNESS (SOURCE VOLTAGE OF COMBINATION METER) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C10-15 C10-13 I033110E03 (a) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (b) Remove the combination meter assembly (See page ME-59). (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position. (e) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition C10-15 - Body ground Ignition switch ON 10 to 14 V (f) Turn the ignition switch to the LOCK position. (g) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition C10-13 - Body ground Always Below 1 Ω NG OK RS REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 RS–283 CHECK WIRE HARNESS (OPEN) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Center Airbag Sensor Assembly Side: A32 Tester connection Condition Specified condition A32-3 (LA) - C10-2 Always Below 1 Ω LA NG REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C10-2 C123782E02 OK 11 CHECK WIRE HARNESS (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance A32 LA Tester connection Condition Specified condition A32-3 (LA) - Body ground Always 1 MΩ or higher NG H040065E26 OK REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) RS RS–284 12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK WIRE HARNESS (SHORT TO B+) (a) Turn the ignition switch to the ON position. (b) Measure the resistance according to the value(s) in the table below. Standard resistance A32 Tester connection Condition Specified condition LA A32-3 (LA) - Body ground Always 1 MΩ or higher NG H040065E26 REPAIR OR REPLACE WIRE HARNESS (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) OK 13 CHECK SRS WARNING LIGHT (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Install the combination meter assembly (See page ME61). (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Check the SRS warning light condition. OK: After the primary check period, SRS warning light goes off for approximately 10 seconds, and remains on. HINT: The primary check period shows approximately 6 seconds after the ignition switch is turned to the ON position. RS NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY GO TO METER / GAUGE SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–49 B0100/13 Short in Driver Side Squib Circuit DESCRIPTION The driver side squib circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0100/13 is recorded when a short circuit is detected in the driver side squib circuit. DTC No. DTC Detecting Condition • B0100/13 • • • Short circuit between D+ wire harness and D- wire harness of driver side squib Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM Center Airbag Sensor Assembly Driver Side Squib 1 2 14 A32 D+ 13 A32 D- RS A36 Spiral Cable H001451E47 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). RS–50 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). 1 CHECK STEERING PAD (DRIVER SIDE SQUIB) Driver Side Squib F E DC Spiral Cable Center Airbag Sensor Assembly Connector “E” SST Color: Orange DLC3 CG DTC B0100/13 TC C C110385E02 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0100/13 is not output. HINT: Codes other than DTC B0100/13 may be output at this time, but they are not related to this check. NG Go to step 2 OK REPLACE STEERING PAD 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the SST (resistance 2.1 Ω) from the spiral cable. (d) Check that the spiral cable connector (on the steering pad side) is not damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–51 OK: The lock button is not disengaged, and the claw of the lock is not deformed or damaged. NG REPLACE SPIRAL CABLE OK 3 CHECK DRIVER SIDE SQUIB CIRCUIT (a) Disconnect the connector from the center airbag sensor assembly. (b) Release the activation prevention mechanism built into connector "B" (See page RS-28). (c) Measure the resistance according to the value(s) in the table below. Resistance Driver Side Squib A F E DC B Spiral Cable Center Airbag Sensor Assembly Connector E D- Tester connection Condition Specified condition D+ - D- Always 1 MΩ or higher NG Go to step 5 D+ Color: Orange C C110386E02 OK RS 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side Squib FE DC Spiral Cable DLC3 C CG Center Airbag Sensor Assembly DTC B0100/13 TC C110387E01 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not related to this check. RS–52 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK USE SIMULATION METHOD TO CHECK 5 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Driver Side Squib (a) Disconnect the instrument panel wire connector from the spiral cable. HINT: The activation prevention mechanism of connector "B" has already been released. (b) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition A36-1 (D+) - A36-2 (D-) Always 1 MΩ or higher NG Connector “C” A36 D+ DC RS C110388E31 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 6 RS–53 CHECK SPIRAL CABLE (a) Release the activation prevention mechanism built into connector "D" (See page RS-28). (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib Tester connection Condition Specified condition D+ - D- Always 1 MΩ or higher F E NG REPLACE SPIRAL CABLE Connector E D- D+ Color: Orange C C110389E01 OK USE SIMULATION METHOD TO CHECK RS RS–285 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light does not Come ON DESCRIPTION See page RS-275. WIRING DIAGRAM See page RS-275. INSPECTION PROCEDURE 1 CHECK BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V NG CHECK AND REPLACE BATTERY OR CHARGING SYSTEM OK 2 CHECK CONNECTOR (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connector is properly connected to the combination meter assembly. OK: The connector is properly connected. NG CONNECT CONNECTOR RS OK 3 CHECK WIRE HARNESS (SOURCE VOLTAGE OF COMBINATION METER) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C10-15 C10-13 I033110E03 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Remove the combination meter assembly (See page ME-59). (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Standard voltage: Tester connection Condition Specified condition C10-15 - Body ground Ignition switch ON 10 to 14 V (g) Turn the ignition switch to the LOCK position. RS–286 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (h) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester connection Condition Specified condition C10-13 - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK SRS WARNING LIGHT (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the combination meter assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Check the SRS warning light condition. OK: After the primary check period, SRS warning light goes off for approximately 10 seconds, and remains on. HINT: The primary check period is approximately 6 seconds after the ignition switch is turned to the ON position. NG OK RS REPLACE CENTER AIRBAG SENSOR ASSEMBLY GO TO COMBINATION METER SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–287 TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. DTCs are displayed by blinking the SRS warning light. WIRING DIAGRAM ECM Center Airbag Sensor Assembly Center J/B 23 TC E8 A J30 J/C C 3C E J29 C 3C Tire Pressure Monitor ECU Suspension Control ECU 6 TC S15 J/C A J30 12 TC T16 19 A32 TC C 3C 5 IC5 H J18 (*1) H J18 H J18 D1 DLC3 13 TC J22 J/C (*1) E E 4 CG A J5 J/C IG *1: 2UZ-FE H046343E01 HINT: When each warning light keeps blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in each ECU is suspected. INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TC OF DLC3 - TC OF CENTER AIRBAG SENSOR ASSEMBLY) (a) Turn the ignition switch to the LOCK position. (b) Disconnect the center airbag sensor assembly connector. RS RS–288 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (c) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: D1 1 Tester connection Condition Specified condition D1-13 (TC) - A32-19 (TC) Always Below 1 Ω 2 3 4 5 6 7 8 NG 9 10 11 12 13 14 15 16 TC REPAIR OR REPLACE WIRE HARNESS (TC OF DLC3 - TC OF CENTER AIRBAG SENSOR ASSEMBLY) Center Airbag Sensor Assembly: A32 TC C123708E01 OK 2 CHECK WIRE HARNESS (CG OF DLC3 - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance DLC3: CG 1 RS D1 2 3 4 5 6 7 8 Tester connection Condition Specified condition D1-4 (CG) - Body ground Always Below 1 Ω NG 9 10 11 12 13 14 15 16 REPAIR OR REPLACE WIRE HARNESS (CG OF DLC3 - BODY GROUND) C128572E06 OK 3 CHECK WIRE HARNESS (TC OF CENTER AIRBAG SENSOR ASSEMBLY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance A32 Tester connection Condition Specified condition A32-19 (TC) - Body ground Always 1 MΩ or higher NG TC H040065E27 REPAIR OR REPLACE WIRE HARNESS OR EACH ECU SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–289 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–411 CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS CURTAIN SHIELD AIRBAG ASSEMBLY LH 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) 9.8 (100, 87 in.*lbf) RS N*m (kgf*cm, ft.*lbf) : Specified torque C C131317E01 RS–412 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). (b) With the curtain shield airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front pillar garnish or roof headlining assembly with a new one: Cuts, minute cracks or marked discoloration on the front pillar garnish or roof headlining assembly around the curtain shield airbag assembly. 2. H042169 H041659 RS INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) With the curtain shield airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag assembly with a new one: • Cuts, minute cracks or marked discoloration on the curtain shield airbag assembly. • Cracks or other damage to the connector. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–289 SYSTEM DIAGRAM Front Seat Inner Belt Assembly RH (Buckle Switch RH) Front Occupant Classification Sensor LH Occupant Classification ECU Front Occupant Classification Sensor RH Rear Occupant Classification Sensor LH Rear Occupant Classification Sensor RH DLC3 Center Airbag Sensor Assembly C Air conditioning Control Assembly (Passenger Airbag ON/OFF Indicator) C110375E04 RS RS–290 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SYSTEM DESCRIPTION 1. DESCRIPTION OF OCCUPANT CLASSIFICATION SYSTEM (a) GENERAL DESCRIPTION. (1) In the occupant classification system, the occupant classification ECU calculates the weight of the occupant based on a signal from the occupant classification sensors. This system recognizes the occupant to be a child if it detects a weight of less than 36 kg (79.37 lb), and disables the front passenger airbag assembly and side airbag (front passenger side). (2) This system is mainly comprised of 4 occupant classification sensors that detect the load on the front passenger seat. The occupant classification ECU controls the system, and the passenger airbag ON/OFF indicator indicates the ON/OFF condition of the front passenger airbag and side airbag (front passenger side). (b) OCCUPANT CLASSIFICATION SENSOR. Rear Occupant Classification Sensor RH Rear Occupant Classification Sensor LH Front Occupant Classification Sensor LH RS Front Occupant Classification Sensor RH Occupant Classification ECU Occupant Load A Occupant Classification Sensor A A - A Cross Section C C110537E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–291 (1) The occupant classification sensors are installed on 4 brackets connecting the seat rail and seat frame. Accordingly, when load is applied to the front passenger seat by an occupant sitting in it, the occupant classification sensors register a distortion. H045951 (c) DESCRIPTION FOR PASSENGER AIRBAG ON/ OFF INDICATOR. (1) The passenger airbag ON/OFF indicator is installed on the air conditioning control assembly. This indicator informs the driver whether the occupant classification ECU puts the front passenger airbag assembly and side airbag (front passenger side) into an active state or inactive state. (2) If a malfunction occurs in the occupant classification system, "OFF" indication of the passenger airbag ON/OFF indicator and the SRS warning light will come on. RS RS–292 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING The intelligent tester can be used in steps 4, 6, 8 and 9. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 PASSENGER AIRBAG ON/OFF INDICATOR CHECK NEXT 4 DTCs CHECK (Present and Past DTCs) (a) Check for DTCs. Result Result Proceed to DTC is output. A DTC is not output. B B GO TO PROBLEM SYMPTOMS TABLE A RS 5 DTCs CHART NEXT 6 CIRCUIT INSPECTION NEXT 7 REPAIR NEXT 8 CLEAR DTCs (Present and Past DTCs) (a) Clear DTCs. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–293 NEXT 9 DTCs CHECK (Present and Past DTCs) (a) Check for DTCs. Result Result Proceed to DTC is not output. A DTC is output. B B Go to step 5 A 10 SYMPTOM SIMULATION (a) Check the passenger airbag ON/OFF indicator condition. Result Result Proceed to Passenger airbag ON/OFF indicator is operating normally. A Passenger airbag ON/OFF indicator ("OFF") and SRS warning light come on. B B Go to step 5 A 11 NEXT END CONFIRMATION TEST RS RS–294 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION 1. ZERO POINT CALIBRATION NOTICE: Make sure that the front passenger seat is not occupied before performing the operation. HINT: Perform the zero point calibration and sensitivity check if any of the following conditions occur. • The occupant classification ECU is replaced. • Accessories (seatback tray and seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON/OFF indicator ("OFF") comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration and sensitivity check procedures HINT: Make sure that zero point calibration has finished normally, and then perform the sensitivity check. (1) Adjust the seat position according to the table below. Intelligent Tester A066288E01 Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position Lifter Height Lowest position (2) Connect the intelligent tester to the DLC3. (3) Turn the ignition switch to the ON position. RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–295 (4) Perform the zero point calibration by following the prompts on the tester screen. ZERO POINT CALIBRATION PROCEDURE “1: DIAGNOSIS” - ”1: OBD/MOBD” - “MODEL YEAR” - “MODEL SELECTION” - “4 RUNNER” - Select the option parts” - “9: OCCUPANT DETECT” Refer to the following screen flow. Refer to the following screen flow. Perform sensitity check. Perform DTC check up repair. RS Sensor information is expressed as OK, MAX. or MIN. in [ ]. If MAX. or MIN. is displayed,, replace the front seat outer belt assembly. C C113452E23 HINT: Refer to the intelligent tester operator's manual for further details. RS–296 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (5) (6) (7) (8) OK: "COMPLETE" is displayed. Perform the sensitivity check by following the prompts on the tester screen. Confirm that the beginning sensor reading is within the standard range. Standard value: -3.2 to 3.2 kg (-7 to 7 lb) Place a 30 kg (66.14 lb) weight (eg. a 30 kg (66.14 lb) of lead mass) onto the front passenger seat. Confirm that the sensitivity is within the standard range. SENSITIVITY CHECK PROCEDURE “1: DIAGNOSIS” - “1: OBD/MOBD” - “MODEL YEAR” - “MODEL SELECTION = 4 RUNNER” - Select the option parts - “9: OCCUPANT DETECT” - Refer to the following screen flow. RS *1: kg = lb Unit can be changed based on unit conversion setting. [System Selection Screen] “1: DIAGNOSIS” - “9: SETUP” - “4: UNIT CONVERSION” - “WEIGHT” (kg = lbs) C C113453E21 Standard value: 27 to 33 kg (59.52 to 72.75 lb) HINT: • When performing the sensitivity check, use a solid metal weight (the check result may not appear properly if a liquid weight is used). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–297 • If the sensitivity deviates from the standard range, retighten the bolts of the front passenger seat taking care not to deform the seat rail. After performing this procedure, if the sensitivity is not within the standard range, replace the front seat assembly RH. • If zero point calibration has not finished normally, replace the front seat assembly RH. RS RS–298 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PROBLEM SYMPTOMS TABLE HINT: Proceed to the troubleshooting for each circuit in the table below. Occupant Classification System Symptom The front passenger seat condition differs from the indication by the passenger airbag ON/OFF indicator (DTC is not output). RS Suspected area Trouble in Passenger Airbag ON/OFF Indicator See page RS-382 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–299 TERMINALS OF ECU 1. OCCUPANT CLASSIFICATION ECU O4 O3 6 54 3 21 121110 9 8 7 6 54 3 21 121110 9 8 7 C C110373E04 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification +B (O3-1) - GND (O6-3) R - W-B Power source (ECU-B Fuse) DIA (O3-2) - GND (O6-3) V - W-B Diagnosis (DLC3) IG switch ON GND (O3-3) - Body ground W-B - Body ground Ground Always Below 1 Ω FSR- (O3-4) - GND (O3-3) B - W-B Center airbag sensor assembly communication line (-) Always Below 1 Ω BGND (O3-5) - GND (O33) GR - W-B Passenger side buckle switch ground line Always Below 1 Ω IG (O3-7) - GND (O3-3) BR - W-B Power source (IG2 Fuse) IG switch ON 10 to 14 V FSR+ (O3-8) - FSR- (O34) W-B Center airbag sensor assembly communication line IG switch ON Pulse generation BSW (O3-9) - BGND (O35) L - GR Passenger side buckle switch line Buckle switch ON Buckle switch OFF Pulse generation SGD1 (O4-1) - GND (O33) G - W-B Occupant classification sensor front LH ground line Always Below 1 Ω SGD2 (O4-2) - GND (O33) O - W-B Occupant classification sensor front RH ground line Always Below 1 Ω SGD3 (O4-3) - GND (O33) W - W-B Occupant classification sensor rear LH ground line Always Below 1 Ω SGD4 (O4-4) - GND (O33) BR - W-B Occupant classification sensor rear RH ground line Always Below 1 Ω GR - W Occupant classification sensor rear LH power supply line IG switch ON, a load is applied to occupant classification sensor rear LH 4.5 to 5.1 V V - BR Occupant classification sensor rear RH power supply line IG switch ON, a load is applied to occupant classification sensor rear RH 4.5 to 5.1 V BR - G Occupant classification sensor front LH signal line IG switch ON, a load is applied to occupant classification sensor front LH 0.2 to 4.7 V L-O Occupant classification sensor front RH signal line IG switch ON, a load is applied to occupant classification sensor front RH 0.2 to 4.7 V SVC3 (O4-5) - SGD3 (O43) SVC4 (O4-6) - SGD4 (O44) SIG1 (O4-7) - SGD1 (O41) SIG2 (O4-8) - SGD2 (O42) Always 10 to 14 V Pulse generation RS RS–300 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Symbols (Terminal No.) SIG3 (O4-9) - SGD3 (O43) SIG4 (O4-10) - SGD4 (O44) SVC1 (O4-11) - SGD1 (O4-1) SVC2 (O4-12) - SGD2 (O4-2) Wiring Color Terminal Description Condition Specification Y-W Occupant classification sensor rear LH signal line IG switch ON, a load is applied to occupant classification sensor rear LH B - BR Occupant classification sensor rear RH signal line IG switch ON, a load is applied to occupant classification sensor rear RH 0.2 to 4.7 V R-G Occupant classification sensor front LH power supply line IG switch ON, a load is applied to occupant classification sensor front LH 4.5 to 5.1 V W-O Occupant classification sensor front RH power supply line IG switch ON, a load is applied to occupant classification sensor front RH 4.5 to 5.1 V 0.2 to 4.7 V DIAGNOSIS SYSTEM CG SG 1. SIL CHECK DLC3 (a) The ECM uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E98 Symbols (Terminal No.) RS Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V HINT: If the display shows a communication error message when connecting the cable of the intelligent tester to the DLC3, turning the ignition switch to the ON position and operating the intelligent tester, there is a problem on the vehicle side or tool side. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 2. Vibrate Slightly Shake Slightly Vibrate Slightly D025083E03 3. RS–301 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be simulated. No matter how experienced or skilled a technician may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will likely overlook something important and make a wrong guess at some points in the repair operation. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the ignition switch is turned to the ON position). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. (b) Simulation method for DTC B1795: Turn the ignition switch from the LOCK to the ON position, hold for 10 seconds, and then back to the LOCK position again 50 times in a row. HINT: DTC B1795 is output if the occupant classification ECU receives the ignition switch LOCK-ON-LOCK signal 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check (1) Turn the ignition switch to the ON position. (2) The passenger airbag ON/OFF indicator ("ON" and "OFF") comes on for approximately 4 seconds, then goes off for approximately 2 seconds. RS RS–302 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (3) Approximately 6 seconds after the ignition switch is turned to the ON position, the passenger airbag ON/OFF indicator will be ON/ OFF depending on the conditions listed below. Condition ON Indicator OFF Indicator Vacant OFF OFF Adult is seated. ON OFF Child is seated. OFF ON Child restraint system is set. OFF ON Front passenger occupant classification system failure OFF ON HINT: • The passenger airbag ON/OFF indicator comes on based on the timing chart below in order to check the indicator light circuit. ON Ignition Switch OFF Passenger Airbag ON/OFF Indicator (”ON”) Passenger Airbag ON/OFF Indicator (”OFF”) 4 Sec. 2 Sec. 4 Sec. 2 Sec. ON OFF ON OFF ON/OFF condition depends on the front passenger detection results. RS H043700E02 • When the occupant classification system has trouble, both the SRS warning light and the passenger airbag ON/OFF indicator ("OFF") come on. In this case, check the DTCs in the "AIRBAG SYSTEM" first. 4. H045951 CHECK PASSENGER AIRBAG ON/OFF INDICATOR (a) Turn the ignition switch to the ON position. (b) Check that the passenger airbag ON/OFF indicator ("ON" and "OFF") comes on for approximately 4 seconds, then goes off for approximately 2 seconds. HINT: Refer to the table in the previous step regarding the passenger airbag ON/OFF indicator when the ignition switch is turned to the ON position and approximately 6 seconds have elapsed. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–303 DTC CHECK / CLEAR 1. Intelligent Tester A066288E01 DTC CHECK HINT: When DTC B1150/23 is detected as a result of troubleshooting for "AIRBAG SYSTEM", perform troubleshooting for the occupant classification system. (a) Check the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. (b) Clear the DTCs. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. RS RS–304 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DATA LIST / ACTIVE TEST HINT: By accessing the DATA LIST displayed by the intelligent tester, you can perform such functions as reading the values of switches and sensors without removing any parts. Reading the DATA LIST as the first step in troubleshooting is one method to shorten labor time. 1. Intelligent Tester DATA LIST FOR OCCUPANT CLASSIFICATION ECU (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Following the display on the tester screen, read the "DATA LIST". A066288E01 Item RS Measurement Item/ Range (Display) Normal Condition Diagnostic Note ON/OFF - IG SW Ignition switch condition/ ON: Ignition switch ON OFF: Ignition switch OFF P BUCKLE SW Buckle switch (Passenger side)/ UNSET: Unfasten the passenger side seat belt SET: Fasten the passenger side seat belt NG: Passenger side seat belt has trouble UNSET/SET - PASSENGER CLASS Passenger classification/ AM50: Adult more than 54 kg (119.05 lb) is seated AF05: Adult (36 to 54 kg (79.37 to 119.05 lb)) is seated CHILD: Child (less than 36 kg (79.37 lb)) is seated CRS: Child restraint system (less than 7 kg (15.43 lb)) and passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb) is set OFF: Vacant AM50/AF05/CHILD/CRS/OFF - SENS RANGE INF Sensor range information/ OK: The value of a sensor is within the range NG: The value of a sensor is over the range OK - FL SENS RANGE Front left sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - FR SENS RANGE Front right sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–305 Measurement Item/ Range (Display) Normal Condition Diagnostic Note RL SENS RANGE Rear left sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - RR SENS RANGE Rear right sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - FL SENS VOL Front left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FR SENS VOL Front right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RL SENS VOL Rear left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RR SENS VOL Rear right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FL SENS WEIGHT Front left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - FR SENS WEIGHT Front right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - RL SENS WEIGHT Rear left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - RR SENS WEIGHT Rear right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - TOTAL WEIGHT Total weight information/ Min.: -68 kg (-149.91 lb) Max.: 128 kg (282.19 lb) -68 to 128 kg (-149.91 to 282.19 lb) - #PRESENT CODES Number of present trouble codes/ Min.: 0, Max.: 255 0 - #CODES Number of DTC recorded/ Min.: 0, Max.: 255 0 - Item RS RS–306 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART 1. If a trouble code is displayed during the DTC check, check the circuit listed for the code in the table below (proceed to the page listed for that circuit). Occupant Classification ECU DTC No. RS Trouble Area See page B1771 Passenger Side Buckle Switch Circuit Malfunction Detection Item 1. Front seat inner belt assembly (Buckle switch RH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-305 B1780 Front Occupant Classification Sensor LH Circuit Malfunction 1. Front seat assembly RH (Front occupant classification sensor LH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-311 B1781 Front Occupant Classification Sensor RH Circuit Malfunction 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-318 B1782 Rear Occupant Classification Sensor LH Circuit Malfunction 1. Front seat assembly RH (Rear occupant classification sensor LH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-325 B1783 Rear Occupant Classification Sensor RH Circuit Malfunction 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-332 B1785 Front Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor LH) 2. Occupant classification ECU RS-339 B1786 Front Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU RS-343 B1787 Rear Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor LH) 2. Occupant classification ECU RS-347 B1788 Rear Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor RH) 2. Occupant classification ECU RS-351 B1793 Occupant Classification Sensor Power Supply Circuit Malfunction 1. Front seat assembly RH (Occupant classification sensors) 2. Occupant classification ECU 3. Seat wire No. 1 RS-366 B1794 Open in Occupant Classification ECU Battery Positive Line 1. Battery 2. ECU-B Fuse 3. Seat wire No. 1 4. Occupant classification system RS-373 B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction 1. Occupant classification ECU 2. Center airbag sensor assembly 3. Floor wire 4. Seat wire No. 1 RS-355 B1795 Occupant Classification ECU Malfunction 1. Front seat inner belt assembly RH (Buckle switch RH) 2. Occupant classification ECU 3. Seat wire No. 1 RS-377 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC No. B1796 Detection Item Sleep Operation Failure of Occupant Classification ECU Trouble Area Occupant classification ECU RS–307 See page RS-380 RS RS–308 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Passenger Side Buckle Switch Circuit Malfunction B1771 DESCRIPTION The passenger side buckle switch circuit consists of the occupant classification ECU and the front seat inner belt assembly RH. DTC B1771 is recorded when a malfunction is detected in the passenger side buckle switch circuit. Troubleshoot DTC B1771 first when DTCs B1771 and B1795 are output simultaneously. DTC No. DTC Detection Condition • B1771 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the passenger side buckle switch circuit for 2 seconds. Passenger side buckle switch malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat inner belt assembly RH (Back switch RH) Occupant classification ECU Seat wire No. 1 WIRING DIAGRAM Occupant Classification ECU B16 Front Seat Inner Belt Assembly RH (Buckle SW RH) 2 9 O3 BSW 1 5 O3 BGND RS H046392E02 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 1 RS–309 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front seat inner belt assembly RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–310 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (SHORT TO B+) Seat Wire No. 1 D A C B Front Seat Inner Belt Assembly RH Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the front seat inner belt assembly RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Connector “B” Tester connection Condition Specified condition O3-9 (BSW) - Body ground Ignition switch ON Below 1 V O3-5 (BGND) - Body ground Ignition switch ON Below 1 V NG O3 REPAIR OR REPLACE SEAT WIRE NO. 1 BGND BSW C C111706E30 OK 4 CHECK SEAT WIRE NO. 1 (OPEN) Seat Wire No. 1 RS D A C B Front Seat Inner Belt Assembly RH Occupant Classification ECU Connector “C” Connector “B” B17 O3 BGND 1 2 BSW Service Wire C C111707E15 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect B17-2 and B17-1 of connector "C". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition O3-9 (BSW) - O3-5 (BGND) Always Below 1 Ω NG REPAIR OR REPLACE SEAT WIRE NO. 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–311 CHECK SEAT WIRE NO. 1 (SHORT) (a) Disconnect the service wire from connector "C". (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 D A C B Front Seat Inner Belt Assembly RH Occupant Classification ECU Tester connection Condition Specified condition O3-9 (BSW) - O3-5 (BGND) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 Connector “B” O3 BGND BSW C C111706E30 OK 6 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 D A C B Front Seat Inner Belt Assembly RH Occupant Classification ECU Tester connection Condition Specified condition O3-9 (BSW) - Body ground Always 1 MΩ or higher O3-5 (BGND) - Body ground Always 1 MΩ or higher NG Connector “B” O3 BGND BSW C C111706E30 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–312 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front seat inner belt assembly RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 RS REPLACE FRONT SEAT INNER BELT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat inner belt assembly RH (See page SB-6). HINT: Perform the inspection using parts from a normal vehicle if possible. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch to the ON position. (f) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position. (i) Check the DTCs (See page RS-300). OK: DTC B1771 is not output. HINT: Codes other than DTC B1771 may be output at this time, but they are not related to this check. OK END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–313 NG 9 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS293). NEXT 10 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT RS END RS–54 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0101/14 Open in Driver Side Squib Circuit DESCRIPTION The driver side squib circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0101/14 is recorded when an open circuit is detected in the driver side squib circuit. DTC No. DTC Detecting Condition • B0101/14 • • • Open circuit in D+ wire harness or D- wire harness of driver side squib Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-46. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–55 CHECK STEERING PAD (DRIVER SIDE SQUIB) DC F E Spiral Cable Driver Side Squib Center Airbag Sensor Assembly Connector “E” SST Color: Orange DLC3 CG DTC B0101/14 TC C C110390E02 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0101/14 is not output. HINT: Codes other than DTC B0101/14 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS RS–56 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB CIRCUIT (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Driver Side Squib A F E DC Tester connection Condition Specified condition D+ - D- Always Below 1 Ω B Spiral Cable Center Airbag Sensor Assembly NG Go to step 4 Connector E D- D+ Color: Orange C C110386E02 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side Squib RS FE DC Spiral Cable DLC3 C CG Center Airbag Sensor Assembly DTC B0101/14 TC C110391E01 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–57 CHECK INSTRUMENT PANEL WIRE (a) Disconnect the instrument panel wire connector from the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Tester connection Condition Specified condition A36-1 (D+) - A36-2 (D-) Always Below 1 Ω NG Driver Side Squib REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector “C” A36 D+ DC C110388E31 OK 5 CHECK SPIRAL CABLE (a) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib F E Connector E D- D+ Color: Orange C C110389E01 Tester connection Condition Specified condition D+ - D- Always Below 1 Ω NG REPLACE SPIRAL CABLE RS RS–58 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK USE SIMULATION METHOD TO CHECK RS RS–314 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Front Occupant Classification Sensor LH Circuit Malfunction B1780 DESCRIPTION The front occupant classification sensor LH circuit consists of the occupant classification ECU and the front occupant classification sensor LH. DTC B1780 is recorded when a malfunction is detected in the front occupant classification sensor LH circuit. DTC No. DTC Detecting Condition • B1780 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front occupant classification sensor LH circuit for 2 seconds. Front occupant classification sensor LH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Front occupant classification sensor LH) Occupant classification ECU Seat wire No. 1 WIRING DIAGRAM O5 Front Occupant Classification Sensor LH SVC1 1 Occupant Classification ECU 11 O4 SVC1 7 SIG1 2 O4 SIG1 RS SGD1 3 1 O4 SGD1 H043062E20 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 1 RS–315 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–316 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (SHORT TO B+) Seat Wire No. 1 A D C B Front Occupant Classification Sensor LH Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Connector “B” Tester connection Condition Specified condition O4-1 (SGD1) - Body ground Ignition switch ON Below 1 V O4-7 (SIG1) - Body ground Ignition switch ON Below 1 V O4-11 (SVC1) - Body ground Ignition switch ON Below 1 V O4 SGD1 NG SIG1 REPAIR OR REPLACE SEAT WIRE NO. 1 SVC1 C140732E01 OK 4 CHECK SEAT WIRE NO. 1 (OPEN) Seat Wire No. 1 RS D A C B Front Occupant Classification Sensor LH Connector “B” Connector “C” Service Wire Occupant Classification ECU O5 SGD1 SVC1 SGD1 SIG1 SIG1 C O4 SVC1 Service Wire C111709E23 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect O5-1 (SVC1) and O5-3 (SGD1), and connect O5-2 (SIG1) and O5-3 (SGD1) of connector "C". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition O4-7 (SIG1) - O4-1 (SGD1) Always Below 1 Ω O4-11 (SVC1) - O4-1 (SGD1) Always Below 1 Ω NG REPAIR OR REPLACE SEAT WIRE NO. 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–317 CHECK SEAT WIRE NO. 1 (SHORT) (a) Disconnect the service wire from connector "C". (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 A D C B Front Occupant Classification Sensor LH Occupant Classification ECU Tester connection Condition Specified condition O4-7 (SIG1) - O4-1 (SGD1) Always 1 MΩ or higher O4-11 (SVC1) - O4-1 (SGD1) Always 1 MΩ or higher O4-7 (SIG1) O4-11 (SVC1) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 Connector “B” O4 SGD1 SIG1 SVC1 C140732E01 OK 6 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 A D C B Front Occupant Classification Sensor LH Occupant Classification ECU Tester connection Condition Specified condition O4-1 (SGD1) - Body ground Always 1 MΩ or higher O4-7 (SIG1) - Body ground Always 1 MΩ or higher O4-11 (SVC1) - Body ground Always 1 MΩ or higher NG Connector “B” SGD1 SIG1 O4 SVC1 C140732E01 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–318 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. RS NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG OK Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–319 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Check the DTCs (See page RS-300). OK: DTC B1780 is not output. HINT: Codes other than DTC B1780 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. RS RS–320 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–321 Front Occupant Classification Sensor RH Circuit Malfunction B1781 DESCRIPTION The front occupant classification sensor RH circuit consists of the occupant classification ECU and the front occupant classification sensor RH. DTC B1781 is recorded when a malfunction is detected in the front occupant classification sensor RH circuit. DTC No. DTC Detecting Condition • B1781 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the front occupant classification sensor RH circuit for 2 seconds. Front occupant classification sensor RH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Front occupant classification sensor RH) Occupant classification ECU Seat wire No. 1 WIRING DIAGRAM O6 Front Occupant Classification Sensor RH SVC2 1 Occupant Classification ECU 12 O4 SVC2 8 SIG2 SGD2 2 3 O4 SIG2 RS 2 O4 SGD2 H043062E52 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. RS–322 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor RH. OK: The connectors are properly connected. NG RS OK CONNECT CONNECTORS, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–323 CHECK SEAT WIRE NO. 1 (SHORT TO B+) Seat Wire No. 1 D A C B Front Occupant Classification Sensor RH Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Connector “B” Tester connection Condition Specified condition O4-2 (SGD2) - Body ground Ignition switch ON Below 1 V O4-8 (SIG2) - Body ground Ignition switch ON Below 1 V O4-12 (SVC2) - Body ground Ignition switch ON Below 1 V O4 SGD2 NG SIG2 REPAIR OR REPLACE SEAT WIRE NO. 1 SVC2 C140732E02 OK 4 CHECK SEAT WIRE NO. 1 (OPEN) Seat Wire No. 1 D A C B Front Occupant Classification Sensor RH Connector “C” Service Wire Occupant Classification ECU Connector “B” O6 O4 SGD2 SVC2 SGD2 SIG2 SIG2 C SVC2 Service Wire C110374E27 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect O6-1 (SVC2) and O6-3 (SGD2), and connect O6-2 (SIG2) and O6-3 (SGD2) of connector "C". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition O4-8 (SIG2) - O4-2 (SGD2) Always Below 1 Ω O4-12 (SVC2) - O4-2 (SGD2) Always Below 1 Ω NG REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–324 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (SHORT) (a) Disconnect the service wire from connector "C". (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 D A C B Front Occupant Classification Sensor RH Occupant Classification ECU Tester connection Condition Specified condition O4-8 (SIG2) - O4-2 (SGD2) Always 1 MΩ or higher O4-12 (SVC2) - O4-2 (SGD2) Always 1 MΩ or higher O4-8 (SIG2) - O4-12 (SVC2) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 Connector “B” O4 SGD2 SIG2 SVC2 C140732E02 OK 6 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 RS D A C B Front Occupant Classification Sensor RH Occupant Classification ECU Tester connection Condition Specified condition O4-2 (SGD2) - Body ground Always 1 MΩ or higher O4-8 (SIG2) - Body ground Always 1 MΩ or higher O4-12 (SVC2) - Body ground Always 1 MΩ or higher NG Connector “B” SGD2 SIG2 O4 SVC2 C140732E02 OK REPAIR OR REPLACE SEAT WIRE NO. 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–325 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG OK Go to step 12 RS RS–326 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Check the DTCs (See page RS-300). OK: DTC B1781 is not output. HINT: Codes other than DTC B1781 may be output at this time, but they are not related to this check. OK END NG RS 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–327 NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–420 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY FRONT SEAT SIDE AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). (b) With the front seat side airbag assembly installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seatback assembly with a new one: Cuts, minute cracks or marked discoloration on the front seatback assembly around the front seat side airbag assembly. 2. H042167 H042168 RS FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) With the front seat side airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat side airbag assembly with a new one: • Cuts, minute cracks or marked discoloration on the front seat side airbag assembly. • Cracks or other damage to the wire harness or connector. CAUTION: Be sure to follow the correct removal and installation procedures. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–421 DISPOSAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front seat side airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the airbag assembly. • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. SST C110371E01 DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-389). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (d) Remove the 4 bolts from the front seat assembly. • For Manual Seat (See page SE-9) • For Power Seat (See page SE-18) HINT: Keep the front seat assembly in the cabin. (e) Install the SST. (1) Disconnect the connector (yellow colored one) from the front seat side airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS RS–422 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Connect the SST connector to the front seat side airbag assembly connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the 4 bolts to the front seat assembly. • For Manual Seat (See page SE-9) • For Power Seat (See page SE-18) Battery SST H041665E01 Battery SST 10 m (33 ft) or more C110476E01 (f) RS 2. (4) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (5) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the front seat side airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–423 HINT: Prepare a battery as the power source to deploy the airbag. SST C110371E01 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (a) Check the function of the SST (See page RS-389). (b) Remove the front seat side airbag assembly. (1) Remove the front seat assembly. • For Manual Seat (See page SE-9) • For Power Seat (See page SE-18) (2) Remove the 2 nuts and the front seat side airbag assembly from the seatback assembly. CAUTION: • When removing the front seat side airbag assembly, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. • When storing the front seat side airbag assembly, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag assembly to the tire. Wire harness: Stripped wire harness section: 1.25 mm2 or more (0.0019 in.2 or more) HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front seat side airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). (1) Install the 2 nuts to the front seat side airbag assembly. H041666 RS RS–424 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Wind the wire harness around each of the stud bolts of the front seat side airbag assembly as shown in the illustration. H042339 H042340 RS Tires (2 or more) Tires (2 or more) C C107074E02 (3) Position the front seat side airbag assembly inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the front seat side airbag assembly may become loose due to the shock when the airbag is deployed. • Always tie down the front seat side airbag assembly with the airbag deployment direction facing inside the tire. NOTICE: The tire will be damaged by airbag deployment, so use an extra tire. (d) Install the SST. (1) Connect the SST connector to the front seat side airbag assembly connector. SST 09082-00750 (e) Place the tires. (1) Place at least 2 tires under the tire which the front seat side airbag assembly is tied to. (2) Place at least 2 tires over the tire which the front seat side airbag assembly is tied to. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–425 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 (f) Front Seat Side Airbag Assembly Battery SST 10 m (33 ft) or more C C107075E02 H000544E01 Install the SST. (1) Connect the SST connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tires. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front seat side airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (h) Dispose of the front seat side airbag assembly. CAUTION: • The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag. • Do not apply water, etc. to a front seat side airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the front seat side airbag assembly from the tire. RS RS–426 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (2) Place the front seat side airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS RS–328 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Rear Occupant Classification Sensor LH Circuit Malfunction B1782 DESCRIPTION The rear occupant classification sensor LH circuit consists of the occupant classification ECU and the rear occupant classification sensor LH. DTC B1782 is recorded when a malfunction is detected in the rear occupant classification sensor LH circuit. DTC No. DTC Detecting Condition • B1782 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the rear occupant classification sensor LH circuit for 2 seconds. Rear occupant classification sensor LH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Rear occupant classification sensor LH) Occupant classification ECU Seat wire No. 1 WIRING DIAGRAM O7 Rear Occupant Classification Sensor LH SVC3 1 Occupant Classification ECU 5 O4 SVC3 9 SIG3 2 O4 SIG3 RS SGD3 3 3 O4 SGD3 H043062E53 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 1 RS–329 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor LH. OK: The connectors are connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–330 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (SHORT TO B+) Seat Wire No. 1 D A C B Rear Occupant Classification Sensor LH Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Connector “B” O4 SGD3 SVC3 Tester connection Condition Specified condition O4-3 (SGD3) - Body ground Ignition switch ON Below 1 V O4-5 (SVC3) - Body ground Ignition switch ON Below 1 V O4-9 (SIG3) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE SEAT WIRE NO. 1 SIG3 C140732E03 OK 4 CHECK SEAT WIRE NO. 1 (OPEN) Seat Wire No. 1 RS D A C B Occupant Classification ECU Rear Occupant Classification Sensor LH Connector “C” Service Wire Connector “B” O7 O4 SGD3 SVC3 SVC3 SGD3 SIG3 SIG3 C Tester connection Condition Specified condition O4-5 (SVC3) - O4-3 (SGD3) Always Below 1 Ω O4-9 (SIG3) - O4-3 (SGD3) Always Below 1 Ω NG Service Wire C110374E28 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect O7-1 (SVC3) and O7-3 (SGD3), and connect O7-2 (SIG3) and O7-3 (SGD3) of connector "C". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE SEAT WIRE NO. 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–331 CHECK SEAT WIRE NO. 1 (SHORT) (a) Disconnect the service wire from connector "C". (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 D A C B Rear Occupant Classification Sensor LH Occupant Classification ECU Tester connection Condition Specified condition O4-5 (SVC3) - O4-3 (SGD3) Always 1 MΩ or higher O4-9 (SIG3) - O4-3 (SGD3) Always 1 MΩ or higher O4-5 (SVC3) - O4-9 (SIG3) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 Connector “B” O4 SGD3 SVC3 SIG3 C140732E03 OK 6 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) (a) Measure the resistance according to value(s) in the table below. Resistance Seat Wire No. 1 D A C B Rear Occupant Classification Sensor LH Occupant Classification ECU Tester connection Condition Specified condition O4-3 (SGD3) - Body ground Always 1 MΩ or higher O4-5 (SVC3) - Body ground Always 1 MΩ or higher O4-9 (SIG3) - Body ground Always 1 MΩ or higher NG Connector “B” SGD3 O4 SVC3 SIG3 C140732E03 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–332 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. RS NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG OK Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–333 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Check the DTCs (See page RS-300). OK: DTC B1782 is not output. HINT: Codes other than DTC B1782 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. RS RS–334 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–335 Rear Occupant Classification Sensor RH Circuit Malfunction B1783 DESCRIPTION The rear occupant classification sensor RH circuit consists of the occupant classification ECU and the rear occupant classification sensor RH. DTC B1783 is recorded when a malfunction is detected in the rear occupant classification sensor RH circuit. DTC No. DTC Detecting Condition • B1783 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the rear occupant classification sensor RH circuit for 2 seconds. Rear occupant classification sensor RH malfunction Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Rear occupant classification sensor RH) Occupant classification ECU Seat wire No. 1 WIRING DIAGRAM O8 Rear Occupant Classification Sensor RH SVC4 1 Occupant Classification ECU 6 O4 SVC4 10 SIG4 2 O4 SIG4 RS SGD4 3 4 O4 SGD4 H043062E54 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. RS–336 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor RH. OK: The connectors are properly connected. NG RS OK CONNECT CONNECTORS, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–337 CHECK SEAT WIRE NO. 1 (SHORT TO B+) Seat Wire No. 1 D A C B Rear Occupant Classification Sensor RH Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Connector “B” O4 SGD4 SVC4 Tester connection Condition Specified condition O4-4 (SGD4) - Body ground Ignition switch ON Below 1 V O4-6 (SVC4) - Body ground Ignition switch ON Below 1 V O4-10 (SIG4) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE SEAT WIRE NO. 1 SIG4 C140732E04 OK 4 CHECK SEAT WIRE NO. 1 (OPEN) Seat Wire No. 1 D A C B Occupant Classification ECU Rear Occupant Classification Sensor RH Connector “C” Connector “B” O8 O4 Service Wire SGD4 SVC4 SGD4 SIG4 C SVC4 Tester connection Condition Specified condition O4-6 (SVC4) - O4-4 (SGD4) Always Below 1 Ω O4-10 (SIG4) - O4-4 (SGD4) Always Below 1 Ω NG SIG4 Service Wire C111709E24 OK (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Using a service wire, connect O8-1 (SVC4) and O8-3 (SGD4), and connect O8-2 (SIG4) and O8-3 (SGD4) of connector "C". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Resistance REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–338 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (SHORT) (a) Disconnect the service wire from connector "C". (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 D A C B Rear Occupant Classification Sensor RH Occupant Classification ECU Tester connection Condition Specified condition O4-6 (SVC4) - O4-4 (SGD4) Always 1 MΩ or higher O4-10 (SIG4) - O4-4 (SGD4) Always 1 MΩ or higher O4-6 (SVC4) - O4-10 (SIG4) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 Connector “B” O4 SGD4 SVC4 SIG4 C140732E04 OK 6 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 RS D A C B Rear Occupant Classification Sensor RH Occupant Classification ECU Tester connection Condition Specified condition O4-4 (SGD4) - Body ground Always 1 MΩ or higher O4-6 (SVC4) - Body ground Always 1 MΩ or higher O4-10 (SIG4) - Body ground Always 1 MΩ or higher NG Connector “B” SGD4 O4 SVC4 SIG4 C140732E04 OK REPAIR OR REPLACE SEAT WIRE NO. 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–339 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG OK Go to step 12 RS RS–340 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Check the DTCs (See page RS-300). OK: DTC B1783 is not output. HINT: Codes other than DTC B1783 may be output at this time, but they are not related to this check. OK END NG RS 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–341 NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–342 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Front Occupant Classification Sensor LH Collision Detection B1785 DESCRIPTION DTC B1785 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor LH if an accident occurs. DTC B1785 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1785 can be cleared by "Zero point calibration" and "Sensitivity check". Therefore, if DTC B1785 is output, first perform "Zero point calibration" and "Sensitivity check". DTC No. B1785 DTC Detecting Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Front occupant classification sensor LH detected a large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Front occupant classification sensor LH) WIRING DIAGRAM See page RS-311. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG RS Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–343 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1785 is not output. HINT: Codes other than DTC B1785 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 RS RS–344 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1785 is not output. HINT: Codes other than DTC B1785 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). NEXT RS 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–345 NEXT END RS RS–346 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Front Occupant Classification Sensor RH Collision Detection B1786 DESCRIPTION DTC B1786 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor RH if an accident occurs. DTC B1786 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1786 can be cleared by "Zero point calibration" and "Sensitivity check". Therefore, if DTC B1786 is output, first perform "Zero point calibration" and "Sensitivity check". DTC No. B1786 DTC Detection Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Front occupant classification sensor RH detected a large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Front occupant classification sensor RH) WIRING DIAGRAM See page RS-318. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG RS Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–347 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1786 is not output. HINT: Codes other than DTC B1786 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 RS RS–348 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1786 is not output. HINT: Codes other than DTC B1786 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). NEXT RS 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–349 NEXT END RS RS–350 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Rear Occupant Classification Sensor LH Collision Detection B1787 DESCRIPTION DTC B1787 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor LH if an accident occurs. DTC B1787 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1787 can be cleared by "Zero point calibration" and "Sensitivity check". Therefore, if DTC B1787 is output, first perform "Zero point calibration" and "Sensitivity check". DTC No. B1787 DTC Detecting Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Rear occupant classification sensor LH detected a large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Rear occupant classification sensor LH) WIRING DIAGRAM See page RS-325. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG RS Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–351 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1787 is not output. HINT: Codes other than DTC B1787 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 RS RS–352 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1787 is not output. HINT: Codes other than DTC B1787 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). NEXT RS 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–353 NEXT END RS RS–354 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Rear Occupant Classification Sensor RH Collision Detection B1788 DESCRIPTION DTC B1788 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor RH if an accident occurs. DTC B1788 is also output when the front seat assembly RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1788 can be cleared by "Zero point calibration" and "Sensitivity check". Therefore, if DTC B1788 is output, first perform "Zero point calibration" and "Sensitivity check". DTC No. B1788 DTC Detection Condition • • • Front seat assembly RH malfunction Occupant classification ECU malfunction Rear occupant classification sensor RH detected a large load Trouble Area • • Occupant classification ECU Front seat assembly RH (Rear occupant classification sensor RH) WIRING DIAGRAM See page RS-332. INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG RS Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–355 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1788 is not output. HINT: Codes other than DTC B1788 may be output at this time, but they are not related to this check. OK END NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG Go to step 8 OK 6 PERFORM ZERO POINT CALIBRATION (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 8 RS RS–356 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1788 is not output. HINT: Codes other than DTC B1788 may be output at this time, but they are not related to this check. OK END NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). NEXT RS 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–357 NEXT END RS RS–358 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction DESCRIPTION The center airbag sensor assembly communication circuit consists of the occupant classification ECU and the center airbag sensor assembly. DTC B1790 is recorded when a malfunction is detected in the center airbag sensor assembly communication circuit. DTC No. DTC Detecting Condition • B1790 • • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the center airbag sensor assembly communication circuit for 2 seconds. Center airbag sensor assembly malfunction Occupant classification ECU malfunction Trouble Area • • • • Occupant classification ECU Center airbag sensor assembly Floor wire Seat wire No. 1 WIRING DIAGRAM Occupant Classification ECU Center Airbag Sensor Assembly 8 FSR+ O3 1 Bl1 3 1 A33 A34 FSR+ (*1) (*2) 4 O3 4 Bl1 2 10 A33 A34 FSR(*1) (*2) RS FSR- *1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag C116312E02 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–359 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check that the connectors are properly connected to the occupant classification ECU and the center airbag sensor assembly. OK: The connectors are properly connected. NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 RS RS–360 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT TO B+) F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly (a) Disconnect the connectors from the occupant classification ECU and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition O3-8 (FSR+) - Body ground Ignition switch ON Below 1 V O3-4 (FSR-) - Body ground Ignition switch ON Below 1 V Connector “E” NG O3 FSR- FSR+ C C110462E30 OK RS Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 4 RS–361 CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (OPEN) A E D C B Center Airbag Sensor Assembly Occupant Classification ECU Connector “B” F A33 (*1) Connector “E” FSR- O3 Service Wire 1 2 3 4 5 6 7 8 9 101112 FSRFSR+ FSR+ A34 (*2) FSR+ *1: with Side and Curtain Shield Airbag Tester connection Condition Specified condition O3-8 (FSR+) - O3-4 (FSR-) Always Below 1 Ω NG *2: without Side and Curtain Shield Airbag FSRC (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) with Side and curtain shield airbag: Using a service wire, connect A33-1 (FSR+) and A33-2 (FSR-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) without Side and curtain shield airbag: Using a service wire, connect A34-3 (FSR+) and A34-10 (FSR-) of connector "B". NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Measure the resistance according to the value(s) in the table below. Resistance Go to step 13 Service Wire C111721E12 OK RS RS–362 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT) (a) Disconnect the service wire from connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly Tester connection Condition Specified condition O3-8 (FSR+) - O3-4 (FSR-) Always 1 MΩ or higher NG Go to step 14 Connector “E” O3 FSR- FSR+ C C110462E30 OK 6 CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT TO GROUND) (a) Measure the resistance according to the value(s) in the table below. Resistance RS F A E DC Occupant Classification ECU B Center Airbag Sensor Assembly Tester connection Condition Specified condition O3-8 (FSR+) - Body ground Always 1 MΩ or higher O3-4 (FSR-) - Body ground Always 1 MΩ or higher NG Connector “E” O3 FSR- FSR+ C C110462E30 OK Go to step 15 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–363 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) NEXT Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. RS RS–364 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT 11 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1790 is not output. HINT: Codes other than DTC B1790 may be output at this time, but they are not related to this check. NG OK RS END REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 12 RS–365 CHECK FLOOR WIRE (SHORT TO B+) Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the floor wire connector from the seat wire No. 1. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Floor Wire Connector “C” Bl1 FSR+ Condition Specified condition Ignition switch ON Below 1 V Bl1-4 (FSR-) - Body ground Ignition switch ON Below 1 V NG FSRC Tester connection Bl1-1 (FSR+) - Body ground REPAIR OR REPLACE FLOOR WIRE C110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–366 13 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE (OPEN) Seat Wire No. 1 Floor Wire F A E D C B Occupant Classification ECU Center Airbag Sensor Assembly (a) Disconnect the floor wire connector from the seat wire No. 1. HINT: The service wire has already been inserted into the connector "B". (b) Measure the resistance according to the value(s) in the table below. Resistance Connector “B” A33 (*1) Connector “C” FSR+ Bl1 FSR+ A34 (*2) FSR+ FSR*1: with Side and Curtain Shield Airbag *2: without Side and Curtain Shield Airbag FSRC Service Wire C111722E08 OK RS Condition Specified condition Always Below 1 Ω NG Service Wire FSR- Tester connection Bl1-1 (FSR+) - Bl1-4 (FSR-) REPAIR OR REPLACE SEAT WIRE NO. 1 REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 14 RS–367 CHECK FLOOR WIRE (SHORT) (a) Disconnect the floor wire connector from the seat wire No. 1. (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Tester connection Condition Specified condition Bl1-1 (FSR+) - Bl1-4 (FSR-) Always 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Floor Wire Connector “C” Bl1 FSR+ FSRC C110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–368 15 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE (SHORT TO GROUND) (a) Disconnect the floor wire connector from the seat wire No. 1. (b) Measure the resistance according to the value(s) in the table below. Resistance Seat Wire No. 1 F A E Occupant Classification ECU D C B Center Airbag Sensor Assembly Floor Wire Bl1 FSR+ FSRC110464E19 OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS Condition Specified condition Bl1-1 (FSR+) - Body ground Always 1 MΩ or higher Bl1-4 (FSR-) - Body ground Always 1 MΩ or higher NG Connector “C” C Tester connection REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1793 RS–369 Occupant Classification Sensor Power Supply Circuit Malfunction DESCRIPTION The occupant classification sensor power supply circuit consists of the occupant classification ECU and the occupant classification sensors. DTC B1793 is recorded when a malfunction is detected in the occupant classification sensor power supply circuit. DTC No. DTC Detecting Condition • B1793 • The occupant classification ECU receives a line short circuit signal, an open circuit signal, a short circuit to ground signal or a short circuit to B+ signal in the occupant classification sensor power supply circuit for 2 seconds. Occupant classification ECU malfunction Trouble Area • • • Front seat assembly RH (Occupant classification sensors) Occupant classification ECU Seat wire No. 1 HINT: When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1793 of the occupant classification system. WIRING DIAGRAM O8 Front Occupant Classification Sensor RH Occupant Classification ECU 6 SVC4 1 O4 SVC4 O6 Front Occupant Classification Sensor RH 12 SVC2 1 RS O4 SVC2 O7 Rear Occupant Classification Sensor LH 5 SVC3 1 O4 SVC3 O5 Rear Occupant Classification Sensor LH SVC1 1 11 O4 SVC1 H043061E07 RS–370 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the under surface of the seat cushion. • In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary. 1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensors. OK: The connectors are properly connected. RS NG OK CONNECT CONNECTORS, THEN GO TO STEP 1 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–371 CHECK SEAT WIRE NO. 1 (SHORT TO B+) O4 (a) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage SVC3 SVC4 SVC2 SVC1 H043111E06 Tester connection Condition Specified condition O4-5 (SVC3) - Body ground Ignition switch ON Below 1 V O4-6 (SVC4) - Body ground Ignition switch ON Below 1 V O4-11 (SVC1) - Body ground Ignition switch ON Below 1 V O4-12 (SVC2) - Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE SEAT WIRE NO. 1 OK 4 CHECK SEAT WIRE NO. 1 (SHORT TO GROUND) O4 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Resistance SVC3 SVC4 SVC2 SVC1 H043111E07 Tester connection Condition Specified condition O4-5 (SVC3) - Body ground Always 1 MΩ or higher O4-6 (SVC4) - Body ground Always 1 MΩ or higher O4-11 (SVC1) - Body ground Always 1 MΩ or higher O4-12 (SVC2) - Body ground Always 1 MΩ or higher NG OK REPAIR OR REPLACE SEAT WIRE NO. 1 RS RS–372 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK SEAT WIRE NO. 1 (OPEN) O4 (a) Measure the resistance according to the value(s) in the table below. Resistance SVC3 SVC4 Tester connection Condition Specified condition O4-5 (SVC3) - O7-1 (SVC3) Always Below 1 Ω O4-6 (SVC4) - O8- 1 (SVC4) Always Below 1 Ω O4-11 (SVC1) - O5-1 (SVC1) Always Below 1 Ω O4-12 (SVC2) - O6-1 (SVC2) Always Below 1 Ω SVC2 SVC1 H043111E08 NG REPAIR OR REPLACE SEAT WIRE NO. 1 OK 6 CHECK SEAT WIRE NO. 1 (SHORT) O4 (a) Measure the resistance according to the value(s) in the table below. Resistance SVC3 SVC4 SVC2 SVC1 H043111E11 RS Tester connection Condition Specified condition O4-5 (SVC3) - O4-6 (SVC4) Always 1 MΩ or higher O4-6 (SVC4) - O4-11 (SVC1) Always 1 MΩ or higher O4-11 (SVC1) - O4-12 (SVC2) Always 1 MΩ or higher O4-12 (SVC2) - O4-5 (SVC3) Always 1 MΩ or higher O4-12 (SVC2) - O4-6 (SVC4) Always 1 MΩ or higher O4-11 (SVC1) - O4-5 (SVC3) Always 1 MΩ or higher NG REPAIR OR REPLACE SEAT WIRE NO. 1 OK 7 CHECK DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in the memory (See page RS300). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–373 HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Check the DTCs (See page RS-300). OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NG Go to step 12 OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG OK Go to step 12 RS RS–374 11 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in the memory (See page RS300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Check the DTCs (See page RS-300). OK: DTC B1793 is not output. HINT: Codes other than DTC B1793 may be output at this time, but they are related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the front seat assembly RH (See page SE-9 for manual seat, SE-18 for power seat). NEXT RS 13 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–375 NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–59 B0102/11 Short to GND in Driver Side Squib Circuit DESCRIPTION The driver side squib circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0102/11 is recorded when a short to ground is detected in the driver side squib circuit. DTC No. DTC Detecting Condition • B0102/11 • • • Short circuit in driver side squib wire harness (to ground) Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-46. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS RS–60 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK STEERING PAD (DRIVER SIDE SQUIB) DC F E Spiral Cable Center Airbag Sensor Assembly Driver Side Squib Connector “E” SST Color: Orange DLC3 CG DTC B0102/11 TC C C110392E02 RS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0102/11 is not output. HINT: Codes other than DTC B0102/11 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS–61 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB CIRCUIT (a) Disconnect the connector from the center airbag sensor assembly. (b) Measure the resistance according to the value(s) in the table below. Resistance Driver Side Squib A F E DC B Spiral Cable Center Airbag Sensor Assembly Tester connection Condition D+ - Body ground Always 1 MΩ or higher D- - Body ground Always 1 MΩ or higher NG Specified condition Go to step 4 Connector E D- D+ Color: Orange C C110386E02 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side Squib FE DC Spiral Cable Center Airbag Sensor Assembly DTC B0102/11 DLC3 C CG TC C110393E01 (a) Connect the connectors to the steering pad and the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Clear the DTCs stored in memory (See page RS-35). (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-35). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not related to this check. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–62 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 CHECK INSTRUMENT PANEL WIRE (a) Disconnect the instrument panel wire connector from the spiral cable. (b) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Driver Side Squib Tester connection Condition Specified condition A36-1 (D+) Body ground Always 1 MΩ or higher A36-2 (D-) Body ground Always 1 MΩ or higher NG Connector “C” A36 REPAIR OR REPLACE INSTRUMENT PANEL WIRE D+ DC C110388E31 OK 5 CHECK SPIRAL CABLE (a) Measure the resistance according to the value(s) in the table below. Resistance Instrument Panel Wire RS A F E D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib Connector E D- D+ Color: Orange C C110389E01 Tester connection Condition Specified condition D+ - Body ground Always 1 MΩ or higher D- - Body ground Always 1 MΩ or higher NG REPLACE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–63 OK USE SIMULATION METHOD TO CHECK RS RS–376 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1794 Open in Occupant Classification ECU Battery Positive Line DESCRIPTION This circuit consists of the occupant classification ECU and the power source circuit (battery, fuse, wire harness). DTC B1794 is recorded when a malfunction is detected in the occupant classification ECU or the power source circuit. HINT: When DTC B1794 is output after switching the ignition switch LOCK-ON-LOCK 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system, the DTC is output again when a malfunction is detected even once after being cleared, unless the normal system code is input. DTC No. DTC Detecting Condition • B1794 • The ignition switch is turned from LOCK to ON, hold for 10 seconds or more, and back to LOCK again 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system. Occupant classification ECU malfunction Trouble Area • • • • Battery ECU-B Fuse Seat wire No. 1 Occupant classification ECU HINT: When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1794 of the occupant classification system. RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–377 WIRING DIAGRAM I18 Ignition SW Engine Room R/B Occupant Classification ECU AM2 2 1 2 Short Pin 1 2 2 7 AM2 2 Driver Side J/B ECU-B 2 2 1 IG2 6 6 1D 2 11 1J IGN 4 1B 4 1L Center J/B B 3E J8 J/C B B B 3E B J/C B J31 J32 15 IO3 5 Bl1 1 O3 +B 14 IO3 6 Bl1 7 O3 IG 3 Bl1 3 O3 GND RS Battery BM H045968E01 INSPECTION PROCEDURE 1 CHECK BATTERY (a) Measure the voltage of the battery. Voltage: 11 to 14 V NG OK REPLACE BATTERY RS–378 2 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FUSE (a) Check the ECU-B fuse. Resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS GND O3 +B IG H043111E10 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connector from the occupant classification ECU. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch to the ON position. (f) Measure the voltage and resistance according to the value(s) in the table below. Standard Tester connection Condition Specified condition O3-1 (+B) - Body ground Ignition switch ON 10 to 14 V O3-7 (IG) - Body ground Ignition switch ON 10 to 14 V O3-3 (GND) - Body ground Always Below 1 Ω NG RS REPAIR OR REPLACE WIRE HARNESS OK 4 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (See page RS-300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position, and wait for at least 10 seconds. (e) Using the intelligent tester, check the DTCs of the occupant classification ECU (See page RS-300). OK: DTC B1794 is not output. HINT: Codes other than code B1794 may be output at this time, but they are not related to this check. NG Go to step 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–379 OK USE SIMULATION METHOD TO CHECK 5 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 6 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform the "Zero point calibration" (See page RS-293). OK: The "COMPLETED" is displayed. NEXT 7 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–380 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1795 Occupant Classification ECU Malfunction DESCRIPTION DTC B1795 is recorded when a malfunction is detected in the occupant classification ECU. Troubleshoot DTC B1771 first when the DTCs B1771 and B1795 are output simultaneously. DTC No. DTC Detecting Condition • • B1795 • Trouble Area Occupant classification ECU circuit malfunction The occupant classification ECU receives a short circuit to ground signal in the passenger side buckle switch circuit for 2 seconds. Occupant classification ECU malfunction • • • Seat wire No. 1 Front seat inner belt assembly RH (Buckle switch RH) Occupant classification ECU HINT: When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1795 of the occupant classification system. WIRING DIAGRAM See page RS-374. INSPECTION PROCEDURE 1 CHECK DTC (a) Turn the ignition switch to the ON position, and wait for at least 10 seconds. (b) Check the DTCs (See page RS-300). Result: A: DTCs B1771 and B1795 are output. B: DTC B1795 is output. HINT: Codes other than DTC B1771 and B1795 may be output at this time, but they are not related to this check. RS A GO TO DTC B1771 B 2 CHECK FUSE (a) Measure the resistance of the ECU-B fuse. Resistance: Below 1 Ω NG OK REPLACE FUSE SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–381 CHECK WIRE HARNESS (SOURCE VOLTAGE) GND O3 +B IG H043111E10 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Disconnect the connector from the occupant classification ECU. (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition O3-1 (+B) - Body ground Always 10 to 14 V O3-7 (IG) - Body ground Ignition switch ON 10 to 14 V (g) Turn the ignition switch to the LOCK position. (h) Measure the resistance according to the value(s) in the table below. Resistance Tester connection Condition Specified condition O3-3 (GND) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 4 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETED" is displayed. RS RS–382 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–427 CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS CONSOLE BOX MOUNTING BRACKET FRONT 17.5 (178, 13) CENTER AIRBAG SENSOR ASSEMBLY CONSOLE BOX DUCT NO. 1 CONSOLE UPPER PANEL GARNISH NO. 2 CONSOLE UPPER PANEL GARNISH NO. 1 CONSOLE UPPER REAR PANEL SUB-ASSEMBLY CONSOLE PANEL SUB-ASSEMBLY UPPER RS CONSOLE BOX ASSEMBLY REAR N*m (kgf*cm, ft.*lbf) : Specified torque C131318E03 RS–428 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY ON-VEHICLE INSPECTION RS 1. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). 2. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). 3. INSPECT CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS DEPLOYED) (a) Replace the center airbag sensor assembly. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The center airbag sensor assembly should be replaced after any of the airbags has deployed, as it has been subjected to the impact. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–383 Sleep Operation Failure of Occupant Classification ECU B1796 DESCRIPTION During sleep mode, the occupant classification ECU reads the condition of each sensor while the ignition switch is off. In this mode, if the occupant classification ECU detects an internal malfunction, DTC B1796 is output. DTC No. B1796 DTC Detecting Condition Trouble Area Occupant classification ECU malfunction Occupant classification ECU INSPECTION PROCEDURE 1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (See page RS-300). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor assembly. (c) Turn the ignition switch to the LOCK position, and wait for at least 10 seconds. (d) Turn the ignition switch to the ON position. (e) Check the DTCs (See page RS-300). OK: DTC B1796 is not output. HINT: Codes other than DTC B1796 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK RS NG 2 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 3 PERFORM ZERO POINT CALIBRATION (a) Connect the negative (-) terminal cable to the battery. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. RS–384 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (d) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: The "COMPLETED" is displayed. NEXT 4 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard values: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–385 Trouble in Passenger Airbag ON / OFF Indicator DESCRIPTION The occupant classification system detects the front passenger seat condition. It then informs a passenger of the front passenger airbag assembly condition (activated/not activated) by the passenger airbag ON/OFF indicator. The table below shows the normal indication condition of the passenger airbag ON/OFF indicator and the front passenger seat condition. Front passenger seat condition ON Indicator OFF Indicator Adult is seated. ON OFF Child is seated. OFF ON Vacant OFF OFF Occupant classification system failure OFF ON INSPECTION PROCEDURE 1 CHECK SRS WARNING LIGHT (a) Turn the ignition switch to the ON position, and check the SRS warning light condition. HINT: If this trouble occurs, the SRS warning light is off. If it is on, a DTC is output. Troubleshoot for the output DTC. OK: The SRS warning light does not come on. NG Go to step 9 OK 2 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CONDITION RS (a) Turn the ignition switch to the ON position. (b) Check if the passenger airbag ON/OFF indicator correctly indicates the front passenger seat condition. OK Front passenger seat condition ON Indicator OFF Indicator ON OFF Adult is seated. Child is seated. OFF ON Vacant OFF OFF Occupant classification system failure OFF ON OK END NG 3 PERFORM ZERO POINT CALIBRATION (a) Turn the ignition switch to the LOCK position. (b) Connect the intelligent tester to the DLC3. RS–386 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Turn the ignition switch to the ON position. (d) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETE" is displayed. NG Go to step 5 OK 4 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 5 OK END 5 RETIGHTEN FRONT SEAT ASSEMBLY RH BOLT (a) Turn the ignition switch to the LOCK position. (b) Loosen the 4 installation bolts of the front seat assembly RH. (c) Tighten the 4 installation bolts of the front seat assembly RH to the specified torque. Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) NG RS Go to step 8 OK 6 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETE" is displayed. NG OK Go to step 8 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–387 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 8 CHECK CONNECTORS (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Check the connectors are properly connected to the occupant classification ECU and the 4 occupant classification sensors. OK: The connectors are connected. (d) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (e) Check the connectors are not damaged or deformed. OK: The connectors are properly normal. NG REPAIR OR REPLACE WIRE HARNESS OK 9 RS CHECK DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (d) Turn the ignition switch to the LOCK position. (e) Clear the DTCs stored in the memory (See page RS300). (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Check the DTCs (See page RS-300). OK: DTC is not output. NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS–388 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery. (c) Replace the occupant classification ECU (See page RS447). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 11 PERFORM ZERO POINT CALIBRATION (a) (b) (c) (d) Connect the negative (-) terminal cable to the battery. Connect the intelligent tester to the DLC3. Turn the ignition switch to the ON position. Using the intelligent tester, perform "Zero point calibration" (See page RS-293). OK: "COMPLETE" is displayed. NEXT 12 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform "Sensitivity check" (See page RS-293). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS NEXT END RS–388 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1 ). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE STEERING WHEEL COVER LOWER NO.3 (a) Using a screwdriver, remove the steering wheel No. 3 cover lower. HINT: Tape up the screwdriver tip before use. 4. REMOVE STEERING WHEEL COVER LOWER NO.2 (a) Using a screwdriver, remove the steering wheel No. 2 cover lower. HINT: Tape up the screwdriver tip before use. 5. REMOVE STEERING PAD (a) Using a "torx" socket wrench (T30), loosen the 2 "torx" screws until the groove along the screw circumference catches on the screw case. F043322 RS H042354 (b) Pull out the steering pad from the steering wheel assembly and support the steering pad with one hand as shown in the illustration. NOTICE: When removing the steering pad, do not pull the airbag wire harness. (c) Using a screw driver, disconnect the 2 connectors from the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (d) Remove the steering pad. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–389 INSTALLATION 1. INSTALL STEERING PAD (a) Support the steering pad with one hand as shown in the illustration. (b) Connect the 2 connectors to the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Connect the horn connector. (d) Confirm that the circumference groove of the "torx" screw fits in the screw case, and place the steering pad onto the steering wheel assembly. (e) Using a "torx" socket wrench (T30), tighten the 2 "torx" screws. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) 2. INSTALL STEERING WHEEL NO.3 COVER LOWER (a) Install the steering wheel No.3 cover lower. 3. INSTALL STEERING WHEEL NO.2 COVER LOWER (a) Install the steering wheel No.2 cover lower. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. INSPECT STEERING PAD (a) With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one: Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion. (b) Make sure that the horn sounds. HINT: If the horn does not sound, inspect the horn system (See page HO-2). 6. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). H042354 H042163 RS RS–390 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the steering pad, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a steering pad that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the steering pad. • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. 1. DISPOSE OF STEERING PAD (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST. SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool RS SST C110371E01 Battery SST C110372E01 (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD SST C110475E01 H042176 RS–391 (2) Check the function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. CAUTION: • Do not connect the SST connector (yellow colored one) to the airbag. • If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace the SST with a new one. (3) Disconnect the SST from the battery. (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (d) Remove the steering column cover lower. (1) While turning the steering wheel assembly to the right and left, remove the 3 screws and steering column cover lower. (e) Install the SST. CAUTION: Check that there is no looseness in the steering wheel assembly and steering pad. (1) Disconnect the airbag connector (yellow colored one) from the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H042347E02 Battery SST 10 m (33 ft) or more C110476E01 (3) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (4) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. RS RS–392 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (f) 2. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF STEERING PAD (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the steering pad, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST. SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool RS SST C110371E01 Battery SST C110372E01 (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD SST C110475E01 Wire Harness Diameter Stripped Wire Harness Section B104882E02 L M H042357E02 RS–393 (2) Check the function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. CAUTION: • Do not connect the SST connector (yellow colored one) to the airbag. • If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so replace the SST with a new one. (3) Disconnect the SST from the battery. (b) Remove the steering pad (See page RS-387). CAUTION: • When removing the steering pad, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. • When storing the steering pad, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the steering pad to the disc wheel. Wire harness: Stripped wire harness section: 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the steering pad, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) Install the 2 bolts with washers into the 2 bolt holes on the steering pad. Bolt: L: 35.0 mm (1.378 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE: • Tighten the bolts by hand until they become difficult to turn. • Do not tighten the bolts excessively. RS RS–394 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (2) After connecting the SST below to each other, connect them to the steering pad. SST 09082-00802 (09082-10801, 0908230801) SST H042358E01 (3) Using 3 wire harnesses, wind wire harness at least 2 times each around each of the bolts installed on the left and right sides of the steering pad. CAUTION: • Tightly wind the wire harness around the bolts so that there is no slack. • Make sure that the wire harness is tight. If there is slack in the wire harness, the steering pad may become loose due to the shock when the airbag is deployed. 2 times or more H042359E03 RS H042360 (4) Face the airbag deployment side of the steering pad upward on top of a tire and wheel set. Separately tie the left and right sides of the steering pad to the disc wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole of the disc wheel. CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the steering pad may become loose due to the shock when the airbag is deployed. • Always tie down the steering pad with the airbag deployment side facing upward. NOTICE: The disc wheel will be damaged by airbag deployment, so use an extra disc wheel. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD SST H042361E02 RS–395 (d) Install the SST. CAUTION: Place the disc wheel on level ground. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tire. Battery SST 10 m (33 ft) or more H040014E06 Y Y X Weight Weight C111122E01 (e) Cover the steering pad (Using a cardboard box). (1) Cover the steering pad with the cardboard box. (2) Place weights on the cardboard box in 4 places totalling at least 190 N (19 kg, 43 lb). Cardboard box size: Must exceed the following dimensions X: 460 mm (18.11 in.) Y: 650 mm (25.59 in.) NOTICE: • When the dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the steering pad is tied to, X should be the following size. X = 460 mm (18.11 in.) + width of tire • If a cardboard box which is smaller than the specified size is used, the cardboard box will be broken by the shock from airbag deployment. RS RS–396 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (f) Inner Diameter Width Tires (3 or more) C111105E06 Cover the steering pad (Using tires). (1) Place at least 3 tires without disc wheels on the tire with disc wheel which the steering pad is tied to. (2) Place the tire with a disc wheel on top of them. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels except for on the top and bottom. NOTICE: • The tires may be damaged by airbag deployment, so use an extra tire. • Do not place the SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. C107322 RS SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD Using a cardboard box: Battery SST 10 m (33 ft) or more Steering Pad Using tires: SST RS–397 (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the disc wheel which the steering pad is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. Battery 10 m (33 ft) or more Steering Pad C111123E01 H040177 (h) Dispose of the steering pad. CAUTION: • The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water, etc. to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the steering pad from the disc wheel. (2) Place the steering pad in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–399 INSPECTION 1. INSPECT SPIRAL CABLE (a) If there are any defects as mentioned below, replace the spiral cable with a new one: Scratches, cracks, dents or chips on the connector or the spiral cable. RS RS–400 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE INSTALLATION 1. INSTALL SPIRAL CABLE (a) Check that the front wheels are facing straight ahead. (b) Set the turn signal switch to the neutral position. NOTICE: If it is not in the neutral position, the pin of the turn signal switch may snap. (c) Install the spiral cable with the 4 screws. NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel assembly. (d) Connect the connectors to the spiral cable. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H042178 2. INSTALL STEERING COLUMN COVER UPPER (a) Install the steering column cover upper. 3. INSTALL STEERING COLUMN COVER LOWER (a) Install the steering column cover lower with the 3 screws. 4. ADJUST SPIRAL CABLE (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. H042177 (c) Rotate the spiral cable counterclockwise slowly by hand until it feels firm. NOTICE: Do not turn the spiral cable by the airbag wire harness. RS H042179 (d) Rotate the spiral cable clockwise approximately 2.5 turns to align the marks. NOTICE: Do not turn the spiral cable by the airbag wire harness. HINT: The spiral cable will rotate approximately 2.5 turns to both the left and right from the center. Marks 5. INSTALL STEERING WHEEL ASSEMBLY (See page SR-21) 6. INSPECT STEERING WHEEL CENTER POINT H042180E02 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–401 7. INSTALL STEERING PAD (See page RS-388) 8. INSTALL STEERING WHEEL COVER LOWER NO. 2 (See page RS-388) 9. INSTALL STEERING WHEEL COVER LOWER NO. 3 (See page RS-388) 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 11. INSPECT STEERING PAD (See page RS-389) 12. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–403 REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 4. REMOVE STEERING WHEEL COVER LOWER NO. 3 (See page RS-387) 5. REMOVE STEERING WHEEL COVER LOWER NO. 2 (See page RS-388) 6. REMOVE STEERING PAD (See page RS-388) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-9) 8. REMOVE STEERING COLUMN COVER LOWER (See page SR-9) 9. REMOVE STEERING COLUMN COVER UPPER 10. DISCONNECT FRONT PASSENGER AIRBAG ASSEMBLY CONNECTOR (a) Disconnect the connector from the passenger airbag assembly connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H042181 11. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: See page IP-12 12. REMOVE DEFROSTER NOZZLE ASSEMBLY (See page IP-12) 13. REMOVE HEATER TO REGISTER DUCT NO. 2 (See page IP-12) 14. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Disengage the 3 clamps. C131377 RS RS–404 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (b) Remove the 3 screws and the front passenger airbag assembly. C131378 (c) Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the front passenger airbag assembly forward. (d) Release the front side wall of the airbag door from the other hook and remove the front passenger airbag assembly. Hook Hook Front Airbag Door C131326E01 INSTALLATION 1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY (a) Install the front passenger airbag assembly with the 3 screws. C131378 (b) Install the 3 clamps. RS C131377 2. INSTALL HEATER TO REGISTER DUCT NO. 2 HINT: See page IP-13 3. INSTALL DEFROSTER NOZZLE ASSEMBLY HINT: See page IP-12 4. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: See page IP-12 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–405 5. CONNECT FRONT PASSENGER AIRBAG ASSEMBLY CONNECTOR (a) Connect the connector to the front passenger airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 6. INSTALL STEERING COLUMN COVER UPPER (See page SR-21) 7. INSTALL STEERING COLUMN COVER LOWER HINT: See page SR-21 8. ADJUST SPIRAL CABLE (See page RS-399) 9. INSTALL STEERING WHEEL ASSEMBLY (See page SR-21) H042181 10. INSPECT STEERING WHEEL CENTER POINT 11. INSTALL STEERING PAD (See page RS-389) 12. INSTALL STEERING WHEEL COVER LOWER NO.2 (See page RS-388) 13. INSTALL STEERING WHEEL COVER LOWER NO.3 (See page RS-388) 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. INSPECT STEERING PAD (See page RS-389) 16. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–406 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the front passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front passenger airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. RS SST C110371E01 DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-389). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (d) Remove the instrument panel under cover subassembly No. 2 (See page IP-9). (e) Remove the glove compartment door assembly (See page IP-9). SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (f) RS–407 Install the SST. (1) Disconnect the connector from the front passenger airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H042181 (2) Connect the SST connector to the front passenger airbag assembly. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H041650E02 Battery SST 10 m (33 ft) or more C110476E01 (3) Move the SST at least 10 m (33 ft) away from the vehicle front side window. (4) Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (g) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. RS RS–408 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the front passenger airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-389). SST C110371E01 RS C131325 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (b) Remove the front passenger airbag assembly (See page RS-402). CAUTION: • When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. • When storing the front passenger airbag assembly, keep the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section: 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front passenger airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–409 (1) Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Inner Diam. Width Tire C131327E01 Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the front passenger airbag assembly may become loose due to the shock when the airbag is deployed. • Always tie down the front passenger airbag assembly with the airbag deployment side facing inside the tire. NOTICE: The tire will be damaged by airbag deployment, so use an extra tire. (d) Install the SST. (1) Connect the SST connector to the front passenger airbag assembly. SST 09082-00700, 09082-00780 RS RS–410 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY Tires (2 or more) Tires (2 or more) (e) Place the tires. (1) Place at least 2 tires under the tire which the front passenger airbag assembly is tied to. (2) Place at least 2 tires over the tire which the front passenger airbag assembly is tied to. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. C131328E01 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 (f) Front Passenger Airbag Assembly Battery SST RS 10 m (33 ft) or more C111107E02 Install the SST. (1) Connect the SST connector. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tires. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY H041436E03 RS–411 (h) Dispose of the front passenger airbag assembly. CAUTION: • The front passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with a deployed airbag. • Do not apply water, etc. to a front passenger airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–413 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTICE: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE ROOF HEADLINING ASSEMBLY HINT: Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (See page IR-7). 4. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY LH (a) Disconnect the connector from the curtain shield airbag assembly LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 11 bolts and the curtain shield airbag assembly LH. HINT: Remove the bolts from front side of the vehicle in order. RS H041655 RS–414 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY LH (a) Install the curtain shield airbag assembly LH with the 11 bolts. HINT: Install the bolts from rear side of the vehicle in order. H041655 Torque: 9.8 N*m (100 kgf*cm, 87 ft.*lbf) NOTICE: Do not twist the curtain shield airbag assembly LH when installing it. (b) Connect the connector to the curtain shield airbag assembly LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS 2. INSTALL ROOF HEADLINING ASSEMBLY HINT: Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (See page IR-14). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–415 DISPOSAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a curtain shield airbag assembly that has an undeployed airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft) away from the curtain shield airbag assembly. • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. 1. SST C110371E01 DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-389). (b) Precaution (See page RS-1). (c) Disconnect the cable from the negative battery terminal. CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. (d) Remove the roof headlining assembly. HINT: Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (See page IR-7). (e) Install the SST. (1) Disconnect the connector from the curtain shield airbag assembly. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. RS RS–416 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY (2) After connecting the SST below to each other, connect them to the curtain shield airbag assembly. SST 09082-00700, 09082-00802 (0908210801, 09082-20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST SST H041656E01 Battery SST 10 m (33 ft) or more C110501E01 (f) RS 2. (3) Move the SST at least 10 m (33 ft) away from the vehicle rear side window. (4) Maintaining enough clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of the curtain shield airbag assembly, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–417 HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (See page RS-389). (b) Remove the curtain shield airbag assembly (See page RS-412). CAUTION: When removing the curtain shield airbag assembly, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. H041657 (c) Remove the bolt from the curtain shield airbag assembly. H041658 (d) Cut off the deployment section of the curtain shield airbag assembly. RS H041659 Wire Harness Diameter Stripped Wire Harness Section B104882E02 (e) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag assembly to the tire. Wire harness: Stripped wire harness section: 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag assembly, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 RS–418 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY Width Inner Diam H041660E01 Tires (2 or more) RS Tires (2 or more) (1) Position the curtain shield airbag assembly inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Make sure that the wire harness is tight. If there is slack in the wire harness, the curtain shield airbag assembly may become loose due to the shock when the airbag is deployed. NOTICE: The tire will be damaged by airbag deployment, so use an extra tire. (f) Install the SST. (1) After connecting the SST below to each other, connect them to the curtain shield airbag assembly. SST 09082-00802 (09082-10801, 0908220801) (g) Place the tires. CAUTION: Do not face the deployment direction of the curtain shield airbag assembly toward the ground. (1) Place at least 2 tires under the tire which the curtain shield airbag assembly is tied to. (2) Place at least 2 tires over the tire which the curtain shield airbag assembly is tied to. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. H041661E01 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. Looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. B105087 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY Curtain Shield Airbag Assembly Battery SST 10 m (33 ft) or more C111112E01 (h) Install the SST. (1) Connect the SST connector. SST 09082-00700, 09082-00802 (0908210801, 09082-20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (2) Move the SST at least 10 m (33 ft) away from the airbag tied down to the tires. (i) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the curtain shield airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (j) H041663 RS–419 Dispose of the curtain shield airbag assembly. CAUTION: • The curtain shield airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a curtain shield airbag assembly with a deployed airbag. • Do not apply water, etc. to a curtain shield airbag assembly with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the curtain shield airbag assembly from the tire. (2) Place the curtain shield airbag assembly in a plastic bag, tie it tightly and dispose of it as other general part disposal. RS SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–429 REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 4. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 5. REMOVE CONSOLE UPPER PANEL GARNISH NO. 1 (See page IP-7) 6. REMOVE CONSOLE UPPER PANEL GARNISH NO. 2 7. REMOVE CONSOLE BOX ASSEMBLY REAR (See page IP-9) 8. REMOVE CONSOLE BOX MOUNTING BRACKET FRONT 9. REMOVE CONSOLE BOX DUCT NO. 1 (See page AC113) 10. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the 3 connectors from the center airbag sensor assembly. (b) Remove the 3 bolts and the center airbag sensor assembly. H042342 RS RS–430 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY INSTALLATION 1. (c) Temporarily install the center airbag sensor assembly with the 3 bolts. NOTICE: • If the center airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the center airbag sensor assembly, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Tighten the 3 bolts to the specified torque. Torque: 17.5 N*m (179 kgf*cm, 13 ft.*lbf) (e) Check that there is no looseness in the installation parts of the center airbag sensor assembly. (f) Connect the 3 connectors to the center airbag sensor assembly. (g) Check that the waterproof sheet is properly set. H042342 RS INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. 2. INSTALL CONSOLE BOX DUCT NO. 1 3. INSTALL CONSOLE BOX MOUNTING BRACKET FRONT 4. INSTALL CONSOLE BOX ASSEMBLY REAR 5. INSTALL CONSOLE UPPER PANEL GARNISH NO. 2 6. INSTALL CONSOLE UPPER PANEL GARNISH NO. 1 7. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 8. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS–64 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B0103/12 Short to B+ in Driver Side Squib Circuit DESCRIPTION The driver side squib circuit consists of the center airbag sensor assembly, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0103/12 is recorded when a short to B+ is detected in the driver side squib circuit. DTC No. DTC Detecting Condition • B0103/12 • • • Short circuit in driver side squib wire harness (to B+) Driver side squib malfunction Spiral cable malfunction Center airbag sensor assembly malfunction Trouble Area • • • • Steering pad (Driver side squib) Spiral cable Center airbag sensor assembly Instrument panel wire WIRING DIAGRAM See page RS-46. INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "check mode" (signal check) with the intelligent tester (See page RS-38). • After selecting the "check mode" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (See page RS-38). RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–65 CHECK STEERING PAD (DRIVER SIDE SQUIB) DC F E Spiral Cable Center Airbag Sensor Assembly Driver Side Squib Connector “E” SST Color: Orange DLC3 CG DTC B0103/12 TC C C110394E02 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the spiral cable. CAUTION: Never connect a tester to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: Do not forcibly insert the SST into the terminals of the connector when connecting. Insert the SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (See page RS-35). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (See page RS-35). OK: DTC B0103/12 is not output. HINT: Codes other than DTC B0103/12 may be output at this time, but they are not related to this check. NG OK REPLACE STEERING PAD Go to step 2 RS RS–66 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2 CHECK DRIVER SIDE SQUIB CIRCUIT Driver Side Squib A F E DC B Spiral Cable Center Airbag Sensor Assembly Connector E (a) Disconnect the connector from the center airbag sensor assembly. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition D+ - Body ground Ignition switch ON Below 1 V D- - Body ground Ignition switch ON Below 1 V NG D- Go to step 4 D+ Color: Orange C C110386E02 OK 3 CHECK CENTER AIRBAG SENSOR ASSEMBLY Driver Side Squib RS FE DC Spiral Cable DLC3 C CG Center Airbag Sensor Assembly DTC B0103/12 TC C110395E01 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connectors to the steering pad and the center airbag sensor assembly. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (f) Clear the DTCs stored in memory (See page RS-35). (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (i) Check the DTCs (See page RS-35). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–67 OK USE SIMULATION METHOD TO CHECK 4 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A F E D C Spiral Cable B Center Airbag Sensor Assembly Driver Side Squib Connector “C” A36 (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the instrument panel wire connector from the spiral cable. (d) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (e) Turn the ignition switch to the ON position. (f) Measure the voltage according to the value(s) in the table below. Voltage Tester connection Condition Specified condition A36-1 (D+) - Body ground Ignition switch ON Below 1 V A36-2 (D-) - Body ground Ignition switch ON Below 1 V D+ NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE DC C110388E31 OK RS RS–68 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK SPIRAL CABLE (a) Measure the voltage according to the value(s) in the table below. Voltage Instrument Panel Wire A F E D C B Spiral Cable Center Airbag Sensor Assembly Driver Side Squib Connector E D- D+ Color: Orange C C110389E01 OK USE SIMULATION METHOD TO CHECK RS Tester connection Condition Specified condition D+ - Body ground Ignition switch ON Below 1 V D- - Body ground Ignition switch ON Below 1 V NG REPLACE SPIRAL CABLE RS–432 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE FRONT AIRBAG SENSOR LH (a) Remove the 2 bolts and the front airbag sensor LH. A: 65 mm (2.559 in.) B: 43 mm (1.693 in.) A RS B C131330E01 (b) Disconnect the connector from the front airbag sensor LH. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–433 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT AIRBAG SENSOR LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Install the front airbag sensor LH with the 2 bolts. A: 65 mm (2.559 in.) B: 43 mm (1.693 in.) A B C131330E01 Torque: Length A 65 mm (2.559 in.) 7.5 N*m (76 kgf*cm, 66 in.*lbf) Length B 43 mm (1.693 in.) 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: • If the front airbag sensor LH has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. • When installing the front airbag sensor LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Connect the connector to the front airbag sensor LH. (e) Check that there is no looseness in the installation parts of the front airbag sensor LH. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–430 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR FRONT AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS 7.5 (76, 66 in.*lbf) A 9.0 (92, 80 in.*lbf) 7.5 (76, 66 in.*lbf) B A FRONT AIRBAG SENSOR RH 9.0 (92, 80 in.*lbf) B FRONT AIRBAG SENSOR LH A: 65 mm (2.559 in.) B: 43 mm (1.693 in.) N*m (kgf*cm, ft.*lbf) : Specified torque C131319E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–431 ON-VEHICLE INSPECTION 1. INSPECT FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). 2. INSPECT FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to the front airbag sensor. If any of the front airbag sensors have defects as mentioned below, replace it with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS DEPLOYED) (a) Replace the front airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The front airbag sensor on the impacted side should be replaced after the steering pad or front passenger airbag assembly has deployed. RS RS–436 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-9) 4. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-8) 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 7. REMOVE LAP BELT OUTER ANCHOR COVER 8. REMOVE CENTER PILLAR GARNISH LOWER LH 9. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH 10. REMOVE SIDE AIRBAG SENSOR LH (a) Remove the 2 nuts and the side airbag sensor LH. (b) Disconnect the connector from the side airbag sensor LH. RS H042349 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–437 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL SIDE AIRBAG SENSOR LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Install the side airbag sensor LH with the 2 nuts. Torque: 17.5 N*m (179 kgf*cm, 13 ft.*lbf) NOTICE: • If the side airbag sensor LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the side airbag sensor LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the side airbag sensor LH. (e) Connect the connector to the side airbag sensor LH. H042349 2. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH 3. INSTALL CENTER PILLAR GARNISH LOWER LH 4. INSTALL LAP BELT OUTER ANCHOR COVER 5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 7. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-17) 8. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-17) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–440 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 4. REMOVE DECK BOARD ASSEMBLY (See page SB26) 5. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR (See page SB-26) 6. REMOVE DECK FLOOR BOX LH 7. REMOVE REAR DOOR SCUFF PLATE LH 8. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 9. REMOVE LAP BELT OUTER ANCHOR COVER REAR NO. 1 SEAT 10. REMOVE DECK TRIM SIDE BOARD UPR LH 11. REMOVE DECK SIDE TRIM COVER LH 12. REMOVE REAR AIRBAG SENSOR LH (a) Disconnect the connector from the rear airbag sensor LH. RS (b) Remove the 2 nuts and the rear airbag sensor LH. H042352 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–441 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL REAR AIRBAG SENSOR LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Install the rear airbag sensor LH with the 2 bolts. Torque: 17.5 N*m (179 kgf*cm, 13 ft.*lbf) CAUTION: • If the rear airbag sensor LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the rear airbag sensor LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Check that there is no looseness in the installation parts of the rear airbag sensor LH. (e) Connect the connector to the rear airbag sensor LH. H042352 2. INSTALL DECK SIDE TRIM COVER LH 3. INSTALL DECK TRIM SIDE BOARD UPR LH 4. INSTALL LAP BELT OUTER ANCHOR COVER REAR NO. 1 SEAT 5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. INSTALL REAR DOOR SCUFF PLATE LH 7. INSTALL DECK FLOOR BOX LH 8. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR 9. INSTALL DECK BOARD ASSEMBLY 10. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 12. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–434 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR SIDE AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS FRONT SEAT OUTER BELT ASSEMBLY LH SIDE AIRBAG SENSOR LH 7.5 (76, 66 in.*lbf) 42 (420, 31) CENTER PILLAR GARNISH LOWER LH REAR DOOR OPENING TRIM WEATHERSTRIP LH 17.5 (178, 13) FRONT DOOR OPENING TRIM WEATHERSTRIP LH RS REAR DOOR SCUFF PLATE LH LAP BELT OUTER ANCHOR COVER 42 (420, 31) FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque C C131320E01 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–435 ON-VEHICLE INSPECTION 1. INSPECT SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). 2. INSPECT SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS DEPLOYED) (a) Replace the side airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The side airbag sensor on the impacted side should be replaced after the front seat side airbag assembly and curtain shield airbag assembly have deployed. RS RS–444 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH (for Manual Seat) (See page SE-9) 4. REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH (for Power Seat) (See page SE-18) 5. REMOVE SEAT TRACK BRACKET COVER INNER FRONT LH (for Manual Seat) (See page SE-9) 6. REMOVE SEAT TRACK BRACKET COVER INNER FRONT LH (for Power Seat) 7. REMOVE SEAT TRACK OUTER COVER LH (for Manual Seat) (See page SE-9) 8. REMOVE SEAT TRACK OUTER COVER LH (for Power Seat) (See page SE-18) 9. REMOVE SEAT TRACK BRACKET COVER INNER LH (for Manual Seat) (See page SE-9) 10. REMOVE SEAT TRACK BRACKET COVER INNER LH (for Power Seat) (See page SE-18) 11. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-9) RS 12. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-18) 13. REMOVE SEAT POSITION SENSOR (a) Disconnect the connector from the seat position sensor. (b) Remove the bolt and seat position sensor. H042353 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–445 INSTALLATION 1. INSTALL SEAT POSITION SENSOR (a) Check that the ignition switch is off. (b) Check that the negative battery (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Install the seat position sensor with a new bolt. Part Number: Bolt: 90119-06871 Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (d) Check that there is no looseness in the installation parts of the seat position sensor. (e) Connect the connector to the seat position sensor. 2. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) (See page SE-13) 3. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) (See page SE-23) 4. INSTALL SEAT TRACK BRACKET COVER INNER LH (for Manual Seat) 5. INSTALL SEAT TRACK BRACKET COVER INNER LH (for Power Seat) 6. INSTALL SEAT TRACK OUTER COVER LH (for Manual Seat) 7. INSTALL SEAT TRACK OUTER COVER LH (for Power Seat) 8. INSTALL SEAT TRACK BRACKET COVER INNER FRONT LH (for Manual Seat) 9. INSTALL SEAT TRACK BRACKET COVER INNER FRONT LH (for Power Seat) 10. INSTALL SEAT TRACK BRACKET COVER OUTER FRONT LH (for Manual Seat) 11. INSTALL SEAT TRACK BRACKET COVER OUTER FRONT LH (for Power Seat) 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 13. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) 14. INSPECT POWER SEAT OPERATION (for Power Seat) 15. INSPECT SEAT HEATER OPERATION (w/ Seat Heater System) 16. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–438 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REAR AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS LAP BELT OUTER ANCHOR COVER REAR NO. 1 SEAT REAR DOOR OPENING TRIM WEATHERSTRIP LH DECK TRIM SIDE BOARD UPR LH REAR AIRBAG SENSOR LH 17.5 (178, 13) 42 (420, 31) REAR DOOR SCUFF PLATE LH DECK TRIM SIDE PANEL ASSEMBLY LH TONNEAU COVER RETRACTOR SUB-ASSEMBLY RS DECK FLOOR BOX LH REAR FLOOR MAT SUPPORT PLATE REAR DECK BOARD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C C131321E01 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–439 ON-VEHICLE INSPECTION 1. INSPECT REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). 2. INSPECT REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT DEPLOYED) (a) Perform a diagnostic system check (See page RS28). (b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the rear airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: Be sure to follow the correct removal and installation procedures. 3. INSPECT REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS DEPLOYED) (a) Replace the rear airbag sensor. CAUTION: Be sure to follow the correct removal and installation procedures. HINT: The rear airbag sensor on the impacted side should be replaced after the curtain shield airbag assembly has deployed. RS RS–448 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU REMOVAL 1. PRECAUTION CAUTION: Be sure to read "PRECAUTION" thoroughly before servicing (See page RS-1). 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working. 3. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat) (See page SE-9) 4. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) (See page SE-18) 5. REMOVE OCCUPANT CLASSIFICATION ECU (a) Disconnect the 2 connectors from the occupant classification ECU. (b) Using a screwdriver, remove the occupant classification ECU. RS H045341 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU RS–449 INSTALLATION 1. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is off. (b) Check that the negative battery (-) terminal is disconnected. CAUTION: After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Install the occupant classification ECU. (d) Connect the 2 connectors to the occupant classification ECU. NOTICE: • If the occupant classification ECU has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. • When installing the occupant classification ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. H045341 2. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat) (See page SE-13) 3. INSTALL FRONT RH SEAT ASSEMBLY (for Power Seat) (See page SE-23) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. INSPECT SLIDE ADJUSTER LOCK (for Manual Seat) 6. INSPECT POWER SEAT OPERATION (for Power Seat) 7. INSPECT SEAT HEATER OPERATION (w/ Seat Heater System) 8. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (See page RS-28). RS RS–442 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR SEAT POSITION SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS FRONT SEAT ASSEMBLY LH SEAT TRACK BRACKET COVER INNER LH SEAT TRACK BRACKET COVER INNER FRONT LH 37 (375, 27) SEAT TRACK OUTER COVER LH 37 (375, 27) 37 (375, 27) RS SEAT TRACK BRACKET COVER OUTER FRONT LH 37 (375, 27) SEAT POSITION SENSOR 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C C131322E01 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–443 ON-VEHICLE INSPECTION 1. INSPECT SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). 2. INSPECT SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS28). (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. CAUTION: Be sure to follow the correct removal and installation procedures. RS RS–446 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU OCCUPANT CLASSIFICATION ECU SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS FRONT SEAT ASSEMBLY OCCUPANT CLASSIFICATION ECU RS C C131323E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION ECU RS–447 ON-VEHICLE INSPECTION 1. INSPECT OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS297). 2. INSPECT OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (See page RS297). (b) Even if the airbag was not deployed, check if there is any damage to the occupant classification ECU. If there are any defects as mentioned below, replace the occupant classification ECU with a new one: • Cracks, dents or chips on the case. • Cracks or other damage to the connector. CAUTION: Be sure to follow the correct removal and installation procedures. RS SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG CUTOFF SWITCH RS–449 CURTAIN SHIELD AIRBAG CUTOFF SWITCH INSPECTION 1. INSPECT RSCA OFF INDICATOR (a) Turn the ignition switch to the ON position. (b) Check that the RSCA OFF indicator comes on for approximately 3 seconds and then goes off. (c) Check that the RSCA OFF indicator goes off after pressing the curtain airbag cut off switch for approximately 2 seconds. 2. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH (a) Remove the instrument panel finish panel subassembly lower (See page IP-7). (b) Remove the curtain airbag cutoff switch from the instrument panel finish panel sub-assembly lower. H043802 (c) Measure the resistance according to the value(s) in the table below. OFF Tester connection Condition Specified condition SW (3) - E (4) OFF (Release) 10 kΩ or higher SW (3) - E (4) ON (Pushed in) Below 1 Ω (d) Inspect the illumination operation. (1) Connect the battery positive terminal to terminal ILL+ (2) of the connector, and the battery negative terminal to terminal ILL- (1), and check that the indicator comes on. ON E ILL+ RS SW ILLH043798E01 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY SB–9 INSTALLATION HINT: Use the same procedures for the LH and RH. 1. INSTALL FRONT SEAT INNER BELT ASSEMBLY (a) Install the inner belt assembly with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 2. INSTALL FRONT SEAT CUSHION SHIELD INNER RH 3. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for Power Seat) 4. INSTALL RECLINING POWER SEAT SWITCH KNOB (for Power Seat) 5. INSTALL RECLINING ADJUSTER RELEASE HANDLE RH (for Manual Seat) 6. INSTALL VERTICAL SEAT ADJUSTER KNOB CAP (for Manual Seat) 7. INSPECT VERTICAL SEAT ADJUSTER KNOB RH (for Manual Seat) 8. INSTALL FRONT SEAT ASSEMBLY RH (a) Place the front seat assembly RH in the cabin. NOTICE: Be careful not to damage the body. (b) Connect the connectors under the front seat assembly RH. (c) Install the front seat assembly RH with the 4 bolts. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) SB SB–12 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY INSPECTION 1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY LH NOTICE: Do not apply battery voltage to pretensioner connector. (a) Inspect the tension reducer operation. (1) Connect the positive lead from the battery to terminal 1 of connector A and the negative lead to terminal 2. (2) Check that the operating noise that the magnetized solenoid is attracting the plunger is heard. (3) Check that the rewinding volume of the seat belt increases when the seat belt is pulled out and the battery negative lead is disconnected. If the result is not as specified, replace the outer belt assembly. Tension Reducer Connector A Tension Reducer Connector B* 2. INSPECT FRONT SEAT OUTER BELT ASSEMBLY RH NOTICE: Do not apply battery voltage to pretensioner connector. * Do not apply battery voltage B064703E01 (a) Inspect the tension reducer operation. (1) Connect the positive lead from the battery to terminal 1 of connector A and the negative lead to terminal 2. (2) Check that the operating noise that the magnetized solenoid is attracting the plunger is heard. (3) Check that the rewinding volume of the seat belt increases when the seat belt is pulled out and the battery negative lead is disconnected. If the result is not as specified, replace the outer belt assembly. Tension Reducer Connector A SB Tension Reducer Connector B* * Do not apply battery voltage B064703E01 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–13 INSTALLATION 1. Unlock Retractor INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH NOTICE: Do not disassemble the retractor. (a) Check the degree of tilt when beginning to lock the ELR. (1) Check that the belt does not lock within 15° of tilt in all the direction but the belt locks over 45° of tilt, when moving the installed retractor gently. If operation is not as specified, replace the outer belt assembly. (b) Install the retractor with the 2 bolts. Torque: For upper bolt 8.5 N*m (87 kgf*cm, 75 in.*lbf) For lower bolt 42 N*m (430 kgf*cm, 31 ft.*lbf) (c) Install the shoulder anchor with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Install the center pillar garnish upper RH. (e) Install the center pillar garnish lower RH. (f) Install the floor anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (g) Install the floor anchor cover. (h) Check the ELR lock. NOTICE: The check should be performed with the outer belt assembly installed. (1) Check that the belt locks when pulling out the belt quickly with the belt installed. If operation is not as specified, replace the outer belt assembly. 45 ° Lock B065022E01 2. INSTALL CENTER PILLAR GARNISH UPPER RH 3. INSTALL CENTER PILLAR GARNISH LOWER RH 4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 6. INSTALL REAR DOOR SCUFF PLATE RH 7. INSTALL FRONT DOOR SCUFF PLATE RH 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL SB SB–14 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY DISPOSAL 1. SB DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE) NOTICE: • Never dispose of a front seat outer belt assembly with a pretensioner that has not been deployed. • The seat belt pretensioner produces an exploding sound when it deploys, so perform the operation outdoors where it will not disturb local residents. • When deploying a front seat outer belt (with a seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. • Use gloves and safety glasses when handling a front seat belt with a deployed pretensioner. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt with a deployed pretensioner. • When deploying the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). Perform the operation in a place away from electrical interference. HINT: When scrapping vehicles equipped with seat belt pretensioners or disposing of a front seat outer belt (with a seat belt pretensioner), always deploy the seat belt pretensioner first in accordance with the procedures described below. If any abnormality occurs during deployment of the seat belt pretensioner, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. (a) Check the function of SST. SST 09082-00700, 09082-00770 CAUTION: When deploying the seat belt pretensioner, always use the specified SST. SST B050515E02 Battery SST B050511E02 (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: At this time, do not connect the yellow connector that will later be connected to the seat belt pretensioner. SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–15 (2) Press the SST deployment switch, and check that the LED of the SST deployment switch lights up. CAUTION: If the LED is lit when the deployment switch is not pressed, the SST may be malfunctioning. Therefore, do not use the SST. SST B050514E02 SST (b) Connect SST. (1) Connect 2 SST, and then connect them to the front seat outer belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector. SST B051763E02 10 m (33 ft) or more B050513E02 B060422 (2) Move the SST at least 10 m (33 ft) away from the front of the vehicle. (3) Close all the doors and windows of the vehicle. NOTICE: Do not damage the SST wire harness. (c) Deploy the front seat outer belt pretensioner. (1) Confirm that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the negative (-) terminal. (3) Press the SST deployment switch and deploy the front seat outer belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of the SST illuminates. (d) Dispose of the front seat outer belt assembly. (1) Remove the SST. (2) Place the outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. CAUTION: • The outer belt becomes very hot when the front seat outer belt pretensioner is deployed, so leave it untouched for at least 30 minutes after it has been deployed. • Use gloves and safety glasses when handling an outer belt with a pretensioner that has been deployed. • Always wash your hands with water after completing the operation. SB SB–16 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY • Do not apply water, etc. to a front seat outer belt assembly with a pretensioner that has been deployed. HINT: When scrapping a vehicle, deploy the front seat outer belt pretensioners, and then scrap the vehicle with the deployed outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When disposing of a pretensioner equipped front seat outer belt, never deploy the belt in the customer's vehicle. • Be sure to follow the procedures listed below when deploying the seat belt pretensioner. (a) Check the function of SST. SST 09082-00700, 09082-00770 CAUTION: When deploying the seat belt pretensioner, always use the specified SST. SST B050515E02 Battery SST SB (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: At this time, do not connect the yellow connector that will later be connected to the seat belt pretensioner. B050511E02 (2) Press the SST deployment switch, and check that the LED of the SST deployment switch lights up. CAUTION: If the LED is lit when the deployment switch is not pressed, the SST may be malfunctioning. Therefore, do not use the SST. SST B050514E02 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SST SB–17 (b) Connect SST. (1) Connect 2 SST, and then connect them to the front seat outer belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the pretensioner connector. SST B051763E02 SST (2) Place the outer belt on the ground and cover it with a tire and wheel assembly. NOTICE: Position the front seat outer belt assembly as shown in the illustration. (3) Position and hold the SST at least 10 m (33 ft) away from the wheel. NOTICE: Do not damage the SST wire harness. SST B069491E02 10 m (33 ft) or more B050541E03 B060422 (c) Deploy the front seat outer belt pretensioner. (1) Check that no one is within a 10 m (33 ft) radius of the wheel. (2) Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (3) Press the SST deployment switch and deploy the front seat outer belt pretensioner. HINT: The seat belt pretensioner will deploy at the same time as the LED of the SST illuminates. (d) Dispose of the front seat outer belt assembly. (1) Remove the wheel and SST. (2) Place the outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. CAUTION: • The outer belt becomes very hot when the front seat outer belt pretensioner is deployed, so leave it untouched for at least 30 minutes after it has been deployed. • Use gloves and safety glasses when handling an outer belt with a pretensioner that has been deployed. • Always wash your hands with water after completing the operation. • Do not apply water, etc. to a front seat outer belt assembly with a pretensioner that has been deployed. SB SB–18 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY HINT: When scrapping a vehicle, deploy the front seat outer belt pretensioners, and then scrap the vehicle with the deployed outer belt installed. SB SEAT BELT – SEAT BELT TENSION REDUCER SB–1 SEAT BELT TENSION REDUCER SEAT BELT RESTRAINTS PARTS LOCATION FRONT SEAT INNER BELT ASSEMBLY RH FRONT SEAT OUTER BELT ASSEMBLY RH SB SOLENOID C131305E02 SB–2 SEAT BELT – SEAT BELT TENSION REDUCER PROBLEM SYMPTOMS TABLE SEAT BELT TENSION REDUCER SYSTEM Symptom Suspected area 1. GAUGE fuse Tension reducer for driver side seat belt does not operate Tension reducer for passenger side seat belt does not operate - 2. Front seat inner belt assembly LH SB-6 3. Front seat outer belt assembly LH SB-11 4. Wire harness - 1. GAUGE fuse - 2. Front seat inner belt assembly RH SB-7 3. Front seat outer belt assembly RH SB-11 4. Wire harness SB See page - SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) SB–19 INSTALLATION HINT: Use the same procedures for the LH and RH. 1. INSTALL REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) 2. INSTALL REAR NO. 1 SEAT CUSHION ASSEMBLY LH 3. INSTALL REAR NO. 1 SEAT ASSEMBLY (a) Install the belt with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) SB SB–3 SEAT BELT – SEAT BELT WARNING SYSTEM SEAT BELT WARNING SYSTEM SEAT BELT RESTRAINTS PARTS LOCATION COMBINATION METER (DRIVE SIDE SEAT BELT WARNING LIGHT) PASSENGER SIDE SEAT BELT WARNING LIGHT ASSEMBLY SEAT BELT WARNING SENSOR (BUILT IN PASSENGER SIDE SEAT) SB FRONT SEAT INNER BELT ASSEMBLY RH FRONT SEAT INNER BELT ASSEMBLY LH C131306E02 SB–4 SEAT BELT – SEAT BELT WARNING SYSTEM PROBLEM SYMPTOMS TABLE SEAT BELT WARNING SYSTEM Symptom Suspected area 1. Fuse 2. Combination meter assembly Driver side seat belt warning light does not operate 3. Center airbag sensor assembly 4. Front seat inner belt assembly LH 5. Wire harness Passenger side seat belt warning light does not operate RS-23 SB-6 - 1. Fuse - 2. Passenger side seat belt warning light assembly - 3. Front seat inner belt assembly RH 4. Wire harness SB See page SB-7 - SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) SB–21 REMOVAL HINT: Use the same procedures for the LH and RH. 1. Claw REMOVE REAR NO. 2 SEAT RH (a) Disengage the claws and remove the seat leg cover. B064892E02 (b) Release the rear seat lock and remove the seat. (c) Remove the headrests. 2. REMOVE REAR NO. 2 SEAT CUSHION ASSEMBLY LH 3. REMOVE REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) (a) Remove the nut and seat beat inner. B064896E01 SB SB–22 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) INSTALLATION HINT: Use the same procedures for the LH and RH. SB 1. INSTALL REAR SEAT INNER BELT ASSEMBLY 2. INSTALL REAR NO. 2 SEAT CUSHION ASSEMBLY LH 3. INSTALL REAR NO. 2 SEAT RH (for Rear No. 2 Seat) (a) Install the belt with the bolt and nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) SB–5 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS CENTER PILLAR GARNISH UPPER RH FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY 42 (430, 31) REAR DOOR WEATHERSTRIP RH FRONT DOOR WEATHERSTRIP RH 42 (430, 31) REAR DOOR SCUFF PLATE RH FRONT DOOR SCUFF PLATE RH 8.5 (87, 75 in.*lbf) CENTER PILLAR GARNISH LOWER RH FLOOR ANCHOR COVER FRONT SEAT OUTER BELT ASSEMBLY RH SB 42 (430, 31) FRONT SEAT ASSEMBLY RH FRONT SEAT INNER BELT ASSEMBLY RH 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131307E04 SB–6 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY REMOVAL HINT: Use the same procedures for LH and RH. 1. REMOVE FRONT SEAT ASSEMBLY RH 2. REMOVE VERTICAL SEAT ADJUSTER KNOB RH (for Manual Seat) 3. REMOVE VERTICAL SEAT ADJUSTER KNOB CAP (for Manual Seat) (See page SE-10) 4. REMOVE VERTICAL ADJUSTING HANDLE NO. 2 (for Manual Seat) (a) Remove the 2 screws and vertical adjusting handle No. 2. 5. REMOVE RECLINING ADJUSTER RELEASE HANDLE RH (for Manual Seat) (a) Using a screwdriver, pry out the reclining adjuster release handle LH. 6. REMOVE RECLINING POWER SEAT SWITCH KNOB (for Power Seat) (a) Using a screwdriver, remove the reclining power seat switch knob. HINT: Tape the screwdriver tip before use. 7. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB (for Power Seat) (a) Using a screwdriver, remove the slide & vertical power seat switch knob. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT SEAT CUSHION SHIELD INNER RH (a) Remove the screw. (b) Using a screwdriver, disengage the 2 claws and clip, and remove the front seat cushion shield inner RH HINT: Tape the screwdriver tip before use. 9. REMOVE FRONT SEAT INNER BELT ASSEMBLY SB INSPECTION Buckle Switch ON 1. A A 3 21 6 54 INSPECT FRONT SEAT INNER BELT ASSEMBLY LH (a) Inspect the buckle switch. (1) Fasten the seat belt (Buckle switch is ON). (2) Inspect the continuity and resistance between the terminals. Standard resistance Terminal No. B060004E01 Specified Condition A-6 - A-3 1,330 Ω A-4 - A-3 Continuity A-5 - A-3 * Continuity SB–7 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY NOTICE: * When the positive and negative poles between terminals are exchanged, there is continuity in one way but no continuity in the other way. (3) Release the seat belt (Buckle switch is OFF). (4) Inspect the continuity and resistance between the terminals. Standard resistance Buckle Switch OFF A A 3 21 6 54 330 Ω A-4 - A-3 No Continuity A-5 - A-3 * No Continuity (b) Inspect the circuit for the airbag seat position sensor. (1) Inspect the continuity between connector A and the connector for the airbag seat position sensor. Standard resistance A Connector for Airbag Seat Position Sensor 3 2 1 Specified Condition A-6 - A-3 NOTICE: * When the positive and negative poles between terminals are exchanged, there is no continuity in either way. If the result is not as specified, replace the inner belt assembly. B060004E02 A Terminal No. Terminal No. Specified Condition A-2 - 1 (Connector for airbag seat position sensor) A-1 - 2 (Connector for airbag seat position sensor) 12 6 5 4 Continuity If the result is not as specified, replace the inner belt assembly. SB B065625E01 2. Buckle Switch ON A A INSPECT FRONT SEAT INNER BELT ASSEMBLY RH (a) Inspect the buckle switch. (1) Fasten the seat belt (Buckle switch is ON). (2) Inspect the continuity and resistance between the terminals. Standard resistance Terminal No. B059310E01 Specified Condition A-2 - A-4 1,330 Ω A-1 - A-3 Continuity SB–8 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY (3) Release the seat belt (Buckle switch is OFF). (4) Inspect the continuity and resistance between the terminals. Standard resistance Buckle Switch OFF A A Terminal No. B059310E03 SB Specified Condition A-1 - A-3 330 Ω A-2 - A-4 No Continuity If the result is not as specified, replace the inner belt assembly. SB–26 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) REMOVAL HINT: Use the same procedures for the LH and RH. 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE REAR NO. 2 SEAT ASSEMBLY LH (with Rear No. 2 Seat) 3. REMOVE REAR NO. 2 SEAT ASSEMBLY RH (with Rear No. 2 Seat) 4. REMOVE NO.2 SEAT LEG COVER (with Rear No. 2 Seat) 5. REMOVE REAR NO. 2 SEAT LOCK ASSEMBLY RH (with Rear No. 2 Seat) (a) Remove the 2 bolts and seat lock. 6. REMOVE BACK DOOR GLASS WEATHERSTRIP 7. REMOVE DECK BOARD SUB-ASSEMBLY (without Rear No. 2 Seat) (a) Remove the 2 bolts and the deck board subassembly. 8. REMOVE DECK BOARD ASSEMBLY (without Rear No. 2 Seat) HINT: See page IR-7 9. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR HINT: See page IR-7 10. REMOVE DECK FLOOR BOX RH (a) Remove the bolt, deck floor box and luggage hold belt striker. SB 11. REMOVE DECK TRIM COVER REAR (a) Using a screwdriver, pry out the trim cover. HINT: Tape the screwdriver tip before use. 12. REMOVE DECK TRIM SIDE BOARD UPR RH (a) Remove the screw and side board. 13. REMOVE SIDE TRIM BOX ASSEMBLY RH (a) Remove the screw and side trim box. 14. REMOVE QUARTER SCUFF PLATE INNER RH (with Rear No. 2 Seat) 15. REMOVE REAR DOOR SCUFF PLATE RH 16. REMOVE REAR DOOR WEATHERSTRIP RH 17. REMOVE DECK TRIM COVER REAR 18. REMOVE REAR FLOOR CARPET ASSEMBLY SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SB–27 19. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (a) Remove the floor anchor cover. (b) Remove the bolt and seat belt assembly outer on the floor anchor side. (c) Remove the side panel assembly . 20. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (with Rear No. 2 Seat) (a) Remove the floor anchor cover. (b) Remove the bolt and No. 2 seat belt outer RH on the floor anchor side. (c) Remove the side panel. 21. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH 22. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH (with Rear No. 2 Seat) (a) Remove the bolt and No. 2 seat belt outer RH on the shoulder anchor side. (b) Remove the side garnish. 23. REMOVE 3 POINT TYPE BELT ASSEMBLY RH (for Rear No. 1 Seat) (a) Remove the 2 bolts on the retractor side, and thoroughly remove the seat belt. SB SB–9 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY FRONT SEAT OUTER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS CENTER PILLAR GARNISH UPPER RH FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY 42 (430, 31) REAR DOOR WEATHERSTRIP RH FRONT DOOR WEATHERSTRIP RH 42 (430, 31) REAR DOOR SCUFF PLATE RH FRONT DOOR SCUFF PLATE RH 8.5 (87, 75 in.*lbf) CENTER PILLAR GARNISH LOWER RH FLOOR ANCHOR COVER FRONT SEAT OUTER BELT ASSEMBLY RH SB 42 (430, 31) FRONT SEAT ASSEMBLY RH FRONT SEAT INNER BELT ASSEMBLY RH 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131307E05 SB–10 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY REMOVAL HINT: Use the same procedures for the LH and RH. Claw A A DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT DOOR SCUFF PLATE RH 3. REMOVE REAR DOOR SCUFF PLATE RH 4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE CENTER PILLAR GARNISH LOWER RH (a) Using a screwdriver, disengage the 6 claws labeled A and 2 claws labeled B. Remove the 2 clips and pillar garnish. HINT: Tape the screwdriver tip before use. 7. REMOVE CENTER PILLAR GARNISH UPPER RH (a) Remove the bolt and disconnect the front seat outer belt (floor anchor side). (b) Remove the 2 bolts. (c) Using a screwdriver, disengage the 6 claws and clip, and remove the pillar garnish. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH NOTICE: • Removal operation concerning the seat belt with the pretensioner must be started in 90 seconds or more after the ignition switch is turned OFF and the battery negative terminal is disconnected. • Carefully read the notices for the "pretensioner" in the SRS airbag system and the outer belt assembly. (a) Remove the bolt and disconnect the front seat outer belt on the shoulder anchor side. B A Clip 1. Claw B A B064143E01 Clip Claw B063595E01 SB SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–11 (b) Disconnect the pretensioner connector as shown in the illustration. (c) Remove the 2 bolts and the outer belt assembly. B065506E01 SB SB–28 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) INSTALLATION HINT: Use the same procedures for the LH and RH. 1. Unlock 45 q Lock SB B065024E01 INSTALL 3 POINT TYPE BELT ASSEMBLY RH (with Rear No. 2 Seat) (a) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor. (b) Check the amount of inclination required to lock the retractor. (1) When the inclination of the retractor is 15°or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If operation is not as specified, replace the belt assembly. (c) Install the rear seat belt inner with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Install the seat shoulder belt cover. (e) Install the seatback board RH. (f) Install the belt on the retractor side with the 4 nuts. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (g) Install the belt LH on the floor anchor side with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (h) Check the ELR lock. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assembly. (i) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt assembly installed. (1) When the belt is pulled out fully, the belt should automatically try to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retract again. If operation is not as specified, replace the belt assembly. SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) 2. Unlock 45 ° Lock B065025E01 SB–29 REMOVE 3 POINT TYPE BELT ASSEMBLY LH (without Rear No. 2 Seat) (a) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor. (b) Check the amount of inclination required to lock the retractor. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If operation is not as specified, replace the belt assembly. (c) Install the rear seat 3 point type belt inner with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Install the belt assembly on the retractor side with the 2 bolts. Torque: for upper bolt 8.5 N*m (87 kgf*cm, 75 ft.*lbf) for lower bolt 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) 3rd seat type: Install the No. 2 seat belt outer RH on the shoulder anchor side with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (f) Install the roof side garnish inner RH. (g) Install the deck trim side panel RH. (h) Install the belt outer on the floor anchor side with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (i) 3rd seat type: Install the No. 2 seat belt outer RH on the floor anchor side with the bolt. (j) Install the floor anchor cover. (k) 3rd seat type: Install the floor anchor cover. (l) Check the ELR lock. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assembly. (m) Check fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt assembly installed. (1) When the belt is pulled out fully, the belt should automatically try to retract. SB SB–30 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) (2) After the belt has fully retracted, the belt should be able to be pulled out and retract again. If operation is not as specified, replace the belt assembly. 3. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH (with Rear No. 2 Seat) 4. INSTALL ROOF SIDE GARNISH INNER RH 5. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (with Rear No. 2 Seat) 6. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH 7. INSTALL REAR FLOOR CARPET ASSEMBLY 8. INSTALL DECK TRIM COVER REAR 9. INSTALL REAR DOOR WEATHERSTRIP RH 10. INSTALL REAR DOOR SCUFF PLATE RH 11. INSTALL QUARTER SCUFF PLATE INNER RH (with Rear No. 2 Seat) 12. INSTALL SIDE TRIM BOX ASSEMBLY RH 13. INSTALL DECK TRIM SIDE BOARD UPR RH 14. INSTALL DECK TRIM COVER REAR 15. INSTALL DECK FLOOR BOX RH 16. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR 17. INSTALL DECK BOARD ASSEMBLY (without Rear No. 2 Seat) 18. INSTALL DECK BOARD SUB-ASSEMBLY (without Rear No. 2 Seat) 19. INSTALL BACK DOOR GLASS WEATHERSTRIP SB 20. INSTALL REAR NO. 2 SEAT LOCK ASSEMBLY RH (with Rear No. 2 Seat) 21. INSTALL NO. 2 SEAT LEG COVER (with Rear No. 2 Seat) 22. INSTALL REAR NO. 2 SEAT ASSEMBLY RH (with Rear No. 2 Seat) 23. INSTALL REAR NO. 2 SEAT ASSEMBLY LH (with Rear No. 2 Seat) 24. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) SB–17 REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) SEAT BELT RESTRAINTS COMPONENTS with REAR NO. 2 SEAT: BACK DOOR WEATHERSTRIP DECK TRIM COVER REAR REAR FLOOR SEAT LOCK COVER SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY ROPE HOOK SB REAR NO. 1 SEAT ASSEMBLY REAR SEAT 3 POINT TYPE BELT ASSEMBLY REAR SEAT BELT ASSEMBLY INNER REAR NO.1 SEAT BELT ASSEMBLY INNER LH 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131311E05 SB–18 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) REMOVAL HINT: Use the same procedures for the LH and RH. SB 1. REMOVE REAR NO. 1 SEAT ASSEMBLY 2. REMOVE REAR NO. 1 SEAT CUSHION ASSEMBLY LH 3. REMOVE REAR SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) (a) Remove the bolt and belt. SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) SB–33 REMOVAL HINT: Use the same procedures for the LH and RH. 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE REAR NO. 2 SEAT ASSEMBLY LH 3. REMOVE REAR NO. 2 SEAT ASSEMBLY RH 4. REMOVE NO.2 SEAT LEG COVER 5. REMOVE REAR NO. 2 SEAT LOCK ASSEMBLY RH (a) Remove the 2 bolts and seat lock. 6. REMOVE BACK DOOR GLASS WEATHERSTRIP 7. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR 8. REMOVE DECK FLOOR BOX RH (a) Remove the 2 bolts and seat lock. 9. REMOVE DECK TRIM COVER REAR (a) Using a screwdriver, pry out the trim cover. HINT: Tape the screwdriver tip before use. 10. REMOVE DECK TRIM SIDE BOARD UPR RH (a) Remove the screw and side board. 11. REMOVE SIDE TRIM BOX ASSEMBLY RH (a) Remove the screw and side trim box. 12. REMOVE QUARTER SCUFF PLATE INNER RH 13. REMOVE REAR DOOR SCUFF PLATE RH 14. REMOVE REAR DOOR WEATHERSTRIP RH 15. REMOVE REAR FLOOR CARPET ASSEMBLY 16. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (a) Remove the floor anchor cover. (b) Remove the bolt and seat belt outer on the floor anchor side. (c) Remove the shoulder anchor cover. (d) Remove the bolt and seat belt outer on the shoulder anchor side. (e) Remove the trim side panel. 17. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH 18. REMOVE 3 POINT TYPE BELT ASSEMBLY RH (for Rear No. 2 Seat) (a) Remove the 2 bolts on the retractor side, and thoroughly remove the seat belt. SB SB–34 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) INSTALLATION HINT: Use the same procedures for the LH and RH. 1. SB INSTALL 3 POINT TYPE BELT ASSEMBLY RH (for Rear No. 2 Seat) (a) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor. (b) Check the amount of inclination required to lock the retractor. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If operation is not as specified, replace the belt assembly. (c) Install the rear No. 2 seat belt inner with the bolt and nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Install the belt on the retractor side with the 2 bolts. Torque: for upper bolt 8.5 N*m (87 kgf*cm, 75 ft.*lbf) for lower bolt 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Install the roof side garnish inner RH. (f) Install the belt outer on the shoulder anchor side with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (g) Install the deck trim side panel RH. (h) Install the belt outer on the floor anchor side with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (i) Install the floor anchor cover. (j) Check the ELR lock. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assembly. (k) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt installed. (1) When the belt is pulled out fully, the belt should automatically try to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retract again. If operation is not as specified, replace the belt assembly. SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) SB–35 2. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH 4. INSTALL REAR FLOOR CARPET ASSEMBLY 5. INSTALL REAR DOOR WEATHERSTRIP RH 6. INSTALL REAR DOOR SCUFF PLATE RH 7. INSTALL QUARTER SCUFF PLATE INNER RH 8. INSTALL SIDE TRIM BOX ASSEMBLY RH 9. INSTALL DECK TRIM SIDE BOARD UPR RH 10. INSTALL DECK TRIM COVER REAR 11. INSTALL DECK FLOOR BOX RH 12. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR 13. INSTALL BACK DOOR GLASS WEATHERSTRIP 14. INSTALL REAR NO. 2 SEAT LOCK ASSEMBLY 15. INSTALL NO.2 SEAT LEG COVER 16. INSTALL REAR NO. 2 SEAT ASSEMBLY RH 17. INSTALL REAR NO. 2 SEAT ASSEMBLY LH 18. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY SB SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) SB–19 REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) SEAT BELT RESTRAINTS COMPONENTS ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR NO. 2 SEAT LEG COVER REAR NO. 2 SEAT LOCK ASSEMBLY RH DECK TRIM SIDE PANEL ASSEMBLY RH COVER REAR DOOR SUCFF PLATE RH QUARTER SCUFF PLATE INSIDE RH 42 (430, 31) SB NO. 2 SEAT BELT ASSEMBLY OUTER RH 8.5 (87, 75 in.*lbf) 42 (430, 31) 42 (430, 31) FLOOR ANCHOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque C131312E03 SB–20 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY (for Rear No. 2 Seat) BACK DOOR WEATHERSTRIP FLOOR SEAT LOCK COVER REAR FLOOR MAT SUPPORT PLATE REAR SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY ROPE HOOK SB REAR NO. 2 SEAT BELT SUB-ASSEMBLY INNER (RH) REAR NO. 2 SEAT BELT SUB-ASSEMBLY INNER (LH) 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131313E03 SB–38 SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) REMOVAL HINT: Use the same procedures for the LH and RH. SB 1. REMOVE REAR SEAT NO. 1 SEAT ASSEMBLY RH 2. REMOVE REAR NO. 1 SEAT CUSHION ASSEMBLY RH 3. REMOVE REAR SEAT BELT ASSEMBLY INNER CENTER (for Rear No. 1 Seat) (a) Remove the bolt and belt. SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) SB–39 INSTALLATION HINT: Use the same procedures for the LH and RH. 1. INSTALL REAR SEAT BELT ASSEMBLY INNER CENTER (for Rear No. 1 Seat) 2. INSTALL REAR NO. 1 SEAT CUSHION ASSEMBLY RH 3. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (a) Install the belt with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) SB SB–22 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SEAT BELT RESTRAINTS COMPONENTS without REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH DECK TRIM SIDE PANEL ASSEMBLY RH 42 (430, 31) 42 (430, 31) 8.5 (87, 75 in.*lbf) SB 42 (430, 31) REAR SEAT 3 POINT TYPE BELT ASSEMBLY INNER 3 POINT TYPE BELT ASSEMBLY 42 (430, 31) FLOOR ANCHOR COVER 42 (430, 31) REAR SEAT BELT ASSEMBLY OUTER CENTER REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque C131308E04 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) without REAR NO. 2 SEAT: SB–23 BACK DOOR GLASS WEATHERSTRIP DECK TRIM COVER REAR DECK BOARD ASSEMBLY REAR FLOOR CARPET ASSEMBLY DECK BOARD SUB-ASSEMBLY SB REAR NO. 2 SEAT ASSEMBLY C131309E03 SB–24 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) with REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR WEATHERSTRIP RH REAR NO. 2 SEAT LEG COVER REAR NO. 2 SEAT ASSEMBLY RH COVER DECK TRIM SIDE PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH QUARTER SCUFF PLATE INNER RH REAR OUTER ANCHOR PLATE RH 42 (430, 31) 3 POINT TYPE BELT ASSEMBLY LH SEAT SHOULDER BELT COVER SB 42 (430, 31) 42 (430, 31) 8.5 (87, 75 in.*lbf) FLOOR ANCHOR COVER 42 (430, 31) 3 POINT TYPE SEAT BELT ASSEMBLY 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131310E03 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) with REAR NO. 2 SEAT: SB–25 BACK DOOR GLASS WEATHERSTRIP DECK TRIM COVER REAR REAR FLOOR SEAT LOCK COVER SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY ROPE HOOK REAR NO. 2 SEAT ASSEMBLY REAR SEAT 3 POINT TYPE BELT ASSEMBLY SB REAR SEAT BELT ASSEMBLY INNER REAR NO.1 SEAT BELT ASSEMBLY INNER LH 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131311E06 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) SB–31 REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) SEAT BELT RESTRAINTS COMPONENTS ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR OPENING TRIM WEATHERSTRIP RH REAR NO. 2 SEAT LEG COVER REAR NO. 2 SEAT LOCK ASSEMBLY RH DECK TRIM SIDE PANEL ASSEMBLY RH COVER REAR DOOR SUCFF PLATE RH QUARTER SCUFF PLATE INSIDE RH 42 (430, 31) SB 3 POINT TYPE BELT ASSEMBLY RH 8.5 (87, 75 in.*lbf) 42 (430, 31) 42 (430, 31) FLOOR ANCHOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque C131312E04 SB–32 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY (for Rear No. 2 Seat) BACK DOOR WEATHERSTRIP FLOOR SEAT LOCK COVER REAR FLOOR MAT SUPPORT PLATE REAR SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY ROPE HOOK SB REAR NO. 2 SEAT BELT SUB-ASSEMBLY INNER (RH) REAR NO. 2 SEAT BELT SUB-ASSEMBLY INNER (LH) 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131313E03 SB–36 SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) SEAT BELT RESTRAINTS COMPONENTS without REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH DECK TRIM SIDE PANEL ASSEMBLY RH 42 (430, 31) 42 (430, 31) SB 8.5 (87, 75 in.*lbf) 42 (430, 31) REAR SEAT 3 POINT TYPE BELT ASSEMBLY INNER 42 (430, 31) REAR SEAT 3 POINT TYPE BELT ASSEMBLY FLOOR ANCHOR COVER 42 (430, 31) REAR SEAT BELT ASSEMBLY OUTER CENTER REAR SEAT BELT ASSEMBLY INNER CENTER N*m (kgf*cm, ft.*lbf) : Specified torque C131308E05 SEAT BELT – REAR CENTER SEAT INNER BELT ASSEMBLY (for Rear No. 1 Seat) with REAR NO. 2 SEAT: SB–37 BACK DOOR WEATHERSTRIP DECK TRIM COVER REAR REAR FLOOR SEAT LOCK COVER SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY ROPE HOOK REAR NO. 1 SEAT ASSEMBLY REAR SEAT 3 POINT TYPE BELT ASSEMBLY SB REAR SEAT BELT ASSEMBLY INNER REAR NO.1 SEAT BELT ASSEMBLY INNER LH 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131311E05 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SB–43 REMOVAL HINT: Use the same procedures for the LH and RH. 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY (with Rear No. 2 Seat) 2. REMOVE REAR NO. 2 SEAT ASSEMBLY LH (with Rear No. 2 Seat) 3. REMOVE REAR NO. 2 SEAT ASSEMBLY RH (with Rear No. 2 Seat) 4. REMOVE NO.2 SEAT LEG COVER (with Rear No. 2 Seat) 5. REMOVE REAR NO. 2 SEAT LOCK ASSEMBLY RH (with Rear No. 2 Seat) (a) Remove the 2 bolts and seat lock. 6. REMOVE BACK DOOR GLASS WEATHERSTRIP 7. REMOVE DECK BOARD SUB-ASSEMBLY (without Rear No. 2 Seat) (a) Remove the 2 bolts and the deck board subassembly. 8. REMOVE DECK BOARD ASSEMBLY (without Rear No. 2 Seat) (See page IR-7) 9. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR HINT: See page IR-7 10. REMOVE DECK FLOOR BOX RH (a) Remove the bolt, deck floor box and luggage hold belt striker. 11. REMOVE DECK TRIM COVER REAR (a) Using a screwdriver, pry out the trim cover. HINT: Tape the screwdriver tip before use. 12. REMOVE DECK TRIM SIDE BOARD UPR RH (a) Remove the screw and side board. 13. REMOVE SIDE TRIM BOX ASSEMBLY RH (a) Remove the screw and side trim box. 14. REMOVE QUARTER SCUFF PLATE INNER RH (with Rear No. 2 Seat) 15. REMOVE REAR DOOR SCUFF PLATE RH 16. REMOVE REAR DOOR WEATHERSTRIP RH 17. REMOVE DECK TRIM COVER REAR 18. REMOVE REAR FLOOR CARPET ASSEMBLY 19. REMOVE DECK TRIM SIDE PANEL ASSEMBLY (a) Remove the floor anchor cover. SB SB–44 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) (b) Remove the bolt and seat belt assembly outer on the floor anchor side. (c) Remove the side panel assembly. 20. REMOVE DECK TRIM SIDE PANEL ASSEMBLY (with Rear No. 2 Seat) (a) Remove the floor anchor cover. (b) Remove the bolt and No. 2 seat belt outer RH on the floor anchor side. (c) Remove the side panel. 21. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH 22. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH (with Rear No. 2 Seat) (a) Remove the bolt and No. 2 seat belt outer RH on the shoulder anchor side. (b) Remove the side garnish. 23. REMOVE REAR SEAT BELT ASSEMBLY OUTER CENTER (a) Remove the rear seatback board RH. (b) Remove the rear seat shoulder belt cover. (c) Remove the nut and rear seat belt. SB SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SB–45 INSTALLATION HINT: Use the same procedures for the LH and RH. 1. Unlock 45 q Lock B065024E01 INSTALL REAR SEAT BELT ASSEMBLY OUTER CENTER (for Rear No. 1 Seat) (a) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor. (b) Check the amount of inclination required to lock the retractor. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If operation is not as specified, replace the belt assembly. (c) Install the belt with the bolt as shown in the illustration. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) NOTICE: Do not make the anchor part run onto the protrusion part of the floor panel. (d) Install the belt on the retractor side with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (e) Install the seat shoulder belt cover. (f) Install the seatback board RH. (g) Install the belt outer on the floor anchor side with the bolt. (h) Check the ELR lock. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assy. (i) Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt assembly installed. (1) When the belt is pulled out fully, the belt should automatically try to retract. (2) After the belt has fully retracted, the belt should be able to be pulled out and retract again. If operation is not as specified, replace the belt assembly. Protrusion Front B063904E01 2. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH (w/ Rear No. 2 Seat) 3. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH SB SB–46 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) 4. INSTALL DECK TRIM SIDE PANEL ASSEMBLY (w/ Rear No. 2 Seat) 5. INSTALL DECK TRIM SIDE PANEL ASSEMBLY 6. INSTALL REAR FLOOR CARPET ASSEMBLY 7. INSTALL DECK TRIM COVER REAR 8. INSTALL REAR DOOR WEATHERSTRIP RH 9. INSTALL REAR DOOR SCUFF PLATE RH 10. INSTALL QUARTER SCUFF PLATE INNER RH (w/ Rear No. 2 Seat) 11. INSTALL SIDE TRIM BOX ASSEMBLY RH 12. INSTALL DECK TRIM SIDE BOARD UPR RH 13. INSTALL DECK TRIM COVER REAR 14. INSTALL DECK FLOOR BOX RH 15. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR 16. INSTALL DECK BOARD ASSEMBLY (w/o Rear No. 2 Seat) 17. INSTALL DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat) 18. INSTALL BACK DOOR GLASS WEATHERSTRIP 19. INSTALL REAR NO. 2 SEAT LOCK ASSEMBLY RH 20. INSTALL NO.2 SEAT LEG COVER (w/ Rear No. 2 Seat) 21. INSTALL REAR NO. 2 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat) 22. INSTALL REAR NO. 2 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat) SB 23. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY (w/ Rear No. 2 Seat) SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SB–39 REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SEAT BELT RESTRAINTS COMPONENTS without REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR WEATHERSTRIP RH REAR DOOR SCUFF PLATE RH DECK TRIM SIDE PANEL ASSEMBLY RH 42 (430, 31) 42 (430, 31) SB 8.5 (87, 75 in.*lbf) 42 (430, 31) REAR SEAT 3 POINT TYPE BELT ASSEMBLY INNER 3 POINT TYPE BELT ASSEMBLY 42 (430, 31) FLOOR ANCHOR COVER 42 (430, 31) REAR SEAT BELT ASSEMBLY OUTER CENTER REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque C131308E04 SB–40 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) without REAR NO. 2 SEAT: BACK DOOR GLASS WEATHERSTRIP DECK TRIM COVER REAR DECK BOARD ASSEMBLY REAR FLOOR CARPET ASSEMBLY DECK BOARD SUB-ASSEMBLY SB REAR SEAT CUSHION ASSEMBLY AND REAR SEATBACK ASSEMBLY C131309E04 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) SB–41 with REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH REAR DOOR WEATHERSTRIP RH REAR NO. 2 SEAT LEG COVER REAR NO. 2 SEAT ASSEMBLY RH COVER DECK TRIM SIDE PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH QUARTER SCUFF PLATE INNER RH REAR OUTER ANCHOR PLATE RH 42 (430, 31) 3 POINT TYPE BELT ASSEMBLY LH SEAT SHOULDER BELT COVER SB 42 (430, 31) 42 (430, 31) 8.5 (87, 75 in.*lbf) FLOOR ANCHOR COVER 42 (430, 31) 3 POINT TYPE SEAT BELT ASSEMBLY 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131310E03 SB–42 SEAT BELT – REAR CENTER SEAT OUTER BELT ASSEMBLY (for Rear No. 1 Seat) with REAR NO. 2 SEAT: BACK DOOR WEATHERSTRIP DECK TRIM COVER REAR REAR FLOOR SEAT LOCK COVER SEAT ANCHOR RAIL NO. 4 SEAT ANCHOR RAIL NO. 4 REAR FLOOR CARPET ASSEMBLY SB ROPE HOOK REAR NO. 1 SEAT ASSEMBLY REAR SEAT 3 POINT TYPE BELT ASSEMBLY REAR SEAT BELT ASSEMBLY INNER REAR NO.1 SEAT BELT ASSEMBLY INNER LH 42 (430, 31) 42 (430, 31) N*m (kgf*cm, ft.*lbf) : Specified torque C131311E05 THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–3 SYSTEM DESCRIPTION 1. OUTLINE OF THEFT DETERRENT SYSTEM • The theft deterrent system will operate when someone attempts to forcibly enter the vehicle, unlock any door or open the engine hood without using the key. This system causes the lights to light up or blink and the horns to sound in order to deter break-in and theft. • The theft deterrent system has 2 modes; one is the active arming mode (see ACTIVE ARMING MODE) and the other is passive arming mode (see PASSIVE ARMING MODE). The passive arming mode can be switched ON/OFF using the specified method. • Each mode has 4 states; a disarmed state, an arming preparation state, an armed state and an alarm sounding state. (a) Disarmed state: • The alarm function is not operating. • The theft deterrent system is not operating. (b) Arming preparation state: • The time until the system goes into the armed state. • The theft deterrent system is not operating. (c) Armed state: • The theft deterrent system is operating. (d) Alarm sounding state: • Alarm function is operating. Alarm time: (60 +- 5 sec.) x 10 HINT: If the vehicle remains in a condition that sets off the alarm (any door remains open, engine hood remains open, ignition switch remains directly connected) after the alarm ends, the alarm will be set off repeatedly a maximum of 10 times for every one of the above specified conditions. Refer to table below for alarm method and time: Alarm Method Alarm Time Headlight Blinking (cycle of 0.4 sec.) Taillight Blinking (cycle of 0.4 sec.) Hazard Warning Light Blinking (cycle of flasher relay) Interior Light Illuminating Vehicle Horn Sounding (approx. 0.4 second cycles) Security Horn Sounding (approx. 0.4 second cycles) Approx. 60 sec. (maximum 10 times) HINT: If any of the doors are unlocked when the key is not in the key cylinder during the armed state, a forced door lock signal will be output (see FORCED DOOR LOCK CONTROL). TD TD–4 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2. ACTIVE ARMING MODE HINT: Active arming mode starts the alarm control immediately after the doors are locked. (a) Active arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Condition (3) Condition (1) Arming Preparation State Condition (2) Condition (5) Armed State Condition (6) Condition (5) Condition (4) Alarm Sounding State TD B112141E01 Condition Item Condition (1) In the disarmed state, when the key is not in the key cylinder, the system state is switched if one of the following conditions is met. 1. With all doors, engine hood closed, lock all doors by key operation. 2. With all doors, engine hood closed, lock all doors by wireless operation. 3. Lock all doors without using key and perform either of the following. – Open any door or the engine hood and then close them all and lock all doors. – Leave all doors locked and engine hood closed. Condition (2) 1. After condition (1) is met, allow approx. 30 seconds to elapse. Condition (3) 1. 2. 3. 4. 5. 6. 7. 8. Unlock all doors by wireless operation. Unlock all doors by key operation. Unlock any door. Open any door. Open engine hood. Insert key into ignition key cylinder. Turn the ignition switch OFF to ON. Reconnect battery. THEFT DETERRENT – THEFT DETERRENT SYSTEM Condition TD–5 Item Condition (4) 1. 2. 3. 4. 5. Open engine hood. Reconnect battery. Open any door. Open any door without key and wireless operation. Directly connect ignition switch without key (or turn ignition switch ON without key). Condition (5) 1. Insert key into ignition key cylinder, turn ignition switch ON and run engine over 550 rpm for 10 to 12 sec. 2. Unlock all doors by wireless operation. 3. Unlock all doors by key operation. 4. Insert key into ignition key cylinder and turn ignition switch from OFF to ON. Condition (6) 1. After approx. 60 seconds, alarm stops and system returns to armed state. 3. PASSIVE ARMING MODE HINT: • Passive arming mode starts the alarm control when the key is not in key cylinder and doors are closed. • Passive arming mode can be switched ON/OFF by the specified method. • The alarm is initially set (when shipped from factory) to active arming mode (not passive arming mode). • During passive arming mode, the theft deterrent system goes into the armed state even if the doors are not locked. • Detecting that the doors are unlocked does not set off the alarm during passive arming mode. • A forced door lock signal is not output during passive arming mode (see FORCED DOOR LOCK CONTROL). • Although the theft deterrent system detects that the doors are opened during passive arming mode, the alarm will not go off immediately because an entry delay time is set. • If any of the following conditions is met during passive arming mode, the theft deterrent system will switch to active arming mode. – With all doors and engine hood closed, lock all doors by key operation. – With all doors and engine hood closed, lock all doors by wireless operation. – Lock all doors without using key and perform either of the following. Open any door or the engine hood and then close them all and lock all doors. / Leave all doors locked and engine hood closed. TD TD–6 THEFT DETERRENT – THEFT DETERRENT SYSTEM (a) Passive arming mode: This system activates as described in the diagram below when one of items for each condition is met. Disarmed State Condition (1) Disarmed State (1) *1 Disarmed State (2) *2 Condition (3) Condition (3) Condition (2) Arming Preparation State Condition (5) Condition (4) Condition (7) Armed State Condition (8) Condition (6) Condition (7) Alarm Sounding State TD B125108E01 HINT: • *1: Disarmed state 1 is the normal disarmed state. • *2: Disarmed state 2 is set from either the disarmed state 1 or the arming preparation state. Condition Item Condition (1) 1. With ignition switch OFF, open any door and pull the key out of the ignition key cylinder. 2. With ignition switch OFF, pull the key out of the ignition key cylinder and open any door. Condition (2) 1. With engine hood closed, close all doors.. 2. With engine hood and all doors closed, close back door. THEFT DETERRENT – THEFT DETERRENT SYSTEM Condition TD–7 Item Condition (3) 1. 2. 3. 4. 5. Unlock all doors by wireless operation. Unlock all doors by key operation. Reconnect battery. Insert key into ignition key cylinder. Turn the ignition switch from OFF to ON. Condition (4) 1. After condition (1) is met, allow approx. 30 seconds to elapse. Condition (5) 1. Open any door. 2. Open engine hood. 3. Open back door. Condition (6) 1. 2. 3. 4. Condition (7) 1. Unlock all doors by wireless operation. 2. Unlock all doors by key operation. 3. Insert key into ignition key cylinder and turn ignition switch from OFF to ON. Condition (8) 1. After approx. 60 sec., alarm stops and system returns to armed state. Open any door and allow entry delay time*1 to elapse. Open engine hood. Reconnect battery. Turn the ignition switch ON without using key. HINT: *1: When any door is opened while all the doors are closed during passive arming mode, the entry delay time starts. If the switch condition (armed state → disarmed state 1 or 2) is met during the entry delay time, the theft deterrent system will return to disarmed state 1 or 2. However, if the switch condition for disarmed state 1 or 2 is not met, the theft deterrent system will recognize it as a theft and set off the alarm. Entry delay time of 0, 14 or 30 sec. can be selected by the customizing function. TD TD–8 THEFT DETERRENT – THEFT DETERRENT SYSTEM 4. PROCEDURE FOR CHANGING OF PASSIVE MODE (ON OR OFF) Vehicle initial condition - No key in the ignition key cylinder - Only the driver side door opened - All the doors unlocked Within 5 seconds Insert and remove the key from the ignition key cylinder 3 times. : Input to the vehicle : Output from the vechicle Close the driver side door. : CORRECT Lock and unlock all the doors 3 times by key or wireless transmitter. *1 : INCORRECT *2 Within 40 secounds Open and close the driver side door *1 Lock and unlock the driver side door lock knob 3 times. TD *1 *2 Open the driver side door. 2 seconds The system performs forced door lock once (answer-back) *1: Any door courtesy OFF to ON *2: Any door lock UNLOCK to LOCK E112668E04 TD–9 THEFT DETERRENT – THEFT DETERRENT SYSTEM *2: Any door lock UNLOCK to LOCK *3: Driver side door OPEN to CLOSE *4: “Driver side door OPEN to CLOSE” is performed once in the previous step. The system performs forced door lock once (answer-back) *2 *3 *3, 4 Unlock the driver side door lock knob. To active mode To passive mode Within 20 seconds Close and open the driver side door twice. *2 Close and open 6 times or more the driver side door 3 to 5 times. 3 times Lock and unlock the driver side door lock knob. *3, 4 5 times Lock and unlock the driver side door lock knob. * 0 sec. 2 seconds 4 times * 14 sec. * 30 sec. The system performs forced door lock once (answer-back) The system performs forced door lock once (answer-back) ACTIVE MODE ON (PASSIVE MODE OFF) PASSIVE MODE ON TD E112669E01 HINT: • Initial mode is PASSIVE MODE OFF. • If the ignition switch is turned ON, change will be cancelled. • * Entry delay time. TD–10 THEFT DETERRENT – THEFT DETERRENT SYSTEM 5. 6. TD 7. FORCED DOOR LOCK CONTROL (a) The forced door lock control prevents the vehicle from being tampered with. Immediately after a door is unlocked (alarm starts), the door is forced to lock by a forced door lock signal. (1) Conditions that force the doors to lock: When the key is not in the key cylinder and 0.4 seconds have elapsed after the previous output of a forced door lock signal, the doors will be forced to lock if any of the following conditions is met: • The theft deterrent system is in the alarm sounding state of active arming mode. • Any door is unlocked. ALARM MEMORY FUNCTION (a) If the alarm is set off (tampering is detected) while the theft deterrent system is armed, it will be recorded by the alarm memory function. Whenever the theft deterrent system is cancelled, the alarm memory function causes the taillights to light up for 2 seconds in order to inform you that the alarm has been set off. (1) Conditions of the alarm memory function that cause the taillights to light up: When the theft deterrent system has entered into the alarm sounding state (tampering has been detected) even once, the taillights will light up for 2 seconds if any of the following conditions is met. • Switched to the disarmed state from the armed state during active arming mode. • Switched to the disarmed state 1 from the armed state during passive arming mode. • Switched to the disarmed state (2) from the armed state during passive mode. HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. PANIC ALARM CONTROL (a) The panic alarm control makes it possible to voluntarily set off the panic alarm by pressing the PANIC (LOCK) switch on the wireless transmitter. (1) Conditions that cause the panic alarm control to set off the panic alarm: The panic alarm control sets off the panic alarm by pressing the PANIC (LOCK) switch on the wireless transmitter over 2.4 seconds under the following conditions: • The ignition switch is OFF. TD–11 THEFT DETERRENT – THEFT DETERRENT SYSTEM 8. • The theft deterrent system is not in the alarm sounding state. (This condition is common both to active arming mode and to passive arming mode.) (2) Conditions that cause the panic alarm control to shut off the alarm: The panic alarm control shuts off the panic alarm when any of the following conditions is met during panic alarm operation: • The ignition switch is ON. • Either of the switches on the wireless transmitter (LOCK/UNLOCK) is pressed. • The panic alarm ends (approx. 60 sec. have passed). • The theft deterrent system switches to the alarm sounding state. Under this condition, the theft deterrent system is controlling the alarm rather than the panic alarm control. In order to cancel this alarm, refer to the theft deterrent system alarm sounding state cancellation procedure. (This condition is common both to active arming mode to passive arming mode.) HINT: Active arming mode: See ACTIVE ARMING MODE. Passive arming mode: See PASSIVE ARMING MODE. SECURITY INDICATOR OUTPUT (a) The theft warning ECU outputs a signal to light up the security indicator, according to the state of the theft deterrent system. However, some of the actual lighting conditions of the security indicator are different from the output signals of the theft warning ECU. Output: State of Theft Deterrent System* Disarmed state 1, 2 Security Indicator Output Signals from Theft warning ECU Actual Lighting Condition OFF OFF (Immobiliser system unset) BLINKING (Immobiliser system set) Arming preparation state ON ON Armed state OFF BLINKING Alarm sounding state ON ON Blinking cycle: Time Security Indicator 0.2 sec. ON 1.8 sec. OFF HINT: • *: The above condition is common both to active arming mode and to passive arming mode. TD TD–12 THEFT DETERRENT – THEFT DETERRENT SYSTEM • When the immobiliser system is set, the security indicator blinks during both the disarmed state and the armed state, due to the output signals from the immobiliser system. TD THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–13 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the theft deterrent system. • The intelligent tester should be used in step 3. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-30). NEXT 3 INSPECT COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To MULTIPLEX COMMUNICATION SECTION A 4 SYMPTOM SIMULATION TD NEXT 5 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B A Go to step 7 TD–14 6 THEFT DETERRENT – THEFT DETERRENT SYSTEM PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) Terminals of ECU (See page TD-14) 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END TD CONFIRMATION TEST TD–15 THEFT DETERRENT – THEFT DETERRENT SYSTEM PROBLEM SYMPTOMS TABLE Proceed to the reference page shown in the table below for each malfunction symptom and troubleshoot each circuit. HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system and the wireless door lock control system are operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system and the wireless door lock control system are operating normally. THEFT DETERRENT SYSTEM Symptom Theft deterrent system cannot be set. Suspected area See page 1. Security indicator light circuit TD-24 2. ECU power source circuit TD-26 3. Un-lock warning switch circuit DL-66 4. Door key lock and unlock switch DL-77 5. Back door key lock and unlock switch DL-80 6. Door courtesy switch circuit TD-14 7. Back door courtesy switch circuit TD-14 8. Engine hood courtesy switch circuit TD-18 Security indicator light does not blink when theft deterrent system is set. Security indicator light circuit TD-24 Alarm sounding state is not canceled when ignition switch is turned ON-OFF 10 times within 15 seconds. 1. Ignition switch circuit TD-22 2. Un-lock warning switch circuit DL-66 Theft deterrent system can be set even when any door is open. Door courtesy switch circuit TD-14 Horn does not sound while theft deterrent system is in warning operation. Security horn circuit TD-20 Headlights do not flash while theft deterrent system is in warning operation. Headlight circuit LI-20 Taillights do not flash while theft deterrent system is in warning operation. Taillights circuit LI-31 Hazard warning lights do not flash while theft deterrent system is in warning operation. Hazard warning switch LI-70 Interior light does not flash while theft deterrent system is in warning operation. Interior light circuit LI-25 Horn sounds even when theft deterrent system is not set. Security horn circuit TD-20 Headlights flash even when theft deterrent system is not set. Headlight circuit LI-20 Taillights flash even when theft deterrent system is not set. Taillights circuit LI-31 Hazard warning lights flash even when theft deterrent system is not set. Hazard warning switch circuit LI-70 Interior light flashes even when theft deterrent system is not set. Interior light circuit LI-25 TD TD–16 THEFT DETERRENT – THEFT DETERRENT SYSTEM TERMINALS OF ECU 1. CHECK THEFT WARNING ECU ASSEMBLY (THEFT DETERRENT ECU) T5 B050657E07 (a) Disconnect the T5 ECU connector, and check the voltage or continuity between each terminal of the wire harness side connector. Symbols (Terminal No.) Wiring Color Condition E (T5-29) - Body ground W-B - Body ground Always Below 1 Ω +B2 (T5-3) - E (T5-29) W-L - W-B Always 10 to 14 V IG (T5-10) - E (T5-29) B-R - W-B Ignition switch OFF to ON +B1 (T5-2) - E (T5-29) W-R - W-B Always Specified Condition Below 1 V → 10 to 14 V 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the T5 ECU connector, and check the voltage between each terminal of the connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition IND (T5-25) - E (T5-29) GR-G - W-B Security indicator light lights up. (It lights up only for 30 sec. in alarming sounding state. It flashes when immobiliser system is operating) 3 to 6 V SH- (T5-1) - E (T5-29) BR-B - W-B Security horn is sounding. (Theft deterrent system is in alarming sounding state) 10 to 14 V If the result is not as specified, the ECU may malfunction. TD TD–17 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2. CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (BODY ECU) B6 1F 1A 1E 1K B5 1C 1D 1H B4 1B 1J 1L 1G Connector 1F Connector 1C Connector B6 Connector 1K Body ECU Connector 1H Connector 1D Connector 1J Connector 1E Connector B5 Connector 1L Connector 1A TD Connector B4 Connector 1B Connector 1G B065529E01 TD–18 THEFT DETERRENT – THEFT DETERRENT SYSTEM (a) Disconnect the J/B connector, and check the voltage or continuity between each terminal of the wire harness side connector. Symbols (Terminal No.) Wiring Color BDR1 (1E-9) - Body ground Condition Specified Condition G-W - Body ground Always 10 to 14 V GND1 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω GND2 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω KSW (B6-14) - Body ground G-Y - Body ground No key in ignition key cylinder → Key inserted 10 kΩ or higher → Below 1Ω If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the J/B connector, and check the voltage between each terminal of the connector. Symbols (Terminal No.) Wiring Color DCTY (B5-23) - Body ground Condition R-B - Body ground Driver side door CLOSED → OPEN 10 to 14 V → Below 1 V PCTY (B5-24) - Body ground R-Y - Body ground Passenger side door CLOSED → OPEN 10 to 14 V → Below 1 V RLCY (B5-11) - Body ground P-B - Body ground Rear door LH CLOSED → OPEN 10 to 14 V → Below 1 V RRCY (B5-12) - Body ground P-L - Body ground Rear door RH CLOSED → OPEN 10 to 14 V → Below 1 V ACT+ (1L-9) - Body ground L-R - Body ground Master switch and driver side door key cylinder OFF → LOCK Below 1 V → 10 to 14 V ACT- (1L-18) - Body ground L-B - Body ground Master switch and driver side door key cylinder OFF → UNLOCK Below 1 V → 10 to 14 V 3. Specified Condition If the result is not as specified, the ECU may malfunction. INSPECT MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) B9 B8 TD B062706E03 (a) Disconnect the B8 ECU connector, and check the voltage of each terminal of the wire harness side connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition BDR (B8-4) - Body ground L - Body ground Always 10 to 14 V BECU (B8-5) - Body ground L-R - Body ground Always 10 to 14 V GND (B8-3) - Body ground W-B - Body ground Ignition switch OFF → ON Below 1 V → 10 to 14 V TD–19 THEFT DETERRENT – THEFT DETERRENT SYSTEM If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the B8 ECU connector, and check the voltage of each terminal of the connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition ACT+ (B9-15) - Body ground L-B - Body ground Back door OPEN → NOT COMPLETELY CLOSED → Monitor in normal rotation (Right turn) → Motor in reverse rotation (left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → 10 to 14 V → Below 1 V → Below 1 V ACT- (B9-14) - Body ground L-R - Body ground Back door OPEN → NOT COMPLETELY CLOSED → Monitor in normal rotation (Right turn) → Motor in reverse rotation (left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → Below 1 V → 10 to 14 V → Below 1 V If the result is not as specified, the ECU may malfunction. TD THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–1 THEFT DETERRENT SYSTEM THEFT DETERRENT SECURITIES PARTS LOCATION ENGINE ROOM R/B - ALT FUSE - AM1 FUSE - ECU-B FUSE SECURITY HORN ASSEMBLY HAZARD WARNING LIGHT TD ENGINE HOOD COURTESY SWITCH HAZARD WARNING LIGHT B120216E04 TD–2 THEFT DETERRENT – THEFT DETERRENT SYSTEM THEFT WARNING ECU ASSEMBLY FRONT DOOR W/ MOTOR LOCK ASSEMBLY RH AIR CONDITIONING CONTROL ASSEMBLY - FRONT DOOR LOCK INTERIOR LIGHT - SECURITY INDICATOR IGNITION OR STARTER SWITCH FRONT COURTESY SWITCH RH REAR DOOR W/ MOTOR LOCK ASSEMBLY RH UN-LOCK WARNING SWITCH - REAR DOOR LOCK REAR COURTESY SWITCH RH HAZARD WARNING LIGHT INSTRUMENT PANEL J/B ASSEMBLY - IG1 RELAY - DOOR FUSE - ECU-IG FUSE TD REAR COURTESY SWITCH LH - BODY ECU W/ MOTOR BACK DOOR LOCK ASSEMBLY - BACK DOOR LOCK FRONT DOOR W/ MOTOR LOCK ASSEMBLY LH - FRONT DOOR LOCK FRONT COURTESY SWITCH LH REAR DOOR W/ MOTOR LOCK ASSEMBLY LH MULTIPLEX NETWORK BACK DOOR ECU - REAR DOOR LOCK - BACK DOOR ECU B120217E03 TD–20 THEFT DETERRENT – THEFT DETERRENT SYSTEM Engine Hood Courtesy Switch Circuit DESCRIPTION The engine hood courtesy switch is built in the engine hood lock assembly. The switch turns on when the engine hood is opened and turns off when the engine hood is closed. WIRING DIAGRAM T5 Theft Warning ECU Assembly E3 Engine Hood Courtesy Switch 4 6 IC3 1 34 DSWH EB C B134206E01 INSPECTION PROCEDURE 1 INSPECT ENGINE HOOD LOCK ASSEMBLY (ENGINE HOOD COURTESY SWITCH) (a) Remove the courtesy switch from hood lock assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance TD Free (ON) Engine Hood Courtesy Switch Tester Connection Condition Specified Condition 1-4 Pushed: OFF (Lock) 10 kΩ or higher 1-4 Not pushed: ON (Unlock) Below 1 Ω Pushed (OFF) NG B064979E01 OK REPLACE ENGINE HOOD LOCK ASSEMBLY TD–21 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2 CHECK HARNESS AND CONNECTOR (THEFT WARNING ECU ASSEMBLY - ENGINE HOOD COURTESY SWITCH) (a) Disconnect the T5 ECU connector and E3 courtesy switch. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side T5 Theft Warning ECU Assembly Symbol (Tester Connection) Specified Condition DSWH (T5-34) - (E3-1) Below 1 Ω DSWH (T5-34) - Body ground 10 kΩ or higher NG E3 Engine Hood Courtesy Switch REPAIR OR REPLACE HARNESS OR CONNECTOR B064977E01 OK 3 CHECK HARNESS AND CONNECTOR (ENGINE HOOD COURTESY SWITCH - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side E3 Engine Hood Courtesy Switch NG B110538E03 OK REPLACE THEFT WARNING ECU ASSEMBLY Tester Connection Specified Condition E3-4 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–28 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH ENGINE HOOD COURTESY SWITCH Free (ON) Engine Hood Courtesy Switch INSPECTION 1. Pushed (OFF) INSPECT ENGINE HOOD COURTESY SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection 1-2 B064979E01 TD Switch Position Specified Condition Free (OFF) 10 kΩ or higher Pushed (ON) Below 1 Ω If the result is not as specified, replace the hood lock assembly. TD–22 THEFT DETERRENT – THEFT DETERRENT SYSTEM Security Horn Circuit DESCRIPTION During the alarm sounding state, the relay in the ECU turns on and off in a cycle of approximately 0.2 seconds, causing the security horn to sound. WIRING DIAGRAM T5 Theft Warning ECU Assembly SECU/HORN 3 +B2 FL MAIN 1 Battery SH- T1 Security Horn Assembly B110509E02 INSPECTION PROCEDURE 1 TD CHECK HARNESS AND CONNECTOR (THEFT WARNING ECU - BATTERY) (a) Disconnect the T5 ECU connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side T5 Theft Warning ECU Assembly Symbol (Tester Connection) Specified Condition +B2 (T5-3) - Body ground 10 to 14 V NG B063408E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR TD–23 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2 INSPECT SECURITY HORN ASSEMBLY (a) Disconnect the T1 security horn connector. (b) Check the operation of the security horn. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Horn body Security horn sounds NG REPLACE SECURITY HORN ASSEMBLY B070004 OK 3 CHECK HARNESS AND CONNECTOR (THEFT WARNING ECU ASSEMBLY - SECURITY HORN ASSEMBLY) Wire Harness Side Connector Front View: T1 Security Horn Assembly (a) Measure the resistance according to the value(s) in the table below. Standard resistance Symbol (Tester Connection) Specified Condition SH- (T5-1) - (T1-1) Below 1 Ω SH- (T5-1) - Body ground 10 kΩ or higher NG Connector Wire Harness View: REPAIR OR REPLACE HARNESS OR CONNECTOR T4 Theft Warning ECU Assembly TD SHB112146E01 OK REPLACE THEFT WARNING ECU ASSEMBLY TD–29 THEFT DETERRENT – SECURITY HORN ASSEMBLY SECURITY HORN ASSEMBLY INSPECTION 1. INSPECT SECURITY HORN ASSEMBLY (a) Check operation of the horn. Standard Measurement Condition Battery positive (+) → Terminal 1 B070004 Battery negative (-) → Horn body Specified Condition Horn sounds If the result is not as specified, replace the security horn assembly. TD TD–24 THEFT DETERRENT – THEFT DETERRENT SYSTEM Ignition Switch Circuit DESCRIPTION When the ignition switch is turned to the ON position, battery positive voltage is applied to terminal IG of the ECU. When battery positive voltage is applied to terminal IG of the ECU while the theft deterrent system is operating, the warning stops. WIRING DIAGRAM I18 Ignition Switch Assembly Theft Warning ECU Assembly ECU-IG 2 AM1 IG1 4 10 T5 IG AM1 2 1 ALT 1 2 Battery B139460E01 INSPECTION PROCEDURE 1 INSPECT FUSES (ECU-IG) (a) Remove the ECU-IG fuse from the instrument panel J/B. (b) Measure the resistance. Standard resistance: Below 1 Ω TD NG REPLACE FUSES OK 2 INSPECT IGNITION SWITCH ASSEMBLY (a) Disconnect the I18 switch connector. TD–25 THEFT DETERRENT – THEFT DETERRENT SYSTEM (b) Measure the resistance according to the value(s) in the table below. Standard resistance I18 Ignition Switch Assembly Tester Connection Switch Position Specified Condition 2-4 ON Below 1 Ω NG REPLACE IGNITION SWITCH ASSEMBLY No Pin ACC LOCK ON START B110511E06 OK 3 CHECK HARNESS OR CONNECTOR (POWER SOURCE) (a) Disconnect the T5 ECU connector. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side T5 Theft Warning ECU Assembly B063408E01 Symbol (Tester Connection) Specified Condition IG (T5-10) - Body ground 10 to 14 V NG OK REPLACE THEFT WARNING ECU ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–26 THEFT DETERRENT – THEFT DETERRENT SYSTEM Security Indicator Light Circuit DESCRIPTION Even in the disarming state, the security indicator light flashes due to a signal output from the immobiliser system. The security indicator light always flashes by receiving a signal from the immobiliser system at any time in the armed state. The theft warning ECU assembly causes the security indicator light to light up or blink only during the customizing function mode or the add mode of the transmitter. WIRING DIAGRAM Theft Warning ECU Assembly D3 Air Conditioning Control Assembly (Security Indicator Light) 7 GND SIND 12 25 T5 IND B139455E01 INSPECTION PROCEDURE TD 1 INSPECT AIR CONDITIONING CONTROL ASSEMBLY (SECURITY INDICATOR LIGHT) (a) Disconnect the A/C control connector. (b) Connect 3 dry batteries of 1.5 V in series. (c) Apply 4.5 V positive voltage between each terminal of the A/C control, and check the lighting condition of the security indicator light. Result D3 A/C Control Assembly (Security Indicator Light) 7 6 5 4 3 2 1 14 13 12 11 10 9 8 B063397E01 Symbols (Terminal No.) Specified Condition SIND (D3-12) - GND (D3-7) Lights up NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the security indicator light does not light up. • Voltage of more than 4.5 V will damage the security indicator light. TD–27 THEFT DETERRENT – THEFT DETERRENT SYSTEM • If the voltage is too low, the security indicator light does not light up. NG REPLACE AIR CONDITIONING CONTROL ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (THEFT WARNING ECU - SECURITY INDICATOR LIGHT) (a) Disconnect the T5 ECU and D3 A/C control connectors. (b) Check the continuity between the wire harness side connectors. Standard resistance Wire Harness Side T5 Theft Warning ECU Assembly Symbols (Terminal No.) Specified Condition IND (T5-25) - SIND (D3-12) Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR D3 A/C Control Assembly (Security Indicator Light) B065620E01 OK 3 CHECK HARNESS AND CONNECTOR (SECURITY INDICATOR LIGHT - BODY GROUND) (a) Disconnect the D3 A/C control connector. (b) Check the continuity between the wire harness side connectors. Standard resistance Wire Harness Side D3 A/C Control Assembly (Security Indicator Light) Symbols (Terminal No.) Specified Condition SIND (D3-12) - Body ground Below 1 Ω NG B065619E01 OK REPLACE THEFT WARNING ECU ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR TD TD–28 THEFT DETERRENT – THEFT DETERRENT SYSTEM ECU Power Source Circuit DESCRIPTION This circuit provides power to operate the theft warning ECU. WIRING DIAGRAM T5 Theft Warning ECU Assembly Short Pin ECU-B 2 1 2 1 2 29 +B1 E Battery B139461E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-B) (a) Remove the ECU-B fuse from the engine room J/B. (b) Measure the resistance. Standard resistance: Below 1 Ω TD NG OK REPLACE FUSE TD–29 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2 CHECK HARNESS AND CONNECTOR (POWER SOURCE) (a) Remove the T5 ECU assembly with the connector still connected. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side T5 Theft Warning ECU Assembly B063408E01 Symbol (Tester Connection) Specified Condition +B1 (T5-2) - Body ground 10 to 14 V OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG 3 CHECK HARNESS AND CONNECTOR (GROUND) (a) Disconnect the T5 ECU connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side T5 Theft Warning ECU Assembly Symbol (Tester Connection) Specified Condition E (T5-29) - Body ground Below 1 Ω NG B063408E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE THEFT WARNING ECU ASSEMBLY TD EI–4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION HINT: The key has 2 codes: The key code (immobiliser code) and the wireless code. Both of these codes need to be registered. Refer to page for the wireless code registration procedures. (a) When adding master keys or sub keys (Additional registration): (1) Register key code (immobiliser code) in the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "A" (b) When replacing the transponder key ECU (New registration): (1) Register the key code (immobiliser code) in the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "B" (2) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "C" (c) When replacing the ECM: (1) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See Procedure Transponder key ECU Procedure "C" 2. EI KEY REGISTRATION (a) Automatic registration (Procedure "B"): The new registration of the key codes (immobiliser codes) is made automatically. HINT: • When installing a new transponder key ECU, the key codes (immobiliser codes) must be registered. • A new transponder key ECU starts in the automatic key code registration mode. In this mode, a maximum of 4 key codes for 3 master keys and 1 sub key can be registered. Since the transponder key ECU can distinguish types of keys, any registration order is acceptable. Automatic Key Code Registration (New Registration) Procedure Security Indicator Condition 1. Start (Procedure "D") Blinking occurs until the first key is inserted. 2. Insert the key into the ignition key cylinder. ON ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM Procedure 3. Registration begins. HINT: The registration will be completed approx. 1 sec. after the key is inserted. 4. Remove the key. 5. Register another key ? Yes: Go to procedure "D" No: Go to procedure "E" EI–5 Security Indicator Condition OFF HINT: Approx. 1 sec. ON HINT: When the maximum number of the key codes is registered, the security indicator remains off until the last key registered is removed. After it is removed, the security indicator starts blinking. 6. End (Procedure "E") HINT: • When no key is inserted in the key cylinder while the system is in automatic key code registration mode, the security indicator remains on. • When the immobiliser system is operating normally and the key is pulled out, the security indicator blinks continuously. • If the key code registration has failed in the automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown below. EI EI–6 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM Security Indicator: 0.2 sec. ON Normal (Immobiliser system is operating normally) OFF 1.8 sec. 0.25 sec. 1 sec. ON Code 2 - 1 OFF 0.25 sec. 0.5 sec. 0.25 sec. 1 sec. ON Code 2 - 2 OFF 0.25 sec. 0.5 sec. 0.25 sec. 1 sec. EI ON Code 2 - 3 OFF 0.25 sec. 0.5 sec. B111593E14 EI–7 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (b) Finish the automatic key code registration mode. The automatic key code registration mode can be forced to end, when at least 1 key code (immobiliser code) for the master key has been registered. (1) Turn the ignition switch on and off 5 times within 10 seconds using the already registered master key. 3. REGISTRATION OF ADDITIONAL KEY (a) Additional registration (Procedure "A"): Register an additional key by using the intelligent tester. HINT: • A maximum of 5 key codes and 3 sub key codes can be registered. • Registration mode will end if any step is not completed within the specified time. • When the ignition cylinder or the key cylinder set is replaced, remove the transmitter module from the original master key. Then install this transmitter module to a new key and use it as master key. If necessary, use this master key to register other keys. NOTICE: When only the ignition key cylinder has been replaced, you can lock or unlock doors by wireless operation using the new key with built in transmitter but not by inserting it in the door key cylinder. Therefore, keep the original key for door lock or unlock operation in order to avoid malfunctions caused by a dead transmitter battery in the new key. Additional Registration Procedure Time (Completion of operation) Security Indicator Condition - Indicator blinks until the first key is inserted. 1. Start 2. Insert the already registered master-key in the ignition key cylinder and turn the ignition switch on. 3. Intelligent tester operation (1) Select IMMOBILISER (2) Select ID UTILITY (3) Select IMMOB CODE REG HINT: After completing the above operation, proceed to the next step in accordance with the prompts on the tester screen. 4. Remove the master key. 5. Insert the key to be registered in the ignition key cylinder. 6. After 60 sec. the key is registered. HINT: The security indicator goes off. 7. Next 8. End EI Within 120 sec. OFF Within 20 sec. of the instruction on the tester Within 10 sec. - ON Blinking OFF EI–8 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM NOTICE: If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown in procedure "B". HINT: • A brief outline of procedures for key code registration is shown above. For detailed information, please refer to the screen of the intelligent tester. • When the immobiliser system is operating normally and the key is pulled out, the security indicator will blink. 4. ERASURE OF KEY CODE (a) Erase key codes by using the intelligent tester. HINT: • All key codes will be erased except for the master-key which is used for erasing the key codes. In order to use a key for which the code has been erased, it is necessary to register the key code again. • The registration operation will be cancelled if any step is not completed within the specified time. Erasing Key Code Procedure Time (Operation Completion Time) Security Indicator Condition - Indicator blinks until the first key is inserted. Within 120 sec. OFF Within 10 sec. of the instruction on the tester ON for 1 sec. then OFF - Blinking 1. Start 2. Insert the already registered master-key in the ignition key cylinder and turn the ignition switch on. EI 3. Intelligent tester operation (1) Select IMMOBILISER (2) Select ID UTILITY (3) Select IMMOB CODE ERA HINT: After completing the above operation, proceed to the next step in accordance with the prompts on the tester screen. 4. Remove the master key. 5. Next 6. End HINT: • A brief outline of procedures for key code registration is shown above. For detailed information, please refer to the screen of the intelligent tester. • When the immobiliser system is operating normally and the key is pulled out, the security indicator will blink. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 5. EI–9 ECU COMMUNICATION ID REGISTRATION NOTICE: • The ECU communication ID should be registered when the transponder key ECU and/or the ECM is replaced in order to match it to the ECM COMMUNICATION ID. • The SFI system cannot be started unless the ECM COMMUNICATION ID matches. (a) ECU communication ID registration (Procedure "C"): Register the ECU COMMUNICATION ID, after the transponder key ECU and/or the ECM is replaced turn the ignition switch to the ON position. (1) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position and leave it as is for 30 minutes. (3) Check that the engine starts. EI EI–10 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM PROBLEM SYMPTOMS TABLE ENGINE IMMOBILISER SYSTEM Symptom Engine does not start EI Suspected area See page 1. Key (Transponder chip malfunction) EI-24 2. Key (Unmatched encryption code) EI-25 3. Key (Unmatched key code) EI-26 4. Key (No communication in immobiliser system) EI-27 5. Key (Communication malfunction) EI-31 6. Transponder key amplifier (Antenna coil open / short) EI-21 7. Transponder key amplifier (No communication in immobiliser system) EI-27 8. Transponder key amplifier (Communication malfunction) EI-31 9. Transponder key ECU assembly (Key unlock warning switch malfunction) EI-18 10. Transponder key ECU assembly (Antenna coil open / short) EI-21 11. Transponder key ECU assembly (No communication in immobiliser system) EI-27 12. Transponder key ECU assembly (Communication malfunction) EI-31 13. Transponder key ECU assembly (Engine immobiliser system malfunction) EI-34 EI–11 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM TERMINALS OF ECU 1. CHECK TRANSPONDER KEY AMPLIFIER I17 B065593E24 (a) Disconnect the I17 amplifier connector and measure the resistance between the terminal of the wire harness side connector and body ground. Symbols (Terminal No.) GND (I17-7) - Body ground Wiring Color Terminal Description L - Body ground Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the I17 amplifier connector and measure the resistance and voltage of each terminal of the connector. Symbols (Terminal No.) VC5 (I17-1) - GND (I17-7) CODE (I17-4) - GND (I177) TXCT (I17-5) - GND (I177) GND (I17-7) - Body ground Wiring Color Terminal Description GR-B - L Key is in ignition key cylinder Demodulated signal of key code date LG-R - L Key code output signal L - Body ground Specified Condition No key is in ignition key cylinder Power source P-L Condition Ground Below 1 V 4.6 to 5.4 V No key is in ignition key cylinder Key is in ignition key cylinder Below 1 V Waveform 1 No key is in ignition key cylinder Key is in ignition key cylinder Below 1 V Waveform 2 Below 1 Ω Always If the result is not as specified, the amplifier may have a malfunction. (c) Inspect using an oscilloscope. (1) Waveform 1 (Reference): Terminal B055023 CODE - GND Tool Setting 10 V/DIV., 10 ms/DIV. Condition Key is in ignition key cylinder EI EI–12 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (2) Waveform 2 (Reference): Terminal TXCT - GND Tool Setting 10 V/DIV., 10 ms/DIV. Condition Key is in ignition key cylinder 2. CHECK TRANSPONDER KEY ECU ASSEMBLY B055024 T8 B111613E12 (a) Disconnect the T8 ECU connector and measure the resistance and voltage between each terminal of the wire harness side connector. Symbols (Terminal No.) +B (T8-1) - GND (T8-14) IG (T8-2) - GND (T8-14) KSW (T8-10) - GND (T814) Wiring Color W-R - W-B B-O - W-B G-Y - W-B Terminal Description Battery Ignition switch Unlock warning switch Condition Specified Condition Always 10 to 14 V Ignition switch OFF Below 1 V Ignition switch ON 10 to 14 V No key is in ignition key cylinder Key is in ignition key cylinder 10 kΩ or higher Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the T8 ECU connector and measure the voltage of each terminal of the connector. Symbols (Terminal No.) EI AGND (T8-13) - Body ground Wiring Color L - Body ground KSW (T8-10) - GND (T814) G-Y - W-B VC5 (T8-8) - AGND (T813) GR-B - W TXCT (T8-12) - AGND (T8-13) CODE (T8-11) - AGND (T8-13) LG-R - W P-G - W Terminal Description Ground Unlock warning switch Power source Transponder key amplifier communication signal Transponder key amplifier ground Condition Specified Condition Always Below 1 Ω No key is in ignition key cylinder 10 to 14 V Key is in ignition key cylinder Below 1 V Ignition switch OFF Below 1 V Ignition switch ON 4.6 to 5.4 V No key is in ignition key cylinder Key is in ignition key cylinder No key is in ignition key cylinder Key is in ignition key cylinder Below 1 V Waveform 1 Below 1 V Waveform 2 EI–13 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM Symbols (Terminal No.) EFIO (T8-6) - GND (T814) EFII (T8-7) - GND (T8-14) Wiring Color Terminal Description W-R - W-B ECM output signal L-R - W-B ECM input signal Condition Specified Condition Ignition switch OFF Below 1 V Ignition switch ON Waveform 3 Ignition switch OFF Below 1 V Ignition switch ON Waveform 4 If the result is not as specified, the ECU may have a malfunction. (c) Inspect using an oscilloscope. (1) Wave form 1 (Reference): Terminal TXCT - AGND Tool Setting 10 V/DIV., 10 ms/DIV. Condition Key is in ignition key cylinder B055023 (2) Wave form 2 (Reference): Terminal CODE - AGND Tool Setting 10 V/DIV., 10 ms/DIV. Condition Key is in ignition key cylinder B055024 (3) Wave form 3 (Reference): Terminal EFIO - GND Tool Setting 5 V/DIV., 5 ms/DIV. Condition Ignition switch ON EI B052547 (4) Wave form 4 (Reference): B052548 Terminal EFII - GND Tool Setting 5 V/DIV., 5 ms/DIV. Condition Ignition switch ON EI–14 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 3. E4 E5 CHECK ECM E6 E7 E8 B050745E06 (a) Disconnect the E6 ECM connector and measure the resistance between the terminal of the wire harness side connector and body ground. Symbols (Terminal No.) E1 (E6-1) - Body ground Wiring Color Terminal Description W-B - Body ground Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the E6 ECM. Measure the voltage between each terminal of the connector according to the value(s) in the table below. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IMI (E7-16) - E1 (E6-1) W-R - W-B Transponder key ECU input signal Ignition switch OFF Below 1 V Ignition switch ON Waveform 1 IMO (E7-15) - E1 (E6-1) L-R - W-B Transponder key ECU output signal Ignition switch OFF Below 1 V Ignition switch ON Waveform 2 If the result is not as specified, there may be a malfunction on the wire harness side. (c) Inspect using an oscilloscope. (1) Waveform 1 (Reference): Terminal IMI - E1 Tool Setting 5 V/DIV., 5 ms/DIV. Condition Ignition switch ON EI B052547 (2) Waveform 2 (Reference): B052548 Terminal IMO - E1 Tool Setting 5 V/DIV., 5 ms/DIV. Condition Ignition switch ON EI–15 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DIAGNOSIS SYSTEM 1. 2. 3. CG SG CANH SIL CANL DESCRIPTION The ECU stores trouble codes when trouble occurs on the vehicle. The diagnostic system allows for reading of the trouble codes from the DLC3. Use the intelligent tester to check and solve the problem. CHECK BATTERY VOLTAGE (a) Check the battery voltage. Standard voltage: 10 to 14 V If the voltage is below 10 V, replace the battery before proceed to the next step. CHECK DLC3 (a) The vehicle's ECU uses ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. Intelligent Tester DLC3 CAN VIM G039021E04 (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch to the ON position and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or tester side. HINT: • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. EI EI–16 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC CHECK / CLEAR Intelligent Tester 1. DLC3 CAN VIM G039021E04 2. EI CHECK DTC (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester ON. (d) Read the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR THE DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester ON. (d) Erase the DTCs by following the directions on the screen. HINT: Refer to the intelligent tester operator's manual for further details. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM EI–1 ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SECURITIES PARTS LOCATION SECURITY INDICATOR LIGHT TRANSPONDER KEY ECU ASSEMBLY TRANSPONDER KEY AMPLIFIER ECM UNLOCK WARNING SWITCH ASSEMBLY EI B139187E01 EI–2 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the engine immobiliser system. • The intelligent tester should be used in steps 4, 5 and 7. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 CRANK ENGINE FOR MORE THAN 10 SECONDS NEXT 4 CHECK FOR DTC (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC (SFI system and engine immobiliser system) by simulating the original activity that the DTC suggested. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC (SFI system) reoccurs, proceed to B. (3) If the DTC (engine immobiliser system) reoccurs, proceed to C. EI B Go to SFI SYSTEM C Go to step 8 A 5 READ VALUE OF INTELLIGENT TESTER ((IMMOBILISER ECU (TRANSPONDER KEY ECU ASSEMBLY) (SWITCH CONDITION)) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the intelligent tester main switch ON. EI–3 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (c) Select the item KEY SW in the DATA LIST and read its value displayed on the intelligent tester. Item KEY SW Measurement Item / Display (Range) Unlock warning switch signal / ON or OFF NG Normal Condition Diagnostic Note ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - Go to DTC B2780 OK 6 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed on the problem symptoms table, proceed to A. (b) If the fault is listed on the problem symptoms table, proceed to B. B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Inspection with the intelligent tester (DATA LIST). (b) Inspection with the intelligent tester (ACTIVE TEST). (c) Terminals of ECU (See page EI-10). NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 NEXT END CONFIRMATION TEST EI EI–17 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the DATA LIST displayed on the intelligent tester, you can read the value of the switch, sensor, actuator, etc. without parts removal. Reading the DATA LIST as the first step in troubleshooting is one way to shorten the labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester ON. (d) Read the DATA LIST according to the display on the tester. Transponder key ECU Measurement Item/Display (Range) Normal Condition Diagnostic Note Unlock warning switch signal / ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - Ignition switch signal / ON or OFF ON: Ignition switch on OFF: Ignition switch off - Immobiliser system status / SET or UNSET UNSET: Ignition switch on SET: Without key - RESPONSE Transponder chip data / NG or OK NG: Data error OK: Data OK - FRAME Transponder chip data / NG or OK NG: Data error OK: Data OK - SERIAL NUMBER Transponder chip data / NG or OK NG: Data error OK: Data OK - ENCRYPT CODE Transponder chip data / NG or OK NG: Data error OK: Data OK - STATUS Transponder chip data / NG or OK NG: Data error OK: Data OK - BCC Transponder chip data / NG or OK NG: Incorrect data being sent. OK: Correct data being sent. - SUB KEY Sub key code signal / NOMATH or MATCH NOMATCH: Non matching sub key code is sent. MATCH: Sub key code is sent. - Master key code signal / NOMATH or MATCH NOMATCH: Non matching master key code is sent. MATCH: Master key code is sent. - REGIST SUB CODE Number of registered sub key / min. 0, max. 15 Number of registered sub key. - REGIST MAS CODE Number of registered master key / min. 0, max. 15 Number of registered master key. - Memory space for key codes registration / NOT FUL or FULL NOT FUL: More key code registration possible. FULL: No more key code registration possible. - Power source / BRAKE or NORMAL BRAKE: Power source open. NORMAL: Power source normal. - Antenna coil condition / NORMAL or FAIL NORMAL: Antenna coil is normal. FAIL: Antenna coil is malfunctioning. - Item KEY SW IG SW IMMOBILISER MASTER KEY REG CODE SPAC +B ANTENNA COIL EI EI–18 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 2. PERFORM ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator, etc. to operate without removing any parts . Performing the ACTIVE TEST as the first step of troubleshooting is one way to shorten labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position. (c) Turn the tester ON. (d) Perform the ACTIVE TEST to the display on the tester. Transponder key ECU EI Item Test Details SECURITY INDIC Turn security indicator ON / OFF Diagnostic Note - EI–19 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for that code. For details of each code, turn the page mentioned below the "DTC No" in the DTC chart. TRANSPONDER KEY ECU DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item Trouble Area See page B2780 Push Switch / Key Unlock Warning Switch Malfunction 1. Unlock warning switch assembly 2. Wire harness 3. Transponder key ECU assembly EI-18 B2784 Antenna Coil Open / Short 1. Transponder key amplifier 2. Wire harness 3. Transponder key ECU assembly EI-21 B2793 Transponder Chip Malfunction Key EI-24 B2794 Unmatched Encryption Code Key EI-25 B2795 Unmatched Key Code Key EI-26 B2796 No Communication in Immobiliser System 1. Key 2. Transponder key amplifier 3. Wire harness 4. Transponder key ECU assembly EI-27 B2797 Communication Malfunction No. 1 1. Key 2. Transponder key amplifier 3. Wire harness 4. Transponder key ECU assembly EI-31 B2798 Communication Malfunction No. 2 1. Key 2. Transponder key amplifier 3. Wire harness 4. Transponder key ECU assembly EI-27 ECM DIAGNOSTIC TROUBLE CODE CHART DTC No. B2799 Detection Item Engine Immobiliser System Trouble Area 1. Wire harness 2. Transponder key ECU assembly 3. ECM See page EI-34 NOTICE: The DTC for the immobiliser system is specified above. If other codes are output, check the DTC chart for the SFI system. EI EI–20 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC Push Switch / Key Unlock Warning Switch Malfunction B2780 DESCRIPTION This DTC will be output if the transponder key ECU does not detect that the unlock warning switch is on even when the ignition switch is on (Under the normal conditions, the unlock warning switch is on when the ignition switch is on). DTC No. DTC Detection Condition Trouble Area Unlock warning switch on is not detected when ignition switch is on B2780 • • • Unlock warning switch assembly Wire harness Transponder key ECU assembly WIRING DIAGRAM T8 Transponder Key ECU Assembly K3 Unlock Warning Switch Assembly J/C W-B 1 2 G-Y C J15 B J14 G-Y 10 KSW A J15 J/C A W-B A EI J5 J/C IG B144970E01 EI–21 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select KEY SW in the DATA LIST and read the value displayed on the intelligent tester. Transponder key ECU Item Measurement Item/Display (Range) Normal Condition Diagnostic Note KEY SW Unlock warning switch signal /ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - OK: ON (Key is in ignition key cylinder) appears on the screen OK REPLACE TRANSPONDER KEY ECU ASSEMBLY NG 2 INSPECT UNLOCK WARNING SWITCH ASSEMBLY (a) Remove the unlock warning switch. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Warning Switch Assembly Connector Front View: Tester Connection Free 1-2 Switch Condition Specified Condition Switch pushed (Key set) Below 1 Ω Switch free (Key removed) 10 kΩ or higher Pushed NG B111614E01 OK REPLACE UNLOCK WARNING SWITCH ASSEMBLY EI EI–22 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 3 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU ASSEMBLY - UNLOCK WARNING SW ASSEMBLY) Wire Harness Side Connector Front View: Transponder Key ECU Assembly (a) Disconnect the T8 ECU and K3 switch connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition T8-10 (KSW) - K3-2 Below 1 Ω T8-10 (KSW) - Body ground 10 kΩ or higher T8 NG REPAIR OR REPLACE HARNESS OR CONNECTOR KSW Unlock Warning Switch Assembly K3 B111594E10 OK 4 CHECK HARNESS AND CONNECTOR (UNLOCK WARNING SW ASSEMBLY - BODY GROUND) Wire Harness Side Connector Front View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition K3-1 - Body ground Below 1 Ω K3 EI NG Unlock Warning Switch Assembly B111599E06 OK REPLACE TRANSPONDER KEY ECU ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR EI–23 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2784 Antenna Coil Open / Short DESCRIPTION The transponder key coil is built into the transponder key amplifier and receives a key code signal from the transponder chip in the key. This signal is amplified by the amplifier, and output to the transponder key ECU. DTC No. DTC Detection Condition B2784 Trouble Area • • • Antenna coil open/short Transponder key amplifier Wire harness Transponder key ECU assembly WIRING DIAGRAM I17 Transponder Key Amplifier T8 Transponder Key ECU Assembly Amplifier ANT1 Coil VC5 1 GR-B 8 CODE 4 P-G 11 TXCT 5 LG-R 12 GND 7 L 13 ANT2 VC5 CODE TXCT AGND B111588E15 INSPECTION PROCEDURE 1 EI READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select ANTENNA COIL in the DATA LIST and read the value displayed on the intelligent tester. Transponder key ECU Item Measurement Item/Display (Range) ANTENNA COIL Antenna coil condition /NORMAL or FAIL Normal Condition NORMAL: Antenna coil is normal. FAIL: Antenna coil is malfunctioning. Diagnostic Note - EI–24 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM OK: NORMAL (Antenna coil is normal) appears on the screen. OK REPLACE TRANSPONDER KEY ECU ASSEMBLY NG 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU ASSEMBLY TRANSPONDER KEY AMPLIFIER) Wire Harness Side Connector Front View: Transponder Key ECU Assembly (a) Disconnect the T8 ECU and I17 switch connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition T8-8 (VC5) - I17-1 (VC5) T8 T8-11 (CODE) - I17-4 (CODE) Below 1 Ω T8-12 (TXCT) - I17-5 (TXCT) T8-13 (AGND) - I17-7 (GND) VC5 CODE TXCT AGND T8-8 (VC5) - Body ground T8-11 (CODE) - Body ground 10 kΩ or higher T8-12 (TXCT) - Body ground T8-13 (AGND) - Body ground Transponder Key Amplifier NG I17 VC5 REPAIR OR REPLACE HARNESS OR CONNECTOR GND CODE TXCT B111591E12 OK 3 EI INSPECT TRANSPONDER KEY ECU ASSEMBLY Wire Harness Side Connector Rear View: Transponder Key ECU Assembly (a) Reconnect the T8 ECU and I17 amplifier connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection T8-8 (VC5) - Body ground T8 AGND Condition Specified Condition No key is in ignition key cylinder Below 1 V Key is in ignition key cylinder 4.6 to 5.4 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance VC5 B111616E16 Tester Connection Condition Specified Condition T8-13 (AGND) - Body ground Always Below 1 Ω ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM NG EI–25 REPLACE TRANSPONDER KEY ECU ASSEMBLY OK REPLACE TRANSPONDER KEY AMPLIFIER EI EI–26 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2793 Transponder Chip Malfunction DESCRIPTION This DTC is output when a malfunction is found in the key during the key code registration or the key code is not registered normally. Replace the key when the key code registration is not performed normally and this DTC is detected. DTC No. B2793 DTC Detection Condition Trouble Area Transponder chip malfunction Key INSPECTION PROCEDURE 1 CHECK DTC OUTPUT (a) Delete the DTC (See page EI-15). (b) Insert the key into the ignition key cylinder. (c) Check that no code is output. OK: No DTC is output. OK END NG 2 RE-REGISTER KEY (a) Delete the DTC (See page EI-15). (b) Re-register the key (See page EI-3) and insert this key into the ignition key cylinder. Check that the engine starts with the key. OK: The engine starts. OK NG EI REPLACE KEY END ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2794 EI–27 Unmatched Encryption Code DESCRIPTION This DTC is output when a key with an incomplete key code is inserted into the ignition key cylinder. DTC No. B2794 DTC Detection Condition Trouble Area Key with incomplete key code inserted Key INSPECTION PROCEDURE 1 RE-REGISTER KEY (a) Delete the DTC (See page EI-15). (b) Re-register the key (See page EI-3) and insert this key into the ignition key cylinder. Check that the engine starts with this key. OK: The engine starts. OK END NG REPLACE KEY EI EI–28 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2795 Unmatched Key Code DESCRIPTION This DTC is output when a key with a code that has not been registered in the ECU is inserted into the ignition key cylinder. DTC No. B2795 DTC Detection Condition Trouble Area Key with unregistered key code is inserted. Key INSPECTION PROCEDURE 1 RE-REGISTER KEY (a) Delete the DTC (See page EI-15). (b) Re-register the key (See page EI-3) and insert key into the ignition key cylinder. Check that the engine starts with this key. OK: The engine starts. OK NG REPLACE KEY EI END EI–29 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2796 No Communication in Immobiliser System DTC B2798 Communication Malfunction No. 2 DESCRIPTION These codes are stored in the memory when a key that does not have a transponder chip is inserted or if communication between the key and transponder key ECU is impossible. DTC No. DTC Detection Condition B2796 B2798 Trouble Area No communication • • • • Key Wire harness Transponder key amplifier Transponder key ECU assembly Communication error • • • • Key Wire harness Transponder key amplifier Transponder key ECU assembly WIRING DIAGRAM I17 Transponder Key Amplifier T8 Transponder Key ECU Assembly Amplifier ANT1 Coil VC5 1 GR-B 8 CODE 4 P-G 11 TXCT 5 LG-R 12 GND 7 L 13 ANT2 VC5 CODE TXCT AGND B111588E16 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. EI EI–30 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (c) Select IMMOBILISER in the DATA LIST and read the value displayed on the intelligent tester. Transponder key ECU Item IMMOBILISER Measurement Item/Display (Range) Immobiliser system status / SET or UNSET Normal Condition UNSET: Ignition switch on SET: Without key Diagnostic Note - OK: UNSET (Ignition switch on) appears on the screen. OK REPLACE TRANSPONDER KEY ECU ASSEMBLY NG 2 CHECK KEYS (a) Insert the vehicle's other key into the ignition key cylinder. (b) Check that the engine starts with this key. OK: The engine starts. OK RE-REGISTER OR REPLACE KEY NG 3 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select ANTENNA COIL in the DATA LIST and read the value displayed on the intelligent tester. Transponder key ECU EI Item Measurement Item/Display (Range) Normal Condition Diagnostic Note ANTENNA COIL Antenna coil condition /NORMAL or FAIL NORMAL: Antenna coil is normal. FAIL: Antenna coil is malfunctioning. - OK: NORMAL (Antenna coil is normal) appears on the screen. OK NG REPLACE TRANSPONDER KEY ECU ASSEMBLY EI–31 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 4 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU ASSEMBLY TRANSPONDER KEY AMPLIFIER) Wire Harness Side Connector Front View: Transponder Key ECU Assembly (a) Disconnect the T8 ECU and I17 amplifier connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition T8-8 (VC5) - I17-1 (VC5) T8 T8-11 (CODE) - I17-4 (CODE) Below 1 Ω T8-12 (TXCT) - I17-5 (TXCT) T8-13 (AGND) - I17-7 (GND) VC5 CODE TXCT AGND T8-8 (VC5) - Body ground T8-11 (CODE) - Body ground 10 kΩ or higher T8-12 (TXCT) - Body ground T8-13 (AGND) - Body ground Transponder Key Amplifier NG I17 VC5 REPAIR OR REPLACE HARNESS OR CONNECTOR GND CODE TXCT B111591E13 OK 5 INSPECT TRANSPONDER KEY ECU ASSEMBLY Wire Harness Side Connector Rear View: Transponder Key ECU Assembly (a) Reconnect the T8 ECU and I17 amplifier connectors. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection T8-9 (VC5) - Body ground T8 AGND Specified Condition Below 1 V Key is in ignition key cylinder 4.6 to 5.4 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance VC5 B111616E17 Tester Connection Condition Specified Condition T8-13 (AGND) - Body ground Always Below 1 Ω NG OK Condition No key is in ignition key cylinder REPLACE TRANSPONDER KEY ECU ASSEMBLY EI EI–32 6 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM CHECK TRANSPONDER KEY AMPLIFIER (a) After replacing the transponder key amplifier with a normally functioning transponder key amplifier, check that the engine starts. OK: The engine starts. NG OK END EI REPLACE TRANSPONDER KEY ECU ASSEMBLY EI–33 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2797 Communication Malfunction No. 1 DESCRIPTION This DTC is output when an error occurs in normal communication. HINT: Some noise found in the communication line. DTC No. B2797 DTC Detection Condition Trouble Area Keys are positioned too close to each other, or noise occurred in communication line. • • • • Key Transponder key amplifier Wire harness Transponder key ECU assembly WIRING DIAGRAM I17 Transponder Key Amplifier CODE T8 Transponder Key ECU Assembly 4 10 P-G CODE B145170E01 INSPECTION PROCEDURE 1 CHECK KEY (a) Check whether the ignition key being used is near other ignition keys, as shown in the illustration. Also, check whether the key ring is in contact with the key grip. Result Example: Result Key is near other keys and/or key ring is in contact with key grip. A Key is not near other keys and / or key ring is not in contact with key grip. B B111583E01 B Go to step 3 A 2 Proceed to CHECK DTC OUTPUT (a) Delete the DTC (See page EI-15). EI EI–34 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (b) Insert the key into the ignition key cylinder. (c) Check that no code is output. OK: No DTC is output. OK END NG 3 CHECK TRANSPONDER KEY AMPLIFIER Wire Harness Side Connector Rear View: Transponder Key ECU Assembly (a) Using an oscilloscope or the intelligent tester, check the waveform between the terminals of the I17 amplifier and T8 ECU connectors. (b) Check that no noise is included in the waveform (an example of noise is shown on the left). Result Tester Connection Specified Condition I17-4 (CODE) - T8-11 (CODE) No noise is present T8 Tool Setting 10 V/DIV., 10 ms/DIV. Condition Key inserted into ignition key cylinder. CODE NG Transponder Key Amplifier I17 CODE EI Noise B111615E12 OK FIND CAUSE OF NOISE AND REMOVE IT EI–35 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 4 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU - TRANSPONDER KEY AMPLIFIER) Wire Harness Side Connector Front View: Transponder Key ECU Assembly (a) Disconnect the T8 ECU and I17 amplifier connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition T8-10 (CODE) - I17-4 (CODE) Below 1 Ω T8 NG CODE REPAIR OR REPLACE HARNESS OR CONNECTOR Transponder Key Amplifier I17 CODE B111591E14 OK 5 CHECK TRANSPONDER KEY AMPLIFIER (a) After replacing the transponder key amplifier with a normally functioning transponder key amplifier, check that the engine starts. OK: The engine starts. NG OK END REPLACE TRANSPONDER KEY ECU ASSEMBLY EI EI–36 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM DTC B2799 Engine Immobiliser System Malfunction DESCRIPTION This DTC is output when the ECM detects errors in communication between the transponder key ECU and the ECM, or in the communication lines. This DTC is also output when an engine start is attempted while the ECU communication ID between the transponder key ECU and the ECM are different. Before troubleshooting for this DTC, make sure that there is no DTC detected in the transponder key ECU. If there is key code-related DTC detected in the transponder key ECU, repair it first. DTC No. DTC Detection Condition • B2799 • Trouble Area Error in communication between ECM and transponder key ECU, and in communication line Communication ID is different during communication with transponder key ECU • • • Wire harness Transponder key ECU assembly ECM WIRING DIAGRAM T8 Transponder Key ECU Assembly ECM 16 IMI E7 15 IMO E7 W-R 6 LR 7 EFIO EFII B118496E08 EI INSPECTION PROCEDURE 1 RE-REGISTER ECU COMMUNICATION ID (a) Re-register the ECU communication ID (See page EI-3) between the transponder key ECU assembly and ECM. (b) Check that the engine starts. OK: The engine starts. OK NG END EI–37 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM 2 CHECK HARNESS AND CONNECTOR (TRANSPONDER KEY ECU ASSEMBLY - ECM) Wire Harness Side Connector Front View: Transponder Key ECU Assembly (a) Disconnect the T8 ECU and E7 ECM connectors. (b) Check the resistance of the wire harness side connectors. Standard resistance Tester Connection T8-6 (EFIO) - E7-16 (IMI) T8 T8-7 (EFII) - E7-15 (IMO) T8-6 (EFIO) - Body ground T8-7 (EFII) - Body ground EFIO Specified Condition Below 1 Ω 10 kΩ or higher EFII NG ECM REPAIR OR REPLACE HARNESS OR CONNECTOR E7 IMO IMI B066229E10 OK 3 CHECK TRANSPONDER KEY ECU ASSEMBLY (a) After replacing the transponder key ECU assembly with a normally functioning transponder key ECU assembly, check that the engine starts. OK: The engine starts. NG REPLACE ECM OK EI END CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–3 SYSTEM DESCRIPTION 1. 2. CRUISE CONTROL SYSTEM This system is controlled by the ECM, and is activated by the throttle position sensor and motor. The ECM controls the following functions: ON-OFF, - (COAST)/SET, + (ACCEL)/RES (RESUME), CANCEL, vehicle speed operation, motor output control, and overdrive control. • The ECM compares the driving vehicle speed from the speed sensor with the stored vehicle speed set through the cruise control main switch. The ECM instructs the throttle valve motor of the throttle body assembly to close the valve when the driving speed is greater than the stored speed, and instructs it to open the valve when the driving speed is less than the stored speed. • The ECM receives signals such as ON-OFF, (COAST)/SET, + (ACCEL)/RES (RESUME), and CANCEL from the cruise control main switch and executes the command. • The ECM illuminates the combination meter's CRUISE main indicator light when it receives a cruise control main switch ON signal. • The ECM cancels the cruise control system when the brake pedal is depressed and the ECM receives a stop light switch signal. • The ECM cancels the cruise control system when the clutch pedal is depressed and the ECM receives a clutch switch signal. LIMIT CONTROL (a) Low speed limit The lowest possible limit of the speed setting range is set at approximately 40 km/h (25 mph). The cruise control system cannot be set when the driving vehicle speed is below the low speed limit. Cruise control operation will be automatically canceled. (b) High speed limit The highest possible limit of the speed setting range is set at approximately 200 km/h (125 mph). The cruise control system cannot be set when the driving vehicle speed is over the high speed limit. Also, + (ACCEL)/RES (RESUME) cannot be used to increase speed beyond the high speed limit. CC CC–4 CRUISE CONTROL – CRUISE CONTROL SYSTEM 3. CC OPERATION OF CRUISE CONTROL The cruise control main switch operates 7 functions: SET, - (COAST), TAP-DOWN, RES (RESUME), + (ACCEL), TAP-UP, and CANCEL. The SET, TAP-DOWN, and - (COAST) functions, and the RES (RESUME), TAPUP, and + (ACCEL) functions are operated with the same switch. The cruise control main switch is an automatic return type switch which turns on only while operating it in the direction of each arrow and turns off after releasing it. (a) SET CONTROL Vehicle speed is stored and constant speed control is maintained when pushing the cruise control main switch to - (COAST)/SET while driving with the main switch on (the CRUISE main indicator light is on), and the vehicle speed is within the set speed range (between the low and high speed limits). (b) - (COAST) CONTROL When the cruise control main switch is set to (COST)/SET and held in that position while the cruise control system is operating, the ECM sends a "throttle valve opening angle 0°" demand signal to the cruise control system. Then the vehicle speed, when the cruise control main switch is released, is stored and maintained. HINT: An actual throttle valve opening angle of 0° is not possible due to the idle speed control, etc. (c) TAP-DOWN CONTROL When tapping down the cruise control main switch to - (COAST)/SET (for approximately 0.6 seconds) while the cruise control system is in operation, the stored vehicle speed decreases each time by approximately 1.6 km/h (1.0 mph). When the cruise control main switch is released from - (COAST)/SET and the difference between the driving and stored vehicle speed is more than 5 km/h (3 mph), the driving vehicle speed is stored and constant speed control is maintained. (d) ACCELERATION CONTROL The throttle valve motor of the throttle body assembly is instructed by the ECM to open the throttle valve when + (ACCEL)/RES (RESUME) on the cruise control main switch is pressed and held while the cruise control system is in operation. When the cruise control main switch is released from + (ACCEL)/RES (RESUME), the vehicle speed is stored and the vehicle is controlled at a constant speed. CRUISE CONTROL – CRUISE CONTROL SYSTEM 4. CC–5 (e) TAP-UP CONTROL When tapping up the cruise control main switch to + (ACCEL)/RES (RESUME) (for approximately 0.6 seconds) while the cruise control system is in operation, the stored vehicle speed increases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (approximately 3.1 mph), the stored vehicle speed will not be changed. (f) RESUME CONTROL If cruise control operation was canceled with the stop light switch or the CANCEL switch, and if driving speed is within the limit range, pushing the cruise control main switch to + (ACCEL)/RES (RESUME) restores vehicle speed memorized at the time of cancellation, and maintains constant speed control. (g) MANUAL CANCEL CONTROL Performing any of the following cancels the cruise control system while in operation (the stored vehicle speed in the ECM is maintained). • Depressing the brake pedal • Depressing the clutch pedal • The shift lever is moved from the D to the N position. • Pushing the cruise control main switch to CANCEL • Turning the cruise control main switch off (the stored vehicle speed in the ECM is not maintained). AUTO CANCEL (FAIL-SAFE) This system has an automatic cancellation function (failsafe) (See page CC-12). CC CC–6 CRUISE CONTROL – CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the cruise control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 PROBLEM SYMPTOM CONFIRMATION NEXT 3 DTC CHECK AND CLEAR* Refer to the DTC CHECK / CLEAR (See page CC-12). NEXT 4 DTC CHECK (OTHER THAN MPX AND CAN SYSTEM DTC)* Result A Result Proceed to DTC is not output A DTC is output B GO TO STEP 6 B 5 DTC CHART Refer to the DIAGNOSTIC TROUBLE CODE CHART (See page CC-14). CC NEXT GO TO STEP 9 6 PROBLEM SYMPTOM CONFIRMATION Result Result Proceed to Symptom occurs A CC–7 CRUISE CONTROL – CRUISE CONTROL SYSTEM A Result Proceed to Symptom does not occur B GO TO STEP 8 B 7 SYMPTOM SIMULATION NEXT Go to step 6 8 PROBLEM SYMPTOMS TABLE Refer to the PROBLEM SYMPTOMS TABLE (See page CC9). NEXT 9 CIRCUIT INSPECTION NEXT 10 TERMINALS OF ECM Refer to TERMINALS OF ECM (See page CC-10). NEXT 11 IDENTIFICATION OF PROBLEM NEXT 12 REPAIR OR REPLACE NEXT 13 NEXT END CONFIRMATION TEST CC CC–8 CRUISE CONTROL – CRUISE CONTROL SYSTEM ROAD TEST 1. E107085 E107086 E107085 CC E107087 PROBLEM SYMPTOM CONFIRMATION (a) Inspect the SET function. (1) Turn the cruise control main switch on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to (COAST)/SET. (4) After releasing the switch, check that the vehicle cruises at the set speed. (b) Inspect the ACCELERATION function. (1) Turn the cruise control main switch on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to (COAST)/SET. (4) Check that vehicle speed increases while the cruise control main switch is pushed to + (ACCEL)/RES (RESUME), and that the vehicle cruises at the newly set speed when the switch is released. (5) Push the cruise control main switch to + (ACCEL)/RES (RESUME) and then release it immediately. Check that vehicle speed increases by approximately 1.6 km/h (1.0 mph) (tap-up control). (c) Inspect the - (COAST) function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) Check that vehicle speed decreases while the cruise control main switch is pushed to (COAST)/SET, and the vehicle cruises at the newly set speed when the switch is released. (5) Push the cruise control main switch to (COAST)/SET, and then release it immediately. Check that vehicle speed decreases by approximately 1.6 km/h (1.0 mph) (tap-down control). (d) Inspect the CANCEL function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) When performing any one of the following, check that the cruise control system is canceled and that the normal driving mode is reset. • Depressing the brake pedal • Depressing the clutch pedal CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–9 • The shift lever is moved from the D to the N position. • Turning the cruise control main switch off • Pulling the cruise control main switch to CANCEL E107086 (e) Inspect the RES (RESUME) function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 40 km/h (25 mph) and 200 km/h (125 mph). (3) Push the cruise control main switch to (COAST)/SET. (4) Cancel the cruise control system by performing any of the above operations (other than turning the main switch off). (5) After pushing the cruise control main switch to + (ACCEL)/RES (RESUME) at a driving speed of more than 40 km/h (25 mph), check that the vehicle resumes the speed set prior to the cancellation. CC CC–10 CRUISE CONTROL – CRUISE CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Be sure to perform the SYMPTOM SIMULATION procedure before replacing the ECM . IF these symptoms do not persist, the cause of the problem may be a poor intermittent electrical contact (open or short) of a wire harness or connector. Cruise control system Symptom Main switch cannot be turned ON. (Cruise indicator light in combination meter is not lit.) Vehicle speed setting cannot be done. (Although indicator light in combination meter is lit when the main switch is turned ON, they go off when vehicle speed is set.) Setting cannot be done. (Indicator light in combination meter is lit when the main switch is turned ON and they remain ON while setting.) While the vehicle is driving with cruise control, the set control is canceled. (Indicator light and CRUISE remain ON.) Hunting (Speed is not constant.) Setting cannot be canceled. (When Coast, Acceleration, Resume, Set speed change and Control switch are operated.) CC DTC is not output, or is output when should not be. CRUISE MAIN indicator light does not light up. Suspected Area See page 1. Cruise control switch circuit CC-21 2. CRUISE MAIN indicator light circuit CC-23 3. Replace ECM ES-434 4. Replace ECM ES-510 1. Cruise control switch circuit CC-21 2. Replace ECM ES-434 3. Replace ECM ES-510 1. Cruise control switch circuit CC-21 2. Stop light switch LI-71 3. PNP switch (A750E) AT-316 4. PNP switch (A750F) AT-326 5. Combination meter system ME-4 6. Replace ECM ES-434 7. Replace ECM ES-510 1. Cruise control switch circuit CC-21 2. Vehicle speed sensor circuit - 3. Stop light switch LI-71 4. CRUISE MAIN indicator light circuit CC-23 5. PNP switch (A750E) AT-316 6. PNP switch (A750F) AT-326 7. Replace ECM ES-434 8. Replace ECM ES-510 1. Vehicle speed sensor circuit - 2. Replace ECM ES-434 3. Replace ECM ES-510 1. Cruise control switch circuit CC-21 2. Replace ECM ES-434 3. Replace ECM ES-510 1. TC and CG terminal circuit CC-25 2. Replace ECM ES-434 3. Replace ECM ES-510 1. Cruise control switch circuit CC-21 2. CRUISE MAIN indicator light circuit CC-23 3. Replace ECM ES-434 4. Replace ECM ES-510 CC–11 CRUISE CONTROL – CRUISE CONTROL SYSTEM TERMINALS OF ECM 1. E4 CHECK ECM E6 E5 E7 E8 G035613E20 Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition E8-23 (TC) - E6-1 (E1) P-L - W-B Ground Ignition switch ON 10 to 14 V E8-23 (TC) - E6-1 (E1) P-L - W-B Ground Ignition switch ON, Connect terminals TC and CG of DLC3 Below 2 V E8-15 (STP) - E6-1 (E1) G-Y - W-B Stop light signal Ignition switch ON, Depress brake pedal 10 to 14 V E8-15 (STP) - E6-1 (E1) G-Y - W-B Stop light signal Ignition switch ON, Release brake pedal Below 1 V E7-2 (CCS) - E6-1 (E1) L-B - W-B Cruise control main switch circuit Ignition switch ON 9 to 14 V E7-2 (CCS) - E6-1 (E1) L-B - W-B Cruise control main switch circuit Ignition switch ON, CANCEL switch hold ON 6.0 to 10.1 V E7-2 (CCS) - E6-1 (E1) L-B - W-B Cruise control main switch circuit Ignition switch ON, -/SET switch hold ON 4.0 to 7.1 V E7-2 (CCS) - E6-1 (E1) L-B - W-B Cruise control main switch circuit Ignition switch ON, +/RES switch hold ON 2.1 to 4.0 V E7-2 (CCS) - E6-1 (E1) L-B - W-B Cruise control main switch circuit Ignition switch ON, MAIN switch hold ON Below 1 V E8-16 (ST1-) - E6-1 (E1) R-L - W-B Stop light signal Ignition switch ON, Depress brake pedal Below 1 V E8-16 (ST1-) - E6-1 (E1) R-L - W-B Stop light signal Ignition switch ON, Release brake pedal 10 to 14 V E7-18 (PI) - E6-1 (E1) LG - W-B Cruise MAIN indicator light signal Ignition switch ON, Cruise control main switch ON 0 to 3 V E7-18 (PI) - E6-1 (E1) LG - W-B Cruise MAIN indicator light signal Ignition switch ON, Cruise control main switch ON 9 to 14 V CC CC–12 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION The ECU controls the cruise control system of the vehicle. The data and DTCs relating to the cruise control system can be read from the DLC3 of the vehicle. If CRUISE MAIN indicator light does not come on after the DTC check, there is a malfunction on the cruise control system. 2. CHECK DLC3 (a) The ECM uses the ISO 9141-2 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminals No.) CC Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 67 Ω CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - CG (4) HIGH-level CAN bus line Ignition switch OFF 3 kΩ or higher CANH (6) - BAT (16) LOW-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch OFF 3 kΩ or higher HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem with either the vehicle or the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. CRUISE CONTROL – CRUISE CONTROL SYSTEM CRUISE MAIN Indicator Light 3. CC–13 CHECK INDICATOR (a) Turn the ignition switch to ON. I033556E01 CRUISE Main Indicator Light 1.5 sec. 0.5 sec. ON OFF BE04034E01 (b) Check that the CRUISE main indicator light illuminates when the cruise control main switch is turned on, and that the indicator light turns off when the main switch is turned off. If the results are not as specified, inspect the CRUISE main indicator light circuit (See page CC-23). HINT: While driving with cruise control, the ECM activates AUTO CANCEL of the cruise control system when a malfunction occurs in one of the following: vehicle speed sensors, stop light switch, or other related parts. When AUTO CANCEL is activated, the CRUISE main indicator light outputs the blinking pattern shown to the left. At the same time, data of the malfunction is stored as a DTC. CC CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–1 CRUISE CONTROL SYSTEM PRECAUTION 1. HANDLING PRECAUTION FOR CRUISE CONTROL SYSTEM (a) Turn the cruise control main switch off when not using the cruise control system. (b) Be careful as the vehicle speed increases when driving downhill with the cruise control system on. (c) The + (ACCEL)/RES (RESUME) operation changes according to the cruise control system status. When the cruise control system is operating, the + (ACCEL) function operates. When the cruise control system is not operating, the RES (RESUME) function operates. (d) If the CRUISE main indicator light blinks while the cruise control system is operating, turn the cruise control main switch off to reset the cruise control system. After the reset, if the cruise control main switch cannot be turned on, or the cruise control system is canceled immediately after turning the cruise control main switch on, the system may have a malfunction. (e) Do not use the cruise control system where the road conditions are as follows: • Heavy traffic • Steep decline • Roads with sharp turns • Icy or snowy roads • Slippery roads CC CC–2 CRUISE CONTROL – CRUISE CONTROL SYSTEM PARTS LOCATION STOP LIGHT SWITCH ASSEMBLY COMBINATION METER ASSEMBLY - CRUISE MAIN INDICATOR LIGHT ECM CRUISE CONTROL MAIN SWITCH DLC3 IGNITION SWITCH DRIVER SIDE J/B - GAUGE FUSE CC - IGN FUSE - STOP FUSE PARK/NEUTRAL POSITION SWITCH ASSEMBLY E116111E03 CC–14 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC CHECK / CLEAR 1. 2. CC DTC CHECK (a) Connect the intelligent tester to the DLC3. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (b) Turn the ignition switch to ON. (c) Read the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DTC CLEAR (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) Operate the intelligent tester to erase the codes. HINT: Refer to the intelligent tester operator's manual for further details. CC–15 CRUISE CONTROL – CRUISE CONTROL SYSTEM FAIL-SAFE CHART HINT: If the following conditions are detected while the cruise control is in operation, the system clears the stored vehicle speed in the ECM and cancels the cruise control operation. Vehicle Condition Auto Cancel Condition • CRUISE main indicator light blinks Re-operation Condition There is open or short in stop light switch circuit There is problem with vehicle speed signal There is problem with throttle position sensor and motor Turn cruise control main switch on again There is problem with input circuit of stop light switch circuit There is problem with cancel circuit • • • Vehicle speed is lower than low speed limit (approx. 40 km/h (25 mph)) while running with cruise control on Push cruise control main switch to + (ACCEL)/RES (RESUME) • Vehicle speed is lower than stored speed by approx. 16 km/h (9.9 mph) or more Push cruise control main switch to - (COAST)/ SET • • • CRUISE main indicator light blinks • CRUISE main indicator light goes off Turn cruise control main switch on again Turn ignition switch off then on again CC CC–27 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MAIN SWITCH CRUISE CONTROL SYSTEM COMPONENTS STEERING WHEEL ASSEMBLY 50 (510, 37) STEERING WHEEL COVER LOWER NO. 2 STEERING WHEEL COVER LOWER NO. 3 CC STEERING PAD N*m (kgf*cm, ft.*lbf) : Specified torque C C131315E06 CC–28 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MAIN SWITCH CC E116111E04 CC–16 CRUISE CONTROL – CRUISE CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator, and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) Read the DATA LIST according to the display on the tester. ECM (Cruise control): Item Measurement Item / Display (Range) VEHICLE SPD Vehicle speed / min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed - MEMORY SPD Cruise control memorized speed / min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual stored vehicle speed - THROTTLE Required throttle opening angle / min. : 0°, max. : 125° Actual required throttle opening Diagnostic Note - Cruise control system active condition / ON or OFF ON: Cruise control activated OFF: Cruise control deactivated MAIN SW (MAIN) Main switch signal (Main CPU) / ON or OFF ON: Main switch on (Pushed on) OFF: Main switch off (Pushed off) "3" MAIN SW (SUB) Main SW signal (Sub CPU) / ON or OFF ON: Main SW ON (Pressed in) OFF: Main SW OFF (Pressed out) "3" CCS READY M Cruise control system standby condition (Main CPU) / ON or OFF ON / OFF: Change ON/OFF each time Main SW is pushed in. "1" CCS READY S Cruise control system standby condition (Sub CPU) / ON or OFF ON / OFF: Change ON/OFF each time Main SW is pushed in. "1" CCS INDICATOR M Cruise indicator signal (Main CPU) / ON or OFF ON: "CCS READY" ON OFF: "CCS READY" OFF "2" CCS INDICATOR S Cruise indicator signal (Sub CPU) / ON or OFF ON: "CCS READY" ON OFF: "CCS READY" OFF "2" CANCEL switch signal / ON or OFF ON: CANCEL switch on OFF: CANCEL switch off - SET/COAST SW -/SET switch signal / ON or OFF ON: -/SET switch on OFF: -/SET switch off - RES/ACC SW +/RES switch signal / ON or OFF ON: +/RES switch on OFF: +/RES switch off - STP LIGHT SW2 M Stop light switch signal (Main CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW2 S Stop light switch signal (Sub CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STP LIGHT SW1 S Stop light switch signal (Sub CPU) / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - PNP switch signal (D position) / ON or OFF ON: Shift lever in D OFF: Shift lever not in D - CRUISE CONTROL CANCEL SW CC Normal Condition SHIFT D POS - HINT: • "3" is OK but "1" is NG → ECM failure • "1" is OK but "2" is NG → DTC output or ECM failure CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–17 • "3" is OK but CRUISE main indicator light does not illuminate → CRUISE main indicator light, wire harness, or ECM failure CC CC–18 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the trouble areas listed for that code in the table below and proceed to the appropriate page. DTC Code CC Detection Item Trouble Area See page P0500 Vehicle Speed Sensor Malfunction -Combination meter assembly -Vehicle speed sensor -Vehicle speed sensor signal circuit -ECM CC-15 P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High -Combination meter assembly -Vehicle speed sensor -Vehicle speed sensor circuit -ECM CC-15 P0571 Brake Switch "A" Circuit -Stop light switch -Stop light circuit -ECM CC-16 P0607 Control Module Performance -ECM CC-20 CC–19 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0500 Vehicle Speed Sensor Malfunction DTC P0503 Vehicle Speed Sensor "A" Intermittent / Erratic / High DESCRIPTION for 2UZ-FE: Refer to DTC P0500 (See page ES-236). for 1GR-FE: Refer to DTC P0500 (See page ES-263). DTC No. DTC Detection Condition Trouble Area P0500 The vehicle speed signal from the vehicle speed sensor is cut for 0.14 sec. or more while cruise control is in operation • • • • Combination meter assembly Vehicle speed sensor Vehicle speed sensor signal circuit ECM P0503 Momentary interruption and noise are detected when a rapid change of vehicle speed occurs while cruise control is in operation • • • • Combination meter assembly Vehicle speed sensor Vehicle speed sensor signal circuit ECM WIRING DIAGRAM for 2UZ-FE: Refer to DTC P0500 (See page ES-237). for 1GR-FE: Refer to DTC P0500 (See page ES-264). INSPECTION PROCEDURE for 2UZ-FE: Refer to DTC P0500 (See page ES-237). for 1GR-FE: Refer to DTC P0500 (See page ES-264). CC CC–20 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0571 Brake Switch "A" Circuit DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECM. When the ECM receives this signal, it cancels the cruise control. The fail-safe function operates to enable normal driving even if there is a malfunction in the stop light signal circuit. The cancellation condition occurs when voltage is applied to terminal STP. When the brake is applied, voltage is normally applied to terminal STP of the ECM through the STOP SW fuse and the stop light switch, and the ECM turns the cruise control off. DTC No. P0571 CC DTC Detection Condition Stop light switch assembly does not turn off even once the vehicle is driven. Trouble Area • • • Stop light switch Stop light switch circuit ECM CC–21 CRUISE CONTROL – CRUISE CONTROL SYSTEM WIRING DIAGRAM ECM Center J/B 15 IC3 G-Y G-Y E E 3C 3C 11 J/C H G-Y J31 E J32 G-Y E8 E8 S12 Stop Light SW 3 ST1- Driver Side J/B J4 J/C B-O 4 STP 16 R-L IC3 R-L 15 23 B-O C 6 IGN 1E C 1D Engine Room R/B J4 J/C G-W G-Y B ALT STOP B 2 2 1 2 2 1 2 1 B 2 AM2 B 2 2 1 2 R R Battery CC B-R 7 AM2 IG2 6 E116138E02 CC–22 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK STOP LIGHT SWITCH OPERATION (a) Check that the stop light lights up when brake pedal is depress and turns OFF when the brake pedal is released. NG INSPECT STOP LIGHT SWITCH CIRCUIT OK 2 INSPECT STOP LIGHT SWITCH 2 1 (a) Remove stop light switch (See page BR-7). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 Switch pin not pushed 10 kΩ or higher 3-4 Switch pin not pushed Below 1 Ω 1-2 Switch pin pushed Below 1 Ω 3-4 Switch pin pushed 10 kΩ or higher 3 4 Free Pushed in E065594E56 (c) Install the stop light switch. NG REPLACE STOP LIGHT SWITCH OK 3 CHECK ECM (a) (b) (c) (d) E8 CC ECM Connector ST1- STP A131509E68 Reconnect the stop light switch connector. Remove the ECM with connectors still connected. Turn the ignition switch to ON. Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Brake Pedal Condition Specified Condition E8-15 (STP) - Body ground Depressed 10 to 14 V E8-15 (STP) - Body ground Released Below 1 V E8-16 (ST1-) - Body ground Depressed Below 1 V E8-16 (ST1-) - Body ground Released 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH - ECM) CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–23 OK REPLACE ECM CC CC–24 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0607 Control Module Performance DESCRIPTION This DTC indicates the internal abnormalities of the ECM. DTC No. DTC Detection Condition • • P0607 Cruise control input signal abnormal. Stop light switch input signal abnormal. Trouble Area • ECM HINT: The ECM receives signals from each sensor to control all functions of the cruise control system. When a trouble code is detected, the fail-safe function remains on until the engine switch is turned off. INSPECTION PROCEDURE 1 NEXT END CC REPLACE ECM CC–25 CRUISE CONTROL – CRUISE CONTROL SYSTEM Cruise Control Switch Circuit DESCRIPTION This circuit carries the -/SET, +/RES and CANCEL signals (each voltage) to the ECM. WIRING DIAGRAM ECM C13 Cruise Control Main Switch ON-OFF 4 L-B CCS 5 ECC CANCEL BR -SET 10 IM2 3 IK1 L-B 2 E7 CCS +RES BR J28 J/C (*2) E(*2) BR E(*2) BR *1: 2UZ-FE *2: 1GR-FE ED (*1) EE (*2) I045663E02 CC CC–26 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT CRUISE CONTROL MAIN SWITCH (a) Remove the cruise control main switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance +/RES ON CANCEL OFF Tester Connection Switch Condition Specified Condition 4-5 Neutral 10 kΩ or higher 4-5 +/RES 210 to 270 Ω 4-5 -/SET 560 to 700 Ω 4-5 CANCEL 1,380 to 1,700 Ω 4-5 Main Switch off 10 kΩ or higher 4-5 Main Switch on Below 1 Ω -/SET 4 5 NG REPLACE CRUISE CONTROL MAIN SWITCH I033811E01 OK 2 CHECK HARNESS AND CONNECTOR (CRUISE CONTROL MAIN SWITCH, BODY GROUND - ECM) (a) Check for open and short circuit in harness and connector between cruise control main switch and ECM (See page IN-38). (b) Check for open and short circuit in harness and connector between cruise control main switch and body ground (See page IN-38). NG CC REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC–27 CRUISE CONTROL – CRUISE CONTROL SYSTEM Cruise Main Indicator Light Circuit DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. WIRING DIAGRAM ECM Driver Side J/B GAUGE 6 1D Combination Meter 4 1G R-L 15 11 C10 C8 LG 18 E7 PI CRUISE Engine Room R/B I18 Ignition S/W B-R R 6 IG2 AM2 7 AM2 2 2 2 B 1 Battery I045664E01 INSPECTION PROCEDURE 1 CHECK COMBINATION METER ASSEMBLY (a) See combination meter troubleshooting (See page ME4). NG REPLACE COMBINATION METER ASSEMBLY OK 2 CC CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - ECM) (a) Check for open and short circuit in harness and connector between combination meter assembly and ECM (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR CC–28 CRUISE CONTROL – CRUISE CONTROL SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC CC–29 CRUISE CONTROL – CRUISE CONTROL SYSTEM TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the system to enter self-diagnostic mode. If a malfunction is present, DTCs will be output. HINT: When a particular warning light remains blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in the relevant ECU is suspected. WIRING DIAGRAM D1 DLC3 TC CG J18 J/C P-L 13 H W-B 4 E Center J/B P-L H J22 J/C C 3C ECM C 3C P-L E J/C A J29 J30 P-L 23 E8 TC W-B E A J5 J/C IG I033551E01 CC CC–30 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK DLC3 (TC TERMINAL VOLTAGE) (a) Turn the ignition switch to ON. (b) Measure the voltage of the DLC3. Standard voltage: 10 to 14 V CG 1 2 3 4 5 6 7 8 OK 9 10111213141516 DLC3 Go to step 3 TC F040034E31 NG 2 CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) (a) Check for open and short circuit in harness and connector between terminal CG of DLC3 and body ground (See page IN-38). NG REPAIR OR REPLACE HARNESS OR CONNECTOR (DLC3 - BODY GROUND) OK 3 CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) (a) Check for open and short circuit in harness and connector between terminal TC of DLC3 and ECM (See page IN-38). NG OK CC CHECK AND REPLACE ECM REPAIR OR REPLACE HARNESS OR CONNECTOR OR EACH ECU CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CC–29 REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL HINT: See page RS-1. 2. REMOVE STEERING WHEEL COVER LOWER NO. 2 3. REMOVE STEERING WHEEL COVER LOWER NO. 3 4. REMOVE STEERING PAD (See page RS-388) 5. REMOVE CRUISE CONTROL MAIN SWITCH (a) Disconnect the connector. E062033 (b) Remove the 2 screws and cruise control main switch. E062034 CC CC–30 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH INSTALLATION CC 1. INSTALL CRUISE CONTROL MAIN SWITCH 2. INSTALL STEERING PAD (See page RS-388) 3. INSTALL STEERING WHEEL COVER LOWER NO. 3 4. INSTALL STEERING WHEEL COVER LOWER NO. 2 5. CONNECT BATTERY NEGATIVE TERMINAL 6. INSPECT STEERING PAD (See page RS-389) 7. INSPECT SRS WARNING LIGHT HINT: See page RS-28. LI–6 LIGHTING – LIGHTING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the lighting system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 INSPECT BATTERY VOLTAGE Standard: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 INSPECT MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to step 8 A LI 5 CHECK FOR DTC* Result Result A DTC is output B B A Proceed to DTC is not output Go to step 8 LI–7 LIGHTING – LIGHTING SYSTEM 6 PROBLEM SYMPTOMS TABLE Result Result Proceed to If fault is not listed in problem symptoms table A If fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Data List / Active Test (See page LI-14) (b) Terminals of ECU (See page LI-11) (c) Inspection NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END LI LI–8 LIGHTING – LIGHTING SYSTEM OPERATION CHECK 1. 2. LI 3. ILLUMINATED ENTRY SYSTEM OPERATION CHECK (a) The light that is lit in the illuminated entry system is explained below: (b) Turn the ignition switch to OFF, close all the doors, and set the driver's door in the lock condition. (c) Unlock the door and open any other door, and check that the room light comes on. Close the door, and check that the room light goes off within 15 seconds. (d) Turn the ignition switch to ON, and open and close any other door. Check that the room light immediately goes off. (e) Turn the ignition switch to OFF. (f) Open and close any door to light the room light. Before the room light goes off within 15 seconds, turn the ignition switch to ON, and check that the room light goes off immediately. (g) Turn the ignition switch OFF. (h) Open and close any door to light the room light. Before the light goes off within 15 seconds, lock the driver door. Check that the light goes off immediately. DOME RELAY CUT OPERATION CHECK (a) Remove the ignition key and close all doors. (b) Open the driver door to light the room light, and leave it as opened. Check that the light goes off in about 30 min. (c) After the room light goes off, close the driver's door. (d) Open any door except the driver's door to turn the room light on, and then open the driver's door. Check that room light goes off within 30 min. after opening the driver's door. (e) Close all the doors. With the ignition key inserted, open any door to light the room light, and then, remove the ignition key. Check that the room light goes off within 30 min. (f) One of the room light switches is on and close all doors. (g) Lock all doors, and check that the room light goes off within 3 sec. SIDE STEP LIGHT OPERATION CHECK (a) Turn the ignition switch to OFF, close all the doors, and set the driver door in the lock condition. (b) Unlock the door and open front or rear doors, and check that the side step light comes on. Close the door and check that the side step light goes off within 15 seconds. (c) Under the conditions that the ignition switch is ON, one of the front or rear doors opens and the shift range is at any positions except for P positions, check that the side step light goes off when the vehicle speed exceeds 8 km/h (4.8 mph). LIGHTING – LIGHTING SYSTEM 4. LI–9 (d) Then, check that the side step light comes on when the vehicle speed become 4 km/h (2.4 mph) or less. LIGHT AUTO CUT OPERATION CHECK (a) Turn the ignition switch to ON, and turn the headlight switch to TAIL or HEAD. (b) Turn the ignition switch to OFF, and open and close the driver's door, check the headlight goes off within 30 sec. LI LI–10 LIGHTING – LIGHTING SYSTEM PROBLEM SYMPTOMS TABLE 1. HEADLIGHT AND TAILLIGHT Symptom Only one headlight comes on. Headlight does not light up. "HI-Beam" does not light (All). "HI-Beam" does not light (One side). "Flash" does not light. Headlight is dark. Only one taillight up. Taillight does not light up. (Headlight is normal) Taillight does not light up. (Headlight does not light) Rear combination light does not light up. Headlight does not light up with engine running and light control switch is in OFF (Day time running light operation). Suspected area See page 1. Bulb - 2. HEAD LH fuse (LWR, UPR) - 3. HEAD RH fuse (LWR, UPR) - 4. Harness or connector - Headlight relay circuit LI-20 1. Headlight dimmer switch LI-68 2. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Headlight Dimmer Switch LI-68 2. Turn signal flasher relay LI-72 3. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Bulb - 2. Harness or connector - Taillight relay circuit LI-31 1. Light Control Switch LI-68 2. Harness or connector - 1. Bulb - 2. Harness or connector - 1. Turn signal flasher and DRL relay LI-72 2. Generator L terminal - 3. Parking brake switch - 4. Multiplex network body ECU - 5. Harness or connector - 2. AUTOMATIC LIGHT CONTROL SYSTEM Symptom Automatic light control system does not operate Suspected area Automatic light control sensor circuit See page LI-22 3. LIGHT AUTO CUT SYSTEM Symptom Suspected area 1. Door courtesy switch Light auto turn off system does not operate. LI Headlight and taillight do not come on. Headlight and taillight stay on. See page - 2. Automatic light control sensor circuit LI-22 3. Multiplex network body ECU - 4. Harness or connector - 1. Multiplex network body ECU - 2. Harness or connector - 1. Multiplex network body ECU - 2. Harness or connector - 4. FOG LIGHT SYSTEM Symptom Front fog light does not light up with light control SW HEAD (Headlight is normal). Suspected area See page 1. FOG Fuse - 2. FOG relay LI-76 3. Fog light switch LI-68 4. Harness or connector - LI–11 LIGHTING – LIGHTING SYSTEM Symptom Only one front fog light does not light up. Suspected area See page 1. Bulb - 2. Harness or connector - 5. TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspected area 1. IG1 Fuse "Hazard" and "Turn" do not light up. Hazard warning light does not light up. (Turn is normal) Turn signal does not light up. (Hazard is normal) Turn signal does not light up in one direction. Only one bulb does not light up. See page - 2. Ignition switch - 3. Turn signal flasher LI-72 4. Harness or connector - 1. Hazard warning switch LI-70 2. Harness or connector - 1. Turn signal switch LI-68 2. Harness or connector - 1. Turn signal switch LI-68 2. Harness or connector - 1. Bulb - 2. Harness or connector - 6. ILLUMINATED ENTRY SYSTEM Symptom Room light assembly No. 1 does not light up. Room light assembly No. 1 does not go off. Courtesy light does not light up. Courtesy light does not go off. Side step light does not light up. Side step light does not go off. Suspected area 1. Illumination circuit See page LI-25 2. Multiplex network body ECU - 1. Illumination circuit LI-25 2. Multiplex network body ECU - 1. Courtesy light LI-63 2. Courtesy light switch - 3. Harness or connector - 4. Driver side junction block assembly - 1. Courtesy light switch - 2. Harness or connector - 3. Courtesy light LI-63 4. Driver side junction block assembly - 1. Side step light LI-65 2. Courtesy light switch - 3. Harness or connector - 4. Multiplex network body ECU - 1. Courtesy light switch - 2. Harness or connector - 3. Side step light LI-65 4. Multiplex network body ECU - LI LIGHTING – HEADLIGHT ASSEMBLY LI–39 ADJUSTMENT 7.62 m (25 ft) 3 m (9.84 ft) E116124E01 1. PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT (a) Prepare the vehicle according to the following conditions: • Ensure that there is no damage or deformation to the body around the headlights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure. • Place the spare tire, tools, and jack in their original positions. • Unload the trunk. • Sit a person of average weight (68 kg, 150 lb) in the driver's seat. 2. PREPARE FOR HEADLIGHT AIMING (Using a screen) (a) Prepare the vehicle according to the following conditions: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot. • Place the vehicle at a 90° angle to the wall. • Position the vehicle (headlight bulb center) 7.62 m (25 ft) away from the wall. • Place the vehicle on a level surface. • Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If it is not possible to achieve this distance, secure a distance of exactly 3 m (9.84 ft) for checking and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. (c) Draw a vertical line down the center of screen (V line). LI LI–40 LIGHTING – HEADLIGHT ASSEMBLY (d) Set the screen as shown in the illustration. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V RH Line V RH Line V Line 7.62 m (25 ft) 3 m (9.84 ft) V Line V LH Line V LH Line H Line H Line 3 m (9.84 ft) 7.62 m (25 ft) E116125E01 HINT: • Stand the screen perpendicular to the ground. • Align the V line on the screen with the center of the vehicle. V LH Line V Line V RH Line H Line Ground I033423E18 LI (e) Draw base lines (H line, V LH and V RH lines) on the screen as shown in the illustration. HINT: • The base lines differ for "low-beam inspection" and "high-beam inspection". • Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb or the manufacturer's name marked on the headlight as the center mark. (1) H Line (Headlight height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low-beam headlights. (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low-beam headlight bulbs). LI–41 LIGHTING – HEADLIGHT ASSEMBLY 3. INSPECT HEADLIGHT AIMING (a) Cover the headlight or disconnect the connector of the headlight on the opposite side to prevent light from the headlight that is not being inspected from affecting headlight aiming inspection. NOTICE: Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, and may easily melt or be damaged due to heat. HINT: When checking the aim of the high-beam, cover the low-beam or disconnect the connector. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. (c) Turn on the headlight and make sure that the cutoff line falls within the specified area as shown in the illustration. Alingning distance is 7.62 m (25 ft): V LH Line V RH Line Low Beam: 101 mm (3.97 in.) H Line 53 mm (2.08 in.) 101 mm (3.97 in.) 40 mm (1.57 in.) H Line 101 mm 101 mm (3.97 in.) (3.97 in.) V LH Line V RH Line 101 mm (3.97 in.) 21 mm (0.82 in.) Cutoff Line High Beam: 40 mm 40 mm (1.57 in.) (1.57 in.) V LH Line V RH Line 40 mm (1.57 in.) H Line H Line 101 mm (3.97 in.) V LH Line V RH Line Low Beam: 40 mm (1.57 in.) Cutoff Line High Beam: Alingning distance is 3 m (9.84 ft): 101 mm 101 mm (3.97 in.) (3.97 in.) 40 mm (1.57 in.) LI 40 mm 40 mm (1.57 in.) (1.57 in.) I041213E07 LI–42 LIGHTING – HEADLIGHT ASSEMBLY Aiming Screw E116126E01 LI 4. ADJUST HEADLIGHT AIMING (a) Adjust the aim vertically: Adjust the headlight aim into the specified range by turning the aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. HINT: • Perform low-beam aim adjustment. • The headlight aim moves down when turning the aiming screw clockwise, and moves up when turning the aiming screw counterclockwise. LIGHTING – HEADLIGHT ASSEMBLY LI–43 REASSEMBLY 1. INSTALL CLEARANCE LIGHT BULB (a) Install the clearance light bulb. 2. INSTALL FRONT TURN SIGNAL LIGHT BULB (a) Install the front turn signal light bulb. 3. INSTALL HEADLIGHT NO. 2 BULB (a) Install the headlight No. 2 bulb. 4. INSTALL HEADLIGHT NO. 1 BULB (a) Install the headlight No. 1 bulb. INSTALLATION 1. INSTALL HEADLIGHT ASSEMBLY (a) Install the headlight assembly with the 3 screws and the bolt. (b) Connect the connectors. 2. INSTALL FRONT BUMPER FILLER (a) Install the front bumper filler with the clip. 3. INSTALL RADIATOR SUPPORT SEAL UPPER 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. INSTALL FRONT BUMPER ASSEMBLY 6. PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT 7. PREPARE FOR HEADLIGHT AIMING (Using a tester) 8. PREPARE FOR HEADLIGHT AIMING (Using a screen) 9. INSPECT HEADLIGHT AIMING E116119 E116118 10. ADJUST HEADLIGHT AIMING 11. PERFORM INITIALIZATION LI LIGHTING – LIGHTING SYSTEM LI–1 LIGHTING SYSTEM PRECAUTION 1. PRECAUTION OF HEADLIGHT BULB REPLACEMENT (a) If the adhered oil is left unremoved from the halogen light surface, the light service life is shortened as it becomes hot when it is turned on. (b) Since the internal pressure of a halogen light is high, dropping, hitting or damaging the bulb may cause the glass to scatter. Therefore, handle it with great care. (c) When replacing bulbs, do not remove until a new bulb is prepared. Because if it is left being removed for a long period of time, the lens may be covered with dirt or moisture. (d) Be sure to use the bulb of the same watt when replacing bulbs. (e) Firmly reinstall the socket after replacing the bulb. Otherwise, cloudy lens or invasion by water will be caused. LI LI–2 LIGHTING – LIGHTING SYSTEM PARTS LOCATION ENGINE ROOM R/B - DOME RELAY - ACC CUT RELAY - HEADLIGHT RELAY - FOG RELAY - STOP LP CTRL RELAY - AMI FUSE - DOME FUSE - ECUB - HEADLIGHT LH FUSE - HEADLIGHT RH FUSE - J/B FUSE - STOP FUSE ENGINE ROOM R/B NO. 3 - TOWING, TAIL RELAY HEADLIGHT ASSEMBLY FOG LIGHT FRONT TURN SIGNAL LIGHT LI C131563E01 LI–3 LIGHTING – LIGHTING SYSTEM TURN SIGNAL FLASHER RELAY TURN SIGNAL FLASHER AND DAYTIME RUNNING LIGHT RELAY AUTOMATIC LIGHT CONTROL SENSOR HEADLIGHT DIMMER SWITCH HAZARD WARNING SWITCH GLOVE BOX LIGHT DRIVER SIDE JUNCTION BLOCK ASSEMBLY TRANSPONDER KEY AMPLIFIER (KEY CYLINDER LIGHT ASSEMBLY) - TAIL RELAY MULTIPLEX NETWORK BODY COMPUTER LI E115632E01 LI–4 LIGHTING – LIGHTING SYSTEM WITH RSA: ROOM LIGHT ASSEMBLY VANITY LIGHT ASSEMBLY REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY PERSONAL LIGHT ASSEMBLY VANITY LIGHT ASSEMBLY ROOM LIGHT ASSEMBLY STEP LIGHT ASSEMBLY LI DOOR COURTESY LIGHT C131564E01 LI–5 LIGHTING – LIGHTING SYSTEM WITH REAR SPOILER: STOP CENTER LIGHT ASSEMBLY TOWING CONVERTER RELAY REAR ROOM LIGHT ASSEMBLY STOP CENTER LIGHT ASSEMBLY LICENSE PLATE LIGHT ASSEMBLY REAR COMBINATION LIGHT ASSEMBLY LI MULTIPLEX NETWORK DOOR COMPUTER BACK DOOR LOCK ASSEMBLY (BACK DOOR COURTESY SWITCH) E115633E01 LI–46 LIGHTING – HEADLIGHT PROTECTOR RETAINER INSTALLATION 1. INSTALL HEADLIGHT PROTECTOR RETAINER UPPER LH HINT: When only the installation part of the headlight unit assembly LH is damaged, it can be repaired inexpensively by using a headlight protector retainer upper LH. In this case, however, the headlight unit assembly LH itself should not be damaged. (a) Cut off the part shaded in the illustration and sand smooth with sandpaper. NOTICE: After cutting off the part, place the headlight protector retainer upper LH against the bosses and gradually file away the old bracket if it interferes with the installation of the supply bracket. I034335 (b) Install the headlight protector retainer upper LH with the 2 screws. I034336 LI 2. INSPECT HEADLIGHT AIMING (See page LI-41) 3. ADJUST HEADLIGHT AIMING (See page LI-42) LI–48 LIGHTING – FOG LIGHT ASSEMBLY ADJUSTMENT 7.62 m (25 ft) 3 m (9.84 ft) E116130E01 LI 1. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT (a) Prepare the vehicle according to the following conditions: • Ensure that there is no damage or deformation to the body around the fog lights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure. • Place the spare tire, tools, and jack in their original positions. • Unload the trunk. • Sit a person of average weight (68 kg, 150 lb) in the driver's seat. 2. PREPARE FOR FOG LIGHT AIMING (a) Prepare the vehicle according to the following conditions: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot. • Place the vehicle at a 90° angle to the wall. • Position the vehicle (fog light bulb center) 7.62 m (25 ft) away from the wall. • Place the vehicle on a level surface. • Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If it is not possible to achieve this distance, secure a distance of exactly 3 m (9.84 ft) for checking and adjustment. (The target zone will change with the distance, so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen. (c) Draw a vertical line down the center of screen (V line). LIGHTING – FOG LIGHT ASSEMBLY LI–49 (d) Set the screen as shown in the illustration. Aligning distance is 3 m (9.84 ft): Aligning distance is 7.62 m (25 ft): V RH Line V RH Line V Line 7.62 m (25 ft) 3 m (9.84 ft) V Line V LH Line V LH Line H Line H Line 7.62 m (25 ft) 3 m (9.84 ft) E116131E01 HINT: • Stand the screen perpendicular to the ground. • Align the V line on the screen with the center of the vehicle. V LH Line V Line (e) Draw base lines (H line, V LH and V RH lines) on the screen as shown in the illustration. HINT: Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark. (1) H Line (Fog light height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the low-beam fog lights. (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights): Draw two vertical lines so that they intersect the H line at each center mark. V RH Line H Line Ground I033423E18 3. INSPECT FOG LIGHT AIMING (a) Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting fog light aiming inspection. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. LI LI–50 LIGHTING – FOG LIGHT ASSEMBLY (c) Turn on the fog light and make sure that the cutoff line falls within the specified area as shown in the illustration. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V LH Line V RH Line V LH Line 133 mm (5.24 in.) H Line V RH Line 52 mm (2.05 in.) H Line I041221E15 4. Aiming Screw E116132E01 LI ADJUST FOG LIGHT AIMING (a) Adjust the fog light aim into the specified range by turning the aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. LIGHTING – FOG LIGHT ASSEMBLY LI–51 REASSEMBLY 1. INSTALL FOG LIGHT BULB (a) Install the fog light bulb. INSTALLATION 1. INSTALL FOG LIGHT ASSEMBLY (a) Engage the 3 claws and install the fog light assembly. 2. INSTALL FRONT BUMPER HOLE COVER (a) Engage the 4 claws and install the front bumper hole cover. 3. INSTALL FRONT BUMPER ASSEMBLY 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT 6. PREPARE FOR FOG LIGHT AIMING 7. INSPECT FOG LIGHT AIMING 8. ADJUST FOG LIGHT AIMING 9. PERFORM INITIALIZATION E116128 E116242 LI LI–56 LIGHTING – LICENSE PLATE LIGHT ASSEMBLY REMOVAL 1. REMOVE BACK DOOR TRIM BOARD (See page ED53) 2. REMOVE BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE 3. REMOVE LICENSE PLATE LIGHT ASSEMBLY (a) Loosen the 4 screws and remove the licence plate light assembly. 4. REMOVE LICENSE PLATE LIGHT LENS (a) Remove the 4 screws and 2 license plate light lenses. 5. REMOVE LICENSE PLATE LIGHT LENS GASKET 6. REMOVE LICENSE PLATE LIGHT BULB (a) Remove the 2 license plate light bulbs as shown in the illustration. 7. REMOVE LICENSE PLATE LIGHT BODY I033435 I033436 I033437 LI LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–57 INSTALLATION 1. INSTALL LICENSE PLATE LIGHT BODY 2. INSTALL LICENSE PLATE LIGHT BULB 3. INSTALL LICENSE PLATE LIGHT LENS GASKET 4. INSTALL LICENSE PLATE LIGHT LENS 5. INSTALL LICENSE PLATE LIGHT ASSEMBLY 6. INSTALL BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE 7. INSTALL BACK DOOR TRIM BOARD LI LI–60 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY INSTALLATION LI 1. INSTALL CENTER STOP LIGHT BULB (without Rear Spoiler) 2. INSTALL CENTER STOP LIGHT ASSEMBLY (with Rear Spoiler) 3. INSTALL REAR SPOILER SUB-ASSEMBLY (with Rear Spoiler) 4. INSTALL CENTER STOP LIGHT ASSEMBLY (without Rear Spoiler) LI–12 LIGHTING – LIGHTING SYSTEM TERMINALS OF ECU 1. Multiplex Network Body Computer Front side: 1A 1F B6 B5 B4 1E 1C 1D 1B Back side: 1G 1J 1L LI 1K 1H I034371E02 LI–13 LIGHTING – LIGHTING SYSTEM Terminal No. (Symbols) Wiring color 1H-2 ←→ Body ground (GND1 ←→ Body ground) - 1K-15, 1L-16 ←→ 1H-2 (LSR ←→ GND1, 2) - 1C-2 ←→ 1H-2 (SIG ←→ GND1, 2) - 1B-4 ←→ 1H-2 (BECU ←→ GND1, 2) - 1A-8, 1K-9 ←→ 1H-2 (ILE ←→ GND1, 2) - 1H-2 ←→ Body ground (GND2 ←→ Body ground) - 1B-8 ←→ 1H-2 (HRLY ←→ GND1, 2) - 1C-1 ←→ 1H-2 (TRLY ←→ GND1, 2) - 1D-5 ←→ 1H-2 (ACC ←→ GND1, 2) - B4-3 ←→ 1H-2 (LMRY ←→ GND1, 2) R ←→ - B4-7 ←→ 1H-2 (DRL ←→ GND1, 2) LG-R ←→ - B4-21 ←→ 1H-2 (LSWD ←→ GND1, 2) W-R ←→ - B4-23 ←→ 1H-2 (MPX2 ←→ GND1, 2) BR-R ←→ - B4-25 ←→ 1H-2 (PCYL ←→ GND1, 2) Y ←→ - B4-26 ←→ 1H-2 (DCYL ←→ GND1, 2) W-G ←→ - B4-30 ←→ 1H-2 (LSWP ←→ GND1, 2) B-W ←→ - B5-6 ←→ 1H-2 (LP ←→ GND1, 2) W-R ←→ - B5-11 ←→ 1H-2 (RLCY ←→ GND1, 2) P-B ←→ - B5-12 ←→ 1H-2 (RRCY ←→ GND1, 2) P-L ←→ - B5-21 ←→ 1H-2 (LCYL ←→ GND1, 2) P-G ←→ - B5-22 ←→ 1H-2 (RCYL ←→ GND1, 2) L-R ←→ - B5-23 ←→ 1H-2 (DCTY ←→ GND1, 2) R-B ←→ - B5-24 ←→ 1H-2 (PCTY ←→ GND1, 2) R-Y ←→ - B6-1 ←→ 1H-2 (HEAD ←→ GND1, 2) R ←→ - B6-3 ←→ 1H-2 (A ←→ GND1, 2) G-O ←→ - Condition Constant Specified condition Below 1 V Rear door lock switch is unlock position Below 1 V Rear door lock switch is lock position 10 to 14 V Ignition switch is OFF Below 1 V Ignition switch is ON 10 to 14 V Constant 10 to 14 V Key cylinder illumination, room light is OFF Below 1 V Key cylinder illumination, room light is ON 10 to 14 V Constant Below 1 V Ignition switch is ON and combination switch is OFF Below 1 V Ignition switch is ON and combination switch is HEAD 10 to 14 V Ignition switch is ON and combination switch is OFF Below 1 V Ignition switch is ON and combination switch is TAIL 10 to 14 V Ignition switch is OFF Below 1 V Ignition switch is ON 10 to 14 V Ignition switch is OFF Below 1 V Ignition switch is ON 10 to 14 V Ignition switch is OFF Below 1 V Ignition switch is ON 10 to 14 V Front LH door lock switch is unlock position Below 1 V Front LH door lock switch is lock position 10 to 14 V Constant Signal waveform Front RH courtesy light is OFF 10 to 14 V Front RH courtesy light is ON Below 1 V Front LH courtesy light is OFF 10 to 14 V Front LH courtesy light is ON Below 1 V Front RH door lock switch is unlock position Below 1 V Front RH door lock switch is lock position 10 to 14 V Side step light is OFF Below 1 V Side step light is ON 10 to 14 V Rear LH door is closed 10 to 14 V Rear LH door is open Below 1 V Rear RH door is closed 10 to 14 V Rear RH door is open Below 1 V Rear LH courtesy light is OFF 10 to 14 V Rear LH courtesy light is ON Below 1 V Rear RH courtesy light is OFF 10 to 14 V Rear RH courtesy light is ON Below 1 V Front LH door is closed 10 to 14 V Front LH door is open Below 1 V Front RH door is closed 10 to 14 V Front RH door is open Below 1 V Ignition switch is ON and combination switch is OFF 10 to 14 V Ignition switch is ON and combination switch is ON Below 1 V Ignition switch is ON and combination switch is OFF 10 to 14 V Ignition switch is ON and combination switch is AUTO Below 1 V LI LI–14 LIGHTING – LIGHTING SYSTEM Terminal No. (Symbols) Wiring color B6-4 ←→ 1H-2 (CLTS ←→ GND1, 2) Y ←→ - B6-6 ←→ 1H-2 (CLTB ←→ GND1, 2) L-Y ←→ - B6-8 ←→ 1H-2 (TAIL ←→ GND1, 2) G ←→ - B6-21 ←→ 1H-2 (CLTE ←→ GND1, 2) G-W ←→ - Condition Specified condition Cover the sensor with hand → Stop covering Signal waveform Ignition switch is OFF Below 1 V Ignition switch is ON 10 to 14 V Ignition switch is ON and combination switch is OFF 10 to 14 V Ignition switch is ON and combination switch is TAIL Below 1 V Constant Below 1 V 2. Multiplex Network Door ECU: B9 B8 I033329E03 Terminal No. (Symbols) Wiring color B8-1 ←→ B8-3 (MPX2 ←→ GND) R ←→ W-B Constant Signal waveform B8-3 ←→ Body ground (GND ←→ Body ground) W-B ←→ - Constant Below 1 V B8-4 ←→ B8-3 (BDR ←→ GND) L ←→ W-B Constant 10 to 14 V B8-5 ←→ B8-3 (BECU ←→ GND) L-R ←→ W-B Constant 10 to 14 V B8-6 ←→ B8-3 (SIG ←→ GND) B ←→ W-B Ignition switch is OFF Below 1 V B9-7 ←→ B8-3 (FULL ←→ GND) LI G-Y ←→ W-B B9-8 ←→ B8-3 (POS ←→ GND) BR-W ←→ W-B B9-21 ←→ B8-3 (LSE ←→ GND) B-R ←→ W-B Condition Specified condition Ignition switch is ON 10 to 14 V Backdoor is closed 10 to 14 V Backdoor is open Below 1 V Backdoor lock switch is unlock position Below 1 V Backdoor lock switch is lock position 10 to 14 V Constant 10 to 14 V LI–35 LIGHTING – HEADLIGHT ASSEMBLY HEADLIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS HEADLIGHT ASSEMBLY FRONT BUMPER FILLER 3.0 (31, 27 in.*lbf) RADIATOR SUPPORT SEAL UPPER 3.0 (31, 27 in.*lbf) LI FRONT BUMPER ASSEMBLY 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque E115634E01 LI–36 LIGHTING – HEADLIGHT ASSEMBLY HEADLIGHT NO. 1 BULB HEADLIGHT NO. 2 BULB FRONT TURN SIGNAL LIGHT BULB FRONT TURN SIGNAL LIGHT SOCKET CLEARANCE LIGHT SOCKET CLEARANCE LIGHT BULB SUPPLY PARTS: HEADLIGHT PROTECTOR RETAINER UPPER LI E115635E01 LIGHTING – LIGHTING SYSTEM LI–15 DTC CHECK / CLEAR 1. 2. USING INTELLIGENT TESTER (a) Hook up the intelligent tester to the DLC3. (b) Monitor the ECU data by following the prompts on the tester screen. HINT: Intelligent tester has a "Snapshot" function which records the monitored data. Please refer to the intelligent tester operator's manual for further details. DTC CLEAR (a) DTCs and freeze frame data will be erased by the intelligent tester operating. LI LI–16 LIGHTING – LIGHTING SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the methods to shorten labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) According to the display on tester, read the "DATA LIST". Item Measurement Item/ Display (Range) D DOR CTY SW Driver's door courtesy SW signal/ON or OFF ON: Driver's door is open OFF: Driver's door is close - P DOR CYT SW Passenger's door courtesy SW signal/ON or OFF ON: Passenger's door is open OFF: Passenger's door is close - Rr DOR CTY SW Rear door courtesy SW signal/ON or OFF ON: Either right or left rear door is open OFF: Both the right and left doors are closed. - HIGH FLASHER SW High flasher SW signal/ ON or OFF ON: High flasher SW is on OFF: High flasher SW is off - AUTO LIGHT SW Auto light SW signal/ON or OFF ON: Light control SW is in Auto position OFF: Light control SW is in except Auto position - HEAD LIGHT SW Head light SW signal/ON or OFF ON: Light control SW is in HEAD position OFF: Light control SW is in except HEAD position - TAIL LIGHT SW Taillight SW signal/ON or OFF ON: Light control SW is in TAIL or HEAD position OFF: Light control SW is in OFF or AUTO position - ACC SW ACC SW signal/ON or OFF ON: IG key is in ACC, ON or START position OFF: IG key is in OFF position - IG SW IG SW signal/ON or OFF ON: IG key is in ON or START position OFF: IG key is in OFF or ACC position - Normal Condition 2. LI Item Diagnostic Note ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of troubleshooting is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) According to the display on tester, perform the "ACTIVE TEST". Test Details Diagnostic Note HAZARD Turns Hazard light flasher relay ON/OFF - DRL RLY (Test Details) Turns DRL relay ON/OFF (Vehicle Condition) IG SW is ON, Engine is stopped and Light control SW is in OFF position. - HEAD LIGHT TAIL LIGHT Turns Head light relay ON/OFF - Turns Taillight relay ON/OFF - LI–17 LIGHTING – LIGHTING SYSTEM Item Test Details Diagnostic Note ILLUMI OUTPUT (Test Details) Turns Interior light and Key illumination ON/ OFF (Vehicle Condition) Interior light SW is in Door position - DOME RLY CUT Dome relay cut ON/OFF - LI LI–44 LIGHTING – HEADLIGHT PROTECTOR RETAINER HEADLIGHT PROTECTOR RETAINER BODY ELECTRICAL LIGHTING COMPONENTS HEADLIGHT ASSEMBLY FRONT BUMPER FILLER 3.0 (31, 27 in.*lbf) RADIATOR SUPPORT SEAL UPPER 3.0 (31, 27 in.*lbf) LI FRONT BUMPER ASSEMBLY 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque E115634E01 LIGHTING – HEADLIGHT PROTECTOR RETAINER LI–45 REMOVAL 1. REMOVE FRONT BUMPER ASSEMBLY 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE RADIATOR SUPPORT SEAL UPPER (See page LI-37) 4. REMOVE FRONT BUMPER FILLER (See page LI-37) 5. REMOVE HEADLIGHT ASSEMBLY (See page LI-37) LI LI–18 LIGHTING – LIGHTING SYSTEM DIAGNOSTIC TROUBLE CODE CHART 1. DTC CHECK If a malfunction code is displayed during the DTC check, check the suspected area listed for that code in the table below, and proceed to the appropriate page. LIGHTING SYSTEM DTC No. B1244 LI Detection Item Light Sensor Circuit Malfunction Suspected Area 1. Light sensor 2. Wire harness 3. Driver side junction block assembly See page LI-16 LI–19 LIGHTING – LIGHTING SYSTEM DTC B1244 Light Sensor Circuit Malfunction DESCRIPTION This DTC is output when failure in the light sensor circuit is detected. DTC No. B1244 DTC Detection Condition • • Malfunction of light sensor Open or short of light sensor circuit Trouble Area • • • Automatic light control sensor Harness or connector Driver side junction block assembly LI LI–20 LIGHTING – LIGHTING SYSTEM WIRING DIAGRAM Multiplex Network Body ECU A39 Automatic Light Control Sensor CLTB L-Y 3 IG1 L-Y G-W 2 IG1 G-W Y 1 IG1 Y 1 CLTE 3 CLTS 4 21 B6 CLTE 4 B6 CLTS Driver Side J/B Assembly I18 Ignition SW 2 AM1 6 B6 CLTB IG1 4 L-Y 3 W-G ACC 2 1C ECU-IG 5 1D ACC 10 22 SIG ACC Engine Room R/B AM1 W-L 2 B 2 ALT 1 2 1 2 2 B 2 W-B Light Control SW W-B G-O 10 IH1 G-O 3 B6 A 16 12 EL A C12 Combination SW OFF AUTO A J/C A J15 J15 W-B A LI J5 J/C Battery IG E072982E01 LI–21 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK LIGHTS (a) Check that the headlight and the taillight come on. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 2 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to DLC3. (b) Turn the ignition switch to ON, and push the intelligent tester main SW ON. (c) Select the item "AUTO LIGHT SW" in the DATA LIST, and read its value displayed on the intelligent tester. OK: Light control SW AUTO → ON Light control SW except AUTO → OFF NG Go to step 5 OK 3 INSPECT AUTOMATIC LIGHT CONTROL SENSOR (a) Measure voltage between terminals as shown in the chart below. (b) Check the continuity between terminal 3 (CLTE) and body ground as shown in the chart below. (c) Using an oscilloscope, check that signal waveform appears between terminals. E065750 Standard voltage Terminal No. (Symbol) Tester connection Condition 1 (CLTB) 1-3 Constant 10 to 14 V 3 (CLTE) 3 - Body ground Constant Continuity 4 (CLTS) 4-3 IG SW ON Dimmer SW AUTO Signal waveform appears depending on outside brightness NG OK Specified condition REPLACE AUTOMATIC LIGHT CONTROL SENSOR LI LI–22 4 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND AUTOMATIC LIGHT CONTROL SENSOR) (a) Check that signal waveform appears between terminals B6-4 (CLTS) and B6-21 (CLTE) of the multiplex network body ECU. Standard: Bar appears (b) Measure voltage between terminals B6-6 (CLTB) and B6-21 (CLTE) of the multiplex network body ECU. Standard voltage: 10 to 14 V (c) Check the continuity between terminal B6-21 (CLTE) of the multiplex network body ECU and body ground. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MULTIPLEX NETWORK BODY ECU 5 CHECK HARNESS AND CONNECTOR (BETWEEN HEADLIGHT DIMMER SWITCH ASSEMBLY AND BODY ECU) (a) Check for open and short circuit in harness and connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HEADLIGHT DIMMER SWITCH ASSEMBLY LI LI–46 LIGHTING – FOG LIGHT ASSEMBLY FOG LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS 3.0 (31, 27 in.*lbf) FOG LIGHT BULB 3.0 (31, 27 in.*lbf) FRONT BUMPER ASSEMBLY LI FOG LIGHT ASSEMBLY 8.0 (82, 71 in.*lbf) FRONT BUMPER HOLE COVER N*m (kgf*cm, ft.*lbf) : Specified torque E115636E01 LIGHTING – FOG LIGHT ASSEMBLY LI–47 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT BUMPER ASSEMBLY 3. REMOVE FRONT BUMPER HOLE COVER (a) Disengage the 4 claws and remove the front bumper hole cover. 4. REMOVE FOG LIGHT ASSEMBLY (a) Disengage the 3 claws and remove the fog light assembly. E116242 E116128 DISASSEMBLY 1. E116129 REMOVE FOG LIGHT BULB (a) Turn the fog light bulb counterclockwise and remove it. LI LI–23 LIGHTING – LIGHTING SYSTEM Headlight Relay Circuit WIRING DIAGRAM Multiplex Network Body ECU Engine Room R/B ECU-B 2 1 W 2 B 2 1 2 2 5 3 2 1 2 W 17 BECU HRLY Driver Side J/B Assembly 2 R-B 2 2 2 1 HEAD (LO RH) H4 Headlight RH (Low) W-B Short Pin 1 11 HEAD (LO LH) R-Y 1 HEAD Relay 4 1B 8 1B W-R 2 H2 Headlight LH (Low) W-B 2 2 R-B 2 2 W-B 1 R W-B B 1 IH1 W-B 1 B6 HEAD R 13 16 H T EL Light Control SW OFF Head C12 Combination SW A J15 J/C A J15 W-B A J5 J/C Battery EA EB IG E064840E01 LI LI–24 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 INSPECT HEADLIGHT RELAY (a) Check the continuity of the headlight relay. Standard Condition E064835 Tester connection Specified condition Constant 1-2 Continuity Constant 3-5 No continuity Apply B+ between terminal 1 and 2 3-5 Continuity NG REPLACE HEADLIGHT RELAY OK 2 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (HEAD) (a) Inspect light control switch continuity. (1) Check that there is a continuity between terminals at each switch position as shown in the chart. Standard I033101 Switch operation Tester connection Specified condition OFF - No continuity HEAD 13 - 16 - 14 Continuity NG REPLACE HEADLIGHT DIMMER SWITCH ASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND HEADLIGHT DIMMER SWITCH ASSEMBLY) (a) Check the continuity terminal B6-1 (HEAD) of the multiplex network body ECU and the headlight dimmer switch assembly. Standard: There is continuity LI NG OK REPLACE MULTIPLEX NETWORK BODY ECU REPAIR OR REPLACE HARNESS OR CONNECTOR LI–52 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY REAR COMBINATION LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS REAR COMBINATION LIGHT BULB REAR COMBINATION LIGHT SOCKET REAR COMBINATION LIGHT BULB LI REAR COMBINATION LIGHT ASSEMBLY E115637E01 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–53 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE REAR COMBINATION LIGHT SERVICE COVER 3. REMOVE REAR COMBINATION LIGHT ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 nuts. (c) Disconnect the pin and remove the rear combination light assembly. Pin E116133E01 Rear Combination Light Socket DISASSEMBLY 1. REMOVE REAR COMBINATION LIGHT BULB (a) Remove the 2 rear combination light sockets. (b) Remove the 2 rear combination light bulbs from the 2 rear combination light sockets. E116134E01 Rear Combination Light Socket REASSEMBLY 1. INSTALL REAR COMBINATION LIGHT BULB (a) Install the 2 rear combination light bulbs to the 2 rear combination light sockets. (b) Install the 2 rear combination light sockets. E116134E01 INSTALLATION 1. 2. INSTALL REAR COMBINATION LIGHT SERVICE COVER 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Pin E116133E01 INSTALL REAR COMBINATION LIGHT ASSEMBLY (a) Connect the connector. (b) Connect the pin and install the rear combination light assembly. (c) Install the 2 nuts. LI LI–25 LIGHTING – LIGHTING SYSTEM Automatic Light Control Sensor Circuit WIRING DIAGRAM Multiplex Network Body ECU A39 Automatic Light Control Sensor CLTB L-Y 3 IG1 L-Y G-W 2 IG1 G-W Y 1 IG1 Y 1 CLTE 3 CLTS 4 21 B6 CLTE 4 B6 CLTS Driver Side J/B Assembly I18 Ignition SW 2 AM1 6 B6 CLTB IG1 4 L-Y 3 W-G ACC 2 1C ECU-IG 5 1D ACC 10 22 SIG ACC Engine Room R/B AM1 W-L 2 B 2 ALT 1 2 1 2 2 B 2 W-B Light Control SW W-B G-O 10 IH1 G-O 3 B6 A 16 12 EL A C12 Combination SW OFF AUTO A J/C A J15 J15 W-B LI A J5 J/C Battery IG E072982E01 LI–26 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK LIGHTS (a) Check that headlight and taillight light up. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 2 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Inspect light control switch continuity. (1) Check that there is a continuity between terminals at each switch position as shown in the chart. Standard Switch operation Tester connection Specified condition OFF - No continuity I033101 NG TAIL 14 - 16 Continuity HEAD 13 - 16 - 14 Continuity AUTO 16 - 12 Continuity REPLACE HEADLIGHT DIMMER SWITCH ASSEMBLY OK 3 INSPECT AUTOMATIC LIGHT CONTROL SENSOR (a) Measure voltage between terminals as shown in the chart below. (b) Check the continuity between terminal 3 (CLTE) and body ground as shown in the chart below. (c) Using an oscilloscope, check that signal waveform appears between terminals. E065750 LI Standard voltage Terminal No. (Symbol) Tester connection Condition Specified condition 1 (CLTB) 1-3 Constant 10 to 14 V 3 (CLTE) 3 - Body ground Constant Continuity IG SW ON Dimmer SW AUTO Signal waveform appears depending on outside brightness 4 (CLTS) 4-3 NG REPLACE AUTOMATIC LIGHT CONTROL SENSOR LIGHTING – LIGHTING SYSTEM LI–27 OK 4 CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND AUTOMATIC LIGHT CONTROL SENSOR) (a) Check that signal waveform appears between terminals B6-4 (CLTS) and B6-21 (CLTE) of the multiplex network body ECU. Standard: Bar appears (b) Measure voltage between terminals B6-6 (CLTB) and B6-21 (CLTE) of the multiplex network body ECU. Standard voltage: 10 to 14 V (c) Check the continuity between terminal B6-21 (CLTE) of the multiplex network body ECU and body ground. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MULTIPLEX NETWORK BODY ECU LI LIGHTING: LICENSE PLATE LIGHT ASSEMBLY: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Vehicle Exterior Section: Lighting (ext) Model Year: 2007 Model: 4Runner Doc ID: RM0000024JQ001X Title: LIGHTING: LICENSE PLATE LIGHT ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION LIGHTING: LICENSE PLATE LIGHT ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION LIGHTING: LICENSE PLATE LIGHT ASSEMBLY: COMPONENTS (2007 4Runner) LI–28 LIGHTING – LIGHTING SYSTEM Illumination Circuit WIRING DIAGRAM Multiplex Network Body ECU W B 8 LSSR W-R 7 IP1 B-W W 10 BA1 W 10 BB1 W LSSR D19 6 Door Lock Detection SW Front RH D21 Door Lock Detection SW Rear RH W LSSR DOOR R-W 16 1L 9 W 1A W W 2 W OFF 1 I20 Interior Light 5 LSR 15 1K 6 L2 Luggage Compartment Light Driver Side J/B 6 1E 22 1J 21 B4 LSWD 30 B4 LSWP D20 Door Lock Detection SW Rear LH 7 LSSR D16 Door Lock Detection SW Front LH 7 IA1 8 1A 13 ILE W 3 ON DOOR 2 W J6 J/C R E 3 R R-G 2 2 R 2 R B 2 5 3 2 DOME 1 2 1 2 2 Short Pin 1 2 ACC AM1 W-L 2 2 2 2 1 2 22 ACC 3 1 R B4 LMRY IC3 23 A14 BR-R IE1 B4 MPX2 BR-R 2 9 R BD1 B 1 ACC W ALT W-G Battery R 2 AM1 9 1K 5 1D Driver Side J/B 2 I18 Ignition SW 3 6 R-W Engine Room R/B DOME R LI I17 Ignition Key Cylinder Light ON B J/C C J12 J13 R E OFF 1 2 1 B8 MPX2 B7 Back Door Lock Detection SW LS3 BR-W 4 8 B9 POS Multiplex Network Door ECU I044307E01 LI–29 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK LIGHTS (a) Check the condition A or B, when room light assembly No. 1 does not light up. Result Condition Proceed to Door Lock → Door Unlock A IG Switch ACC → OFF B B Go to step 10 A 2 CHECK DOOR LOCK (a) Check which door light does not light up. Result Condition Proceed to Driver side door A Passenger side door B Rear door C Back door D B Go to step 5 C Go to step 7 D Go to step 9 A 3 CHECK FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH (a) Check the continuity between terminal 8 (LSSR) of front door with motor lock assembly LH and body ground. Standard Door lock position Specified condition Lock No continuity Unlock Continuity NG OK REPLACE FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH LI LI–30 4 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND FRONT DOOR WITH MOTOR LOCK ASSEMBLY) (a) Check the continuity between terminal 8 (LSSR) of the front door with motor door lock assembly LH and B4-21 (LSWD) of the multiplex network body ECU. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MULTIPLEX NETWORK BODY ECU 5 CHECK FRONT DOOR WITH MOTOR LOCK ASSEMBLY RH (a) Check the continuity between terminal 7 (LSSR) of the front door with motor lock assembly RH and body ground. Standard Door lock position Specified condition Lock No continuity Unlock Continuity NG REPLACE FRONT DOOR WITH MOTOR LOCK ASSEMBLY RH OK 6 CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND FRONT DOOR WITH MOTOR LOCK ASSEMBLY) (a) Check the continuity between terminal 7 (LSSR) of the front door with motor door lock assembly RH and B4-30 (LSWP) of the multiplex network body ECU. Standard: There is continuity LI NG OK REPLACE MULTIPLEX NETWORK BODY ECU REPAIR OR REPLACE HARNESS OR CONNECTOR LI–31 LIGHTING – LIGHTING SYSTEM 7 CHECK REAR DOOR LOCK (a) Check which door light does not light up. (b) Measure voltage between terminals when unlocking the door. Standard Malfunction part Tester connection Specified condition Rear door LH 6 (LSSR) - Body ground No continuity → Continuity Rear door RH 6 (LSSR) - Body ground No continuity → Continuity NG REPLACE REAR DOOR LOCK OK 8 CHECK HARNESS AND CONNECTOR (BETWEEN DRIVER SIDE JUNCTION BLOCK AND REAR DOOR LOCK) (a) Check the continuity between terminals as shown in the chart below. Standard Malfunction part Tester connection Condition Rear door LH 1L-16 (LSR) - Rear door lock LH Continuity Rear door RH 1K-15 (LSR) - Rear door lock RH Continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE DRIVER SIDE JUNCTION BLOCK 9 CHECK WITH MOTOR BACK DOOR LOCK ASSEMBLY (a) Measure voltage between terminal 4 (LS3) of with motor back door lock assembly and body ground. Standard Door lock position Specified condition Lock No continuity Unlock Continuity NG E065741 OK REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE WITH MOTOR BACK DOOR LOCK ASSEMBLY LI LI–32 10 LIGHTING – LIGHTING SYSTEM CHECK DRIVER SIDE JUNCTION BLOCK (a) Measure voltage between terminal 1D-5 (ACC) of the driver side junction block and body ground. Standard voltage IG SW Specified condition ACC 10 to 14 V OFF Below 1 V OK Go to step 12 NG 11 CHECK HARNESS AND CONNECTOR (BETWEEN DRIVER SIDE JUNCTION BLOCK AND IGNITION SWITCH) (a) Check the continuity between terminal 1D-5 (ACC) of the driver side junction block and the ignition switch assembly. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE IGNITION OR STARTER SWITCH ASSEMBLY 12 CHECK DRIVER SIDE JUNCTION BLOCK (ILE) (a) Measure voltage between terminals as shown in the chart below when turning the ignition switch to OFF. Standard voltage LI Item Tester connection Specified condition Transponder key amplifier (Ignition key cylinder light) 1K-9 (ILE) - Body ground 10 to 14 V → Below 1 V Room light assembly No. 1, No. 2 (Interior light, Luggage compartment Light) 1A-8 (ILE) - Body ground 10 to 14 V → Below 1 V NG REPLACE DRIVER SIDE JUNCTION BLOCK OK 13 CHECK HARNESS AND CONNECTOR (BETWEEN DRIVER SIDE JUNCTION BLOCK AND LIGHT) (a) Disconnect the connector of the driver side junction block. LI–33 LIGHTING – LIGHTING SYSTEM (b) Check the continuity between terminals as shown in the chart below. Standard Item Tester connection Specified condition Transponder key amplifier 1K-9 (ILE) - Transponder key amplifier Continuity Room light assembly No. 1, No. 2 1A-8 (ILR) - Room light assembly Continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 14 CHECK TRANSPONDER KEY AMPLIFIER (IGNITION KEY CYLINDER LIGHT) (a) Check the continuity between terminals of transponder key amplifier (ignition key cylinder light). Standard: There is continuity. NG REPLACE TRANSPONDER KEY AMPLIFIER OK 15 CHECK ROOM LIGHT ASSEMBLY NO.1 (a) Check the continuity between terminals of the room light assembly No. 1. Standard: There is continuity. NG REPLACE ROOM LIGHT ASSEMBLY NO.1 OK REPLACE ROOM LIGHT ASSEMBLY NO.2 LI LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–57 HIGH MOUNTED STOP LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS REAR SPOILER SUB-ASSEMBLY WITHOUT REAR SPOILER CENTER STOP LIGHT ASSEMBLY - CENTER STOP LIGHT BULB LI B120201E01 LI–58 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY REMOVAL 5 Claws 1. REMOVE CENTER STOP LIGHT ASSEMBLY (without Rear Spoiler) (a) Release the 5 fitting claws as shown in the illustration. (b) Disconnect the connector and remove the center stop light assembly. 2. REMOVE REAR SPOILER SUB-ASSEMBLY (with Rear Spoiler) 3. REMOVE CENTER STOP LIGHT ASSEMBLY (with Rear Spoiler) (a) Disconnect the connector. I033438E01 I034339 (b) Install the strap on the connector of center stop light assembly. Strap I033910E02 (c) Remove the 2 screws. (d) Pass the connector through the inside the rear spoiler sub-assembly and remove the center stop light assembly with bracket. HINT: Leave the strap inside the rear spoiler subassembly. LI I033439 (e) Remove the 2 nuts and center stop light assembly. I033440 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY 4. LI–59 REMOVE CENTER STOP LIGHT BULB (without Rear Spoiler) (a) Remove the center stop light socket and center stop light bulb as shown in the illustration. (b) Remove the center stop light bulb from the center stop light socket. I033441 LI LI–34 LIGHTING – LIGHTING SYSTEM Taillight Relay Circuit WIRING DIAGRAM Multiplex Network Body ECU Driver Side J/B Assembly L-W G To Another Illumination System TAIL 1 1C 5 1L 1 2 18 5 3 F3 Front Parking Light LH W-B TAIL G 9 1B G 11 1B 2 1 F4 Front Parking Light RH W-B 2 J/C 1 J39 J/C R14 Rear Combination Light LH A J40 G W-B 6 Tail TRLY G B 4 B 13 1F R15 Rear Combination Light RH A J40 A W-B J41 A J40 G W-B 6 W-B Tail 4 2 BD1 G B B G RH W-B G 3 14 T EL 8 IH1 OFF Tail 16 2 BH1 B10 License Plate Light 10 3 W-B BD1 BH1 C12 Combination SW G W-B LH 4 8 B6 TAIL G A J/C A J15 J15 W-B W-B W-B W-B Engine Room R/B LI L-W J/B 2 2 B Battery ALT 2 2 1 2 1 A J5 J/C B 2 EB EA BL IG E064839E01 LI–35 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK LIGHTS (a) Check the condition A, B or C, when taillight does not light up. Result Condition Proceed to All A Parking light only B Combination light only C B Go to step 5 C Go to step 7 A 2 INSPECT TAILLIGHT RELAY (a) Inspect taillight relay continuity. Standard B016200 Condition Tester connection Specified condition Constant 1-2 Continuity Constant 3-5 No continuity Apply B+ between terminals 1 and 2 3-5 Continuity NG REPLACE TAILLIGHT RELAY OK 3 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Inspect light control switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Standard I033101 OK Switch operation Tester connection Specified condition OFF - No continuity TAIL 16 - 16 Continuity NG REPLACE HEADLIGHT DIMMER SWITCH ASSEMBLY LI LI–36 4 LIGHTING – LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR (BETWEEN BODY ECU AND HEADLIGHT DIMMER SWITCH ASSEMBLY) (a) Check the continuity between terminal B6-8 (TAIL) of the multiplex network body ECU and the headlight dimmer switch assembly. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MULTIPLEX NETWORK BODY ECU 5 INSPECT LH HEADLIGHT ASSEMBLY (PARKING LIGHT) (a) Check that there is a continuity between terminals of headlight assembly. Standard: ON: Continuity OFF: No continuity OK REPLACE LH HEADLIGHT ASSEMBLY NG 6 CHECK HARNESS AND CONNECTOR (BETWEEN DRIVER SIDE JUNCTION BLOCK AND LH HEADLIGHT ASSEMBLY) (a) Check the continuity between the terminal parking light assembly and driver side junction block. Standard Item LI Tester connection Specified condition Parking lamp LH 1 - 1B-9 Continuity Parking lamp RH 1 - 1B-11 Continuity NG OK REPLACE DRIVER SIDE JUNCTION BLOCK REPAIR OR REPLACE HARNESS OR CONNECTOR LIGHTING – LIGHTING SYSTEM 7 LI–37 INSPECT REAR COMBINATION LIGHT ASSEMBLY LH (a) Check that there is a continuity between terminals of rear combination light assembly. Standard: ON: Continuity OFF: No continuity OK REPLACE REAR COMBINATION LIGHT ASSEMBLY LH NG 8 CHECK HARNESS AND CONNECTOR (BETWEEN DRIVER SIDE J/B AND REAR COMBINATION LIGHT ASSEMBLY) (a) Check the continuity terminals 4 of the combination light and 1F-13 of the driver side junction block. Standard: There is continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE DRIVER SIDE JUNCTION BLOCK LI LI–60 LIGHTING – PERSONAL LIGHT ASSEMBLY PERSONAL LIGHT ASSEMBLY INSPECTION 1. E057880 LI INSPECT ROOF CONSOLE BOX ASSEMBLY (a) Check that there is continuity between terminals 1 and 5 when the switch is operated. Standard: ON: Continuity OFF: No continuity LIGHTING – HEADLIGHT ASSEMBLY LI–37 REMOVAL 1. REMOVE FRONT BUMPER ASSEMBLY 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Using a clip remover, remove the 10 clips and radiator support seal upper. 4. REMOVE FRONT BUMPER FILLER (a) Remove the clip and the front bumper filler. 5. REMOVE HEADLIGHT ASSEMBLY (a) Disconnect the connector. E116117 E116118 (b) Remove the bolt, 3 screws, and the headlight assembly. E116119 DISASSEMBLY 1. REMOVE HEADLIGHT NO. 1 BULB (a) Remove the headlight No. 1 bulb as shown in the illustration. LI E116241 LI–38 LIGHTING – HEADLIGHT ASSEMBLY 2. REMOVE HEADLIGHT NO. 2 BULB (a) Remove the headlight No. 2 bulb as shown in the illustration. 3. REMOVE FRONT TURN SIGNAL LIGHT BULB (a) Remove the front turn signal light bulb as shown in the illustration. 4. REMOVE CLEARANCE LIGHT BULB (a) Remove the clearance light bulb as shown in the illustration. HINT: • Since the low-beam light and the high-beam light are a unit, if the aim on one is correct, the other should also be correct. However, check both beams just to make sure. • Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as left and right of the V line with low-beam (SAE J599). • Alignment distance is 3 m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as left and right of the V line with low-beam (SAE J599). • Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as left and right of the V line with high-beam (SAE J599). • Alignment distance is 3 m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as left and right of the V line with high-beam (SAE J599). • Alignment distance is 7.62 m (25 ft): The cutoff line is 53 mm (2.08 in.) below the H line with low-beam. • Alignment distance is 3 m (9.84 ft): The cutoff line is 21 mm (0.82 in.) below the H line with low-beam. E116121 E116122 E116123 LI LI–61 LIGHTING – ROOM LIGHT ASSEMBLY ROOM LIGHT ASSEMBLY INSPECTION 1. E050228 INSPECT NO. 1 ROOM LIGHT ASSEMBLY (a) Check that there is continuity between terminals at each switch position as shown in the chart. Standard Switch operation Tester connection Specified condition OFF - No continuity DOOR 1-2 Continuity ON 1-3 Continuity LI LI–66 LIGHTING – STEP LIGHT ASSEMBLY INSPECTION 1. LI INSPECT STEP SUB-ASSEMBLY (a) Check that there is continuity between terminals when the courtesy light switch is operated. Standard: ON: Continuity OFF: No continuity LIGHTING – STEP LIGHT ASSEMBLY LI–67 INSTALLATION 1. INSTALL STEP LIGHT BULB 2. INSTALL STEP SUB-ASSEMBLY LI LIGHTING – HEADLIGHT DIMMER SWITCH LI–69 INSTALLATION 1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY 2. INSTALL STEERING COLUMN UPPER COVER (See page SR-21) 3. INSTALL STEERING COLUMN LOWER COVER (See page SR-21) LI LI–62 LIGHTING – REAR ROOM LIGHT ASSEMBLY REAR ROOM LIGHT ASSEMBLY INSPECTION 1. E050228 LI INSPECT NO. 2 ROOM LIGHT ASSEMBLY (a) Check that there is continuity between terminals at each switch position as shown in the chart. Standard Switch operation Tester connection Specified condition OFF - No continuity DOOR 1-2 Continuity ON 1-3 Continuity LIGHTING – DOOR COURTESY LIGHT LI–63 DOOR COURTESY LIGHT INSPECTION 1. INSPECT COURTESY LIGHT ASSEMBLY (a) Check that there is continuity between terminals when the switch is operated. Standard: ON (When shaft is pressed): No continuity OFF (When shaft is not pressed): Continuity LI LI–64 LIGHTING – STEP LIGHT ASSEMBLY STEP LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS STEP SUB-ASSEMBLY LI C131564E02 LIGHTING – STEP LIGHT ASSEMBLY LI–65 REMOVAL 1. REMOVE STEP SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and side step light assembly. 2. REMOVE STEP LIGHT BULB I034337 LI LI–66 LIGHTING – GLOVE BOX LIGHT GLOVE BOX LIGHT INSPECTION 1. LI INSPECT GLOVE BOX LIGHT ASSEMBLY (a) Check that there is continuity between terminals when the switch is operated. Standard: ON (When shaft is pressed): No continuity OFF (When shaft is not pressed): Continuity LIGHTING – HEADLIGHT DIMMER SWITCH LI–67 HEADLIGHT DIMMER SWITCH BODY ELECTRICAL LIGHTING COMPONENTS STEERING COLUMN UPPER COVER HEADLIGHT DIMMER SWITCH ASSEMBLY STEERING COLUMN LOWER COVER LI C131331E06 LI–68 LIGHTING – HEADLIGHT DIMMER SWITCH REMOVAL 1. REMOVE STEERING COLUMN LOWER COVER (See page SR-9) 2. REMOVE STEERING COLUMN UPPER COVER 3. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and headlight dimmer switch assembly. I033442 INSPECTION 1. I033101 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Inspect the light control switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition OFF - No continuity TAIL 14 - 6 Continuity HEAD 13 - 16 - 14 Continuity AUTO 16 - 12 Continuity (b) Inspect the headlight dimmer switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition FLASH 7 - 8 - 16 Continuity LOW BEAM 16 - 17 Continuity HI BEAM 7 - 16 Continuity (c) Inspect the turn signal switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. LI Switch operation Tester connection Specified condition Right turn 2-3 Continuity Neutral - No continuity Left turn 1-2 Continuity (d) Inspect the front fog light switch continuity. (1) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition OFF - No continuity ON 10 - 11 Continuity LI–70 LIGHTING – HAZARD WARNING SWITCH HAZARD WARNING SWITCH INSPECTION 1. E065753 INSPECT HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Check that there is continuity between terminals at each switch position as shown in the chart. Switch operation Tester connection Specified condition OFF 2-3 No continuity ON 2-3 Continuity Illumination circuit 4-5 Continuity (b) Inspect illumination operation. (1) Connect the battery positive (+) lead to terminal 4 and the battery negative (-) lead to terminal 5, then check that the illumination lights up. LI LI–71 LIGHTING – STOP LIGHT SWITCH 4 3 STOP LIGHT SWITCH INSPECTION 1. 1 Free 2 Pushed in E065594E50 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Check that the continuity between terminals at each switch position, as shown in the chart. Standard Switch position Tester connection Specified condition Switch pin free 1-2 No continuity Switch pin free 3-4 Continuity Switch pin pushed in 1-2 Continuity Switch pin pushed in 3-4 No continuity LI LI–72 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY TURN SIGNAL FLASHER ASSEMBLY ON-VEHICLE INSPECTION 1. E015683 INSPECT TURN SIGNAL FLASHER ASSEMBLY (without Daytime Running Light) (a) Measure voltage between terminals as shown in the chart below. Standard voltage Tester connection Condition Specified condition 1 - Ground Turn ignition switch ON Battery positive voltage 1 - Ground Turn ignition switch OFF No voltage 4 - Ground Constant Battery positive voltage 7 - Ground Constant Continuity (b) Connect the connector to the turn signal flasher, and turn the ignition switch to ON, and inspect the wire harness side connector from the back side as shown in the chart. Standard voltage Tester connection Condition Specified condition 2 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 2 - Ground Turn signal switch (right turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 3 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 3 - Ground Turn signal switch (left turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 5 - Ground Turn signal switch (left turn) OFF → ON 10 to 14 V → 0 V 6 - Ground Turn signal switch (right turn) OFF → ON 10 to 14 V → 0 V 8 - Ground Hazard switch OFF → ON 10 to 14 V → 0 V 2. INSPECT TURN SIGNAL FLASHER ASSEMBLY (with Daytime Running Light) (a) Measure voltage between terminals as shown in the chart below. LI E064832 Standard voltage Tester connection Condition Specified condition 9 - Ground Constant Continuity 1 - Ground Turn ignition switch ON Battery positive voltage 1 - Ground Turn ignition switch OFF No voltage 6 - Ground Constant Battery positive voltage LI–73 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY (b) Connect the connector to the turn signal flasher and turn the ignition switch to ON, and inspect the wire harness side connector from the back side as shown in the chart. Standard voltage Tester connection Condition Specified condition 2 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 2 - Ground Turn signal switch (right turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 2 - Ground Turn signal switch (right turn) ON → OFF 10 to 14 V (60 to 120 time per minutes) → 10 to 14 V 3 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 3 - Ground Turn signal switch (right turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 4 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 4 - Ground Turn signal switch (left turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 4 - Ground Turn signal switch (left turn) ON → OFF 10 to 14 V (60 to 120 time per minutes) → 10 to 14 V 5 - Ground Hazard switch OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 5 - Ground Turn signal switch (left turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 7 - Ground Turn signal switch (left turn) OFF → ON 10 to 14 V → 0 V 8 - Ground Turn signal switch (right turn) OFF → ON 10 to 14 V → 0 V 10 - Ground Hazard switch OFF → ON 10 to 14 V → 0 V LI LI–74 LIGHTING – HEADLIGHT RELAY HEADLIGHT RELAY ON-VEHICLE INSPECTION 1. E064835 INSPECT HEADLIGHT RELAY (a) Remove the headlight relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the headlight relay. LI LI–75 LIGHTING – TAILLIGHT RELAY TAILLIGHT RELAY ON-VEHICLE INSPECTION 1. B113729 INSPECT TAILLIGHT RELAY (a) Remove the taillight relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the taillight relay. LI LIGHTING – TOWING CONVERTER RELAY LI–81 REMOVAL 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE BACK DOOR WEATHERSTRIP 3. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-7) 4. REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-7) 5. REMOVE DECK BOARD ASSEMBLY (See page IR-7) 6. REMOVE DECK FLOOR BOX RH (See page IR-8) 7. REMOVE DECK FLOOR BOX LH (See page IR-8) 8. REMOVE DECK TRIM COVER REAR (See page IR-8) 9. REMOVE DECK TRIM SIDE BOARD UPR LH (See page IR-8) 10. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-9) 11. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER LH (See page IR-10) 12. REMOVE TOWING CONVERTER RELAY (a) Disconnect the connector. (b) Remove the bolt and towing converter relay. I033447 LI LI–82 LIGHTING – TOWING CONVERTER RELAY INSTALLATION 1. INSTALL TOWING CONVERTER RELAY 2. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER LH (See page IR-16) 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-16) 4. INSTALL DECK TRIM SIDE BOARD UPR LH (See page IR-18) 5. INSTALL DECK TRIM COVER REAR 6. INSTALL DECK FLOOR BOX LH (See page IR-18) 7. INSTALL DECK FLOOR BOX RH (See page IR-18) 8. INSTALL DECK BOARD ASSEMBLY (See page IR-18) 9. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-18) 10. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-18) 11. INSTALL BACK DOOR WEATHERSTRIP 12. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY LI LI–76 LIGHTING – FOG LIGHT RELAY FOG LIGHT RELAY ON-VEHICLE INSPECTION 1. B113729 INSPECT FOG LIGHT RELAY (a) Remove the fog light relay. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the fog light relay. LI LIGHTING – TOWING CONVERTER RELAY LI–77 TOWING CONVERTER RELAY BODY ELECTRICAL LIGHTING COMPONENTS TOWING CONVERTER RELAY LI E115633E02 LI–78 LIGHTING – TOWING CONVERTER RELAY DECK TRIM COVER REAR DECK FLOOR BOX RH DECK BOARD SUB-ASSEMBLY LI B120186E03 LIGHTING – TOWING CONVERTER RELAY LI–79 BACK DOOR WEATHERSTRIP REAR FLOOR MAT SUPPORT PLATE REAR DECK BOARD ASSEMBLY DECK TRIM COVER REAR DECK FLOOR BOX LH ROOF SIDE GARNISH ASSEMBLY INNER LH DECK TRIM SIDE PANEL ASSEMBLY LH LI B120187E03 LI–80 LIGHTING – TOWING CONVERTER RELAY ON-VEHICLE INSPECTION 1. INSPECT TOWING CONVERTER RELAY (a) Measure voltage between terminals as shown in the chart below. E064833 LI Tester connection Condition Specified condition 1 - Ground Constant Battery positive voltage 2 - Ground Turn signal switch (right turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 2 - Ground Depress the brake pedal Battery positive voltage 3 - Ground Turn signal switch (right turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 4 - Ground Turn signal switch (left turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) 4 - Ground Depress the brake pedal Battery positive voltage 6 - Ground Constant Continuity 8 - Ground Depress the brake pedal Battery positive voltage 9 - Ground Turn signal switch (left turn) OFF → ON 0 V → 10 to 14 V (60 to 120 time per minutes) WW–3 WIPER AND WASHER – WIPER AND WASHER SYSTEM PARTS LOCATION FRONT WIPER MOTOR FRONT WIPER ARM AND BLADE ASSEMBLY ENGINE ROOM R/B ALT FUSE AMI FUSE J/B FUSE WASHER MOTOR WW C131566E01 WW–4 WIPER AND WASHER – WIPER AND WASHER SYSTEM MULTIPLEX NETWORK DOOR ECU BACK REAR WIPER ARM AND BLADE ASSEMBLY REAR WIPER MOTOR WW B120207E01 WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–5 WIPER SWITCH DRIVER SIDE JUNCTION BLOCK ASSEMBLY FR WIP-WSH FUSE WW B120208E01 WW–6 WIPER AND WASHER – WIPER AND WASHER SYSTEM PROBLEM SYMPTOMS TABLE FRONT WIPER AND WASHER SYSTEM: Symptom Suspected Area 1. FR WIP-WSH Fuse Front wiper and washer systems do not operate (All). - 2. Windshield wiper switch assembly 3. Harness or connector Front wiper system does not operate. WW-38 - 1. Windshield wiper switch assembly WW-38 2. Front wiper motor assembly WW-24 3. Harness or connector Front washer system does not operate. See page - 1. Windshield wiper switch assembly WW-38 2. Front washer motor assembly WW-40 3. Harness or connector - REAR WIPER AND WASHER SYSTEM: Symptom Rear wiper and washer systems do not operate (All). Rear wiper system does not operate. Rear washer system does not operate. WW Suspected Area 1. ALT, AMI ECU-IG Fuse See page - 2. Wiper and washer switch circuit WW-13 1. Wiper and washer switch circuit WW-13 2. Rear wiper motor circuit WW-10 1. Wiper and washer switch circuit WW-13 2. Washer motor circuit WW-18 WW–7 WIPER AND WASHER – WIPER AND WASHER SYSTEM TERMINALS OF ECU 1. Multiplex Network Body Computer Front side: 1A 1F B6 B5 B4 1E 1C 1D 1B Back side: 1G 1J 1L 1K WW 1H I034371E01 WW–8 WIPER AND WASHER – WIPER AND WASHER SYSTEM Standard voltage Terminal No. (Symbols) Wiring color Condition 1B-1 - 1H-2 (WMTR - GND1, 2) - Rear washer switch OFF → ON 1H-2 - Body ground (GND1 - Body ground) - Constant 1C-2 - 1H-2 (SIG - GND1, 2) - Ignition switch is OFF → ON 1H-2 - Body Ground (GND2 - Body ground) - Constant Specified condition 10 to 14 V → Below 1 V Below 1 V Below 1 V → 10 to 14 V Below 1 V B4-23 - 1H-2 (MPX2 - GND1, 2) BR-R - - Ignition switch is ON B6-9 - 1H-2 (RWINT - GND1, 2) BR-W - - Ignition switch is ON and rear wiper switch is OFF → INT 10 to 14 V → Below 1 V B6-10 - 1H-2 RWON - GND1, 2) GR-R - - Ignition switch is ON and rear wiper switch is OFF → ON 10 to 14 V → Below 1 V 2. Signal waveform Multiplex Network Door ECU Back: B9 B8 I033329E02 Standard voltage Terminal No. (Symbols) WW Wiring color Condition Specified condition B8-1- B8-3 (MPX2 - GND) R - W-B Ignition switch is ON B8-3 - Body ground (GND - Body ground) W-B - - Constant Below 1 V B8-4 - B8-3 (BDR - GND) L - W-B Constant 10 to 14 V B8-6 - B8-3 (SIG - GND) B - W-B Ignition switch is OFF → ON B9-1 - B8-3 (WIP- - GND) R-G - W-B Ignition switch is ON and wiper switch ON or INT Puls generation B9-2 - B8-3 (WIP+ - GND) Y-G - W-B Ignition switch is ON and wiper switch ON or INT Puls generation Signal waveform Below 1 V → 10 to 14 V B9-3 - B8-3 (W - GND) BR-B - W-B Ignition switch is ON Puls generation B9-11 - B8-3 (IC+ - GND) Y-G - W-B Ignition switch is ON Below 1 V → 10 to 14 V B9-16 - B8-3 (IC1 - GND) B-O - W-B Back door power window up and down Puls generation B9-17 - B8-3 (IC2 - GND) W-R - W-B Back door power window up and down Puls generation WW–9 WIPER AND WASHER – WIPER AND WASHER SYSTEM Terminal No. (Symbols) B9-23 - B8-3 (IC- - GND) Wiring color L-W - W-B Condition Constant Specified condition Below 1 V WW WW–10 WIPER AND WASHER – WIPER AND WASHER SYSTEM DATA LIST / ACTIVE TEST 1. Item Measurement Item/ Display (Range) WIPER TURN SW Rear wiper turn position switch signal/ON or OFF ON: Rear wiper is turning position OFF: Rear wiper is other position - WIPER RTRCT SW Rear wiper retracting switch signal/ON or OFF ON: Rear wiper is retract position OFF: Rear wiper is other position - WIPER STOP POS Rear wiper stop position signal/ON or OFF ON: Rear wiper is stop position OFF: Rear wiper is other position - Normal condition 2. Item REAR WIPER WW DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the methods to shorten the labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) According to the display on tester, read the "DATA LIST". Diagnostic note ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of troubleshooting is one of the methods to shorten the labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to ON. (c) According to the display on tester, perform the "ACTIVE TEST". Test Details Rear wiper ON/OFF Diagnostic Note - WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–11 Rear Wiper Motor Circuit DESCRIPTION • This circuit provides power to operate the combination switch. • Perform this inspection with the back door window glass fully closed. WW WW–12 WIPER AND WASHER – WIPER AND WASHER SYSTEM WIRING DIAGRAM Multiplex Network Door ECU Back R G B11 Back Door Power Window Motor SSRB PLS2 PLS E R23 Rear Wiper Motor Rear Wiper Position SW 4 Y-B 5 R-B 1 Y-G 6 B-O 2 W-R 3 L-W 2 G-R 1 P-B 3 BR-B 5 Y-G 4 R-G ECU-IG 2 1C L-Y 2 AM1 IG1 4 POWER 1 1C L-W B 1C2 ICSGND P W WIP+ WIP- 1 B8 MPX2 8 1F B-R 5 BD1 B 6 B8 SIG 2 1F L-O 6 BD1 L 4 B8 BDR W-B 10 BD1 W-B 3 B8 GND 2 2 AM1 1 A J40 ALT 2 2 1C1 R J/B 2 2 1C+ 9 BD1 2 1 Engine Room R/B W-L BDDN Driver Side J/B Assembly I18 Ignition SW L-W 18 B9 12 B9 3 B9 2 B9 1 B9 BDUP BR-R Multiplex Network Body ECU W-L 13 B9 25 B9 11 B9 16 B9 17 B9 23 B9 1 2 J/C A W-B J40 B 1 2 WW Battery BO E065745E01 WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–13 INSPECTION PROCEDURE 1 CHECK MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR POWER WINDOW MOTOR CIRCUIT) (a) Inspect the back door power window motor operation (See page WS-5). NG REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH OK 2 INSPECT REAR WIPER MOTOR ASSEMBLY (a) Measure voltage between terminals 4 and 5 of windshield wiper switch assembly, when rear wiper switch is ON. Standard voltage: 10 to 14 V OK REPLACE REAR WIPER MOTOR ASSEMBLY E034081 NG 3 CHECK MULTIPLEX NETWORK DOOR ECU BACK (REAR WIPER MOTOR CIRCUIT) (a) Measure voltage between terminals B9-1 (WIP-) and B92 (WIP+) of multiplex network door ECU back, when rear wiper switch is ON. Standard voltage: 10 to 14 V OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG REPLACE REAR WIPER MOTOR ASSEMBLY WW WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–1 WIPER AND WASHER SYSTEM PRECAUTION 1. PRECAUTION OF WASHER NOZZLE ADJUSTMENT (a) Do not clean or adjust the washer nozzle with a safety pin etc. because; (1) the washer nozzle tip is made of resin and could be damaged. (2) adjustment is not necessary because the washer nozzle is spray type. (b) In case the washer nozzle is clogged with wax etc., remove the objects and clean the nozzle hole with a soft resin brush etc. WW WW–2 WIPER AND WASHER – WIPER AND WASHER SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORK SHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 PROBLEM SYMPTOMS TABLE NEXT 4 TERMINAL OF ECU NEXT 5 CIRCUIT INSPECTION NEXT 6 IDENTIFICATION OF PROBLEM NEXT 7 REPAIR OR REPLACE NEXT 8 WW NEXT END CONFIRMATION TEST WW–14 WIPER AND WASHER – WIPER AND WASHER SYSTEM Wiper and Washer Switch Circuit DESCRIPTION • This circuit provides power to operate the combination switch. • Perform this inspection with the back door window glass fully closed. WW WW–15 WIPER AND WASHER – WIPER AND WASHER SYSTEM WIRING DIAGRAM Multiplex Network Body ECU Driver Side J/B Assembly I18 Ignition SW ECU-IG W-L 2 1C L-Y 2 AM1 IG1 4 LG-B 1 1B B-O M 4 3 W2 Washer Motor 10 W-B 2 2 1H 16 3 IC3 4 GR-R LG-B BR-W 12 SIG WMTR GND2 GND1 6 IH1 GR-R 10 B6 RWON 7 IH1 BR-W 9 B6 RWINT 10 13 WR EW +1R C1R C14 Combination SW Washer OFF INT ON Washer 2 W-B A J/C J15 J15 W-B W-B Engine Room R/B W-L B AM1 ALT 2 2 2 2 12 1 B 2 A J5 J/C Battery A WW IG E065742E01 WW–16 WIPER AND WASHER – WIPER AND WASHER SYSTEM INSPECTION PROCEDURE 1 CHECK VEHICLE CONDITION (a) Check the condition A, B or C, when rear wiper or rear washer system does not operate. Result Condition Proceed to Rear wiper and washer systems do not operate. A Rear wiper system does not operate. B Rear washer system does not operate. C B Go to step 4 C Go to step 6 A 2 INSPECT WINDSHIELD WIPER SWITCH ASSEMBLY (a) Check the continuity of the windshield wiper switch assembly. Rear Wiper Switch Switch position Tester connection Specified condition OFF - No Continuity INTO 2 (EW) - 13 (C1R) Continuity ON 2 (EW) - 10 (+1R) Continuity Rear Washer Switch E034825 Switch position Tester connection Specified condition OFF - No continuity ON (OFF position side) 2 (EW) - 12 (WR) Continuity ON (ON position side) 2 (EW) - 10 (+1R) - 12 (WR) Continuity (b) Check the continuity between the terminals 2 (EW) of windshield wiper switch assembly and body ground. Standard: There is continuity NG WW REPLACE WINDSHIELD WIPER SWITCH ASSEMBLY OK 3 INSPECT DRIVER SIDE JUNCTION BLOCK (SIG) (a) Measure the voltage between terminals 1C-2 and 1H-2 of driver side junction block when ignition key is ON. WW–17 WIPER AND WASHER – WIPER AND WASHER SYSTEM Standard voltage Switch position Tester connection Specified condition OFF 1C-2 (SIG) - 1H-2 (GND) Below 1 V ON 1C-2 (SIG) - 1H-2 (GND) 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPAIR OR REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH REAR 4 INSPECT WINDSHIELD WIPER SWITCH ASSEMBLY (a) Check the continuity the windshield wiper switch assembly. Rear Wiper Switch E034825 Switch position Tester connection Specified condition OFF - No Continuity INTO 2 (EW) - 13 (C1R) Continuity ON 2 (EW) - 10 (+1R) Continuity NG REPLACE WINDSHIELD WIPER SWITCH ASSEMBLY OK 5 CHECK MULTIPLEX NETWORK BODY ECU (a) Check the continuity terminals multiplex network body ECU and body ground, when rear wiper switch operated. Standard resistance Switch position Tester Connection Specified Condition INT B6-9 (RWINT) - Body ground No continuity → Continuity ON B6-10 (RWON) - Body ground No continuity → Continuity NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WW WW–18 6 WIPER AND WASHER – WIPER AND WASHER SYSTEM WINDSHIELD WIPER SWITCH ASSEMBLY (a) Check the continuity the windshield wiper switch assembly. Rear Washer Switch E034825 Switch position Tester connection Specified condition OFF - No continuity ON (OFF position side) 2 (EW) -12 (WR) Continuity ON (ON position side) 2 (EW) - 10 (+1R) - 12 (WR) Continuity NG REPLACE WINDSHIELD WIPER SWITCH ASSEMBLY OK 7 INSPECT DRIVER SIDE JUNCTION BLOCK (a) Check the continuity terminals driver side junction block and body ground, when rear washer switch operated. Standard resistance Switch position Tester connection Specified condition ON (OFF position side) 1B-1 (WMTR) - Body ground No continuity → Continuity ON (ON position side) 1B-1 (WMTR) - Body ground No continuity → Continuity NG REPLACE REAR WASHER MOTOR AND PUMP ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE WW WIPER AND WASHER – FRONT WIPER MOTOR WW–21 FRONT WIPER MOTOR BODY ELECTRICAL WIPER AND WASHER COMPONENTS FRONT WIPER ARM HEAD CAP FR WIPER ARM RH FR WIPER ARM LH FRONT FENDER TO COWL SIDE SEAL RH COWL TOP VENTILATOR LOUVER SUB- ASSEMBLY WW FRONT FENDER TO COWL SIDE SEAL LH B120221E03 WW–22 WIPER AND WASHER – FRONT WIPER MOTOR WINDSHIELD WIPER MOTOR AND LINK - WINDSHIELD WIPER MOTOR ASSEMBLY ENGINE ROOM R/B ALT FUSE AMI FUSE J/B FUSE WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY WW C131566E02 WIPER AND WASHER – FRONT WIPER MOTOR WW–23 REMOVAL 1. REMOVE FRONT WIPER ARM HEAD CAP (a) Using a small screwdriver, remove the 2 front wiper arm head cap. HINT: Tape the screwdriver tip before use. 2. REMOVE FR WIPER ARM RH (a) Operate the wiper and stop the windshield wiper motor assembly at the automatic stop position. (b) Remove a nut and FR wiper arm RH. 3. REMOVE FR WIPER ARM LH (a) Remove a nut and FR wiper arm LH. 4. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (a) Remove the clip. (b) Release the 2 claws, and remove the front fender to cowl side seal LH. 5. REMOVE FRONT FENDER TO COWL SIDE SEAL RH 6. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (a) Remove the 2 clips. (b) Using a clipremover, disengage the meshing of 6 clips. I033031 : Clip 2 Claws I033032E02 6 Clips I033033E01 (c) Remove the 9 claws and cowl top ventilator louver sub-assembly. 9 Claws I033034E01 WW WW–24 WIPER AND WASHER – FRONT WIPER MOTOR 7. REMOVE WINDSHIELD WIPER MOTOR AND LINK (a) Disconnect the connector and remove the 2 bolts. (b) Slide the wiper link assembly to vehicle's passenger's side. Disengage the meshing of the rubber pin and remove the wiper link assembly. 8. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY (a) Using a screwdriver and disengage the meshing of 2 rods at the clank arm pivot of the windshield wiper motor assembly. HINT: Tape the screwdriver tip before use. I033035 E066043 (b) Remove the 2 bolts and windshield wiper motor assembly. I033038 INSPECTION WW 1. E034081 INSPECT WINDSHIELD WIPER MOTOR ASSEMBLY (a) LO Operation Check (1) Connect the battery (+) to terminal 1 (+1) of the connector, the battery (-) to terminal 5 (E) of the connector, and check that the motor operates with low speed (LO). WIPER AND WASHER – FRONT WIPER MOTOR WW–25 (b) HI Operation Check (1) Connect the battery (+) to terminal 4 (+2) of the connector, the battery (-) to terminal 5 (E) of the connector, and check that the motor operates with high speed (HI). (c) Automatic Stop Operation Check (1) Connect the battery (+) to terminal 1 (+1) of the connector, the battery (-) to terminal 5 (E) of the connector. With the motor being rotated at low speed (LO), disconnect terminal 1 (+1) to stop the wiper motor operation at any position except the automatic stop position. (2) Using a SST, connect terminal 1 (+1) and 3 (S), and the battery (+) to terminal 2 (B) to restart the motor operation at low speed. SST 09843-18040 (3) Check the automatic stop position. Standard: See the illustration. Automatic Stop Position E065740E02 WW WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–19 Washer Motor Circuit DESCRIPTION • This circuit provides power to operate the combination switch. • Perform this inspection with the back door window glass fully closed. WW WW–20 WIPER AND WASHER – WIPER AND WASHER SYSTEM WIRING DIAGRAM Multiplex Network Body ECU Multiplex Network Door ECU Back 13 B9 BDUP Y-B BDDN IC+ IC1 IC2 R 4 25 B9 11 B9 16 B9 17 B9 R-B G 5 Y-G SSRB 1 B-O PLS2 6 W-R PLS 2 23 IC- B9 1 MPX2 B8 L-W E 3 9 BD1 R B11 Back Door Power Window Motor A14 IE1 BR-R I18 Ignition SW W-L 2 AM1 L-Y IG1 4 LG-B IC3 LG-B 4 3 W2 Washer Motor 12 WR EW B-O M 2 1C 1 1B 2 1H C14 Combination SW Washer OFF 2 W-B A J/C A J15 J15 BR-R 23 B4 MPX2 ECU-IG 10 2 16 4 SIG WMTR GND2 GND1 W-B Engine Room R/B W-L B AM1 W-B ALT 2 2 2 2 1 2 B 1 2 A J5 J/C WW Battery A IG E065746E01 WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–21 INSPECTION PROCEDURE 1 CHECK MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR POWER WINDOW MOTOR CIRCUIT) (a) Inspect the back door power window motor operation (See page WS-5). NG REPAIR OR REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH OK REPAIR OR REPLACE DRIVER SIDE JUNCTION BLOCK WW WIPER AND WASHER – FRONT WIPER RUBBER WW–27 FRONT WIPER RUBBER BODY ELECTRICAL WIPER AND WASHER COMPONENTS FRONT WIPER BLADE FRONT WIPER RUBBER BRACKING PLATE WIPER RUBBER FRONT WIPER RUBBER BACKING PLATE E101448E06 WW WW–28 WIPER AND WASHER – FRONT WIPER RUBBER REMOVAL 1. REMOVE FRONT WIPER BLADE (a) Remove the front wiper blade from the front wiper arm. NOTICE: Do not fold down the front wiper arm with the front wiper blade being remove from it. 2. REMOVE WIPER RUBBER (a) Remove the front wiper rubber from the front wiper blade. (b) Remove the 2 wiper rubber backing plates from the wiper rubber. INSTALLATION Curve 1. INSTALL WIPER RUBBER (a) Install the 2 wiper rubber backing plates to the wiper rubber. NOTICE: Be careful to observe and keep direction of curvature for correct replacement. E059361E15 (b) Install the wiper rubber so that the head part (Larger side) of the wiper rubber faces the arm axis side. NOTICE: Push the front wiper blade into the grooves of the wiper rubber to engage them completely. E057398 WW WW–26 WIPER AND WASHER – FRONT WIPER MOTOR INSTALLATION Wiper Arm Serration 1. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY (a) Apply MP grease to the clank arm pivot of the windshield wiper motor assembly. (b) Install the windshield wiper motor assembly with 2 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 2. INSTALL WINDSHIELD WIPER MOTOR AND LINK (a) Install the meshing of the rubber pin. (b) Install the windshield wiper link assembly with the 2 bolts. Torque: 7 N*m (71 kgf*cm, 62 in.*lbf) (c) Connect the connector. 3. INSTALL FR WIPER ARM LH (a) Operate the wiper, and stop the windshield wiper motor assembly at the automatic stop position. (b) Scrape off the serration part of the wiper arm with a round file or equivalent. (c) Clean the wiper pivot serration with the wire brush. Wire Brush Wiper Pivot Serration E058837E24 (d) Install the front wiper arm LH with a nut to the position shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18.4 ft.*lbf) HINT: Hold down the arm hinge with hand to fasten a nut. Installation Position Mark WW I034372E01 WIPER AND WASHER – FRONT WIPER MOTOR 4. Installation Position Mark I034373E01 WW–27 INSTALL FR WIPER ARM RH (a) Scrape off the serration part of the wiper arm with a round file or equivalent. (b) Clean the wiper pivot serration with the wire brush. (c) Install the front wiper arm RH with a nut at the position shown in the illustration. Torque: 25 N*m (255 kgf*cm, 18.4 ft.*lbf) HINT: Hold down the arm hinge with hand to fasten a nut. (d) Operate the wiper while running the water or the washer fluid over the window, and check the wiping condition and that the rear wiper does not hit against the vehicle body. WW WW–29 WIPER AND WASHER – REAR WIPER MOTOR REAR WIPER MOTOR BODY ELECTRICAL WIPER AND WASHER COMPONENTS WIPER ARM HEAD CAP 5.5 (56, 49 in.*lbf) REAR WIPER ARM REAR WIPER MOTOR GROMMET WW N*m (kgf*cm, ft.*lbf) : Specified torque B120202E01 WW–30 WIPER AND WASHER – REAR WIPER MOTOR BACK DOOR SERVICE HOLE COVER LH WW BACK DOOR TRIM BOARD Non-reusable part B120203E01 WIPER AND WASHER – REAR WIPER MOTOR WW–31 REAR WIPER MOTOR ASSEMBLY WW B120207E02 WW–32 WIPER AND WASHER – REAR WIPER MOTOR REMOVAL 4 Claws 1. REMOVE BACK DOOR TRIM BOARD (See page ED53) 2. REMOVE BACK DOOR SERVICE HOLE COVER LH (See page ED-53) 3. REMOVE REAR WIPER ARM HEAD CAP (a) Release the 4 claws and remove the rear wiper arm head cap. 4. REMOVE REAR WIPER ARM (a) Remove a nut and rear wiper arm. 5. REMOVE REAR WIPER MOTOR GROMMET 6. REMOVE REAR WIPER MOTOR ASSEMBLY (a) Remove the 2 grommets. I033023E01 I033024 (b) Remove the 3 bolts. I033025 (c) Using a clipremover, remove the clamp. (d) Disconnect the connector and remove the rear wiper motor assembly. WW I033026 WIPER AND WASHER – REAR WIPER MOTOR WW–33 INSPECTION 1. E034081 REMOVE REAR WIPER MOTOR ASSEMBLY (a) Operation Check (1) Connect the battery (+) to terminal 4 of the rear wiper motor assembly, the battery (-) to terminal 5 of the rear wiper motor assembly. Check that the motor turns clockwise. (2) Reverse the polarity, and check that the motor turns counterclockwise. WW WIPER AND WASHER – REAR WIPER RUBBER WW–35 REAR WIPER RUBBER BODY ELECTRICAL WIPER AND WASHER COMPONENTS REAR WIPER BLADE REAR WIPER RUBBER REAR WIPER RUBBER BACKING PLATE REAR WIPER RUBBER BACKING PLATE E110466E05 REMOVAL 1. 60° E060751E02 REMOVE REAR WIPER BLADE (a) Raise the rear wiper blade to the position as shown in the illustration, to the extent that the meshing of the claw is disengaged with the click sound. NOTICE: Be careful not to break the claw. (b) Pull straight the rear wiper blade to vehicle's left from the wiper arm. NOTICE: Do not fold the rear wiper arm with the rear wiper blade being removed from it. WW WW–36 WIPER AND WASHER – REAR WIPER RUBBER 2. Push Pull Stopper E060704E06 REMOVE REAR WIPER RUBBER (a) Place the rear wiper with the rear end of the rubber protruded from the blade stopper as shown in the illustration. NOTICE: Do not pull out the wiper rubber forcibly. Otherwise the backing plates are deformed or blade claw is damaged. HINT: Pushing the position close to the middle of the blade will raise the rubber, which could be easier to pull it out. INSTALLATION Curve 1. INSTALL REAR WIPER RUBBER (a) Install the 2 wiper rubber backing plates to the rear wiper rubber. NOTICE: Be careful to observe and keep direction of curvature for correct replacement. E059361E15 (b) Insert the rear wiper rubber from the claw of the middle of the rear wiper blade into the rear end position. (c) After passing the rear wiper rubber through the rear end side claw, protrude it from the rear end stopper and pass it through the front tip side claw. I034384 WW WW–34 WIPER AND WASHER – REAR WIPER MOTOR INSTALLATION 1. INSTALL REAR WIPER MOTOR ASSEMBLY (a) Install the rear wiper motor assembly with 3 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Install the clamp and connect the connector. 2. INSTALL REAR WIPER MOTOR GROMMET (a) As shown in the illustration, install the rear wiper motor grommet with it is position mark upside. 3. INSTALL REAR WIPER ARM (a) Scrape off the serration part of the wiper arm with a round file or equivalent. (b) Clean the rear wiper pivot serration with the wire brush. (c) Stop the rear wiper motor assembly at the automatic stop position. Installation Position Mark Rear Wiper Grommet I033027E01 Wiper Arm Serration Wire Brush Wiper Pivot Serration E058837E24 WW WIPER AND WASHER – REAR WIPER MOTOR WW–35 (d) Hold the slider to the position "A" and install the arm & blade assembly with the nut temporally. (e) Move the slider to the position "B" and tighten the nut to install the arm & blade assembly. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) HINT: Hold down the arm hinge with hand to fasten a nut. (f) Set the arm & blade assembly by moving it back to the rise-up position. (g) Operate the rear wiper while running the water or the washer fluid over the window, and check the wiping condition and that the rear wiper does not hit against the vehicle body. Position A: Position B: 4. I033028E01 INSTALL BACK DOOR SERVICE HOLE COVER LH (See page ED-60) WW WIPER AND WASHER – WIPER SWITCH WW–37 WIPER SWITCH BODY ELECTRICAL WIPER AND WASHER COMPONENTS WINDSHIELD WIPER SWITCH ASSEMBLY STEERING COLUMN COVER STEERING COLUMN COVER LOWER WW C131331E05 WW–38 WIPER AND WASHER – WIPER SWITCH REMOVAL 1. REMOVE STEERING COLUMN COVER LOWER (See page SR-9) 2. REMOVE STEERING COLUMN COVER 3. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (a) Disconnect the connector. I033194 (b) Remove the 2 screws and windshield wiper switch assembly. I033195 INSPECTION 1. E034825 INSPECT WINDSHIELD WIPER SWITCH ASSEMBLY (a) Continuity Check (1) Check the continuity of each terminal of the connector. Front Wiper Switch Switch position Tester connection Specified condition OFF 16 (+S) - 7 (+1) Continuity INTO 16 (+S) - 7 (+1) Continuity LO 17 (+B) - 7 (+1) Continuity HI 17 (+B) - 8 (+2) Continuity Rear Wiper Switch WW Switch position Tester connection Specified condition OFF - No Continuity INTO 2 (EW) - 13 (C1R) Continuity ON 2 (EW) - 10 (+1R) Continuity Front Washer Switch Switch position Tester connection Specified condition OFF - No Continuity ON 11 (WF) - 2 (EW) Continuity Rear Washer Switch Switch position Tester connection Specified condition OFF - No Continuity WIPER AND WASHER – WIPER SWITCH WW–39 Switch position Tester connection Specified condition ON (OFF position side) 2 (EW) - 12 (WR) Continuity ON (ON position side) 2 (EW) - 10 (+1R) - 12 (WR) Continuity (b) Intermittent Operation Check (1) Connect the voltmeter (+) terminal to terminal 7 (+1) of the connector, the voltmeter (-) terminal to terminal 2 (EW) of the connector. (2) Connect the battery (+) to terminal 17 (+B) of the connector, the battery (-) to terminal 2 (EW) and 16 (+S) of the connector. (3) Turn the wiper switch to INT. (4) Connect the battery (+) to terminal 16 (+S) of the connector for 5 seconds. (5) Connect the battery (-) to terminal 16 (+S) of the connector. Operate the intermittent wiper relay and check voltage between terminal 7 (+1) and terminal 2 (EW). FAST: Connect the battery (-) to terminal 16 (+S) SLOW: Connect the battery (-) to terminal 16 (+S) 7 (+1) - 2 (EW) Voltage between terminals 1.6 +- 1 seconds 10.7 +- 5 seconds E056399E32 Washer Switch 7 (+1) - 2 (EW) Voltage between terminals Approx. 0.3 second Approx. 2.2 seconds I030007E04 (c) Operation Check (Front Wiper) (1) Turn the wiper switch to OFF. (2) Connect the battery (+) to terminal 17 (+B) of the connector, the battery (-) to terminal 16 (+S) and 2 (EW) of the connector. (3) Connect the voltmeter (+) terminal to terminal 7 (+1) of the connector and the voltmeter (-) terminal to terminal 2 (EW) of the connector. Turn the washer switch to ON and OFF, and check voltage between terminal 7 (+1) and terminal 2 (EW). WW WW–40 WIPER AND WASHER – WIPER SWITCH INSTALLATION WW 1. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY 2. INSTALL STEERING COLUMN COVER 3. INSTALL STEERING COLUMN COVER LOWER WW–40 WIPER AND WASHER – WASHER MOTOR WASHER MOTOR ON-VEHICLE INSPECTION 1. E065747 WW INSPECT WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY (a) Operation Check (1) Pour the washer fluid into the washer jar with the washer motor and the pump installed to the washer jar assembly. (2) Connect the battery (+) to terminal 1 of the washer motor and the pump, the battery (-) to terminal 2 of the washer motor and the pump. Check that the water comes out from the washer jar. WW–41 WIPER AND WASHER – WASHER NOZZLE WASHER NOZZLE ADJUSTMENT 1. INSPECT WASHER NOZZLE SUB-ASSEMBLY (a) With the engine running, check that the point where the washer fluid hits the windshield is within the range indicated by the hatched line. Front: A A A A A A B D C I H J E F G K M O L N P A: 150 mm (5.91 in.) I: 384.6 mm (15.142 in.) B: 30 mm (1.18 in.) J: 288.2 mm (11.346 in.) C: 236.5 mm (9.311 in.) K: 85.2 mm (3.354 in.) D: 60 mm (2.36 in.) L: 77.1 mm (3.035 in.) E: 364.4 mm (14.346 in.) M: 247 mm (9.72 in.) F: 240.1 mm (9.453 in.) N: 366.7 mm (14.437 in.) G: 207.8 mm (8.181 in.) O: 568.3 mm (22.374 in.) H: 60 mm (2.36 in.) P: 557.2 mm (21.937 in.) WW I033029E01 WW–42 WIPER AND WASHER – WASHER NOZZLE 2. INSPECT REAR WASHER NOZZLE SUB-ASSEMBLY (a) With the engine running, check the point where the washer fluid hits the rear window is within the range indicated by the hatched line. Rear: A B C D E F G H A: 114.2 mm (4.496 in.) B: 60.3 mm (2.374 in.) C: 107 mm (4.21 in.) D: 210.4 mm (8.283 in.) E: 41.6 mm (1.638 in.) F: 56.4 mm (2.22 in.) G: 102.7 mm (4.043 in.) H: 153.8 mm (6.055 in.) I033030E01 WW DL–4 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OPERATION CHECK 1. 2. DL DOOR LOCK FAIL-SAFE (a) When a malfunction in the door control switch (manual switch, interlocked with key operation) has been detected, door lock/unlock operation becomes disabled. CHECK ELECTRICAL DOOR LOCK OPERATION NOTICE: The following inspection procedure are based on the assumption that the vehicle has not been customized using intelligent tester. (a) Check the basic function. (1) Check that all doors lock when the door control switch (for manual operation) is turned to LOCK and all doors unlock when turned to UNLOCK. (2) Check that all doors lock when the driver side door lock key cylinder is turned to LOCK using the key. (3) Check that only the driver side door unlocks when the driver side door lock key cylinder is turned to UNLOCK and all doors unlock when turned to UNLOCK once again within 3 seconds using the key (2-step unlocking function). (b) Check the key lock-in prevention function. NOTICE: In order to prevent the key from being actually locked-in, the inspection should be performed with the driver side door window open. (1) Have the key inserted into the ignition key cylinder. (2) With the driver side door open, check that all doors unlock immediately after the door lock knob for the driver side door is turned to LOCK. (3) With the driver side door open, check that all doors unlock immediately after the door control switch (for manual operation) is turned to LOCK. (4) With the driver side door open, turn the driver side door lock knob to LOCK and hold it for 2 seconds or more, and then close the driver side door. Then check that all doors unlock. (c) Check the security function. (1) Close all doors with the driver side door window open so that the door control switch can be operated from outside the vehicle. (2) Pull out the key, open the driver side door and then close and lock the door without using the key. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–5 (3) Pull out the key, close and lock the driver side door by key operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (4) Pull out the key, close the driver side door and lock the door by wireless door lock operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. HINT: Check that the security function is canceled under the following conditions: • The ignition switch is turned ON. • The driver side door is unlocked using the key. • The door control switch (for manual operation) is turned to UNLOCK after the door control knob is turned to UNLOCK manually. • The doors are unlocked by wireless operation. (d) Check the illumination function. (1) Set the interior light switch in the DOOR position. (2) With all doors locked, check that all doors unlock when the driver side door lock cylinder is turned to UNLOCK using the key. At the same time, the interior light comes on. (3) Check that the interior light goes off in approximately 15 seconds if the doors have not been opened for a while. (e) Check the automatic locking function interlocked with the shift lever. (1) When any door is unlocked with all doors closed and the engine started, check that all doors automatically lock when the shift lever is moved into any position from the P position. (2) When any door is unlocked after all doors automatically lock, check that all doors attempt to automatically lock once again (retry function). The retry function is canceled when any of the following conditions is fulfilled: • All doors are locked. • Any door is opened. • The shift lever is moved into the P position. • The doors are locked or unlocked by the user. • The ignition switch is turned OFF. • The engine is stopped. DL DL–6 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PROBLEM SYMPTOMS TABLE POWER DOOR LOCK CONTROL SYSTEM: Symptom All doors lock and unlock functions do not operate via master switch, driver side door key cylinder Key lock-in prevention function does not work properly (Manual operation and operation interlocked with key are active) Only back door can not be opened (Unlocked) DL Suspected area See page 1. DOOR1 fuse DL-12 2. ECU-B fuse DL-12 3. Power window regulator master switch assembly DL-12 4. Front door lock assembly LH DL-12 5. Instrument panel junction block assembly (body ECU) DL-12 6. Wire harness DL-12 1. Unlock warning switch assembly DL-17 2. Courtesy light switch assembly LH (Driver side door) DL-17 3. Instrument panel junction block assembly (body ECU) DL-17 4. Wire harness DL-17 1. Back door opener switch assembly DL-21 2. w/ Motor back door lock assembly LH (Back door lock) DL-21 3. Instrument panel junction block assembly (body ECU) DL-21 4. Wire harness DL-21 DL–7 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM TERMINALS OF ECU 1. Vehicle Rear Side CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (BODY ECU) Vehicle Right Side Vehicle Front Side 1H 1F B6 1A 1E 1K B5 1C B4 1B 1D 1J 1L 1G Body ECU 1F B6 1E 1K 1B 1L B4 DL B062708E01 DL–8 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (a) Disconnect the 1B, 1E, 1F, 1H, 1K, 1L, B4 and B6 J/ B connectors, and check the voltage or continuity of each terminal of the vehicle side connectors. Symbols (Terminal No.) BDR1 (1E-9) - Body Ground Wiring Color Condition Specified Condition G-W - Body ground Always 10 to 14 V W-R - Body ground Always 10 to 14 V GND1 or GND2 (1H-2) - Body Ground W-B - Body ground Always Below 1 Ω KSW (B6-14) - Body Ground G-Y - Body ground No key inserted in ignition key cylinder → Key inserted 10 kΩ or higher → Below 1Ω L1(1K-5) - Body Ground L-W - Body ground Door control switch (Master switch) OFF → LOCK 10 kΩ or higher → Below 1Ω UL1 (1K-1) - Body Ground L-O - Body ground Door control switch (Master switch) OFF → UNLOCK 10 kΩ or higher → Below 1Ω L2 (1K-3) - Body Ground L - Body ground Driver side door key cylinder OFF → LOCK 10 kΩ or higher → Below 1Ω UL3 (B4-12) - Body Ground G - Body ground Driver side door key cylinder OFF → UNLOCK twice (within 3 sec.) 10 kΩ or higher → Below 1Ω BECU (1B-4) - Body Ground BECU (1F-12) - Body Ground BECU (1L-4) - Body Ground If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the J/B connectors 1B, 1E, 1F, 1H, 1K, 1L, B4 and B6, and check the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Color DCTY (B5-23) - Body Ground R-B - Body ground ACT+ (1L-9) - Body Ground L-R - Body ground Condition Specified Condition Driver door CLOSED → OPEN 10 to 14 V → Below 1 V Door control switch (master switch or passenger side switch) or driver door key cylinder OFF → LOCK Below 1 V → 10 to 14 V → Below 1 V Door control switch (master switch or passenger side switch) or driver door key cylinder OFF → LOCK Below 1 V → 10 to 14 V → Below 1 V ACT+ (1L-6) - Body Ground L-R - Body ground ACT+ (1L-11) - Body Ground L-R - Body ground ACT+ (1L-10) - Body Ground L-R - Body ground ACT- (1L-18) - Body Ground L-B - Body ground ACT- (1L-23) - Body Ground L-B - Body ground ACT- (1L-22) - Body Ground L-B - Body ground ACTD (B4-10) - Body Ground L-B - Body ground Driver side door key cylinder OFF → 2-step unlocking Below 1 V → 10 to 14 V → Below 1 V LSWD (B4-21) - Body Ground W-R - Body ground Driver side door UNLOCK → LOCK 10 to 14 V → Below 1 V LSWP (B4-30) - Body Ground B-W - Body ground Passenger side door UNLOCK → LOCK 10 to 14 V → Below 1 V LSR (1L-16) - Body Ground W - Body ground Rear left door UNLOCK → LOCK 10 to 14 V → Below 1 V LSR (1K-15) - Body Ground W - Body ground Rear right door UNLOCK → LOCK 10 to 14 V → Below 1 V If the result is not as specified, the vehicle may be defective. In this case, check the harness, connector and fuse between the ECU and battery. Then repair or replace it if necessary. DL DL–9 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2. B9 CHECK MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) B8 B062706E03 (a) Disconnect the B8 and B9 ECU connectors, and check the voltage or continuity of each terminal of the wire harness side connectors. Symbols (Terminal No.) BDR (B8-4) - Body Ground Wiring Color L - Body ground Condition Always Specified Condition 10 to 14 V BECU (B8-5) - Body Ground L-R - Body ground Always 10 to 14 V GND (B8-3) - Body Ground W-B - Body ground Always Below 1 Ω SIG (B8-6) - Body Ground B - Body ground No key inserted in ignition key cylinder → Key inserted 10 k Ω or higher → Below 1Ω Back door opener switch OFF → ON 10 k Ω or higher → Below 1Ω HSW+ (B9-10) - Body Ground V - W - Body ground HSW- (B9-22) - Body Ground LG-R - Body ground HALF (B9-6) - Body Ground R-G - Body ground Back door OPEN → CLOSED 10 k Ω or higher → Below 1Ω LSE (B9-21) - Body Ground B-R - Body ground Always Always If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the connectors, and check the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Color Condition Specified Condition L-B - Body ground Back door OPEN → NOT COMPLETELY CLOSED → Motor in normal rotation (Right turn) → Motor in revers rotation (Left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → 10 to 14 V → Below 1 V → Below 1 V ACT- (B9-14) - Body Ground L-R - Body ground Back door OPEN → NOT COMPLETELY CLOSED → Motor in normal rotation (Right turn) → Motor in revers rotation (Left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → Below 1 V → 10 to 14 V → Below 1 V FULL (B9-7) - Body Ground G-Y - Body ground Back door CLOSED → OPEN 10 to 14 V → Below 1 V POS (B9-8) - Body Ground BR-W - Body ground Back door OPEN → Closer in operation → CLOSED Below 1 V 10 to 14 V → Below 1 V ACT+ (B9-15) - Body Ground If the result is not as specified, the vehicle may be defective. In this case, check the harness, connector and fuse between the ECU and battery. Then repair or replace it if necessary. DL DL–10 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DIAGNOSIS SYSTEM CG SG 1. SIL 1 2 3 4 5 6 7 8 BAT CHECK DLC3 (a) The vehicle's body ECU uses ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAEJ1962 and matches the ISO 9141-2 format. 9 10 11 1213141516 A082779E04 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DL DL–11 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester with CAN VIM to the DLC3. (b) Turn the ignition switch ON. (c) Read the DATA LIST according to the display on the tester. BODY: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note Unlock warning switch signal / ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CYT SW Passenger side door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Right or left rear door is open OFF: Right and left rear doors are closed - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Passenger side door is lock is in UNLOCK position OFF: Passenger side door lock is in LOCK position - Rr LOCK POS SW Rear door lock position switch signal / ON or OFF ON: Rear door lock is in UNLOCK position OFF: Rear door lock is in LOCK position - Ignition switch signal / ON or OFF ON: Key is in ON or START position OFF: Key is in OFF or ACC position - Driver side door lock position switch signal / ON or OFF ON: Driver side door lock is in unlock position OFF: Driver side door lock is in lock position - Manual door lock switch LOCK signal / ON or OFF ON: Manual door lock switch is in LOCK position OFF: Manual door lock switch is in neutral position (Common to driver side and passenger side mode) - Manual door lock switch UNLOCK signal / ON or OFF ON: Manual door lock switch is in UNLOCK position OFF: Manual door lock switch is in neutral position (Common to driver side and passenger side) - DOR KEY SW-LOCK Key operation door lock switch signal / ON or OFF ON: Key operation door lock switch is in lock position OFF: Key operation door lock switch is in neutral position (Common to driver side and passenger side mode) - P DOR KEY SW-UL Key operation passenger door unlock switch signal / ON or OFF ON: Passenger key operation door lock switch is in unlock position OFF: Passenger key operation door lock switch is in neutral position - KEY UNLK WRN SW IG SW D LOCK POS SW D/L SW-LOCK D/L SW-UNLOCK DL DL–12 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note Key operation driver door unlock switch signal / ON or OFF ON: Driver key operation door lock switch is in unlock position OFF: Driver key operation door lock switch is in neutral position - Key operation driver door 2-step unlock switch signal / ON or OFF ON: All doors are unlocked when driver side door key cylinder is turned to unlock twice (2-step unlocking function) OFF: Only driver side door is unlocked when driver side door key cylinder is turned to unlock once - Park/neutral position switch signal / ON or OFF ON: Ignition switch ON, vehicle speed 0 km/h and shift to any position except P position → Shift to P position → all doors unlock OFF: Ignition switch ON, vehicle speed 0 km/h and shift to any position except P position - AUTO LOCK/SHIFT Shift lever in any position other than P position signal / ON or OFF ON: All doors lock when shift lever is shifted to any position other P from P position OFF: No door locks when shift lever is shifted to any position other than P from P position - OPEN DOOR WARN Door courtesy switch signal / ON or OFF ON: Each door is open OFF: All doors are closed - AUTO LOCK DELAY Door courtesy switch signal / 30s or 60s 30s: Door auto locking time is 30 sec. 60s: Door auto locking time is 60 sec. - D DOR KEY SW-UL UNLK/KEY TWICE UNLOCK/PARK BACK DOOR: Item Normal Condition Diagnostic Note KEY SW (UNLK) Back door key lock and unlock switch signal / ON or OFF ON: Back door lock key cylinder is turned to unlock OFF: Key is in back door lock key cylinder (original position) - KEY SW (LOCK) Back door key lock and unlock switch signal / ON or OFF ON: Back door lock key cylinder is turned to unlock OFF: Key is in back door lock key cylinder (original position) - HALF LATCH SW Back door half latch switch signal /ON or OFF ON: Back door is open OFF: Back door is closed - FULL LATCH SW Back door full latch switch (courtesy SW) signal / ON or OFF ON: Back door is closed OFF: Back door is open - DOOR HANDLE SW Back door opener switch signal / ON or OFF ON: Back door opener is pushed OFF: Back door opener is not pushed - Back door position switch signal / UNLOCK or LOCK UNLOCK: Back door is unlock LOCK: Back door is lock - LOCK STATUS Measurement Item / Display (Range) 2. DL ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of troubleshooting is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. DL–13 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (c) According to the display on the tester, perform the ACTIVE TEST. BODY: Item Test Details Diagnostic Note Turn open door warning light ON / OFF (All doors are closed) - DOOR LOCK Drive door lock motor at all doors LOCK / OFF - DOOR LOCK Drive door lock motor at all doors UNLOCK / OFF - OPN DOR WRN LGT DL DL–44 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. DATA LIST HINT: The wireless door lock control data list can be displayed while the intelligent tester is connected to the DLC3 with the ignition switch in the ON position. Follow the prompts on the tester screen to access the DATA LIST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON. (c) Read the DATA LIST according to the display on the tester. BODY: Item (Display) KEY UNLK WRN SW Measurement Item / Display (Range) Unlock warning switch / ON or OFF 2. Normal Condition Diagnostic Note ON: Ignition key is inserted OFF: Ignition key is not inserted - ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows components such as the relay, VSV and actuator to operate without removing parts. Performing the ACTIVE TEST as the first step in troubleshooting is one way to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, preform the ACTIVE TEST. HINT: The ignition switch must be turned to the ON position to proceed with the ACTIVE TEST using the intelligent tester. BODY: Item (Display) DL Test Details Diagnostic Note BUZZ CONT SOUND Turns wireless door lock buzzer ON /OFF - BUZZ RESP SOUND Turns wireless door lock buzzer ON / OFF - DL–45 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If a trouble code is displayed during the DTC check, inspect the circuit listed for that code. For details of the code, refer to the "See page" in the DTC chart. • Inspect the fuse and relay before investigating the suspected areas shown in the table below. WIRELESS DOOR LOCK CONTROL SYSTEM DTC No. Detection Item Suspected Area See page B1242 Wireless Door Lock Tuner Circuit Malfunction 1. Wire harness 2. Door control receiver 3. Instrument panel J/B (Multiplex network body ECU) DL-42 DL DL–46 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DTC B1242 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION This DTC is output when a ground short is detected in terminal RDA or PRG. DTC No. B1242 DTC Detection Condition Trouble Area • • • Ground short in terminal RDA or PRG Door control receiver Wire Harness Instrument panel J/B assembly (Body ECU) WIRING DIAGRAM Instrument Panel J/B Assembly D7 Door Control Receiver Body ECU PRG RDA 3 G-O A13 IE1 G-O 3 B5 PRG 2 L-R A12 IE1 L-R 4 B5 RDA B062222E01 DL INSPECTION PROCEDURE 1 CHECK DOOR CONTROL RECEIVER (a) Check that the wireless system when a new or normal door control receiver is installed. (b) Check that no DTC is output. DL–47 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM OK REPLACE DOOR CONTROL RECEIVER NG 2 CHECK HARNESS AND CONNECTOR (DOOR CONTROL RECEIVER - BODY ECU) (a) Disconnect the D7 receiver connector. (b) Disconnect the B5 J/B connector. (c) Check the continuity between the wire harness side connectors. Standard resistance Wire Harness Side D7 Door Control Receiver B5 Instrument Panel J/B Assembly Symbols (Terminal No.) Specified Condition RDA (D7-2) - RDA (B5-4) Below 1 Ω PRG (D7-3) - PRG (B5-3) Below 1 Ω (d) Check the continuity between the D7 receiver connector B5 J/B connector and body ground. Standard resistance Symbols (Terminal No.) Specified Condition RDA (D7-2) or RDA (B5-4) - Body ground 10 kΩ or higher PRG (D7-3) or PRG (B5-3) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR B062225E02 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL DL–1 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BODY ELECTRICAL DOOR LOCK PARTS LOCATION UN-LOCK WARNING SWITCH ASSEMBLY DOOR CONTROL SWITCH FRONT DOOR LOCK RH FRONT COURTESY LIGHT SWITCH RH DRIVER SIDE JUNCTION BLOCK ASSEMBLY - BODY ECU REAR DOOR LOCK RH REAR COURTESY LIGHT SWITCH RH POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY BACK DOOR OPENER SWITCH ASSEMBLY - DOOR CONTROL SWITCH MULTIPLEX NETWORK BACK DOOR ECU FRONT DOOR LOCK LH FRONT COURTESY LIGHT SWITCH LH - BACK DOOR ECU DL REAR COURTESY LIGHT SWITCH LH REAR DOOR LOCK LH W/ MOTOR BACK DOOR LOCK ASSEMBLY - BACK DOOR LOCK B120209E02 DL–2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the power door lock control system. • The intelligent tester should be used in steps 3 and 5. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-30). NEXT 3 INSPECT COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B GO TO MULTIPLEX COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE Result Result DL A Fault is listed on problem symptoms table B B After repair, go to step 7 A 5 Proceed to Fault is not listed on problem symptoms table OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–3 (See page DL-6) (b) DATA LIST/ACTIVE TEST (See page DL-9) NEXT 6 REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT END DL DL–48 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM Only Wireless Control Function is Inoperative DESCRIPTION The door control receiver receives a signal from the transmitter and sends this signal to the body ECU. Then, the body ECU controls operation of the door locks except the back door lock in response to this signal, while the body ECU sends a signal to the back door ECU at the same time. Receiving this signal, the back door ECU controls operation of the back door lock. Also, the back door ECU causes the back window to open, receiving a signal from the transmitter via the body ECU. WIRING DIAGRAM Instrument Panel J/B Assembly D7 Door Control Receiver PRG 1 W-B A A J40 J40 J/C A J41 E +B C G-Y J15 2 J15 J/C W-B W-B A BO 3 G-O A13 IE1 G-O 3 B5 PRG 2 L-R A12 IE1 L-R 4 B5 RDA 5 R To Battery K3 Un-lock Warning Switch Assembly 1 W-B RDA Body ECU J/C B E G-Y J14 J18 J/C 14 A G-Y B6 KSW J19 J5 J/C A W-B A BL 1G B062223E01 DL INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS (a) Check the wireless door lock control system (See page DL-29). OK END DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DL–49 NG 2 CHECK TRANSMITTER BATTERY (a) After replacing the transmitter battery with a new or normal one and then operating the transmitter LOCK/ UNLOCK in the standard operation, check that the doors can lock and unlock even after operating it more than 3 times. NOTICE: Standard operation, herein, means operation by pressing the transmission switch for 1 second, directing the transmitter to the vehicle in a location that is 100 cm (39.37 in.) away from the driver side door outside handle in the right direction. NG Go to step 7 OK REPLACE TRANSMITTER BATTERY 3 CHECK WIRELESS DOOR LOCK BUZZER (a) Check if the wireless door lock buzzer sounds. Result Condition Proceed To Buzzer sounds A Buzzer does not sound Go to "No Answer-Back (Hazard Warning Light and Wireless Door Lock Buzzer)" (See page DL-52) A 4 SWITCH TO SELF DIAGNOSTIC MODE (a) Switch to self-diagnostic mode using the intelligent tester. (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON and turn the intelligent tester main switch on. HINT: Refer to the intelligent tester operator's manual for further details. (b) Switch to self-diagnostic mode by performing the following (Manual operation): (1) Put the vehicle under the initial condition (See page DL-29). (Procedure "A") (2) Insert the key into the ignition key cylinder and remove it. (Procedure "B") DL DL–50 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM Buzzer Output: T1: 0.13 seconds T2: 0.5 seconds ON (3) Within 5 seconds after the key is removed, insert the key into the ignition key cylinder again. (Procedure "C") (4) Turn the ignition switch ON and turn it back OFF. (Procedure "D") (5) Within 30 seconds of turning the ignition switch OFF again, perform the following 9 times: Turn the ignition switch ON and turn it back to OFF. (Procedure "E") HINT: • Turning the ignition switch to the ON position after Procedure "E" has been completed will end the self-diagnostic mode. • Do not lock or unlock doors during the selfdiagnostic mode. NOTICE: If the self-diagnostic mode cannot be achieved, the system will return to normal mode. (c) Check that the system has switched to self-diagnostic mode by checking the sound of the wireless door lock buzzer. OK: The sound pattern of the wireless door lock buzzer should be the same as the patterns shown in the timing chart on the illustration. NG Go to step 9 OFF T1 T2 B110075E01 OK 5 CHECK BY SELF DIAGNOSTIC MODE (a) Check the diagnostic outputs when the door control transmitter switch is held down. The diagnostic outputs can be checked by the sound of the wireless door lock buzzer. DL DL–51 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM Buzzer Output: Normal Wave (LOCK Switch): T1 Unmatched Recognition Code: T3 ON Wave is being received OFF ON Normal Wave (UNLOCK Switch): OFF T1 T2 T1 T3 ON OFF No Diagnostic Output: Normal Wave (PANIC Switch or BACK WINDOW Switch): OFF T3 T3 ON T1: 0.13 seconds OFF T2: 0.25 seconds T3: 0.5 seconds B110076E16 Result Condition Proceed To Unmatched recognition code is output A Normal waves patterns from the wireless door lock buzzer are output for LOCK, UNLOCK, PANIC and BACK WINDOW B No diagnostic outputs are recorded C B C REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY Go to step 7 A 6 DL REGISTER RECOGNITION CODE (a) Check that the system can switch to the rewrite mode or add mode and whether a recognition code can be registered. DL–52 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM OK: The system can switch to the rewrite mode or add mode, and a recognition code can be registered. NG Go to step 8 OK END 7 CHECK RESPONSE OF DOOR CONTROL RECEIVER (a) When a new or normal door control transmitter switch for the same type vehicle is held down, check that a diagnosis of unmatching recognition code is output. OK: Unmatched recognition code is output. NG Go to step 12 OK REPLACE DOOR CONTROL TRANSMITTER 8 REPLACE DOOR CONTROL RECEIVER (a) Replace door control receiver with normal one. NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY OK REPLACE DOOR CONTROL RECEIVER 9 CONFIRM SELF DIAGNOSTIC MODE (a) Confirm input method for self-diagnostic mode. Result Condition DL Proceed To Method for changing system self-diagnostic mode works A Method for changing system self-diagnostic mode does not work B B A Go to step 4 DL–53 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM 10 INSPECT UNLOCK WARNING SWITCH (a) Disconnect the unlock warning switch connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Unlock Warning Switch: Free Tester Connection Condition Specified Condition 1-2 Switch pressed (Key set) Below 1 Ω 1-2 Switch free (Key removed) 10 kΩ or higher Pressed NG REPLACE UNLOCK WARNING SWITCH 2 1 4 3 B110108E08 OK 11 CHECK HARNESS AND CONNECTOR (BODY ECU - UN-LOCK WARNING SWITCH) (a) Disconnect the body ECU (B6) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side K3 Un-lock Warning Switch Tester Connection Condition Specified Condition B6-14 (KSW) - K3-2 Always Below 1 Ω B6-14 (KSW) - Body ground Always 10 kΩor higher K3-2 - Body ground Always Below 1 Ω NG B6 Body ECU REPAIR OR REPLACE HARNESS OR CONNECTOR B062226E03 OK DL DL–54 12 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECT DOOR CONTROL RECEIVER (POWER SOURCE) (a) Disconnect the D7 door control receiver connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness Side Tester Connection Specified Condition D7-5 (+B) - Body ground 10 to 14 V NG D7 Door Control Receiver B059092E10 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 13 INSPECT DOOR CONTROL RECEIVER (E TERMINAL) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition D7-1 (E) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR D7 Door Control Receiver B059092E10 OK 14 INSPECT DOOR CONTROL RECEIVER (a) Reconnect D7 receiver connector, and check the voltage according to the value(s) in the table below. Standard voltage Door Control Receiver Symbols (Terminal No.) Condition Specified Condition RDA (D7-2) - Body ground Ignition switch OFF, no key in ignition key cylinder, all doors closed and each transmitter switch OFF → ON Below 1 V → Approx. 6 to 7 V → Below 1 V B051174E03 NOTICE: Check the output voltage with the bar graph display. DL OK NG Go to step 16 DL–55 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM 15 CHECK HARNESS AND CONNECTOR (BODY ECU - DOOR CONTROL RECEIVER) (a) Disconnect the receiver (D7) connector and body ECU (B5) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side D7 Door Control Receiver B5 Body ECU Tester Connection Condition Specified Condition D7-2 (RDA) - B5 -4 (RDA) Always Below 1 Ω D7-2 (RDA) - Body ground Always 10 kΩor higher B5- 4 (RDA) - Body ground Always 10 kΩor higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR B062225E03 OK 16 REPLACE DOOR CONTROL RECEIVER (a) Replace the door control receiver with normal one. OK: The system returns to normal operation. NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY OK REPLACE DOOR CONTROL RECEIVER DL DL–56 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM No Answer-Back (Hazard Warning Light and Wireless Door Lock Buzzer) DESCRIPTION If there is no answer-back of the hazard warning lights and wireless door lock buzzer while the wireless control function is operating normally, the hazard light signal and the wireless door lock buzzer signal output from the body ECU may be malfunctioning. NOTICE: Confirm that the answer-back function has been switched on as a result of customization before starting troubleshooting. DL DL–57 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM WIRING DIAGRAM with Daytime Running Light Instrument Panel J/B Assembly W3 Wireless Door Lock Buzzer 2 Body ECU 10 1B 9 Y-B 6 1B 7 14 1J 8 1 D2 Turn Signal Flasher Relay 10 HAZ P-B W To Hazard Warning Signal Switch W without Daytime Running Light Body ECU P-B 10 1B 9 Y-B 6 1B 7 8 1 8 10 IF1 W 14 1J To Hazard Warning Signal Switch W 15 1J W HAZ Instrument Panel J/B Assembly T9 Turn Signal Flasher Relay EHW BZR2 15 1J W3 Wireless Door Lock Buzzer 2 BZR BZR BZR2 HAZ DL B134205E01 INSPECTION PROCEDURE DL–58 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM When using intelligent tester: 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS (a) Check that the wireless door lock functions operate when the transmitter is used (See page DL-29). Result Condition Proceed To Wireless door lock functions operate normally but hazard warning light answer-back does not occur A Wireless door lock functions operate normally but wireless door lock buzzer answer-back does not occur B Wireless door lock functions do not operate Go to "Only Wireless Control Function is Inoperative" (See page DL-44) B Go to step 4 A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (HAZARD WARNING LIGHT) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select the ACTIVE TEST mode on the intelligent tester. BODY: Item (Display) HAZARD Vehicle Condition / Test Details Diagnostic Note Turns the turn signal flasher relay ON / OFF Observe headlight and rear combination light for correct operation (d) Check that "ON" and "OFF" of the hazard warning lights on the headlight and rear combination light turn on and off when the intelligent tester is used. OK: The hazard warning lights turn on or off in accordance with commands of the intelligent tester. NG Go to step 3 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL 3 CHECK HAZARD WARNING LIGHTS (a) Check that the hazard warning lights flash continuously when the hazard warning light switch is pressed. OK: Hazard warning lights flash continuously. NG INSPECT LIGHTING SYSTEM DL–59 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (WIRELESS DOOR LOCK BUZZER) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the intelligent tester main switch on. (c) Select the ACTIVE TEST mode on the intelligent tester. BODY: Item (Display) Vehicle Condition / Test Details Diagnostic Note BUZZ CONT SOUND Turns wireless door lock buzzer ON / OFF Buzzer can be heard BUZZ RESP SOUND Turns wireless door lock buzzer ON / OFF Buzzer can be heard (d) Check that the buzzer sounds/stops when turning the wireless door lock buzzer on/off by using the intelligent tester. Result Condition Proceed To Buzzer sounds/stops A Buzzer does not sound or sounds constantly B B Go to step 5 A REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 5 INSPECT WIRELESS DOOR LOCK BUZZER (a) Disconnect the wireless door lock buzzer connector. (b) Measure the resistance according to the value(s) in the table below. HINT: The buzzer circuit is built into the ECU, not into the buzzer itself. When battery voltage is applied directly to the buzzer, the buzzer does not sound. Resistance Wireless Door Lock Buzzer: 2 1 Tester Connection Condition Specified Condition 1-2 Always Approx. 1 kΩ NG B110079E04 OK REPLACE WIRELESS DOOR LOCK BUZZER DL DL–60 6 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (WIRELESS DOOR LOCK BUZZER - INSTRUMENT PANEL J/B) (a) Disconnect the buzzer connector (W3) and J/B (1B) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side W3 Wireless Door Lock Buzzer Tester Connection Condition Specified Condition W3-1 - 1B-10 (BZR) Always Below 1 Ω W3-2 - 1B - 6 (BZR2) Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR 1B Instrument Panel J/B Assembly B062227E02 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY When not using intelligent tester: 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS (a) Check that the wireless door lock functions operate when the transmitter is used (See page DL-29). Result Condition Proceed To Wireless door lock functions operate normally but hazard warning light answer-back does not occur A Wireless door lock functions operate normally but wireless door lock buzzer answer-back does not occur B Wireless door lock functions do not operate DL Go to "Only Wireless Control Function is Inoperative" (See page DL-44) B A Go to step 3 DL–61 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM 2 CHECK HAZARD WARNING LIGHTS (a) Check that the hazard warning lights flash continuously when the hazard warning light switch is pressed. OK: Hazard warning lights flash continuously. NG INSPECT LIGHTING SYSTEM OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 3 INSPECT WIRELESS DOOR LOCK BUZZER (a) Disconnect the wireless door lock buzzer connector. (b) Measure the resistance according to the value(s) in the table below. HINT: The buzzer circuit is built into the ECU, not into the buzzer itself. When battery voltage is applied directly to the buzzer, the buzzer does not sound. Resistance Wireless Door Lock Buzzer: 2 1 Tester Connection Condition Specified Condition 1-2 Always Approx. 1 kΩ NG REPLACE WIRELESS DOOR LOCK BUZZER B110079E04 OK DL DL–62 4 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (WIRELESS BUZZER - INSTRUMENT PANEL J/B) (a) Disconnect the buzzer (W3) connector and J/B (1B) connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness Side W3 Wireless Door Lock Buzzer Tester Connection Condition Specified Condition W3-1 - 1B-10 (BZR) Always Below 1 Ω W3-2 - 1B - 6 (BZR2) Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR 1B Instrument Panel J/B Assembly B062227E02 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL DL–62 DOOR LOCK – KEY REMINDER WARNING SYSTEM OPERATION CHECK 1. DL REMOVE CHECK FUNCTION (a) Check that the key reminder warning buzzer sounds. (1) With the driver side door closed, insert the key into the ignition key cylinder and then turn the key to LOCK or ACC. (2) Check that the buzzer sounds intermittently if the driver side door is opened. (b) Check that the key reminder warning buzzer stops. (1) Check that the buzzer stops sounding if any of the following operations is performed while the buzzer is sounding: • Close the driver side door (front door courtesy light switch is off). • Turn the ignition switch ON. • Pull out the key from the ignition key cylinder. DL–63 DOOR LOCK – KEY REMINDER WARNING SYSTEM PROBLEM SYMPTOMS TABLE KEY REMINDER WARNING SYSTEM: Symptom Key reminder buzzer does not sound Suspected Area See page 1. Unlock warning switch assembly DL-66 2. Front door courtesy light switch circuit (Driver side) DL-66 3. Combination meter assembly DL-66 4. Instrument panel junction block assembly (Body ECU) - 5. Wire harness - DL DL–64 DOOR LOCK – KEY REMINDER WARNING SYSTEM TERMINALS OF ECU 1. DL CHECK INSTRUMENT PANEL J/B ASSEMBLY (BODY ECU) (a) Disconnect the B6 ECU connector and 1F, 1E, 1B, 1L and 1H J/B connectors. DL–65 DOOR LOCK – KEY REMINDER WARNING SYSTEM Vehicle Rear Side Right Side Vehicle Front Side 1H B6 1F B5 1E 1L 1B Body ECU 1F 1E B5 Body ECU 1H 1L B6 1B DL B064139E01 (b) Measure the voltage and resistance according to the value(s) in the table below. Symbols (Terminal No.) BECU (1F-12) - Body ground Wiring Color W-R - Body ground Condition Always Specified Condition 10 to 14 V DL–66 DOOR LOCK – KEY REMINDER WARNING SYSTEM Symbols (Terminal No.) Wiring Color Condition Specified Condition BECU (1B-4) - Body ground W-R - Body ground Always 10 to 14 V BECU (1L-4) - Body ground W-R - Body ground Always 10 to 14 V BDR1 (1E-9) - Body ground G-W - Body ground Always 10 to 14 V GND1 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω GND2 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω G-Y - Body ground No key in ignition key cylinder → Key inserted KSW (B6-14) - Body ground 10 kΩ or higher → Below 1 Ω HINT: If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the B6 connectors. (d) Measure the voltage according to the value(s) in the table below. DL Symbols (Terminal No.) Wiring Color Condition Specified Condition DCTY (B5-23) - Body ground R-B - Body ground Driver door CLOSED → OPEN 10 to 14 → 0 V DL–67 DOOR LOCK – KEY REMINDER WARNING SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION Key reminder warning system data can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle's ECU uses ISO 9141-2 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 DLC3 F040034E03 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 3 kΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF 3 kΩ or higher HINT: If the display shows a communication error message after connecting the intelligent tester to the DLC3 and turning the ignition switch to the ON position, there is a problem with either the vehicle or the intelligent tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's operator's manual. DL DL–68 DOOR LOCK – KEY REMINDER WARNING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester with CAN VIM to the DLC3. (b) Turn the ignition switch ON. (c) Read the DATA LIST. BODY (Body ECU): Tester Display KEY UNLK WRN SW D DOR CTY SW DL Measurement Item/Range Normal Condition Diagnostic Note Unlock warning switch signal /ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - Driver side door courtesy switch signal /ON or OFF ON: Driver side door is open OFF: Driver side door is closed - DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–69 Key Reminder Buzzer does not Sound DESCRIPTION When the ignition switch is OFF, the key is in the ignition key cylinder, and the driver side door is opened, the body ECU operates the combination meter to cause the buzzer to sound. DL DL–70 DOOR LOCK – KEY REMINDER WARNING SYSTEM WIRING DIAGRAM Instrument Panel Junction Block Assembly Body ECU D12 Door Courtesy Light Switch (Driver Side) J/C 1 R-B F J18 H J19 R-B 23 B5 DCTY E J18 A J19 G-Y 14 B6 KSW K3 Un-lock Warning Switch Assembly J/C W-B 1 W-B C G-Y J15 2 B J14 A J15 A J15 G-Y W-B A J5 J/C IG Combination Meter 19 C9 V-G 15 B6 KSWO 8 C10 W-L 11 B6 DCY2 Buzzer Meter ECU DL F044179E02 INSPECTION PROCEDURE DL–71 DOOR LOCK – KEY REMINDER WARNING SYSTEM When using intelligent tester: 1 READ VALUE OF INTELLIGENT TESTER (COURTESY LIGHT SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Select the item "D DOR CTY SW" in the DATA LIST and read its value displayed on the intelligent tester. Standard: ON: Driver side door is open OFF: Driver side door is closed OK Go to step 4 NG 2 INSPECT COURTESY LIGHT SWITCH (DRIVER SIDE) Courtesy Light Switch (a) Remove the courtesy light switch. (b) Measure the resistance according to the value(s) table below. Standard resistance Free Pushed Terminal No. 1 - Body ground B058556E24 NG Condition Specified Condition Switch Free Below 1 Ω Switch Pushed 10 kΩ or higher REPLACE COURTESY LIGHT SWITCH OK DL DL–72 3 DOOR LOCK – KEY REMINDER WARNING SYSTEM CHECK HARNESS AND CONNECTOR (BODY ECU - COURTESY LIGHT SWITCH) (a) Disconnect the D12 door courtesy light switch (driver side) and B5 ECU connectors. (b) Measure the resistance according to the value(s) table below. Standard resistance Wire Harness Side B5 Body ECU Symbols (Terminal No.) Specified Condition DCTY (B5-23) - (D12-1) Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR D12 Front Door Courtesy Light Switch (Driver Side) 1 B064136E01 OK 4 CHECK BUZZER (COMBINATION METER) (a) Check buzzer (combination meter). (See page ME-4) NG GO TO COMBINATION METER SYSTEM OK 5 READ VALUE OF INTELLIGENT TESTER (KEY UN-LOCK WARNING SWITCH) (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Select the item "KEY UNLK WRN SW" in the DATA LIST and read its value displayed on the intelligent tester. Standard: ON: The key is in the ignition key cylinder OFF: No key is in the ignition key cylinder DL OK NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL–73 DOOR LOCK – KEY REMINDER WARNING SYSTEM 6 INSPECT UN-LOCK WARNING SWITCH ASSEMBLY Not Pushed (a) Remove the un-lock warning switch. (b) Measure the resistance according to the value(s) table below. Standard resistance Pin Pushed B062710E01 NG Terminal No. Condition Specified Condition 1-2 Free 10 kΩ or higher 1-2 Pushed Below 1 Ω REPLACE UN-LOCK WARNING SWITCH ASSEMBLY OK 7 CHECK HARNESS AND CONNECTOR (BODY ECU - UN-LOCK WARNING SWITCH) (a) Disconnect the B6 ECU connector. (b) Disconnect the K3 warning switch connector. (c) Measure the resistance according to the value(s) table below. Standard resistance Wire Harness Side B6 Body ECU NG K3 Un-lock Warning Switch Assembly Symbols (Terminal No.) Specified Condition KSW (B6-14) - (K3-2) Below 1 Ω K3-1 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B064670E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL When not using intelligent tester: 1 CHECK COURTESY LIGHT SWITCH (a) Put the dome light assembly No. 2 switch in the door position and open the driver side door. Then check that the courtesy light switch comes on. DL–74 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK Go to step 3 NG 2 INSPECT COURTESY LIGHT SWITCH (a) Remove the courtesy light switch. (b) Measure the resistance according to the value(s) table below. Standard resistance Free Pushed Terminal No. 1 - Body ground Condition Specified Condition Free Below 1 Ω Pushed 10 kΩ or higher Body ground B058556E21 NG REPLACE COURTESY LIGHT SWITCH OK 3 CHECK HARNESS AND CONNECTOR (BODY ECU - COURTESY LIGHT SWITCH) (a) Disconnect the D12 door courtesy light switch (driver side) and B5 ECU connectors. (b) Measure the resistance according to the value(s) table below. Standard resistance Wire Harness Side B5 Body ECU Symbols (Terminal No.) Specified Condition DCTY (B5-23) - (D12-1) Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR D12 Front Door Courtesy Light Switch (Driver Side) 1 B064136E01 DL OK 4 CHECK BUZZER (COMBINATION METER) (a) Check buzzer (combination meter). (See page ME-4) NG GO TO COMBINATION METER SYSTEM DL–75 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK 5 INSPECT UN-LOCK WARNING SWITCH ASSEMBLY Not Pushed (a) Remove the un-lock warning switch. (b) Measure the resistance according to the value(s) table below. Standard resistance Pin Terminal No. Pushed 1-2 B062710E01 NG Condition Specified Condition Free 10 kΩ or higher Pushed Below 1 Ω REPLACE UN-LOCK WARNING SWITCH ASSEMBLY OK 6 CHECK HARNESS AND CONNECTOR (BODY ECU - UN-LOCK WARNING SWITCH) (a) Disconnect the B6 ECU connectors. (b) Disconnect the K3 warning switch connector. (c) Measure the resistance according to the value(s) table below. Standard resistance Wire Harness Side B6 Body ECU NG K3 Un-lock Warning Switch Assembly Symbols (Terminal No.) Specified Condition KSW (B6-14) - (K3-2) Below 1 Ω K3-1 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B064670E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL DL–14 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM All Doors LOCK / UNLOCK Functions do not Operate Via Master Switch, Driver Side Door Key Cylinder DESCRIPTION The body ECU receives a switch signal from the master switch and the driver side door key cylinder, and then drives the door lock motor. WIRING DIAGRAM Driver Side J/B Assembly D17 Power Window Regulator Master Switch Assembly (Door Lock Switch) L 1 5 E UL 8 5 1K 1 1K 19 15 L1 UL1 D18 Door Lock Control Switch Assembly (Passenger Side) Body ECU UNLOCK 5 6 LOCK D16 Front Door w/ Motor Lock Assembly LH L UL 7 DL E UL LSSR L 3 1K 20 L2 9 10 12 B4 UL3 1 10 B4 ACTD 8 21 B4 LSWD 4 30 B4 LSWP B134220E01 DL–15 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM D19 Front Door w/ Motor Lock Assembly RH LSSR 8 E UL L 7 1 4 9 1L 18 1L 23 24 ACT+ ACT- 6 1L D20 Rear Door w/ Motor Lock Assembly LH LSSR 9 E UL L 6 1 4 16 1L 5 LSR 23 1L 11 1L D21 Rear Door w/ Motor Lock Assembly RH LSSR 9 E UL L 6 1 4 15 1K 22 1L 10 1L DL B134221E01 DL–16 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Select the active test, and then check that the power door lock operates. HINT: During the active test, the intelligent tester sends signal to the body ECU to drive all the power door lock motor. If the all power door lock operates, the power door lock motor itself and the wire harness between the power door lock motor and body ECU are considered normal. BODY: Item Test Details Diagnostic Note DOOR LOCK Drive door lock motor at all doors LOCK/OFF - DOOR LOCK Drive door lock motor at all doors UNLOCK/ OFF - NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY OK 2 CHECK MASTER SWITCH OR KEY CYLINDER (a) Check master switch or key cylinder operation. (1) When manual door lock/unlock operation via the master switch can not be performed, proceed to A. (2) When manual door lock/unlock operation via the door lock control switch (passenger side) can not be performed, proceed to B. (3) When manual door lock/unlock operation interlocked with the driver side door lock key cylinder can not be performed, proceed to C. A DL B Go to step 4 C Go to step 5 DL–17 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Remove the master switch. (b) Inspect the door lock control switch continuity. Standard resistance Unlock Lock Door Lock Control Switch Terminal No. Door Lock Position Specified Condition 1-5 Lock Below 1 Ω - OFF 10 kΩ or higher 1-8 Unlock Below 1 Ω OK REPAIR OR REPLACE HARNESS OR CONNECTOR B059539E21 NG REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 4 INSPECT DOOR CONTROL SWITCH ASSEMBLY Passenger Side Switch (a) Passenger side switch: Inspect the door lock control switch continuity. Standard resistance Lock Unlock Terminal No. Door Lock Position 3-6 Lock Below 1 Ω - OFF 10 kΩ or higher 3-5 Unlock Below 1 Ω OK No Pin (1 and 2) No Pin (4) B134223E01 NG REPLACE DOOR CONTROL SWITCH ASSEMBLY Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR DL DL–18 5 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT FRONT DOOR W/MOTOR LOCK ASSEMBLY LH (a) Apply battery voltage and inspect operation of the door lock motor. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock Unlock Lock B056798E02 Lock (b) Inspect the door lock and unlock switch continuity. Standard resistance Unlock Terminal No. Door Lock Position Specified Condition 7-9 Lock Below 1 Ω - OFF - 7 - 10 Unlock Below 1 Ω (c) Inspect the position switch continuity. Standard resistance Terminal No. 7-8 OK DL Door Lock Position Specified Condition Lock 10 kΩ or higher Unlock Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B056797E02 NG REPLACE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH DL–26 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM BODY ELECTRICAL DOOR LOCK PARTS LOCATION WIRELESS DOOR LOCK BUZZER DL DOOR CONTROL TRANSMITTER B120214E02 DL–27 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM FRONT DOOR LOCK RH DOOR CONTROL SWITCH UN-LOCK WARNING SWITCH ASSEMBLY FRONT COURTESY LIGHT SWITCH RH REAR DOOR LOCK RH INSTRUMENT PANEL J/B ASSEMBLY REAR COURTESY LIGHT SWITCH RH - BODY ECU DOOR CONTROL RECEIVER POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY BACK WINDOW REGULATOR SUB-ASSEMBLY - DOOR CONTROL SWITCH FRONT DOOR LOCK LH W/ MOTOR BACK DOOR LOCK ASSEMBLY FRONT COURTESY LIGHT SWITCH LH REAR COURTESY LIGHT SWITCH LH REAR DOOR LOCK LH MULTIPLEX NETWORK BACK DOOR ECU - BACK DOOR ECU DL B120215E02 DL–19 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Key Lock-in Prevention Function does not Work Properly (Manual Operation and Operation Interlocked with Key are Active) DESCRIPTION The un-lock warning switch turns ON when the key is inserted in the ignition key cylinder. The courtesy light switch turns ON when the driver side door is opened. These 2 switches are monitored by the body ECU. In order to prevent the key from being locked in, the body ECU controls door locking operation according to conditions of these switches, so the doors are not locked. WIRING DIAGRAM Driver Side J/B Assembly D12 Courtesy Light Switch Assembly 1 23 B5 K3 Un-lock Warning Switch Assembly Body ECU 14 B6 B134222E01 DL DL–20 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Using the intelligent tester, check that the un-lock warning switch signal is output when the switch is operated. BODY: Item Measurement Item/ Display (Range) KEY UNLK WRN SW Key un-lock warning SW signal/ON or OFF Normal Condition Diagnostic Note ON: Key is in ignition key cylinder OFF: Key is not in ignition key cylinder OK - Go to step 4 NG 2 INSPECT UN-LOCK WARNING SWITCH ASSEMBLY Free (a) Remove the un-lock warning switch. (b) Inspect the un-lock warning switch continuity. Standard resistance Pin Terminal No. 1-2 Pushed NG B062710E02 OK DL Condition Specified Condition Free 10 kΩ or higher Pushed Below 1 Ω REPLACE UN-LOCK WARNING SWITCH ASSEMBLY DL–21 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK HARNESS AND CONNECTOR (UN-LOCK WARNING SWITCH - BODY ECU) (a) Disconnect the K3 un-lock warning switch and B12 body ECU connectors. (b) Check the continuity between the terminals of the unlock warning switch (K3) and body ECU (B6) connectors. Standard resistance (Check for open) Wire Harness Side K3 Unlock Warning Switch Symbols (Terminal No.) Specified Condition (K3-2) - KSW (B6-14) Below 1 Ω (K3-1) - Body ground Below 1 Ω NG B6 Body ECU REPAIR OR REPLACE HARNESS OR CONNECTOR B065425E01 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 4 READ VALUE OF INTELLIGENT TESTER (a) Using the intelligent tester, check that the driver door courtesy switch signal is output when the switch is operated. BODY: Item Measurement Item/ Display (Range) D DOR CTY SW Driver door courtesy SW signal / ON or OFF Normal Condition ON: Driver door is open OFF: Driver door is closed OK Diagnostic Note - REPLACE COURTESY LIGHT SWITCH NG DL DL–22 5 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT COURTESY LIGHT SWITCH (a) Remove the courtesy light switch. (b) Inspect the courtesy light switch continuity. Standard resistance Free Pushed Terminal No. 1 - Body ground Body ground NG B058556E21 Condition Specified Condition Free Below 1 Ω Pushed 10 kΩ or higher REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 CHECK HARNESS AND CONNECTOR (COURTESY LIGHT SWITCH - BODY ECU) Wire Harness Side D12 Front Door Courtesy Light Switch (a) Disconnect the courtesy light switch and body ECU connectors. (b) Check the continuity between the terminals of the courtesy light switch (D12) and body ECU (B5) connectors. Standard resistance (Check for open) 1 NG B5 Body ECU Symbols (Terminal No.) Specified Condition (D12-1) - DCTY (B5-23) Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B065420E02 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–59 KEY REMINDER WARNING SYSTEM BODY ELECTRICAL DOOR LOCK PARTS LOCATION COMBINATION METAR - KEY REMINDER BUZZER INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - BODY ECU FRONT DOOR COURTESY LIGHT SWITCH LH UN-LOCK WARNING SWITCH DL B120213E02 DL–60 DOOR LOCK – KEY REMINDER WARNING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the key reminder warning system. • The intelligent tester should be used in steps 5. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page ED-3). NEXT 3 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed on problem symptoms table A Fault is listed on problem symptoms table B B After repair, go to step 6 A 4 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page DL-62) (b) DATA LIST/ACTIVE TEST (See page DL-65) NEXT 5 DL NEXT REPAIR OR REPLACE DOOR LOCK – KEY REMINDER WARNING SYSTEM 6 DL–61 CONFIRMATION TEST NEXT END DL DL–23 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Only Back Door cannot be Opened DESCRIPTION The signal for manual unlocking operation on driver side door and the signal for unlocking operation interlocked with the driver side door lock key cylinder are sent to the back door ECU from the body ECU using the MPX line. Also, the signal of the back door opener switch is directly sent to the back door ECU. In response to these signals, the back door ECU controls the back door lock. WIRING DIAGRAM Multiplex Network Door ECU Back (Back Door ECU) V-W 10 B9 HSW+ LG-R 22 B9 HSW- B10 Back Door Opener Switch Assembly 2 1 B7 w/ Motor Back Door Lock Assembly (Back Door Lock) 5 R-G 6 B9 HALF 6 G-Y 7 B9 FULL 4 BR-W 8 B9 POS 1 L-B 15 B9 ACT+ 2 L-R 14 B9 ACT- 3 B-R 21 B9 LSE DL B064455E01 DL–24 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (a) Check the data list of back door opener switch. BODY: Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note DOOR HANDLE SW Back door opener SW signal / ON or OFF ON: Back door opener is pushed OFF: Back door opener is not pushed - OK Go to step 4 NG 2 INSPECT BACK DOOR OPENER SWITCH ASSEMBLY (a) Remove the back door opener switch. (b) Inspect the back door opener switch continuity. Standard resistance Terminal No. 1-2 Free OK DL NG Pushed B062727E01 Condition Specified Condition Free 10 kΩ or higher Pushed Below 1 Ω REPLACE BACK DOOR OPENER SWITCH ASSEMBLY DL–25 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK HARNESS AND CONNECTOR (BACK DOOR OPENER SWITCH - BACK BODY) (a) Disconnect the B10 back door opener switch and B9 back door ECU connectors. (b) Check the continuity between the terminals of the back door opener switch (B10) and back door ECU (B9) connectors. Standard resistance (Check for open) : Wire Harness Side B10 Back Door Opener Switch Symbols (Terminal No.) NG B9 Back Door ECU Specified Condition (B10-1) - HSW- (B9-22) Below 1 Ω (B10-2) - HSW+ (B9-10) Below 1 Ω REPAIR OR REPLACE HARNESS OR CONNECTOR B065426E01 OK 4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Select the active test, and then check that the power door lock operates. HINT: During the active test, the intelligent tester sends signal to the body ECU to drive the all power door lock motor. If the all power door lock operates, the power door lock motor itself and the wire harness between the power door lock motor and body ECU are considered normal. BODY: Item Test Details DOOR LOCK Drive the door lock motor at all doors LOCK/ OFF - DOOR LOCK Drive the door lock motor at all doors UNLOCK/ OFF - OK NG Diagnostic Note REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY DL DL–26 5 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT W/MOTOR BACK DOOR LOCK ASSEMBLY (a) Check operation of the door lock. (1) Using a screwdriver, push the latch in order to put the back door lock in the locked condition (full-latch position). (2) Connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2. Then, check operation of the latch. Standard: The latch turns to the open-latch position (3) Inspect motor operation when battery voltage is applied to the terminals. Standard Full-latch Open-latch B065423E02 DL Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Clockwise (Motor in normal rotation) Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Counterclockwise (Motor in reverse rotation) DL–27 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (b) Check the back door courtesy switch continuity. (1) Check the continuity between the terminals of the courtesy switch. Standard resistance Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Half-latch position 4-5 Below 1 Ω Full-latch position, Over-latch position 4-5 10 kΩ or higher (c) Check the back door latch switch continuity. (1) Check the continuity between the terminals of the latch switch. Standard resistance Open-latch Half-latch Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Over-latch position 4-6 Below 1 Ω Half-latch position, Full-latch position 4-6 10 kΩ or higher (d) Check the position switch continuity. (1) Connect the battery positive (+) lead to connector terminal 1 and the negative (-) lead to connector terminal 2. Standard resistance Full-latch Over-latch B062719E01 Door Lock Latch Position Terminal No. Specified Condition Any position other than motor stop position (Motor in operation) 3-4 Below 1 Ω Motor stop position (Gear in original position) 3-4 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE W/MOTOR BACK DOOR LOCK ASSEMBLY DL DOOR LOCK – TRANSMITTER BATTERY DL–73 TRANSMITTER BATTERY REPLACEMENT 1. (a) Using a screwdriver, pry out the transmitter case. NOTICE: Do not forcibly pry out the case. (b) Remove the battery (lithium battery). NOTICE: • Do not push the terminals with your finger. • Prying up the battery (lithium battery) to forcibly remove it will cause deformation of the terminals. • Do not touch the battery with wet hands. Water may cause unexpected rust. • Do not touch or move any components inside the transmitter, or it may interfere with the proper operation. B062228 2. B062229E01 REMOVE TRANSMITTER BATTERY NOTICE: Special caution should be taken for handling each component as they are precision electronic components. INSTALL TRANSMITTER BATTERY (a) Install a new battery (lithium battery) with the positive (+) side up, as shown in the illustration. NOTICE: • Be sure that the positive side and the negative side of the transmitter battery are faced correctly. • Be careful not to bend the electrode of the transmitter battery insertion. • Be careful that no dust or oil adheres to the transmitter case. (b) Install the case. DL DL–28 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: The wireless door lock control system troubleshooting procedures are based on the premise that the power door lock control system is operating normally. Check the power door lock control system first before troubleshooting the wireless door lock control system. Use this procedure to troubleshoot the wireless door lock control system. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer to confirm the trouble (See page IN-30). NEXT 3 INSPECT COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM (a) Use the intelligent tester to check for normal function of the multiplex communication system. (1) (ECU unconnected, communication line malfunctioning) If no code is output, proceed to A. (2) (ECU unconnected, communication line malfunctioning) If any code is output, proceed to B. B Go To CAN COMMUNICATION SECTION A 4 DTC CHECK (a) Check for a DTC and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC reoccurs, proceed to B. DL B A Go To DTC chart DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM 5 DL–29 SYMPTOM SIMULATION NEXT 6 PROBLEM SYMPTOMS TABLE (a) If the fault is not listed in the problem symptoms table, proceed to A. (b) If the fault is listed in the problem symptoms table, proceed to B. B Go to step 7 A 7 PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM (a) Terminals of ECU (See page DL-38) (b) DATA LIST/ACTIVE TEST (See page DL-40) NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END DL DL–74 DOOR LOCK – DOOR CONTROL TRANSMITTER DOOR CONTROL TRANSMITTER INSPECTION 1. B062233E01 DL INSPECT ELECTRICAL KEY TRANSMITTER SUBASSEMBLY (a) Inspect operation of the transmitter. (1) Remove the battery (lithium battery) from the transmitter (See page DL-73). (2) Install a new or normal battery (lithium battery). (3) If a new or normal battery is not available, connect 2 new 1.5 V batteries in a series. Connect the positive (+) battery electrode to the battery receptacle side terminal, and the negative (-) battery electrode to the bottom terminal, and apply a voltage of 3 V to the transmitter. (4) In a location that is approximately 1 m (3.28 ft.) away from the driver side outside door handle, point the key plate of the transmitter at the vehicle and check operation of the transmitter by pressing the transmission switches on the transmitter body. Standard: The door lock can be operated via remote control. HINT: • The minimum operational distance differs depending on the operator, the way the transmitter is held, and the location. • Since the transmitter uses faint electric waves, the operational distance might be shortened if noise or a strong electric wave occurs in the area where the frequency is used. (5) Install the battery (lithium battery). (b) Inspect the battery capacity. HINT: • The capacity of the battery can be determined only when the battery is installed in the transmitter. For a lithium battery used in the transmitter, a voltage of more than 2.5 V is shown on the tester until the energy is completely consumed without the battery installed in the transmitter. Therefore, it is necessary to measure the voltage with the battery installed in the transmitter (a resistance of 1.2 kΩ is applied to the battery) to check the amount of energy left in the battery. • If the transmitter is faulty, the amount of energy left in the battery might not be checked correctly. (1) Remove the battery (lithium battery) from the transmitter (See page DL-73). DOOR LOCK – DOOR CONTROL TRANSMITTER DL–75 (2) Connect the lead to the negative (-) terminal of the transmitter and install the battery. Lead B062236E02 B062232 (3) Connect the positive (+) tester probe to the positive (+) side of the battery (lithium battery) and the negative (-) tester probe to the lead respectively. (4) Press one of the transmission switches on the transmitter for approximately 1 second. (5) Press the same or another transmission switch again and check the voltage. Standard voltage: 2.2 V or higher NOTICE: • If the temperature of the battery is low, the inspection cannot be done correctly. If the outcome of the test is less than 2.2 V, conduct the test again after leaving the battery in a place with a temperature of 18°C (64°F) for more than 30 minutes. • The automatic power-off function causes the battery voltage to be 2.5 V or more (with no resistance applied to the battery) when 0.8 seconds have passed after the switch is pressed. Therefore, make sure to read the voltage immediately after the switch is pressed. (6) Disconnect the lead. (7) Set the battery (lithium battery) in the transmitter. DL DL–30 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM OPERATION CHECK 1. 2. DL FUNCTIONS AND OPERATING CONDITIONS (a) Wireless door LOCK / UNLOCK function: This function operates only when the following 3 condition are met. (1) No key is inserted into the ignition key cylinder. (2) All the doors are closed. (3) The power door lock system and the back door power window control system operate normally. HINT: • The UNLOCK, BACK WINDOW and PANIC function operates even when a door is open. • The UNLOCK, BACK WINDOW and PANIC function operates even when the key is inserted into the ignition key cylinder, however the ignition switch must be in the OFF position. (b) The transmitter's operational area differs depending on the situation. (1) The operational area differs depending on the operators and the ways the transmitter is held. (2) In certain areas, the transmitter will only operate partially, the operational area will be reduced due to the vehicle body shape and the influence of the surrounding environment. (3) Since the transmitter uses faint electric waves, strong electric waves or noise in the frequency used may reduce the operational area or the transmitter may not function. (4) When the battery weakens, the operational area is reduced or the transmitter may not function. HINT: If the door control transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, it may cause the battery to weaken or cause other such problems. CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS HINT: • The switches described below transmit signals and are built into the door control transmitter. • The transmitter's operational area must be taken into account while checks are being made. (a) Make sure the vehicle is in the initial condition described below. (1) The followings are the vehicle's initial condition. • No key is in the ignition key cylinder • All the doors closed • The power door lock system and the back door power window control system operate normally. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DL–31 (b) Check the basic function. (1) In the operational area, check that all the doors lock when pressing the LOCK switch (However, this will not happen when the key is in the ignition key cylinder or any door is open). (2) In the operational area, check that the only driver's door unlocks when pressing the UNLOCK switch and pressing the switch once again within 3 seconds unlocks all the other doors. HINT: The UNLOCK and BACK WINDOW operation is possible even when any of the doors is open. (3) In the operational area, check that the back window opens when the BACK WINDOW switch has been pressed for 0.8 seconds. (c) Check the chattering prevention function. (1) If a switch is pressed, check that the corresponding operation occurs only once. If the switch is held down, check that the corresponding operation occurs only once and does not repeatedly activate. Lastly, if a switch is pressed at 1 second intervals, check that the corresponding operation activates once for every press of the switch. (d) Check the automatic locking function. (1) Check that if all of the doors are unlocked with the UNLOCK switch and none of the doors are opened or locked within approximately 30 seconds, the doors automatically relock. (2) Check that if all of the doors are unlocked with the UNLOCK switch and a door is opened or locked within approximately 30 seconds, the automatic locking function does not operate. (e) Check the switch operation fail-safe function. (1) Check that when the key is in the ignition cylinder, the switches cannot lock or unlock doors (unless the system is in the recognition code registration mode.) (f) Check the repeat function. (1) If the lock switch is pressed while the movement of the driver side door control knob is restricted, check that, 1 second later, the repeat function attempts to lock all of the doors again. (g) Check the operation stop function when a door is open or not completely close. (1) If a door is open or not completely closed, check that the doors cannot be locked by the LOCK switch and buzzer sounds for 10 seconds. DL DL–32 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (h) Check the hazard warning lights flashing and wireless door lock buzzer sounding function (answer back). (1) When the LOCK switch is pressed, check that the hazard warning lights flash once and the buzzer sounds once, simultaneously with locking operation of all the doors. (2) When the UNLOCK switch is pressed once, check that the hazard warning lights flash twice, the buzzer sounds twice, simultaneously with the unlocking operation of the driver side door. (3) When the UNLOCK switch is pressed again within 3 seconds, check that the hazard warning lights flash twice, the buzzer sounds twice, simultaneously with the unlocking operation of all the doors. (4) When the BACK WINDOW switch is pressed for 0.8 seconds, check that the buzzer sounds once, simultaneously with the opening operation of the back window. (i) Check the remote panic function. (1) Check that the horns sounds, headlights and taillights flash and the interior light remains on for 60 seconds when the PANIC switch is pressed, and that sounding and flashing stop when either of the PANIC, LOCK, UNLOCK or BACK WINDOW switch is pressed. DL DL–76 DOOR LOCK – DOOR CONTROL SWITCH DOOR CONTROL SWITCH INSPECTION Unlock Lock 1. Door Lock Control Switch INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Measure the resistance according to the Value(s) in the table below. Standard resistance Terminal No. Switch Position Specified Condition 1-5 Lock Below 1 Ω - OFF 10 kΩ or higher 1-8 Unlock Below 1 Ω If the result is not as specified, replace the switch assembly. B059539E21 Passenger Side Switch 2. Lock Unlock INSPECT DOOR CONTROL SWITCH ASSEMBLY (a) Passenger side switch: Measure the resistance according to the value(s) in the table below. Standard resistance Terminal No. Switch Position Specified Condition 3-6 Lock Below 1 Ω - OFF 10 kΩ or higher 3-5 Unlock Below 1 Ω No Pin (1 and 2) No Pin (4) B134223E01 3. INSPECT BACK DOOR OPENER SWITCH ASSEMBLY (a) Inspect the back door opener switch continuity. Standard resistance Terminal No. 1-2 DL Pushed Free B062727E01 Condition Specified Condition Free 10 kΩ or higher Pushed Below 1 Ω If the result is not as specified, replace the switch assembly. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DL–33 REGISTRATION HINT: • Register the recognition code if the door control transmitter or the door control receiver has been replaced. • Add mode is used to register new recognition codes while still retaining codes already registered. This mode is used when a new transmitter is added. If the number of registered codes exceeds 4, the previously registered codes will be erased in order, starting from the oldest registered code. • Rewrite mode is used to erase all the previously registered recognition codes in order to register all new recognition codes. This mode is used when the transmitter or the door control receiver is exchanged for a new one. • Confirmation mode is used to confirm the number of recognition codes already registered before another recognition code is registered. • All clear mode is used to erase all the registered codes and disable the wireless door lock function. This mode is used when the transmitter is lost. • All the following registration procedures must be performed in order. 1. REGISTER RECOGNITION CODE USING INTELLIGENT TESTER (a) Select Add mode or Rewrite mode and perform the following operation: (1) Turn the ignition switch to the ON position. (2) Select the add or rewrite mode according to the intelligent tester display. (3) Press LOCK and UNLOCK on the transmitter simultaneously for more than 1 second. (Procedure "A") (4) Press either of the switches on the door control transmitter again for more than 1 second. (Procedure "B") HINT: The Procedure "B" must be performed within 3 seconds after the first operation. DL DL–34 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (5) The body ECU automatically performs the power door LOCK-UNLOCK operation after the switch on the door control transmitter is turned off, in order to indicate whether registration has been completed correctly or not. Response to Registration Completion LOCK-UNLOCK Occurs Once: LOCK-UNLOCK Occurs Twice: Registration of recognition code has been completed. Registration of recognition code has failed. T1 T1 LOCK LOCK UNLOCK UNLOCK T1 T1: Approx. 1 second B110067E03 DL HINT: • Complete the Procedure "A", "B" and "Response to Registration Completion" within 30 seconds. • If the LOCK-UNLOCK operation is performed twice, registration of the recognition code has failed. Perform registration procedures from the beginning once again. (6) If registration is continued, the next recognition code must be registered in the door control transmitter within 40 seconds. HINT: Up to 4 recognition codes can be registered. (b) Completing the registration mode. (1) The registration mode will cease when any of the following occurs: • The intelligent tester is used to order completion. • The intelligent tester is disconnected. (c) Perform the following after registration is completed. (1) Perform the wireless door lock control operation check (See page DL-29). HINT: If the wireless door lock control does not operate, perform the registration procedure again. (d) Select Confirmation mode and perform the following operation: (1) Number of registered code is shown. (2) Registration procedures are completed. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM 2. DL–35 REGISTER RECOGNITION CODE MANUAL OPERATION (a) Ensure that the following conditions are met: (1) No key is in the ignition key cylinder. (2) Driver side door is opened (Other doors are closed). (3) Driver side door is unlocked. (b) When the above conditions are met, perform the following: (1) Insert and remove the key from the ignition key cylinder twice. (End in remove) (Procedure "A") HINT: Complete this step within 5 seconds. (2) Close and open the driver side door twice. (End in open) (Procedure "B") (3) Insert and remove the key from the ignition key cylinder. (Procedure "C") (4) Close and open the driver side door twice. (End in open) (Procedure "D") (5) Insert the key into the ignition key cylinder and close all doors. (Procedure "E") HINT: Complete the Procedure "B" through "E" within 40 seconds. (6) Turn the ignition switch from LOCK to ON and back to LOCK at approximately 1 second intervals according to the number of times shown in the illustration. (Procedure "F") Number of ON-LOCK Operations of the Ignition Switch Add Mode: Confirmation Mode: ON-LOCK operation: 1 time ON-LOCK operation: 3 times T1 T1 ON ON LOCK LOCK Rewrite Mode: T1 Prohibition Mode: ON-LOCK operation: 2 times T1 ON-LOCK operation: 5 times T1 T1 ON ON LOCK LOCK T1 DL T1: Approx. 1 second B110068E06 DL–36 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM HINT: If the number of on ON-LOCK operations of the ignition switch is 0, 4 or 6 or more, there will be no response (power door lock and unlock operation) to show which mode has been selected. (7) Remove the key from the ignition key cylinder. (Procedure "G") HINT: Complete the Procedure "F" and "G" within 40 seconds. (8) The body ECU automatically performs the power door LOCK-UNLOCK operation within 3 seconds after the mode has been selected and informs the technician of the selected mode using the following response patterns. Response to a Selected Mode (Power Door Lock Operation) Add Mode: Confirmation Mode: LOCK-UNLOCK operation: 1 time LOCK-UNLOCK operation: The number of registered codes (1 - 5 times) 1st time T1 T2 LOCK LOCK UNLOCK UNLOCK T2 Rewrite Mode: Prohibition Mode: LOCK-UNLOCK operation: 2 times LOCK-UNLOCK operation: 5 times T1 T1 T1 LOCK LOCK UNLOCK UNLOCK 2nd time T1 T1: Approx. 1 second T2: Approx. 2 seconds B110069E02 DL HINT: • When the confirmation mode or all clear mode has been selected, the registration procedure will be completed. • In the confirmation mode, when the LOCKUNLOCK operation is performed twice, the number of registered recognition codes is 2. • In the confirmation mode, when 0 codes are registered, the LOCK-UNLOCK operation is automatically performed 5 times. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DL–37 (c) Registration of the door control transmitter. (1) If the add mode or rewrite mode has been selected, press LOCK and UNLOCK on the transmitter simultaneously for more than 1 second. (Procedure "H") (2) Press either of the switches on the door control transmitter for more than 1 second. (Procedure "I") HINT: • The Procedure "I" must be performed within 3 seconds after the first operation. • A recognition code must be registered in the door control transmitter within 40 seconds after a selected mode is responded to. (3) The body ECU automatically performs the power door LOCK-UNLOCK operation within 3 seconds after the switch on the door control transmitter is turned off, in order to indicate whether registration has been completed correctly or not. Response to Registration Completion LOCK-UNLOCK Occurs Once: LOCK-UNLOCK Occurs Twice: Registration of recognition code has been completed. Registration of recognition code has failed. T1 T1 LOCK LOCK UNLOCK UNLOCK T1 T1: Approx. 1 second B110067E03 HINT: If the LOCK-UNLOCK operation is performed twice, registration of the recognition code has failed. Perform registration procedures from the beginning once again. (4) If registration is continued, the next recognition code must be registered in the door control transmitter within 40 seconds. HINT: Up to 4 recognition codes can be registered. (d) Completing the registration mode. (1) The registration mode will cease when any of the following occurs: • Any of the doors is opened. • The key is inserted into the ignition key cylinder. DL DL–38 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (e) Perform the following after registration is completed. (1) Perform the wireless door lock control operation check (See page DL-29). HINT: If the wireless door lock control does not operate, perform the registration procedure again. DL DL–77 DOOR LOCK – FRONT DOOR LOCK FRONT DOOR LOCK INSPECTION 1. Unlock Lock INSPECT FRONT DOOR W/MOTOR LOCK ASSEMBLY LH (a) Apply battery voltage and inspect operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. B056798E02 Lock Unlock (b) Inspect the door lock and unlock switch continuity. Standard resistance Terminal No. Door Lock Position Specified Condition 7-9 Lock Below 1 Ω - OFF - 7 - 10 Unlock Below 1 Ω If the continuity is not as specified, replace the door lock assembly. (c) Inspect the position switch continuity. Standard resistance Terminal No. 7-8 Door Lock Position Specified Condition Lock 10 kΩ or higher Unlock Below 1 Ω If the continuity is not as specified, replace the door lock assembly. B056797E02 DL DL–78 DOOR LOCK – FRONT DOOR LOCK 2. Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. Unlock Lock B059885E02 DL INSPECT FRONT DOOR W/MOTOR LOCK ASSEMBLY RH (a) Apply battery voltage and inspect operation of the door lock motor. OK DL–39 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM PROBLEM SYMPTOMS TABLE WIRELESS DOOR LOCK CONTROL SYSTEM: Symptom Only wireless control function does not operate (Prepare new or normal transmitter of the same type vehicle) No answer-back (Hazard warning light and wireless door lock buzzer) Suspected area See page 1. Transmitter battery DL-44 2. Door control transmitter DL-44 3. Door control receiver DL-44 4. Un-lock warning switch assembly DL-44 5. Wire harness - 6. Instrument panel J/B (Body ECU) - 1. Wireless door lock buzzer DL-52 2. Lighting system LI-8 3. Wire harness - 4. Instrument panel J/B (Body ECU) - DL DL–40 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM TERMINALS OF ECU 1. Vehicle Rear Side CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (BODY ECU) Vehicle Right Side Vehicle Front Side 1H B6 1E B5 1J 1C 1D 1B Body ECU Body ECU 1E 1D B6 1C 1B B5 1H 1J DL B062230E01 (a) Disconnect the B6 J/B connector. DL–41 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (b) Disconnect the 1B, 1C, 1E and 1H J/B connectors. (c) Check the voltage or continuity of each terminal of the wire harness side connectors. Symbols (Terminal No.) Wiring Condition Specified Condition KSW (B6-14) - Body ground G-Y - Body ground No key in ignition key cylinder → Key inserted BDR1 (1E-9) - Body ground G-W - Body ground Always 10 to 14 V BECU (1B-4) - Body ground W-R - Body ground Always 10 to 14 V SIG (1C-2) - Body ground L-Y - Body ground Ignition switch ON 10 to 14 V ACC (1D-5) - Body ground W-G - Body ground Ignition switch ON 10 to 14 V GND1 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω GND2 (1H-2) - Body ground W-B - Body ground Always Below 1 Ω 10 kΩ or higher If the result is not as specified, there may be a malfunction on the wire harness side. (d) Reconnect the B6 J/B connector. (e) Reconnect the 1B, 1C, 1D, 1E and 1H J/B connectors. (f) Check the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Condition Specified Condition Below 1 V → 6 V → Below 1V RDA (B5-4) - Body ground L-R - Body ground Ignition switch OFF, no key in ignition key cylinder, all doors closed and transmitter switch OFF → ON DCTY (B5-23) - Body ground R-B - Body ground Driver's door CLOSED → OPEN 10 to 14 V → Below 1 V PCTY (B5-24) - Body ground R-Y - Body ground Passenger's door CLOSED → OPEN 10 to 14 V → Below 1 V RLCY (B5-11) - Body ground P-B - Body ground Rear door LH CLOSED → OPEN 10 to 14 V → Below 1 V RRCY (B5-12) - Body ground P-L - Body ground Rear door RH CLOSED → OPEN 10 to 14 V → Below 1 V HAZ (1J-14) - Body ground W - Body ground BZR (1B-10) - Body ground P-B - Y-B Answer-back OFF → Answer-back ON Pulse generation Wireless buzzer OFF → ON Pulse generation If the result is not as specified, the J/B assembly (body ECU) may have a malfunction. DL DL–79 DOOR LOCK – REAR DOOR LOCK REAR DOOR LOCK INSPECTION 1. Lock Unlock INSPECT REAR DOOR W/MOTOR LOCK ASSEMBLY LH (a) Apply battery voltage and inspect operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock If the operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Standard resistance Terminal No. B056800E02 Door Lock Position Specified Condition 6-9 Lock 10 kΩor higher 6-9 Unlock Below 1 Ω If the continuity is not as specified, replace the door lock assembly. 2. Unlock INSPECT REAR DOOR W/MOTOR LOCK ASSEMBLY RH (a) Apply battery voltage and inspect operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Standard resistance Lock B056799E02 Terminal No. Door Lock Position Specified Condition 6-9 Lock 10 kΩor higher 6-9 Unlock Below 1 Ω If the continuity is not as specified, replace the door lock assembly. DL DL–42 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DIAGNOSIS SYSTEM CG SG 1. DESCRIPTION The multiplex network body ECU stores trouble codes when trouble occurs on the vehicle. The diagnostic system allows for reading of the trouble codes from the DLC3. Use the intelligent tester to check and solve the problem. 2. CHECK DLC3 (a) The multiplex network body ECU uses ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAEJ1962 and matches the ISO 9141-2 format. SIL 1 2 3 4 5 6 7 8 9 10 11 1213141516 BAT A082779E04 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle or in the tester. • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM DL–43 DTC CHECK / CLEAR 1. DTC CHECK/CLEAR (USING INTELLIGENT TESTER:) (a) DTC check (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Read the DTCs on the tester screen. (b) DTC clear (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Clear the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DL DL–80 DOOR LOCK – BACK DOOR LOCK BACK DOOR LOCK INSPECTION 1. Fuel-latch Open-latch B065423E01 INSPECT W/MOTOR BACK DOOR LOCK ASSEMBLY (a) Check operation of the door lock. (1) Using a screwdriver, push the latch in order to put the back door lock in the locked condition (full-latch position). (2) Connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2. Then, check operation of the latch. Standard: The latch turns to the open-latch position (3) Inspect motor operation when battery voltage is applied to the terminals. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Clockwise (Motor in normal rotation) Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Counterclockwise (Motor in reverse rotation) If the operation is not as specified, replace the door lock assembly. DL DL–81 DOOR LOCK – BACK DOOR LOCK (b) Check the back door courtesy switch continuity. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Half-latch position 4-5 Below 1 Ω Full-latch position, Over-latch position 4-5 10 kΩ or higher If the continuity is not as specified, replace the door lock assembly. (c) Check the back door latch switch continuity. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Open-latch Half-latch Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Over-latch position 4-6 Below 1 Ω Half-latch position, Full-latch position 4-6 10 kΩ or higher If the continuity is not as specified, replace the door lock assembly. (d) Check the position switch continuity. (1) Connect the battery positive (+) lead to connector terminal 1 and the negative (-) lead to connector terminal 2. Standard resistance Full-latch Over-latch B062719E01 Door Lock Latch Position Terminal No. Specified Condition Any position other than motor stop position (Motor in operation) 3-4 Below 1 Ω Motor stop position (Gear in original position) 3-4 10 kΩ or higher If the continuity is not as specified, replace the door lock assembly. DL ME–4 METER – METER / GAUGE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 PROBLEM SYMPTOM CONFIRMATION NEXT 4 PROBLEM SYMPTOMS TABLE NEXT 5 CIRCUIT INSPECTION NEXT 6 REPAIR OR REPLACE NEXT 7 NEXT END ME CONFIRMATION TEST ME–5 METER – METER / GAUGE SYSTEM PROBLEM SYMPTOMS TABLE MALFUNCTION SYSTEM: Symptom Suspected Area See page Entire combination meter does not operate. Combination Meter Circuit ME-24 Light control rheostat malfunction. Light Control Rheostat Circuit ME-49 Buzzer does not sound. Warning Buzzer Circuit ME-38 Seat belt warning light for driver seat does not operate. Seat Belt Warning Light Circuit ME-43 Seat belt warning light for passenger seat does not operate. Seat Belt Warning Light Circuit ME-45 Average fuel consumption/instantaneous fuel consumption/possible running distance display malfunction. Multi-information Display Circuit ME-53 METER GAUGES: Symptom Speedometer malfunction. Suspected Area See page Speedometer Circuit ME-26 Tachometer malfunction. Tachometer Circuit ME-29 Fuel receiver gauge malfunction. Fuel Receiver Gauge Circuit ME-32 Engine coolant temperature receiver gauge malfunction. Engine Coolant Temperature Receiver gauge Circuit ME-35 WARNING LIGHTS: Symptom Check engine warning light does not come on. Charge warning light does not come on. Brake warning light does not come on. Brake warning light does not go off. ABS warning light does not come on. ABS warning light does not go off. Airbag warning light does not come on. Suspected Area See page 1. Wire Harness or Connector - 2. MIL Circuit for 1GR-FE ES-397 3. MIL Circuit for 2UZ-FE ES-479 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Generator - 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Parking Brake Switch - 3. Brake Fluid Level Warning Switch ME-22 4. Brake Warning Light Circuit BC-172 5. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Parking Brake Switch - 3. Brake Fluid Level Warning Switch ME-22 4. Brake Warning Light Circuit BC-167 5. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS Warning Light Circuit BC-161 3. Brake Master Cylinder Sub-assembly - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS Warning Light Circuit BC-157 3. Brake Master Cylinder Sub-assembly - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Airbag Warning Light Circuit RS-282 3. Combination Meter Assembly ME-59 ME ME–6 METER – METER / GAUGE SYSTEM Symptom Airbag warning light does not go off. Door open warning light does not come on. Fuel level warning light does not come on. Low oil pressure warning light does not come on. VSC warning light does not come on. VSC warning light does not go off. A/T oil temp warning light does not come on. Tire pressure warning light does not come on. Suspected Area See page 1. Wire Harness or Connector - 2. Airbag Warning Light Circuit RS-275 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Door Courtesy Light Switch LI-63 3. Body ECU - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Fuel Sender Gauge Assembly ME-21 3. Indication Sensor Assembly - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Low Oil Pressure Warning Switch ME-21 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. VSC Warning Light Circuit BC-161 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. VSC Warning Light Circuit BC-157 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ECM - 3. Combination Meter Assembly ME-59 1. Tire Pressure Switch - 2. Wire Harness or Connector - 3. Tire Pressure Warning System TW-58 4. Combination Meter Assembly ME-59 INDICATOR LIGHTS: Symptom Fr. FOG indicator light does not come on. Turn indicator light does not come on. A/T shift indicator light does not come on. Hi beam indicator light does not come on. ME 4WD indicator light does not come on (for 4WD). 4LO indicator light does not come on (for 4WD). Suspected Area See page 1. Lighting System LI-8 2. Combination Meter Assembly ME-59 1. Light Control System LI-8 2. Wire Harness or Connector - 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Park/Neutral Position Switch Circuit - 3. Wire Harness or Connector - 4. Combination Meter Assembly ME-59 1. Light Control System LI-8 2. Wire Harness or Connector - 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. 4WD Control Switch Circuit - 3. 4WD Control ECU - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. 4WD Control Switch Circuit - 3. 4WD Control ECU - 4. Combination Meter Assembly ME-59 ME–7 METER – METER / GAUGE SYSTEM Symptom Suspected Area 1. Washer Level Warning Switch Washer level indicator light does not come on (for Canada). AUTO LSD indicator light does not come on (for 2WD). AUTO LSD indicator light does not go off (for 2WD). VSC OFF indicator light does not come on (for 4WD). VSC OFF indicator light does not go off (for 4WD). DAC indicator light does not come on (for 4WD). DAC indicator light does not go off (for 4WD). Center diff. lock indicator light does not come on (for 4WD). SLIP indicator light does not come on. SLIP indicator light does not go off. CRUISE indicator light does not come on. RSCA OFF indicator light does not come on (with Side Airbag). RSCA OFF indicator light does not go off (with Side Airbag). MAINT REQD indicator light does not come on (for U.S.A.). See page ME-23 2. Wire Harness or Connector - 3. Combination Meter Assembly ME-59 1. AUTO LSD Switch - 2. Wire Harness or Connector - 3. ABS & Traction Actuator Assembly BC-196 4. Combination Meter Assembly ME-59 1. AUTO LSD Switch - 2. Wire Harness or Connector - 3. ABS & Traction Actuator Assembly BC-192 4. Combination Meter Assembly ME-59 1. 4WD Control Switch - 2. Wire Harness or Connector - 3. ABS & Traction Actuator Assembly BC-178 4. Combination Meter Assembly ME-59 1. 4WD Control Switch - 2. Wire Harness or Connector - 3. ABS & Traction Actuator Assembly BC-175 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS & Traction Actuator Assembly BC-188 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS & Traction Actuator Assembly BC-184 3. Combination Meter Assembly ME-59 1. Center Diff. Lock Switch - 2. Wire Harness or Connector - 3. 4WD Control ECU - 4. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS & Traction Actuator Assembly BC-182 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. ABS & Traction Actuator Assembly BC-180 3. Combination Meter Assembly ME-59 1. Wire Harness or Connector - 2. Cruise Main Indicator Light Circuit CC-23 3. Combination Meter Assembly ME-59 1. RSCA OFF Switch - 2. Wire Harness or Connector - 3. Center Airbag Sensor Assembly RS-38 4. Combination Meter Assembly ME-59 1. RSCA OFF Switch - 2. Wire Harness or Connector - 3. Center Airbag Sensor Assembly RS-38 4. Combination Meter Assembly ME-59 1. Refer to Troubleshooting ME-23 2. Combination Meter Assembly ME-59 ME ME–8 METER – METER / GAUGE SYSTEM Symptom AIRSUS indicator light does not come on (with Air Suspension). ME Suspected Area See page 1. Wire Harness or Connector - 2. Height Control Circuit SC-18 3. Combination Meter Assembly ME-59 ME–9 METER – METER / GAUGE SYSTEM TERMINALS OF ECU 1. C11 COMBINATION METER ASSEMBLY C10 C9 C8 E113263E01 Symbols (Terminal No.) TIRE PRESS (C8-1) Body ground Wiring Color P-B - Body ground Terminal Description Tire pressure signal Condition Specified Condition Turn the ignition switch to the ON position, TIRE PRESSURE indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, TIRE PRESSURE indicator light ON Below 1 V ME ME–10 Symbols (Terminal No.) AIRSUS HI (C8-2) (*1) Body ground Wiring Color Y - Body ground AIRSUS N (C8-3) (*1) Body ground Y-B - Body ground AIRSUS LO (C8-4) (*1) Body ground BR-B - Body ground AIRSUS OFF (C8-5) (*1) Body ground WASHER (C8-6) (*2) Body ground CHECK E/G (C8-7) - Body ground OIL PRS (C8-8) - Body ground RSCA OFF (C8-10) (*3) Body ground CRUISE (C8-11) - Body ground DAC (C8-12) (*4) - Body ground ME METER – METER / GAUGE SYSTEM A/T OIL TEMP (C8-15) Body ground Y-G - Body ground V-W - Body ground R-B - Body ground LG-B - Body ground L-Y - Body ground LG - Body ground BR-Y - Body ground P - Body ground Terminal Description Auto height control signal Auto height control signal Auto height control signal Auto height control signal Washer level signal Check engine indicator light signal Oil pressure signal Roll sending of curtain shield airbag OFF singal CRUISE indicator light signal Downhill assist control signal A/T OIL TEMP indicator light signal Condition Specified Condition Turn the ignition switch to the ON position, HI indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, HI indicator light ON Below 1 V Turn the ignition switch to the ON position, N indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, N indicator light ON Below 1 V Turn the ignition switch to the ON position, LO indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, LO indicator light ON Below 1 V Turn the ignition switch to the ON position, OFF indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, OFF indicator light ON Below 1 V Turn the ignition switch to the ON position, washer level indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, washer level indicator light ON Below 1 V Turn the ignition switch to the ON position, CHECK E/G warning light ON Below 1 V Turn the ignition switch to the ON position, CHECK E/G warning light OFF 10 to 14 V Turn the ignition switch to the ON position, OIL PRESS indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, OIL PRESS indicator light ON Below 1 V Turn the ignition switch to the ON position, RSCA OFF indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, RSCA OFF indicator light ON Below 1 V Turn the ignition switch to the ON position, CRUISE indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, CRUISE indicator light ON Below 1 V Turn the ignition switch to the ON position, DAC indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, DAC indicator light ON Below 1 V Turn the ignition switch to the ON position, A/T OIL TEMP indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, A/T OIL TEMP indicator light ON Below 1 V METER – METER / GAUGE SYSTEM Symbols (Terminal No.) CHARGE (C8-16) - Body ground ALL DOOR INPUT (C817) - Body ground BRAKE LEVEL (C8-18) Body ground ACTIVE BRAKE (C8-19) Body ground Wiring Color GR - Body ground V-Y - Body ground LG - Body ground B-L - Body ground Terminal Description CHARGE warning light signal All door condition signal ME–11 Condition Specified Condition Turn the ignition switch to the ON position, CHARGE warning light OFF 10 to 14 V Turn the ignition switch to the ON position, CHARGE warning light ON Below 1 V Any door open Below 1 V All the door is closed 10 to 14 V Turn the ignition switch to the ON position, BRAKE warning light OFF 10 to 14 V Turn the ignition switch to the ON position, BRAKE warning light ON Below 1 V Turn the ignition switch to the ON position, BRAKE warning light OFF 10 to 14 V Turn the ignition switch to the ON position, BRAKE warning light ON Below 1 V A/C signal (UART INPUT) Turn the ignition switch to the ON position Signal wave A/C signal (UART OUTPUT) Turn the ignition switch to the ON position Signal wave Brake fluid level warning light signal BRAKE warning light signal UART IN (C9-2) - Body ground BR-B - Body ground UART OUT (C9-3) - Body ground W-L - Body ground SP INPUT (C9-4) - Body ground GR-R - Body ground Speed signal (Input) Turn the ignition switch to the ON position, turn the wheel slowly Pulse generation (See waveform 1) 4P-OUT (C9-5) - Body ground V-FR - Body ground Speed signal (Output) Turn the ignition switch to the ON position, turn the wheel slowly Pulse generation (See waveform 1) TM INPUT (C9-6) - Body ground B-W - Body ground Tachometer signal Turn the ignition switch to the ON position, engine idle speed Pulse generation (See waveform 2) TEMP COMMUNICATION INPUT (C9-7) - Body ground L-B - Body ground A/C signal (Temp. input) Turn the ignition switch to the ON position Pulse generation (See waveform 3) TAU-G INPUT (C9-8) Body ground R-L - Body ground Injector No. 1 signal Turn the ignition switch to the ON position Pulse generation (See waveform 4) Turn the ignition switch to the ON position, driver side seat belt warning light OFF 10 to 14 V Turn the ignition switch to the ON position, driver side seat belt warning light blinks Below 1 V Turn the ignition switch to the ON position, passenger side seat belt warning light blinks Below 1 V Turn the ignition switch to the ON position, passenger side seat belt warning light OFF 10 to 14 V Turn the ignition switch off Below 1 V Turn the ignition switch to the ON position 10 to 14 V Turn the ignition switch to the ON position, passenger side seat belt warning light OFF 10 to 14 V Turn the ignition switch to the ON position, passenger side seat belt warning light blinks Below 1 V D SEAT BELT INPUT (C912) - Body ground P SEAT BELT INPUT (C913) - Body ground ST SIGNAL INPUT (C916) - Body ground P SEAT BELT OUT (C918) - Body ground G-Y - Body ground L-R - Body ground B-Y - Body ground LG - Body ground Driver seat belt warning light signal Passenger seat belt warning light signal (Input) Start signal Passenger seat belt warning light signal (Output) ME ME–12 Symbols (Terminal No.) KEY INPUT (C9-19) Body ground A/T (R) (C10-1) - Body ground ACTIVE AIRBAG INPUT (C10-2) - Body ground Wiring Color V-G - Body ground R-Y - Body ground B-Y - Body ground FUEL (FR) (C10-3) - Body ground BR-R - Body ground TAU-B INPUT (C10-5) Body ground B-O - Body ground TURN R (C10-6) - Body ground L-Y - Body ground Terminal Description Ignition key signal A/T shift indicator light signal Airbag indicator light signal Fuel signal IG2 signal Turn indicator light RH signal RHEOSTAT (TR) (C10-7) Body ground W-G - Body ground Rheostat Signal D DOOR INPUT (C10-8) Body ground W-L - Body ground Driver door condition signal ILL+ (C10-9) - Body ground TURN L (C10-10) - Body ground ME METER – METER / GAUGE SYSTEM G - Body ground L-B - Body ground Condition Specified Condition Turn the ignition switch to the ON position, ignition key is inserted Below 1 V Turn the ignition switch to the ON position, ignition key is not inserted 10 to 14 V Turn the ignition switch to the ON position, A/T (R) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (R) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, AIRBAG indicator light OFF Below 1 V Turn the ignition switch to the ON position, AIRBAG indicator light ON 8 to 14 V Turn the ignition switch to the ON position, fuel level is FULL Below 1 V Turn the ignition switch to the ON position, fuel level is EMPTY 4 to 5 V Turn the ignition switch off Below 1 V Turn the ignition switch to the ON position 10 to 14 V Turn the ignition switch to the ON position, turn signal RH indicator light OFF Below 1 V Turn the ignition switch to the O, position, turn signal RH indicator light ON 10 to 14 V Turn the ignition switch to the ON position, light control rheostat is turned volume up → volume down Pulse generation (See waveform 5) Driver door OPEN Below 1 V Driver door CLOSE 10 to 14 V Light control switch off Below 1 V Light control switch TAIL 10 to 14 V Turn the ignition switch to the ON position, turn signal LH indicator light OFF Below 1 V Turn the ignition switch to the ON position, turn signal LH indicator light ON 10 to 14 V Ground (Fuel ground) Always Below 1 V Always Below 1 V Illumination signal Turn indicator light LH signal FUEL GND (C10-11) Body ground P - Body ground E/G GND (C10-13) - Body ground BR - Body ground Ground (Engine ground) IGN2 (C10-15) - Body ground Turn the ignition switch off Below 1 V R-L - Body ground IG2 signal Turn the ignition switch to the ON position 10 to 14 V +B (C10-16 ) - Body ground R - Body ground Battery Always 10 to 14 V Turn the ignition switch to the ON position, VSC OFF (*4), AUTO LSD (*5) indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, VSC OFF (*4), AUTO LSD (*5) indicator light ON Below 1 V VSC OFF (*4) / AUTO LSD (*5) (C10-17) - Body ground L-W - Body ground VSC OFF signal (*4) AUTO LSD signal (*5) METER – METER / GAUGE SYSTEM Symbols (Terminal No.) VSC TRAC (C10-18) (*4) Body ground SLIP (C10-20) - Body ground 4WD (C11-5) (*6) - Body ground CTR DIFF LOCK (C11-6) (*4) - Body ground Wiring Color Y-R - Body ground R - Body ground W-G - Body ground G-R - Body ground 4LO (C11-7) (*2) - Body ground BR-W - Body ground Fr. FOG (C11-10) - Body ground G - Body ground BEAM+ (C11-12) - Body ground R-W - Body ground BEAM- (C11-13) - Body ground A/T (L) (C11-14) - Body ground A/T (2) (C11-15) - Body ground A/T (3) (C11-16) - Body ground A/T (4) (C11-17) - Body ground A/T (D) (C11-18) - Body ground R-W - Body ground B-L - Body ground P-L - Body ground L - Body ground G - Body ground W - Body ground Terminal Description ME–13 Condition Specified Condition Turn the ignition switch to the ON position, VSC TRAC indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, VSC TRAC indicator light ON Below 1 V Turn the ignition switch to the ON position, SLIP indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, SLIP indicator light ON Below 1 V Turn the ignition switch to the ON position, 4WD indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, 4WD indicator light ON Below 1 V Turn the ignition switch to the ON position, CTR DIFF LOCK indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, CTR DIFF LOCK indicator light ON Below 1 V Turn the ignition switch to the ON position, 4WD indicator light OFF 10 to 14 V Turn the ignition switch to the ON position, 4WD indicator light ON Below 1 V Front fog light signal Turn the ignition switch to the ON position, Fr. FOG indicator light OFF Below 1 V Hi-beam signal Always 10 to 14 V 10 to 14 V Hi-beam signal Turn the ignition switch to the ON position, BEAM indicator light OFF Turn the ignition switch to the ON position, BEAM indicator light ON Below 1 V Turn the ignition switch to the ON position, A/T (L) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (L) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, A/T (2) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (2) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, A/T (3) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (3) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, A/T (4) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (4) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, A/T (D) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (D) indicator light ON 10 to 14 V VSC TRAC signal SLIP signal 4WD indicator light signal CTR DIFF LOCK signal Low speed four-wheel drive signal A/T shift indicator light signal A/T shift indicator light signal A/T shift indicator light signal A/T shift indicator light signal A/T shift indicator light signal ME ME–14 METER – METER / GAUGE SYSTEM Symbols (Terminal No.) A/T (N) (C11-19) - Body ground A/T (P) (C11-20) - Body ground Wiring Color Terminal Description G-W - Body ground G-B - Body ground A/T shift indicator light signal A/T shift indicator light signal Condition Specified Condition Turn the ignition switch to the ON position, A/T (N) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (N) indicator light ON 10 to 14 V Turn the ignition switch to the ON position, A/T (P) indicator light OFF Below 1 V Turn the ignition switch to the ON position, A/T (P) indicator light ON 10 to 14 V *1: with Air Suspension *2: for Canada *3: with Side Airbag *4: for 4WD *5: for 2WD *6: for 1GR-FE, 4WD (a) Waveform 1 (Reference): Using an oscilloscope: OK GND Item Condition Tool setting 5 V/DIV., 10 ms/DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) HINT: As vehicle speed increases, the cycle of the signal waveform narrows. I043789E01 (b) Waveform 2 (Reference): Using an oscilloscope: OK Item Condition Tool setting 5 V/DIV., 20 ms/DIV. Vehicle condition Engine idle speed GND I043790E02 (c) Waveform 3 (Reference): Using an oscilloscope: OK A GND ME 415.792 to 419.792 ms I032122E01 Item Condition Tool setting 5 V/DIV., 100 ms/DIV. Vehicle condition Engine idle speed HINT: As the engine coolant temperature rises, the period "A" shown in the illustration becomes longer. Reference Engine Coolant Temperature A Less than 50°C (122.0°F) 96.304 to 100.304 ms 83°C (181.4°F) 231.472 to 235.472 ms 120°C (248.0°F) 383.024 to 387.024 ms ME–15 METER – METER / GAUGE SYSTEM (d) Waveform 4 (Reference): Using an oscilloscope: OK Item Condition Tool setting 10 V/DIV., 20 ms/DIV. Vehicle condition Engine idle speed GND E123284E02 (e) Waveform 5 (Reference): Using an oscilloscope: OK A Item GND I037750E04 Condition Tool setting 2 V/DIV., 1 ms/DIV. Vehicle condition Ignition switch ON, light control switch TAIL or HEAD HINT: Duty ratio changes as the illumination becomes darker (the period "A" shown in the illustration becomes longer). ME ME–16 METER – METER / GAUGE SYSTEM 2. COMBINATION METER INNER CIRCUIT C8-2 (AIR SUS (HI)) (*1) C8-3 (AIR SUS (N)) (*1) HI (*1) N (*1) C8-4 (AIR SUS (LO)) (*1) LO (*1) C8-5 (AIR SUS (OFF)) (*1) OFF (*1) DRIVE CIRCUIT FR FOG C11-10 (Fr. FOG) TURN L C10-10 (TURN L) TURN R C10-6 (TURN R) HEAD (*5) ILL DRIVE CIRCUIT ILL P R N D 4 DRIVE CIRCUIT *1: with Air Suspension *5: for U.S.A. 3 2 L C11-20 (A/T P) C10-1 (A/T R) C11-19 (A/T N) C11-18 (A/T D) C11-17 (A/T 4) C11-16 (A/T 3) C11-15 (A/T 2) C11-14 (A/T L) ME E116252E02 ME–17 METER – METER / GAUGE SYSTEM TAIL (*4) BEAM C11-13 (BEAM-) C8-17 (ALL DOOR INPUT) DOOR DUTY OUT C9-19 (KEY INPUT) C10-8 (D DOOR INPUT) C10-7 (RHEOSTAT (TR)) +B C10-16 (+B) TAIL C10-9 (ILL+) C10-15 (IGN2) IG KEY D-BELT D-DOOR C9-12 (D SEAT BELT INPUT) C10-13 (E/G INPUT) C11-12 (BEAM+) 4P OUT E/G EARTH C9-5 (4P OUTPUT) C9-16 (ST SIGNAL INUPT) ST O/D TRIP TR C9-7 (TEMP COMMUNICATION INPUT) SPEED C9-6 (TM INPUT) C9-4 (SP INPUT) SI C9-13 (P SEAT BELT INPUT) TACHO DRIVER FUEL C10-3 (FUEL (FR)) FS C10-11 (FUEL (GND)) FE TEMP FUEL W C9-18 (P SEAT BELT OUT) C9-2 (UART IN) C9-3 (UART OUT) DRIVER CIRCUIT OIL MAINT (*5) C9-8(TAU-G INPUT) BZ ME C10-5 (TAU-B INPUT) *4: for Canada INCLINATION SSR *5: for U.S.A. E116112E02 ME–18 METER – METER / GAUGE SYSTEM C10-2 (ACTIVE AIRBAG INPUT) REVERSE AIRBAG C11-4 (ACTIVE ABS) REVERSE ABS C8-19 (ACTIVE BRAKE) REVERSE BRAKE CHARGE C8-16 (CHARGE) WASHER (*4) C8-6 (WASHER) (*4) OIL PRESS C8-8 (OIL PRS) 4WD (*2) C11-5 (4WD) (*2) 4LO (*2) C11-7 (4LO) (*2) C11-6 (CTR DIFF LOCK) (*2) CTR DIFF LOCK (*2) CHECK ENG C8-7 (CHECK E/G) A/T OIL TEMP C8-15 (A/T OIL TEMP) CRUISE C8-11 (CRUISE) DAC (*2) C8-12 (DAC) (*2) SLIP C10-20 (SLIP) VSC C10-18 (VSC TRAC) (*2) VSC OFF (*2) AUTO LSD (*3) C10-17 (VSC OFF) (*2) (AUTO LSD) (*3) C8-1 (TIRE PRESS) REVERSE TIRE PRS *1: with Air Suspension *2: for 4WD *3: for 2WD *4: Canada C8-10 (RSCA OFF) (*6) RSCA OFF (*1) *5: U.S.A. *6: with Side Airbag ME E116113E01 METER – METER / GAUGE SYSTEM Connector No. C8 C9 Terminals No. ME–19 Wire harness side 1 Tire Pressure WARNING ECU (TIRE PRESS) 2 Suspension Control ECU (HI) (*1) 3 Suspension Control ECU (N) (*1) 4 Suspension Control ECU (LO) (*1) 5 Suspension Control ECU (OFF) (*1) 6 Washer Level Sensor (*2) 7 ECM (CHECK ENGINE) 8 Engine Oil Pressure Switch 9 - 10 Center Airbag Sensor Assembly (RSCA OFF) (*3) 11 ECM (CRUISE) 12 ABS & Traction Actuator assembly (DAC) (*4) 13 - 14 - 15 ECM (A/T OIL TEMP) 16 Generator (CHARGE) 17 Main Body ECU (AL DOOR INPUT) 18 Brake Fluid Level Warning Switch 19 ABS & Traction Actuator Assembly (ACTIVE BRAKE) 20 - 1 - 2 A/C Control Amplifier (UART IN) 3 A/C Control Amplifier (UART OUT) 4 ABS & Traction Actuator Assembly (SP INPUT) 5 Each part that use the vehicle speed signal (4P OUT) 6 ECM (TM INPUT) 7 A/C Control Amplifier (TEMP COMMUNICATION INPUT) 8 INJECTOR NO. 1 (TAU-G INPUT) 9 - 10 - 11 - 12 Driver Side Front Seat Inner Belt Assembly (INPUT) 13 Passenger Side Front Seat Inner Belt Assembly (INPUT) 14 - 15 - 16 STA Relay (ST SIGNAL INPUT) 17 - 18 Passenger Side Front Seat Inner Belt Assembly (OUTPUT) 19 Main Body ECU (KEY INPUT) 20 - ME ME–20 Connector No. METER – METER / GAUGE SYSTEM Terminals No. 1 C10 C11 ME Wire harness side Park/Neutral Position Switch (R) 2 Center Airbag Sensor Assembly (ACTIVE AIRBAG INPUT) 3 Fuel Sender Gauge Assembly (FUEL (FR)) 4 - 5 IGN Fuse (TAU-B INPUT) 6 Turn Signal Flasher (TURN R) 7 Ground 8 Main Body ECU (D DOOR INPUT) 9 Tail Relay (ILL+) 10 Turn Signal Flasher (TURN L) 11 Ground (Fuel Ground) 12 - 13 Ground (Engine Ground) 14 - 15 GAUGE Fuse (IGN2) 16 DOME Fuse (+B) 17 ABS & Traction Actuator Assembly (VSC OFF (*4), AUTO LAD (*5)) 18 ABS & Traction Actuator Assembly (VSC) (*4) 19 - 20 ABS & Traction Actuator Assembly (SLIP) 1 - 2 - 3 - 4 ABS & Traction Actuator Assembly (ACTIVE ABS) 5 4WD Control ECU (4WD) (*4) 6 4WD Control ECU (CTR DIFF LOCK) (*4) 7 4WD Control ECU (4LO) (*4) 8 - 9 - 10 Front Fog Light Relay (Fr. FOG) 11 - 12 Headlight (HI) Fuse (BEAM+) 13 Light Control Switch (BEAM-) 14 Transmission Control Switch (L) 15 Transmission Control Switch (2) 16 Park/Neutral Position Switch (3) 17 Transmission Control Switch (4) 18 Transmission Control Switch (D) 19 Park/Neutral Position Switch (N) 20 Park/Neutral Position Switch (P) *1: with Air Suspension *2: for Canada *3: with Side Airbag *4: for 4WD *5: for 2WD *6: for 1GR-FE, 4WD ME–21 METER – METER / GAUGE SYSTEM ON-VEHICLE INSPECTION 1. INSPECT SPEEDOMETER (a) Check the operation. (1) Using a speedometer meter tester, check the speedometer indication according to the table below. Reference: mph (for U.S.A.) Chassis dynamometer indication Acceptable range 20 mph 20.0 to 23.0 mph 40 mph 40.0 to 43.5 mph 60 mph 60.0 to 64.0 mph 80 mph 80.0 to 84.5 mph 100 mph 100.0 to 105.0 mph Reference: mph (for Canada, Mexico) Chassis dynamometer indication Acceptable range Data in ( ) are for reference 20 km/h (17.5 to 21.5 km/h) 40 km/h 38.0 to 42.0 km/h 60 km/h 58.0 to 63.0 km/h 80 km/h 78.0 to 84.0 km/h 100 km/h 98.5 to 104.5 km/h 120 km/h 119.0 to 125.0 km/h 140 km/h 139.0 to 146.0 km/h 160 km/h 159.0 to 167.0 km/h NOTICE: Tire wear, as well as over or under inflation will cause errors. (2) Check the deviation from the acceptable value of the speedometer indication. Reference: Below 0.3 km/h (0.19 mph) 2. INSPECT TACHOMETER (a) Check operation. (1) Connect the tune-up test tachometer and start the engine. NOTICE: • Reversing the connection of the tachometer will damage the transistors and the insides of the diodes. • When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. (2) Compare the result of the test with the standard indication. DC 13.5 V, at 25°C (77°F) Reference: 2UZ-FE Chassis dynamometer indication (r/min) Acceptable range (r/min) Data in ( ) are for reference 700 630 to 770 1,000 (900 to 1,100) 2,000 (1,850 to 2,150) ME ME–22 METER – METER / GAUGE SYSTEM Acceptable range (r/min) Data in ( ) are for reference Chassis dynamometer indication (r/min) 3,000 2,800 to 3,200 4,000 (3,800 to 4,200) 5,000 4,800 to 5,200 6,000 (5,750 to 6,250) Standard indication (rpm) Acceptable range (rpm) Data in ( ) are for reference 700 630 to 770 Reference: 1GR-FE 1,000 (900 to 1,100) 2,000 (1,850 to 2,150) 3,000 2,800 to 3,200 4,000 (3,800 to 4,200) 5,000 4,800 to 5,100 6,000 (5,750 to 6,250) 3. INSPECT FUEL RECEIVER GAUGE (a) Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, then check the position of the receiver gauge needle. OK: Needle position is on (EMPTY). (c) Connect terminals 2 and 3 on the wire harness side connector of the fuel sender gauge. (d) Turn the ignition switch ON, then check the position of the receiver gauge needle. OK: Needle position is on (FULL). 4. INSPECT FUEL LEVEL WARNING LIGHT (a) Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, then check that the fuel level needle indicates EMPTY and the fuel level warning light comes on. OK: Fuel level warning light comes on. 5. INSPECT SEAT BELT WARNING LIGHT (for Driver Side) (a) Turn the ignition switch to ON, and check that the warning light blinks. (b) Fasten the outer belt to the inner belt and check that the warning light goes off. (c) Disconnect the connector from the front seat inner belt assembly (driver side), and connect the terminal on the wire harness side connector to body ground. (d) Turn the ignition switch to ON, and check that the warning light blinks. 6. INSPECT LOW ENGINE OIL PRESSURE WARNING LIGHT (a) Disconnect the connector from the low oil pressure switch. Fuel Sender Gauge Connector Front View: FE FS I030899E13 ME METER – METER / GAUGE SYSTEM ME–23 (b) Turn the ignition switch ON. (c) Ground the terminal of the wire harness side connector, then check the low oil pressure warning light. OK: Low engine oil pressure warning light comes on. 7. INSPECT BRAKE WARNING LIGHT (a) Inspect the parking brake warning light. (1) Disconnect the connector from the parking brake switch. (2) Turn the ignition switch ON. (3) Ground the terminal of the wire harness side connector, then check the parking brake warning light. OK: Brake warning light comes on. (b) Inspect the brake fluid level warning light. (1) Disconnect the connector from the brake fluid level warning switch. (2) Turn the ignition switch ON. (3) Connect a terminal to the other terminal of the wire harness side connector, then check the brake fluid level warning switch. OK: Brake warning light comes on. 8. INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Measure the resistance between the terminals. Resistance: Float up (switch off): 10 kΩ or higher (d) Use a syphon, etc. to take fluid out of the reservoir tank. (e) Measure the resistance between the terminals. Resistance: Float down (switch on): Below 1 Ω (f) Pour the fluid back in the reservoir tank. 9. INSPECT SEAT BELT WARNING BUZZER (for Driver Side) (a) Check the warning buzzer function. (1) Turn the ignition switch to ON, and check that the driver's seat belt warning sounds if the driver's seat belt is not fastened. (2) Check that the buzzer stops in about 4 to 8 seconds. 10. INSPECT KEY REMINDER WARNING BUZZER (a) Check the warning buzzer function. (1) Turn the ignition switch off, and check that the key reminder warning sounds when the ignition key is inserted in the key cylinder and the front driver side door is opened. ME ME–24 METER – METER / GAUGE SYSTEM 11. INSPECT TRIP METER (a) Check the operation. (1) Turn the ignition switch to ON, and check that the mode indication changes in the order of "ODO" → "TRIP A" → "TRIP B" → "ODO" by pressing the trip switch. HINT: When turning the ignition switch to the ON position, the first mode that appears on the display is the previously indicated mode. (2) Check that the indicated data in "TRIP A" and "TRIP B" is reset by pressing the trip switch for more than 0.5 seconds. I033950 12. REMOVE WASHER LEVEL WARNING SWITCH (a) Inspect the circuit. (1) Disconnect the connector from the washer level warning switch. (2) Turn the ignition switch to ON. (3) Connect the terminal of the wire harness side connector and body ground, then check the condition of the washer level warning light. 13. OIL MAINTENANCE INDICATOR RESETTING PROCEDURE Indicator Condition: State Condition Specified State Blinking The vehicle runs 4,500 to 5,000 miles after the previous setting The indicator blinks for 12 seconds after the ignition switch is ON (including 3 seconds for a bulb check) Continuously Illuminated The vehicle runs over 5,000 miles after the previous setting The indicator is continuously illuminated after the ignition switch is ON. (a) Set the display window to ODO. (b) Turn the ignition switch off. (c) While pressing the reset switch, turn the ignition switch ON. Keep pressing the reset switch for at least 5 seconds to complete the reset procedure. Check that the "OIL MAINT" indicator light goes off. HINT: • If the ignition switch is turned off during the reset procedure: LCD: off IND: off • If the reset switch is not pressed for at least 5 seconds during the reset procedure: LCD: return to ODO IND: previous state ME ME–50 METER – METER / GAUGE SYSTEM Operating Light Control Rheostat does not Change Light Brightness WIRING DIAGRAM R13 Light Control Rheostat ILLE T Combination Meter Assembly From Another Illumination J/C 6 A J8 W-G 3 E J9 W-G 7 C10 J/C A J15 A J14 W-B 5 RHEOSTAT (TR) W-B J/C C J10 G 4 J16 J/C C J10 G B B A J11 9 C10 ILL+ G Driver Side J/B G TAIL Relay 5 To Multiplex Body ECU 1L J7 J/C J20 J/C 8 IG Y-R 1 Y-R H A H Y-R A 1 TAIL 3 5 2 1 2 IG1 1C 1J I18 Ignition Switch Engine Room R/B ALT 2 1 1C AM1 2 1 2 2 2 AM1 J/B B 1 2 2 L-W 2 2 BR (*2) B L-Y IG1 4 W-L 13 7 IM1 BR C10 E/G GND J5 J/C ME A Battery IG BR (*1) EE ED *1: 2UZ-FE *2: 1GR-FE A133756E01 ME–51 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 CHECK TAILLIGHT (a) Check that the tail light comes on when the ignition switch is turned to the ON position and light control switch is in the TAIL or HEAD position. OK: Tail light comes on. NG GO TO LIGHTING SYSTEM OK 2 CHECK ILLUMINATION (a) Check that the illumination of the radio and player, center cluster module switch, etc. can be adjusted by the light control rheostat switch. OK: The illumination can be adjusted. NG Go to step 6 OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the C10 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Combination Meter Assembly (Right Side of Vehicle) Connector Front View: Tester connection Condition Specified condition C10-9 - Body ground Ignition switch ON and light control switch TAIL or HEAD 10 to 14 V ILL+ (c) Measure the resistance according to the value(s) in the table below. Standard resistance C10 Tester connection Condition Specified condition C10-13 - Body ground Always Below 1 Ω E/G GND E113267E02 OK NG REPAIR OR REPLACE HARNESS OR CONNECTOR ME ME–52 4 METER – METER / GAUGE SYSTEM CHECK HARNESS AND CONNECTOR (LIGHT CONTROL RHEOSTAT - COMBINATION METER) (a) Disconnect the R13 and C10 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Light Control Rheostat Wire Harness View: R13 Tester connection Condition Specified condition R13-3 (-) - C10-7 (RHEOSTAT (TR)) Always Below 1 Ω R13-3 (-) - Body ground Always 10 kΩ or higher (-) NG Combination Meter Assembly (Right Side of Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C10 RHEOSTAT (TR) I039610E01 OK 5 INSPECT LIGHT CONTROL RHEOSTAT (a) Remove the light control rheostat with connector still connected. Light Control Rheostat Wire Harness View: R13 (-) I038343E01 (b) Measure the voltage according to the value(s) in the table below. OK A ME Tester connection Condition Specified condition R13-3 (-) - Body ground Light control rheostat is turned volume up → volume down Pulse generation (See waveform 1) GND Waveform: Item Condition I037750E04 Tool setting 2 V/DIV., 1 ms./DIV. Vehicle condition Ignition switch ON and light control switch TAIL or HEAD ME–53 METER – METER / GAUGE SYSTEM HINT: Duty ratio changes as the illumination becomes darker (period "A" shown in the illustration becomes longer). NG REPLACE LIGHT CONTROL RHEOSTAT OK REPLACE COMBINATION METER ASSEMBLY 6 INSPECT LIGHT CONTROL RHEOSTAT (POWER SOURCE) (a) Disconnect the R13 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Light Control Rheostat Wire Harness View: R13 Tester connection Condition Specified condition R13-1 (IG) - Body ground Ignition switch ON 10 to 14 V R13-4 (T) - Body ground Light control switch TAIL or HEAD 10 to 14 V IG E T E069145E08 (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition R13-5 (E) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE COMBINATION METER ASSEMBLY ME ME–54 METER – METER / GAUGE SYSTEM Multi-display Power Source Circuit DESCRIPTION Confirm that the speedometer, the tachometer, the fuel receiver gauge and SFI system are normal, then check this circuit. Refer to SFI system for 1GR-FE (See page ES-31) or 2UZ-FE (See page ES-35). HINT: If this circuit has a malfunction, average fuel consumption display/instantaneous fuel consumption display/ possible running distance display cannot be displayed correctly. ME ME–55 METER – METER / GAUGE SYSTEM WIRING DIAGRAM Combination Meter Assembly A/C Control Amplifier 19 DMOT A17 BR-B 20 DMIN A17 W-L 3 C9 UART OUT J26 (*1) J27 (*2) J/C ECM #10 2 C9 UART IN 2 E6 R-L A (*1) A (*1) D (*2) D (*2) 8 IM2 R-L R-L 8 TAU-G C9 INPUT J/C B J8 B-O D J9 5 C10 TAU-B INPUT B-O Driver Side J/B IGN 11 1J 6 1D B-R I18 Ignition Switch Engine Room R/B AM2 B 2 1 2 2 R 7 AM2 IG2 6 Battery *1: for 2UZ-FE *2: for 1GR-FE I038353E01 ME ME–56 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 INSPECT COMBINATION METER ASSEMBLY (TAU-B) Combination Meter Assembly (Right Side of Vehicle) Connector Front View: (a) Remove the combination meter assembly. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition C10-5 (TAU-B INPUT) Body ground Ignition switch ON 10 to 14 V NG C10 REPAIR OR REPLACE HARNESS OR CONNECTOR TAU-B INPUT E113267E03 OK 2 INSPECT COMBINATION METER ASSEMBLY (TAU-G) Combination Meter Assembly (Left Side of Vehicle) Connector Front View: (a) Check the input signal waveform. (1) Remove the combination meter assembly. (2) Connect the oscilloscope to terminal C9-8 (TAU-G INPUT) and body ground. (3) Start the engine. C9 TAU-G INPUT E113265E05 (4) Check the signal waveform according to the condition(s) in the table below. Waveform: ME Item Condition Tool setting 10 V/DIV., 20 ms/DIV. Vehicle condition Engine idle speed GND HINT: As the engine speed goes higher, the frequency becomes shorter. A005115E03 NG Go to step 3 ME–57 METER – METER / GAUGE SYSTEM OK 3 CHECK HARNESS AND CONNECTOR (ECM - COMBINATION METER) (a) Disconnect the E6 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Wire Harness View: Tester connection Condition E6-2 (#10) - C9-8 (TAU-G INPUT) Always Below 1 Ω E6-2 (#10) - Body ground Always 10 kΩ or higher NG Specified condition REPAIR OR REPLACE HARNESS OR CONNECTOR E6 #10 Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C9 TAU-G INPUT C E116116E01 OK 4 CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY (LCD DISPLAY) (a) Check the LCD display appears. OK: LCD display appears. NG OK GO TO AIR CONDITIONING SYSTEM ME ME–58 5 METER – METER / GAUGE SYSTEM CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - COMBINATION METER) Air Conditioning Amplifier Wire Harness View: A17 DMIN DMOT Combination Meter Assembly (Left Side of Vehicle) Connector Front View: (a) Disconnect the A17 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition A17-19 (DMOT) - C9-2 (UART IN) Always Below 1 Ω A17-19 (DMOT) - Body ground Always 10 kΩ or higher A17-20 (DMIN) - C9-3 (UART OUT) Always Below 1 Ω A17-20 (DMIN) - Body ground Always 10 kΩ or higher NG UART IN C9 UART OUT I038359E01 OK REPLACE COMBINATION METER ASSEMBLY ME Specified condition REPAIR OR REPLACE HARNESS OR CONNECTOR ME–1 METER – METER / GAUGE SYSTEM METER / GAUGE SYSTEM BODY ELECTRICAL METER PARTS LOCATION REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY FUEL SENDER GAUGE ASSEMBLY COMBINATION METER ASSEMBLY ENGINE ROOM R/B - DOME FUSE - AM2 FUSE - SHORT PIN FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY WASHER LEVEL SENSOR PARK/NEUTRAL POSITION SWITCH ME E115629E01 ME–2 METER – METER / GAUGE SYSTEM SKID CONTROL ECU (ABS & TRACTION ACTUATOR ASSEMBLY) A/C CONTROL AMPLIFIER PASSENGER SEAT BELT WARNING LIGHT LIGHT CONTROL RHEOSTAT 4WD CONTROL ECU ECM ODO/TRIP SWITCH OCCUPANT DETECTION SENSOR DRIVER SIDE J/B - BODY ECU CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY (PASSENGER SIDE) FRONT SEAT INNER BELT ASSEMBLY (DRIVER SIDE) TIRE PRESSURE WARNING ECU ME E115630E02 METER – METER / GAUGE SYSTEM 2UZ-FE: ME–3 ENGINE COOLANT TEMPERATURE SENSOR OIL PRESSURE SWITCH 1GR-FE: ENGINE COOLANT TEMPERATURE SENSOR OIL PRESSURE SWITCH ME E115631E01 METER – COMBINATION METER ME–61 REASSEMBLY 1. INSTALL INCLINATION SENSOR ASSEMBLY 2. INSTALL NO. 1 COMBINATION METER COVER 3. INSTALL SPEEDOMETER GLASS INSTALLATION 1. INSTALL COMBINATION METER ASSEMBLY (a) Pull the positions shown in the illustration in the arrow mark direction to make the check pins unseen form the surface. B064629 (b) Check that the connector on the instrument panel side is in place. (c) Install the combination meter assembly with the 3 screws. (d) Tighten the screw shown in the illustration and check that the check pin protrudes. B063039 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 3. INCLINATION SENSOR ZERO DEGREE CORRECTION NOTICE: • When replacing or removing/installing the combination meter assembly and inclination sensor assembly, be sure to perform zero degree correction of the inclination sensor. • When performing zero degree correction, install the combination meter assembly and perform it in level surface. • Also perform zero degree correction when the body level setting is inclined because of vehicle height adjustment. (a) Turn the ignition switch off. (b) While pressing the RESET switch, turn the ignition switch on. (c) Within 5 seconds after the ignition switch is turned on, repeat pressing and releasing the RESET switch 3 times and keep holding the last press for more than 5 seconds. (Buzzer sounds for a second) NOTICE: If the buzzer does not sound, perform this procedure from the beginning. ME ME–62 METER – COMBINATION METER (d) Release the RESET switch when buzzer sounds. IG+ RESET S/W BUZZER OFF OFF ON ON ON OFF <= 5s <= 5s 5s 800 Hz 800 Hz 1s 5s 1s <= 30s MODE DURING MODE JUDGMENT CORRECTION MODE NORMAL B064233E01 (e) Press the RESET switch again and keep pressing for more than 5 seconds. (Buzzer sounds for a second again) HINT: • When the buzzer sounds twice, reset operation is completed. • The buzzer sound of the first and second time is the same. NOTICE: If the buzzer does not sound or keep sounding for more than 1 second, perform the procedure from the beginning. ME ME–25 METER – METER / GAUGE SYSTEM Entire Combination Meter does not Operate WIRING DIAGRAM Driver Side J/B I18 Ignition Switch 6 B-R R 7 AM2 IG2 6 C2 IC4 R Combination Meter Assembly 4 GAUGE J7 J/C 15 C10 IGN2 F J9 R 16 C10 +B 7 IM1 BR 13 C10 E/G GND J/C R R D R-L 1G 1D D H J8 Engine Room R/B DOME 2 2 1 1 2 Short Pin 2 BR (*2) W 2 BR (*1) AM2 2 2 1 2 B Battery EE ED *1: 2UZ-FE *2: 1GR-FE C E116279E01 INSPECTION PROCEDURE 1 INSPECT FUSE (a) Check the AM2 fuse in the engine room R/B. Standard resistance: Below 1 Ω (b) Check the GAUGE fuse in the driver side J/B. Standard resistance: Below 1 Ω (c) Check the DOME fuse in the engine room R/B. Standard resistance: Below 1 Ω NG REPLACE FUSE ME ME–26 METER – METER / GAUGE SYSTEM OK 2 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the C10 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Combination Meter Assembly (Right Side of Vehicle) Connector Front View: C10 +B Tester Connection Condition Specified Condition C10-16 (+B) - Body ground Always 10 to 14 V C10-15 (IGN2) - Body ground Ignition switch ON 10 to 14 V (c) Measure the resistance according to the value(s) in the table below. Standard resistance IGN2 E/G GND E113267E01 Tester Connection Condition Specified Condition C10-13 (E/G GND) - Body ground Always Below 1 Ω NG OK REPLACE COMBINATION METER ASSEMBLY ME REPAIR OR REPLACE HARNESS OR CONNECTOR ME–58 METER – COMBINATION METER COMBINATION METER BODY ELECTRICAL METER COMPONENTS COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY ME B120190E03 METER – COMBINATION METER ME–59 NO. 1 COMBINATION METER COVER INCLINATION SENSOR ASSEMBLY SPEEDOMETER GLASS B134264E02 REMOVAL 1. 7 Clips B062746E01 REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (a) Disengage the 7 clips. (b) Disconnect the connectors and remove the instrument cluster finish panel sub-assembly. ME ME–60 METER – COMBINATION METER 2. REMOVE COMBINATION METER ASSEMBLY (a) Remove the 3 screws. (b) Loosen the 2 bolts and remove the combination meter assembly. B062747 DISASSEMBLY 6 Claws 1. REMOVE SPEEDOMETER GLASS (a) Remove the 2 screws. (b) Disengage the 6 claws and remove the speedometer glass. 2. REMOVE NO. 1 COMBINATION METER COVER (a) Remove the 10 screws and No. 1 combination meter cover. 3. REMOVE INCLINATION SENSOR ASSEMBLY (a) Remove the 2 screws and inclination sensor assembly. B062754E01 B062755 ME B062756 ME–27 METER – METER / GAUGE SYSTEM Speedometer Malfunction WIRING DIAGRAM ABS & Traction Actuator Assembly SP1 C 12 S28 Combination Meter Assembly 4 C9 SP INPUT E110183E11 ME ME–28 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (COMBINATION METER - ABS & TRACTION ACTUATOR ASSEMBLY) (a) Disconnect the S28 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Brake Actuator Assembly Wire Harness Connector Front View: S28 Tester Connection Condition S28-12 (SP1) - C9-4 (SP INPUT) Always Below 1 Ω S28-12 (SP1) - Body ground Always 10 kΩ or higher NG Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR SP1 Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C9 SP INPUT A133752E01 OK 2 INSPECT COMBINATION METER ASSEMBLY (a) Reconnect the C9 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Brake Actuator Assembly Wire Harness Connector Front View: S28 Tester connection Condition Specified condition S28-12 (SP1) - Body ground Ignition switch ON 10 to 14 V NG ME SP1 A133753E01 REPLACE COMBINATION METER ASSEMBLY ME–29 METER – METER / GAUGE SYSTEM OK 3 INSPECT COMBINATION METER ASSEMBLY (a) Check the input signal waveform. (1) Remove the combination meter assembly. (2) Connect the oscilloscope to terminal C9-4 and body ground. (3) Start the engine. Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C9 SP INPUT E113265E01 (4) Check the signal waveform according to the condition(s) in the table below. GND Item Condition Tool setting 5 V/DIV., 20 ms/DIV. Vehicle condition Driving at approx. 20 km/h (12.4 mph) HINT: As vehicle speed increases, the cycle of the signal waveform narrows. A005135E07 NG GO TO BRAKE CONTROL SYSTEM OK REPLACE COMBINATION METER ASSEMBLY ME ME–30 METER – METER / GAUGE SYSTEM Tachometer Malfunction DESCRIPTION When turn the ignition switch to the ON position, the combination meter assembly communicates with the ECM by the direct line. WIRING DIAGRAM Combination Meter Assembly ECM TACH 1 E8 13 C11 TM IN E118032E04 ME ME–31 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 INSPECT COMBINATION METER ASSEMBLY Combination Meter Assembly (Left Side of Vehicle) Wire Harness View: C9 TM INPUT (a) Check the input signal waveform. (1) Remove the combination meter assembly with the connector(s) still connected. (2) Connect the oscilloscope to the terminals C9-6 (TM INPUT) and body ground. (3) Start the engine. (4) Check the signal waveform according to the condition(s) in the table below. Item Condition Tool Setting 5 V/DIV., 10 ms/DIV. Vehicle Condition Engine idle speed OK: The waveform is displayed as shown in the illustration. NG Go to step 2 GND E123279E02 OK REPLACE COMBINATION METER ASSEMBLY ME ME–32 2 METER – METER / GAUGE SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the C9 and E9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Wire Harness View: E7 TACH Combination Meter Assembly Wire Harness View: (Left Side of Vehicle) C9 TM INPUT E113266E04 OK REPLACE ECM ME Tester Connection Condition Specified Condition TACH (E9-1) - TM INPUT(C9-6) Always Below 1 Ω TM INPUT (C9-6) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR ME–33 METER – METER / GAUGE SYSTEM Fuel Receiver Gauge Malfunction WIRING DIAGRAM Combination Meter Assembly F14 Fuel Pump Fuel Sender Y-B 2 3 BR-R 2 IE1 Y-B 11 C10 FUEL GND 1 IE1 BR-R 3 C10 FUEL (FR) I032726E02 INSPECTION PROCEDURE 1 CHECK HARNESS OR CONNECTOR (a) Disconnect the F10 connector from the fuel sender gauge assembly. (b) Check the meter indicator conditions according to the table below. Standard Fuel Sender Gauge Connector Front View: Wire connection Condition Specified condition 2-3 Short circuit (Ignition switch ON) Fuel gauge indicates "F" or more (Combination meter) F14 I030899E16 (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition 2 - Body ground Ignition switch ON 10 to 14 V NG Go to step 3 OK 2 INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Remove the fuel sender gauge assembly. ME ME–34 METER – METER / GAUGE SYSTEM (b) Check that the float position is between E and F. (c) Measure the resistance between terminals 2 and 3 of the connector according to the value(s) in the table below. Standard resistance F 1/2 11.9 mm Float level Float position mm (in.) Resistance (Ω) F 88.6 (3.49) +- 3 (0.12) 4.0 +- 1 1/2 6.4 (0.25) 59 E 102.9 (4.05) +- 3 (0.12) 110.0 +- 2.5 E I038335E01 NG INSPECT INCLINATION SENSOR ASSEMBLY OK REPLACE COMBINATION METER ASSEMBLY 3 CHECK HARNESS AND CONNECTOR (FUEL SENDER GAUGE ASSEMBLY COMBINATION METER) (a) Disconnect the C10 and F14 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Fuel Sender Gauge Connector Front View: F14 FS FE Combination Meter Assembly (Right Side of Vehicle) Connector Front View: Tester connection Condition Specified condition C10-3 (FUEL (FR)) - F14-3 Always Below 1 Ω C10-11 (FUEL GND) - F14-2 Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR C10 FUEL (FR) FUEL GND I038340E01 OK 4 ME INSPECT INCLINATION SENSOR ASSEMBLY (a) Inspect the inclination sensor assembly. NG REPLACE INCLINATION SENSOR ASSEMBLY METER – METER / GAUGE SYSTEM ME–35 OK REPLACE COMBINATION METER ASSEMBLY ME ME–36 METER – METER / GAUGE SYSTEM Engine Coolant Temperature Receiver Gauge Malfunction WIRING DIAGRAM Combination Meter Assembly ECM 7 C9 14 THWO E7 TEMP COMMUNICATION INPUT E2 Engine Coolant Temperature Sensor THW 21 E4 E2 E4 2 1 28 E123280E03 INSPECTION PROCEDURE HINT: If there is an open or short in the engine coolant temperature sensor circuit, the ECM outputs DTCs. Perform troubleshooting with the "SFI System" (See page ES-31 for 1GR-FE) (See page ES-35 for 2UZFE). 1 ME CHECK DTC (a) Check if DTC is output. Result Proceed to DTC P0115 is not output. A DTC P0115 is output. B B GO TO ENGINE CONTROL SYSTEM ME–37 METER – METER / GAUGE SYSTEM A 2 INSPECT COMBINATION METER ASSEMBLY Combination Meter Assembly Wire Harness View: (Left Side of Vehicle) C9 TEMP COMMUNICATION INPUT (a) Check the input signal waveform. (1) Remove the combination meter assembly with connectors still connected. (2) Connect the oscilloscope to the terminal C9-7 (TEMP COMMUNICATION INPUT) and body ground. (3) Start the engine. (4) Check the signal waveform according to the condition(s) in the table below. Item Condition Tool setting 5 V/DIV., 100 ms/DIV. Vehicle condition Engine idle speed HINT: As the coolant temperature rises, the period "A" shown in the illustration becomes longer. A GND NG Go to step 3 415.792 to 419.792 ms E123282E02 OK REPLACE COMBINATION METER ASSEMBLY ME ME–38 3 METER – METER / GAUGE SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM) (a) Disconnect the C9 and E7 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Wire Harness View: Tester Connection E7 THWO Combination Meter Assembly Wire Harness View: (Left Side of Vehicle) Specified Condition Always Below 1 Ω THWO (E7-14) - Body ground Always 10 kΩ or higher NG C9 TEMP COMMUNICATION INPUT E113266E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR ME Condition TEMP COMMUNICATION INPUT (C9-7) - THWO (E7-14) REPLACE ECM ME–39 METER – METER / GAUGE SYSTEM Warning Buzzer does not Sound WIRING DIAGRAM Combination Meter Assembly Body ECU 15 KSWO B6 19 C9 KEY INPUT V-G 11 13 DBKL B4 8 D DOOR C10 INPUT W-L DCY2 B6 G-Y B J21 D J20 C J8 G-Y C J9 G-Y K J44 L 12 C9 D SEAT BELT INPUT J/C D J20 8 IE1 D G-Y J43 (*1) (*1) 10 L BK1 (*2) G-Y (*2) J53 J/C 1 W-B BK1 (*1) W-B B (*1) B B15 Front Seat Inner Belt Assembly (Driver Side) J/C W-B (*2) BL A J43 A J44 W-B (*2) 4 3 *1: without Driving Position Memory ME *2: with Driving Position Memory C E116114E01 ME–40 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 CHECK BUZZER (a) Check that all of the warning buzzers sound. Result Proceed to All warning buzzers do not sound A Key reminder warning buzzer does not sound B Seat belt warning buzzer does not sound C B Go to step 2 C Go to step 4 A REPLACE COMBINATION METER ASSEMBLY 2 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the C9 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C9 KEY INPUT E113265E02 ME Tester Connection Condition Specified Condition C9-19 (KEY INPUT) Body ground Key is inserted Below 1 V C9-19 (KEY INPUT) Body ground Key is not inserted 10 to 14 V ME–41 METER – METER / GAUGE SYSTEM (c) Disconnect the C10 connector. (d) Measure the voltage according to the value(s) in the table below. Standard voltage Combination Meter Assembly (Right Side of Vehicle) Connector Front View: C10 Tester Connection Condition Specified Condition C10-8 (D DOOR INPUT) Body ground Door is open Below 1 V C10-8 (D DOOR INPUT) Body ground Door is closed 10 to 14 V NG Go to step 3 D DOOR INPUT E113265E03 OK REPLACE COMBINATION METER ASSEMBLY 3 CHECK HARNESS AND CONNECTOR (COMBINATION METER - MULTIPLEX NETWORK BODY ECU) (a) Disconnect the B6 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Multiplex Network Body ECU Connector Front View: KSWO B6 Tester Connection Condition Specified Condition B6-15 (KSWO) - C9-19 (KEY INPUT) Always Below 1 Ω B6-15 (KSWO) - Body ground Always 10 kΩ or higher Combination Meter Assembly (Left Side of Vehicle) Connector Front View: KEY INPUT C9 I038349E01 ME ME–42 METER – METER / GAUGE SYSTEM (c) Disconnect the B6 and C10 connectors. (d) Measure the resistance according to the value(s) in the table below. Standard resistance Multiplex Network Body ECU Connector Front View: DCY2 B6 Tester Connection Condition Specified Condition B6-11 (DCY2) - C10-8 (D DOOR INPUT) Always Below 1 Ω B6-11 (DCY2) - Body ground Always 10 kΩ or higher NG Combination Meter Assembly (Right Side of Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR C10 D DOOR INPUT I038350E01 OK GO TO KEY REMINDER WARNING SYSTEM 4 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the C9 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Assembly (Left Side of Vehicle) Connector Front View: Tester Connection Condition Specified Condition C9-12 (D SEAT BELT INPUT) - Body ground Seat belt is unfastened Below 1 Ω C9-12 (D SEAT BELT INPUT) - Body ground Seat belt is fastened 10 kΩ or higher C9 NG D SEAT BELT INPUT E113265E04 ME OK REPLACE COMBINATION METER ASSEMBLY Go to step 5 ME–43 METER – METER / GAUGE SYSTEM 5 INSPECT FRONT SEAT INNER BELT ASSEMBLY LH (a) Disconnect the B12 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Front View: B15 Tester Connection Condition Specified Condition B15-3 - B15-4 Seat belt is unfastened Below 1 Ω B15-3 - B15-4 Seat belt is fastened 10 kΩ or higher Front Seat Inner Belt Assembly (Driver Side) B059092E09 NG GO TO KEY REMINDER WARNING SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR ME ME–44 METER – METER / GAUGE SYSTEM Driver Side Seat Belt Warning Light does not Operate WIRING DIAGRAM Combination Meter Assembly Body ECU J/C 13 DBKL B4 B G-Y J21 J/C D J20 G-Y C J8 8 IE1 D J43 C J8 G-Y 12 C9 D SEAT BELT INPUT J/C D J20 G-Y (*1) K J44 L (*1) 10 L BK1 (*2) G-Y (*2) J53 J/C 1 W-B BK1 (*1) W-B B (*1) B B15 Front Seat Inner Belt Assembly (Driver Side) J/C W-B (*2) BL A J43 A J44 W-B (*2) 4 3 *1: without Driving Position Memory *2: with Driving Position Memory C ME E116115E01 ME–45 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 INSPECT COMBINATION METER ASSEMBLY (a) Disconnect the C9 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Combination Meter Assembly (Left Side of Vehicle) Connector Front View: Tester Connection Condition Specified Condition C9-12 (D SEAT BELT INPUT) - Body ground Seat belt is unfastened Below 1 Ω C9-12 (D SEAT BELT INPUT) - Body ground Seat belt is fastened 10 kΩ or higher C9 NG Go to step 2 D SEAT BELT INPUT E113265E04 OK REPLACE COMBINATION METER ASSEMBLY 2 INSPECT FRONT SEAT INNER BELT ASSEMBLY LH (a) Disconnect the B15 connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Connector Front View: Tester Connection Condition B15-3 - B15-4 Seat belt is unfastened Below 1 Ω B15-3 - B15-4 Seat belt is fastened 10 kΩ or higher B15 Specified Condition Front Seat Inner Belt Assembly (Driver Side) I045351E01 NG REPLACE FRONT SEAT INNER BELT ASSEMBLY LH OK REPAIR OR REPLACE HARNESS OR CONNECTOR ME ME–46 METER – METER / GAUGE SYSTEM Front Passenger Side Seat Belt Warning Light Malfunction WIRING DIAGRAM D3 Passenger Seat Belt Warning Light Combination Meter Assembly PBEW IG+ 18 C9 LG 3 2 P SEAT BELT OUTPUT to IG1 Fuse Y-R Airbag Sensor Assembly Center FSR+ FSRPBEW 1 3 A33 A34 (*1) (*2) 10 2 A33 A34 (*1) (*2) 2 A32 W 1 BI1 B 4 BI1 L-R 13 C9 P SEAT BELT INPUT Occupant Detection ECU FSR- 4 O3 B 8 FSR+ O3 W 9 O3 L BSW B16 Front Seat Inner Belt Assembly (Passenger Side) 2 *1: with Side Airbag 5 O3 BGND GR 1 *2: without Side Airbag I045360E01 ME ME–47 METER – METER / GAUGE SYSTEM INSPECTION PROCEDURE 1 SYSTEM CHECK (INDICATOR CHECK) (a) Disconnect the A32 connector. (b) Check the operation of the warning light according to the table below. Standard Wire Harness View: Center Airbag Sensor Assembly PBEW A32 H040065E28 Tester Connection Condition Specified Condition No connection Ignition switch ON Warning light OFF A32-2 (PBEW) - Body ground Ignition switch ON Warning light Blinks NG Go to step 3 OK 2 SYSTEM CHECK (INDICATOR CHECK) (a) Connect the A32 connector. (b) Check the operation of the warning light according to the table below. Standard Condition Bulb Condition Result Ignition switch ON (Passenger does not sit on) OFF OK Ignition switch ON (Passenger sits on) Blinks OK Ignition switch ON (Passenger sits on and seat belt is fastened) OFF OK Ignition switch ON (Passenger sits on and seat belt is unfastened) Blinks OK Check with the auto cut off switch in the AUTO position (w/ airbag cut off switch). NG GO TO AIRBAG SYSTEM OK REPLACE COMBINATION METER ASSEMBLY ME ME–48 3 METER – METER / GAUGE SYSTEM CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR ASSEMBLY COMBINATION METER ASSEMBLY) (a) Disconnect the A32 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Center Airbag Sensor Assembly PBEW A32 Combination Meter Assembly (Left Side of Vehicle) Connector Front View: Tester Connection Condition Specified Condition A32-2 (PBEW) - C9-13 (P SEAT BELT INPUT) Always Below 1 Ω C9-13 (P SEAT BELT INPUT) Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR C9 P SEAT BELT INPUT I045389E02 OK 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - PASSENGER SEAT BELT WARNING LIGHT) (a) Disconnect the D3 and C9 connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Passenger Seat Belt Warning Light PBEW D3 Tester Connection Condition Specified Condition D3-3 (PBEW) - C9-18 (P SEAT BELT OUTPUT) Always Below 1 Ω D3-3 (PBEW) - Body ground Always 10 kΩ or higher NG Combination Meter Assembly (Left Side of Vehicle) Connector Front View: C9 ME P SEAT BELT OUTPUT I038356E01 REPAIR OR REPLACE HARNESS OR CONNECTOR ME–49 METER – METER / GAUGE SYSTEM OK 5 INSPECT PASSENGER SEAT BELT WARNING LIGHT (a) Disconnect the D3 connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: D3 Passenger Seat Belt Warning Light PBEW Tester Connection Condition Specified Condition D3-2 (PBEW) - Body ground Ignition switch ON 10 to 14 V NG I038357E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE COMBINATION METER ASSEMBLY ME AV–3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM SYSTEM DIAGRAM 10 SPEAKER SYSTEM: Steering Pad Switch Combination Meter Antenna Spiral Cable Speed Signal Switch Signal Radio Receiver (Master Unit) Television Display Assembly (Slave Unit) (*1) Stereo Component Amplifier Sound Signal (*1) (Slave Unit) Speakers Sound Signal Stereo Jack Adapter Sound Signal (*1) : AVC-LAN *1: with Rear Seat Entertainment System E119757E03 AV AV–4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 6 SPEAKER SYSTEM: Steering Pad Switch Combination Meter Antenna Spiral Cable Speed Signal Switch Signal Radio Receiver (Master Unit) Television Display Assembly (Slave Unit) (*1) (*1) Sound Signal Speakers Stereo Jack Adapter Sound Signal Sound Signal (*1) : AVC-LAN *1: with Rear Seat Entertainment System E119758E03 AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–5 SYSTEM DESCRIPTION 1. DISC PLAYER OUTLINE (a) A CD player uses a laser pickup to read digital signals recorded on CDs. By converting the digital signals to analog, music and other content can be played. CAUTION: Do not look directly at the laser pickup because the CD player uses an invisible laser beam. Be sure to operate the player only as instructed. NOTICE: • Do not disassemble any part of the CD player. • Do not apply oil to the CD player. • Do not insert anything but a CD into the CD player. (b) Usable discs (1) The CD player can only play audio CDs, CD-Rs (CD-Recordable), and CD-RWs (CDReWritable) that have any of the following marks: E119759 (c) Precautions for use of discs NOTICE: • Copy-protected CDs cannot be played. • CD-Rs and CD-RWs may not be played depending on the recording conditions or characteristics of the discs, or due to damage, dirt, or deterioration caused by leaving the discs in the cabin for a long time. • Unfinalized CD-Rs and CD-RWs cannot be played. • Keep the discs away from dirt. Be careful not to damage the discs or leave your fingerprints on them. • Hold discs by the outer edge and center hole with the label side up. • Leaving the disc exposed halfway out of the slot for a long time after pressing the disc eject button may cause deformation of the disc, making the disc unusable. • If discs have adhesive tape, stickers, CDR labels, or any traces of such labels attached, the discs may not be ejected or player malfunctions may result. AV AV–6 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • Keep the discs away from direct sunlight. (Exposure to direct sunlight may cause deformation of the disc, making the disc unusable.) • Do not use odd-shaped CDs because these may cause player malfunctions. • Do not use discs whose recording portion is transparent or translucent because they may not be inserted, ejected, or played normally. HINT: • When it is cold or it is raining, if the windows mist up, mist and also dew may form in the player. In such a case, the CD may skip or the CD may stop in the middle of play. Ventilate or dehumidify the cabin for a while before using the player. • The CD may skip if the player experiences strong vibrations when the vehicle is driven on rough road or similar uneven surface(s). (d) Cleaning NOTICE: Do not use a lens cleaner because it may cause a malfunction in the pickup portion of the player. I100151 2. (1) If dirt is on the disc surface, wipe it clean with a soft dry cloth such as an eyeglass cleaner for plastic lenses from the inside to the outside in a radial direction. NOTICE: • Pressing on the disc by hand or rubbing the disc with a hard cloth may scratch the disc surface. • Use of solvent such as a record spray, antistatic agent, alcohol, benzine, and thinner, or a chemical cloth may cause damage to the disc, making the disc unusable. MP3/WMA OUTLINE (a) Playable MP3 file standards Compatible standard MP3 (MPEG1 LAYER3, MPEG2 LSF LAYER 3) Compatible sampling frequency • • MPEG1 LAYER3: 32, 44.1, 48 (kHz) MPEG2 LSF LAYER3: 16, 22.05, 24 (kHz) • MPEG1 LAYER3: 64, 80, 96, 112, 128, 160, 192, 224, 256, 320 (kbps) MPEG2 LSF LAYER3: 64, 80, 96, 112, 128, 144, 160 (kbps) Compatible with VBR Compatible bit rate Compatible channel mode • • Stereo, joint stereo, dual channel, monaural (b) Playable WMA file standards AV Compatible standard WMA Ver. 9 Compatible sampling frequency 32, 44.1, 48 (kHz) Compatible bit rate • • Ver. 9: CBR48, 64, 80, 96, 128, 160, 192, 256, 320 (kbps) Compatible with playback of channel 2 only AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–7 (c) ID3 tag and WMA tag (1) Additional textual information called ID3 tag can be input to MP3 files. Information such as song titles and artist names can be stored. HINT: This player is compatible with the ID3 tags of ID3 Ver. 1.0 and 1.1, and ID3 Ver. 2.2 and 2.3. (Number of characters complies with ID3 Ver. 1.0 and 1.1.) (2) Additional textual information called WMA tag can be input to WMA files. Information such as song titles and artist names can be stored. (d) Usable media (1) Only CD-ROMs, CD-Rs (CD-Recordable), and CD-RWs (CD-ReWritable) only can be used to play MP3/WMA files. NOTICE: • CD-Rs and CD-RWs are more easily affected by a hot and humid environment than discs used for normal audio CDs. For this reason, some CD-Rs and CD-RWs may not be played. • If there are fingerprints or scratches on the disc, the disc may not be played or the CD may skip. • Some CD-Rs and CD-RWs deteriorate if they are left in the cabin for a long time. • Keep CD-Rs and CD-RWs in a storage case that is impenetrable to light. (e) Usable media format (1) Usable media format Disc format CD-ROM Mode 1, CD-ROM XA Mode 2 Form1 File format ISO9660 Level 1 and Level 2 (Joliet, Romeo) HINT: • As for MP3/WMA files written in any format other than those above, the contents of the files may not be played normally or the file names or folder names may not be displayed correctly. • This player is compatible with multi-session discs and can play CD-Rs and CD-RWs on which MP3/WMA files are added. However, only the first session can be played. • Discs whose first session includes both music data and MP3 or WMA format data cannot be played. (2) Standard and restrictions Maximum directory levels 8 levels Maximum number of characters for a folder name/file name 32 characters Maximum number of folders 192 (Including empty folders, route folders, and folders that do not contain MP3/WMA files) Maximum number of files in a disc 255 (Including non-MP3/WMA files) AV AV–8 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (f) 3. File names (1) Only files with an extension of ".mp3" or ".wma" can be recognized and played as MP3 or WMA files. (2) Save MP3 or WMA files with an extension of ".mp3" or ".wma". NOTICE: If saving non-MP3 or non-WMA files with an extension of ".mp3" or ".wma", those files are wrongly recognized as MP3 or WMA files and played. A loud noise may occur and damage to the speaker may result. AVC-LAN DESCRIPTION (a) What is AVC-LAN? Example: Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100319E09 AV AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short to +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4. 5. AV–9 • If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the radio and navigation assembly is equipped, it is the master unit. • The radio receiver contains a resistor that is necessary to enable communication on the different AVC-LAN circuits. • The car audio system with an AVC-LAN circuit has a diagnostic function. • Each component has a specified number (3digit) called a physical address. Each function has a number (2-digit) called a logical address. COMMUNICATION SYSTEM OUTLINE (a) Components of the audio system communicate with each other via the AVC-LAN. (b) The master component of the AVC-LAN is a radio receiver with a 60 to 80 Ω resistor. This is essential for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the audio system will stop functioning. DIAGNOSTIC FUNCTION OUTLINE (a) The audio system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. AV AV–10 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 BASIC INSPECTION (a) Turn the ignition switch ON. (b) Check whether or not the radio receiver turns on. Result Result Proceed to Radio receiver turns on A Radio receiver does not turn on B B Go to step 6 A 4 CHECK FOR DTC (a) Check for DTCs and note any codes that are output. (b) Delete the DTCs. (c) Recheck for DTCs by simulating the operation indicated by the DTCs. HINT: • If the system cannot enter the diagnosis mode, inspect the AVC-LAN and all the components that connect to the AVC-LAN for short circuits and repair or replace the problem part. • Even if the malfunction symptom is not confirmed, check the DTCs. This is because the system stores past DTCs. • Check and clear past DTCs. Then check for DTCs. AV Result Result Proceed to DTC is output again A DTC is not output B AV–11 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM B Go to step 6 A 5 DIAGNOSTIC TROUBLE CODE CHART Find the output code on the diagnostic trouble code chart (See page AV-27). NEXT Go to step 8 6 PROBLEM SYMPTOMS TABLE Refer to the problem symptoms table (See page AV-13). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page AV-15). NEXT 8 ADJUST, REPAIR OR REPLACE NEXT 9 CONFIRMATION TEST NEXT END AV AV–49 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition 01-DF *1 The device with a display fails and the master is switched to the audio device. Also when a communication error between sub-master (audio) and master occurs, this code is stored. Trouble Area • • • • Radio receiver power source circuit AVC-LAN circuit between the radio receiver and the component which has stored this code Radio receiver Component which has stored this code HINT: *1: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch in the ACC or ON position, this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-146). If the power source circuit is operating normally, proceed to the next step. NEXT AV AV–50 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG REPLACE RADIO RECEIVER 6 Speaker System Wire Harness View: R4 TXM- TXM+ E119766E04 OK 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV AV–51 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: (*1) Service Check Mode (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component Physical address Stereo component amplifier 440 Television display assembly 1B0 HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AV AV–52 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 4 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 R1 ATX+ (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 TX- S22 9 TXM+ R4 (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 TXM+ R4 6 Speaker System: (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- AV E119767E03 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG AV–53 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO RECEIVER (a) Replace the radio receiver with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE COMPONENT WHICH HAS STORED THIS CODE OK END AV AV–54 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from the master device cannot be received. - 01-E3 The registration demand signal from the slave device is output. Or the registration demand signal is output by receiving connection confirmation signal from the submaster device. - 01-E4 The multiple frame transmission is incomplete. - HINT: Even if no fault is present, this a trouble code may be stored depending on the battery condition or engine start voltage. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. These DTCs do not indicate a malfunction. AV AV–55 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E2 ON / OFF Indication Parameter Error DESCRIPTION DTC No. 01-E2 DTC Detection Condition The command for ON/OFF control from the master device has a problem. Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO RECEIVER NEXT END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–1 AUDIO AND VISUAL SYSTEM PRECAUTION 1. OBSERVE HANDLING AND OPERATIONAL PRECAUTIONS (a) Please explain to the customer that when the negative terminal is disconnected from the battery, the channel information memory of the AM/FM broadcast stations in the radio receiver is cleaned. If necessary, make a note of the recorded channel information before the negative terminal is disconnected, then reset the information after the negative terminal is reconnected. (b) The removal/installation of the radio receiver should be performed after all audio CDs are ejected from the radio receiver. HINT: If audio CDs cannot be ejected due to the malfunction of the radio receiver, do not try to drag them out by force. Bring the vehicle to the repair plant. (c) Fasten the earth bolt securely when the antenna cord is removed or installed. HINT: Failing to fasten the earth bolt securely causes noise at the time of radio wave reception. (d) Do not touch the cone paper of the speaker. AV AV–2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM PARTS LOCATION FRONT CENTER SPEAKER - FRONT STEREO COMPONENT SPEAKER RADIO RECEIVER FRONT SIDE SPEAKER - FRONT NO. 2 SPEAKER RH TELEVISION DISPLAY ASSEMBLY (*2) SPIRAL CABLE STEREO JACK ADAPTER WINDOW GLASS ANTENNA WIRE STEERING PAD SWITCH ENGINE ROOM R/B (*1) REAR NO. 2 SPEAKER FRONT SIDE SPEAKER - FRONT NO. 2 SPEAKER LH FRONT SIDE SPEAKER - FRONT NO. 1 SPEAKER NO. 1 SPEAKER WITH BOX REAR SPEAKER - WOOFER BOX SPEAKER ASSEMBLY STEREO COMPONENT AMPLIFIER *1: 10 Speaker System *2: with Rear Seat Entertainment System AV E119756E01 AV–56 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-10 DVD Player Mechanical Error DTC 44-11 DVD Insertion and Ejection Error DTC 44-12 DVD Reading Abnormal DESCRIPTION DTC No. DTC Detecting Condition 44-10 A mechanical error in the DVD player is detected while the DVD is not being inserted or ejected. 44-11 DVD insertion or ejection is failed. 44-12 DVD read problem occurs. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END AV REPLACE TELEVISION DISPLAY ASSEMBLY Trouble Area Television display assembly AV–57 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-41 Wrong Disc DTC 44-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detecting Condition 44-41 An unsuitable disc is inserted. 44-42 The disc cannot be read. Trouble Area • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT 3 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT AV AV–58 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END AV REPLACE TELEVISION DISPLAY ASSEMBLY AV–59 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-43 DVD-ROM Abnormal DESCRIPTION DTC No. 44-43 DTC Detecting Condition Trouble Area • • DVD-ROM operation is abnormal. DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER DVD IS INSERTED (a) Make sure that the DVD is a video DVD or a CD with an MP3 file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal DVD or CD HINT: • Translucent or uniquely-shaped DVDs or CDs cannot be played. • For details on playable DVDs or CDs, refer to the Owner's Manual. NG END OK 2 CHANGE DISC (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END AV AV–60 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-44 DVD Error DTC 44-48 Excess Current DTC 44-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. DTC Detecting Condition 44-44 Operation error in the DVD mechanism. 44-48 Excess current is present in the DVD player. 44-50 Malfunction in insertion / ejection system. Trouble Area Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the television display assembly. OK: Malfunction disappears. NG OK END AV REPLACE TELEVISION DISPLAY ASSEMBLY AV–61 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-45 Eject Error DTC 44-51 Elevator Error DTC 44-52 Clamp Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 44-45 Disc cannot be ejected. 44-51 Mechanical error occurs during elevator operation. 44-52 Error occurs in DVD player clamp. Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK TELEVISION DISPLAY ASSEMBLY (a) Check if a disc can be changed, inserted or ejected normally. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END AV AV–62 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-46 Scratched / Reversed Disc DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 44-46 Scratches or dirt is found on DVD surface or DVD is set upside down. • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT DISC IS INSERTED PROPERLY (a) Check whether or not the disc is inserted upside down. OK: Disc is properly inserted. NG INSPECT DISC OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 3 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. AV I100151 NEXT AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–63 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END AV AV–64 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-47 High Temperature DESCRIPTION DTC No. 44-47 DTC Detecting Condition Trouble Area Sensor detects that DVD unit temperature is high. (Over 80°C) Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK TELEVISION DISPLAY ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the television display assembly becomes sufficiently low, and start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG OK END AV REPLACE TELEVISION DISPLAY ASSEMBLY AV–65 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-78 DSP Error DESCRIPTION DTC No. 44-78 DTC Detecting Condition Trouble Area An error occurs during the decode process (MP3/ WMA). - INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NOTICE: • This code may be output even if there is no malfunction. • If this code is output frequently, replace the television display assembly. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END AV AV–66 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 44-7D Disc cannot be Played DTC 44-7E No Playable Files DTC 44-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area • • An incompatible MP3/WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 44-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 44-7F A copy-protected file, which cannot be played, is used. 44-7D • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG OK END AV REPLACE TELEVISION DISPLAY ASSEMBLY AV–67 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-10 CD Player Mechanical Error DTC 62-11 CD Insertion and Ejection Error DTC 62-12 CD Reading Abnormal DTC 63-10 CD Changer Mechanical Error DTC 63-11 CD Insertion and Ejection Error DTC 63-12 CD Reading Abnormal DESCRIPTION DTC No. DTC Detecting Condition 62-10 A mechanical error in the CD player is detected while the CD is not being inserted or ejected. 62-11 CD insertion or ejection is failed. 62-12 CD read problem occurs. 63-10 A mechanical error in the CD changer is detected while the CD is not being inserted or ejected. 63-11 CD insertion or ejection is failed. 63-12 CD read problem occurs. Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO RECEIVER NEXT END AV AV–68 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-41 Wrong Disc DTC 62-42 Disc cannot be Read DTC 63-41 Wrong Disc DTC 63-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detecting Condition 62-41 An unsuitable disc is inserted. 62-42 The disc cannot be read. 63-41 An unsuitable disc is inserted. 63-42 The disc cannot be read. Trouble Area • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. AV I100151 NEXT AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 AV–69 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 4 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–70 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-43 CD-ROM Abnormal DTC 63-43 CD-ROM Abnormal DESCRIPTION DTC No. DTC Detecting Condition 62-43 CD-ROM operation is abnormal 63-43 CD-ROM operation is abnormal Trouble Area • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CHANGE DISC OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another and recheck. (1) Replace the CD with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. AV NG REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–71 OK END AV AV–72 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-44 CD Abnormal DTC 62-48 Excess Current DTC 62-50 Tray Insertion / Ejection Error DTC 63-44 CD Abnormal DTC 63-48 Excess Current DTC 63-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. DTC Detecting Condition 62-44 Operation error in the CD mechanism 62-48 Excess current is present in the CD player 62-50 Malfunction in insertion/ejection system 63-44 Operation error in the CD mechanism 63-48 Excess current is present in the CD changer 63-50 Malfunction in insertion/ejection system Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio receiver. OK: Malfunction disappears. NG AV OK END REPLACE RADIO RECEIVER AV–73 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-45 Eject Error DTC 62-51 Elevator Error DTC 62-52 Clamp Error DTC 63-45 Eject Error DTC 63-51 Elevator Error DTC 63-52 Clamp Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 62-45 Disc cannot be ejected. 62-51 Mechanical error occurs during elevator operation. 62-52 Error occurs in CD player clamp. 63-45 Magazine cannot be ejected. 63-51 Mechanical error occurs during elevator operation. 63-52 Error occurs in CD changer clamp. Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Check if a disc can be changed, inserted or ejected normally. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–12 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFICATION OF NOISE SOURCE 1. Frequency 300 kHz 30 kHz Designation Radio Description (a) Radio frequency band (1) Radio broadcasts use the radio frequency bands shown in the table below. LF MF Modulation HF VHF FM Amplitude modulation MF: Medium Frequency 300 MHz 30 MHz AM Radio Wave LF: Low Frequency 30 MHz HF: High Frequency Frequency modulation VHF: Very High Frequency E108734E01 (b) Service area (1) The service areas of AM and FM broadcasts are vastly different. Sometimes an AM broadcast can be received very clearly but an FM stereo cannot. FM stereo has the smallest service area, and is prone to pick up static and other types of interference such as noise. (c) Radio reception problems HINT: In addition to static, other problems such as "phasing", "multipath", and "fade out" exist. These problems are not caused by electrical noise, but by the radio signal propagation method itself. FM (Stereo) FM (Monaural) AM E108735E01 Phasing Ionosphere I100011E02 AV (1) Phasing AM broadcasts are susceptible to electrical interference and another kind of interference called phasing. Occurring only at night, phasing is the interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off the ionosphere and the other signal is received directly from the transmitter. AV–13 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (2) Multipath Multipath is a type of interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off buildings or mountains and the other signal is received directly from the transmitter. Multipath I100012E02 (3) Fade out Fade out is caused by objects (buildings, mountains, and other such large obstacles) that deflect away part of a signal, resulting in a weaker signal when the object is between the transmitter and vehicle. High frequency radio waves, such as FM broadcasts, are easily deflected by obstructions. Low frequency radio waves, such as AM broadcasts, are much more difficult to deflect. (d) Noise problem Technicians must have a clear understanding about each customer's noise complaint. Use the following table to diagnose noise problems. Fade Out I100013E02 Radio Frequency Noise Occurrence Condition Presumable Cause AM Noise occurs in a specified area Foreign noise AM Noise occurs when listening to an intermittent broadcast An identical program transmitted from multiple towers can cause noise where the signals overlap AM Noise occurs only at night Music beat from a distant broadcast FM Noise occurs while driving in a specified area Multipath or phasing noise resulting from a change in FM frequency HINT: If the noise does not match the examples above, refer to the descriptions about phasing and multipath. AV AV–74 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-46 Scratched / Reversed Disc DTC 63-46 Scratched / Reversed Disc DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 62-46 Scratches or dirt is found on CD surface or CD is set upside down. 63-46 Scratches or dirt is found on CD surface or CD is set upside down. • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG REINSERT CD PROPERLY OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG I100152 OK AV CHANGE DISC AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 AV–75 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT 4 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REINSERT CD PROPERLY (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page AV-19). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–76 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-47 High Temperature DTC 63-47 High Temperature DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 62-47 Sensor detects that CD unit temperature is high. (Over 80°C) 63-47 Sensor detects that CD unit temperature is high. (Over 80°C) Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio receiver becomes sufficiently low, and start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AV–77 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-78 DSP Error DTC 63-78 DSP Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 62-78 An error occurs during the decode process (MP3/ WMA). - 63-78 An error occurs during the decode process (MP3/ WMA). - INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NOTICE: • These codes may be output even if there is no malfunction. • If these codes are output frequently, replace the radio receiver. 1 CLEAR DTC (a) Clear the DTCs (See page AV-19). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–150 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM REAR SEAT ENTERTAINMENT SYSTEM BODY ELECTRICAL AUDIO / VISUAL PARTS LOCATION FRONT CENTER SPEAKER - RADIO AND NAVIGATION ASSEMBLY (*2) -FRONT STEREO COMPONENT SPEAKER - RADIO RECEIVER (*1) FRONT SIDE SPEAKER FRONT SIDE SPEAKER -FRONT NO. 2 SPEAKER LH -FRONT NO. 2 SPEAKER RH ENGINE ROOM R/B TEREVISION DISPLAY ASSEMBLY VIDEO TERMINAL FRONT SIDE SPEAKER -FRONT NO. 1 SPEAKER REAR SPEAKER REAR NO. 2 SPEAKER (*1) STEREO COMPONENT AMPLIFIER NO. 1 SPEAKER WITH BOX -WOOFER BOX SPEAKER ASSEMBLY AV *1: without Navigation System *2: with Navigation System E119737E01 AV–151 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM SYSTEM DIAGRAM Radio Receiver (*1) Radio and Navigation Assembly (*2) Stereo Component Amplifier Speakers (*2) Television Display Assembly Remote Controller Wireless Headphone Video Terminal : Display Signal *1: without Navigation System *2: with Navigaiton System : Sound Signal : AVC-LAN E119738E01 AV AV–78 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-7D Disc cannot be Played DTC 62-7E No Playable Files DTC 62-7F Copyright Protection Error DTC 63-7D Disc cannot be Played DTC 63-7E No Playable Files DTC 63-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area • • An incompatible MP3/WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 62-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 62-7F A copy-protected file, which cannot be played, is used. 63-7D • • An incompatible MP3/WMA file is used Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 63-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 63-7F A copy-protected file, which cannot be played, is used. 62-7D • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG OK AV END REPLACE RADIO RECEIVER AV–79 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Noise Occurs INSPECTION PROCEDURE 1 NOISE CONDITION (a) Check in which direction the noise comes from (front left or right, or rear left or right). (1) Check in which direction the noise comes from. OK: The location of the noise source can be determined. NG Go to step 3 OK 2 CHECK SPEAKERS (a) Check the installation conditions of the speaker units that are located near the noise source and that there are no cracks, scratches, deformation, or other failures. Result Condition Proceed to A speaker is installed incorrectly A Foreign objects are in the speaker B A speaker cone paper is broken C No malfunction is found D A REINSTALL SPEAKER B REMOVE FOREIGN OBJECT C REPLACE SPEAKER D 3 CHECK NOISE CONDITIONS (a) Check the noise condition. HINT: The radio has a noise prevention function to reduce noise when listening to the radio. If a loud noise occurs, check whether the ground at the antenna mounting base and the noise prevention unit are installed and wired correctly. Conditions under which noise occurs Noise Source Noise increases when the accelerator pedal is depressed, but stops when the engine is stopped. Generator Noise occurs during A/C or heater operation. Noise occurs when the vehicle accelerates rapidly on an unpaved road or after the ignition switch is turned ON or ACC. Blower motor Fuel pump AV AV–80 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Conditions under which noise occurs Noise Source Noise occurs when the horn switch is pressed and released or when pressed and held. Horn Noise occurs synchronously with the blink of the turn signal. Flasher Noise occurs during window washer operation. Washer Noise occurs while the engine is running, and continues even after the engine is stopped. Noise occurs during wiper operation. Water temperature sensor Wiper Noise occurs when the brake pedal is depressed. Stop light switch Others Static electricity HINT: • In the chart's left column, find the situation that matches the customer's complaint. Then, in the right column, find the part that is causing the noise. Check the noise filter on or for the part. • To save time and avoid a misdiagnosis, first make sure that the noise is not coming from outside the vehicle. • Noise should be removed in descending order of loudness. • Setting the radio to a frequency where no signal is received may make recognition of the noise problem easier. OK: The noise source can not be determined. NG REPAIR OR REPLACE NOISE SOURCE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–81 Pressing Power Switch does not Turn on System INSPECTION PROCEDURE 1 CHECK VEHICLE CONDITION (a) Check that conditions in the cabin are not likely to cause condensation. HINT: This problem occurs when the cabin is humid and the temperature changes rapidly. This may produce condensation, resulting in a short circuit. OK: Condensation is not likely to be produced. NG DRY OUT CABIN AND RECHECK CONDITION OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–82 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check radio receiver setting. (1) Check that the volume is not set to "0". (2) Check that "MUTE" is off. OK: The volume is not set to "0" and "MUTE" is off. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–83 Sound Quality is Bad Only when CD is Played (Volume is Too Low) INSPECTION PROCEDURE 1 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another one and recheck. (1) Check if the problem recurs using another CD. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–84 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD cannot be Ejected INSPECTION PROCEDURE 1 CHECK OPERATION (a) Press the CD EJECT switch of the radio receiver for 2 seconds or more and check that the CD is ejected. OK: CD is ejected. NG REPLACE RADIO RECEIVER OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Insert another CD and check if it is ejected. OK: CD is ejected. NG OK END AV REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–85 CD cannot be Inserted / Played or CD is Ejected Right After Insertion INSPECTION PROCEDURE 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD. HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CHANGE DISC OK 2 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG REINSERT CD PROPERLY OK 3 CHECK CD (a) Clean the disc by wiping it with a soft cloth from the inside to the outside in a radial direction. OK: Malfunction disappears. NOTICE: Do not use a conventional record cleaner or antistatic preservative. NG I100151 Go to step 4 AV AV–86 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK END 4 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with a normal one and check that the malfunction disappears. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–87 CD Sound Skips INSPECTION PROCEDURE 1 CHECK CD (a) Check the CD. OK: The CD is clean. HINT: If dirt is on the CD surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NG CLEAN CD OK 2 CHECK CD (a) Check that the CD is not deformed or cracked. OK: No deformation or cracks on the CD. NG CHANGE DISC I100152 OK 3 CHECK OPERATION USING ANOTHER CD (a) Check using another CD. (1) Check if the problem recurs using another CD. OK: The problem does not occur. OK END NG 4 CHECK RADIO RECEIVER (a) Check the radio receiver installation condition. (1) Check that the radio receiver is properly installed. OK: Radio receiver is properly installed. AV AV–88 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG OK REPLACE RADIO RECEIVER AV REINSTALL RADIO RECEIVER PROPERLY AV–89 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Broadcast cannot be Received or Poor Reception INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check the radio's automatic station search function. (1) Check the radio's automatic station search function by activating it. OK: The radio's automatic station search function works properly. OK REPLACE RADIO RECEIVER NG 2 INSPECT RADIO RECEIVER Wire Harness View (10 Speaker System): R1 (a) Disconnect the radio receiver connector R1 or R2. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition ANT - Body ground Ignition SW ON Radio SW ON 10 to 14 V NG ANT REPLACE RADIO RECEIVER Wire Harness View (6 Speaker System): R2 ANT AV E120110E01 AV–90 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 3 CHECK OPTIONAL COMPONENTS (a) Check optional components (sun-shade film, telephone antenna, etc.). (1) Check if any optional components, such as sunshade film or telephone antenna that may decrease reception capacity, are installed. OK: Optional components are installed. NOTICE: Do not remove any optional components installed by the customer without his or her consent. OK REMOVE OPTIONAL COMPONENTS AND CHECK AGAIN (SEE NOTICE ABOVE) NG 4 CHECK RADIO RECEIVER E050367 (a) Preparation for check (1) Remove the antenna plug from the radio receiver. (b) Check for noise (1) Turn the ignition switch to the ACC position with the radio receiver connector connected. (2) Turn the radio on and put into AM mode. (3) Place a screwdriver, thin wire, or other metal object on the radio receiver's antenna jack and check that noise can be heard from the speaker. OK: Noise occurs. NG OK AV REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5 AV–91 CHECK GLASS ANTENNA (a) Check for continuity of the antenna. HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTICE: When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. Tester Probe Tin Foil Antenna Wire NG REPAIR GLASS ANTENNA E111994E01 OK 6 CHECK ANTENNA CORD (a) Remove the antenna plug of the radio receiver and antenna. (b) Measure the resistance between the antenna and radio receiver to check for an open circuit in the antenna cord. Standard resistance: Below 1 Ω (c) Measure the resistance between the antenna cord and body ground to check for a short circuit in the antenna cord. Standard resistance: 10 kΩ or higher NG REPLACE ANTENNA CORD OK 7 REPLACE AMPLIFIER ANTENNA (a) Replace the amplifier antenna and check if radio broadcasts can be received normally. OK: Radio broadcasts can be received. OK NORMAL OPERATION AV AV–92 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPLACE RADIO RECEIVER AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–93 Poor Sound Quality in All Modes (Low Volume) INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Set "BASS", "MID", and "TREB" to the initial values and check that sound is normal. OK: Malfunction disappears. OK END NG 2 COMPARE WITH ANOTHER VEHICLE OF SAME MODEL (a) Compare with another vehicle of the same model. (1) Compare with another vehicle of the same model which does not have trouble to see if there is any difference in the sound quality. OK: No difference is found. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–94 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Leveliser) built into the radio receiver. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio sound even when vehicle noise increases (as vehicle noise increases, the volume is turned up etc.). HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Radio Receiver 3 R5 From A/C Control Assembly From Moon Roof Control ECU SPD From ECM From 4WD Control ECU From Tire Pressure Monitor ECU 5 C9 From Main Body ECU Combination Meter From Speed Sensor E120038E01 AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–95 INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: the vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG CHECK COMBINATION METER OK 2 INSPECT RADIO RECEIVER (a) Disconnect the radio receiver connector R5. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch to the ON position. Radio Receiver Wire Harness View: R5 SPD E120042E03 (4) Measure the voltage between terminal SPD of the radio receiver and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V REPLACE RADIO RECEIVER Below 2 V 0 Turn the wheel E110855E03 NG AV AV–96 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO RECEIVER) (a) Disconnect the radio receiver connector R5 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View: R5 Tester Connection Condition Specified Condition SPD - C9-5 Ignition switch OFF Below 1 Ω NG SPD Combination Meter (Left Side of Vehicle) Connector Front View: C9-5 E120043E01 OK AV REPAIR OR REPLACE HARNESS AND CONNECTOR AV–97 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO RECEIVER) (a) Disconnect the radio receiver connector R5 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View: R5 Tester Connection Condition Specified Condition SPD - Body ground Ignition switch OFF 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. SPD Combination Meter (Left Side of Vehicle) Connector Front View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR OR EACH ECU C9-5 E120043E01 OK REPLACE COMBINATION METER AV AV–98 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio receiver. If there is an open in the circuit, the audio system cannot be operated using the steering pad switch. If there is a short in the circuit, the same condition as that when the switch is continuously depressed occurs. Therefore, the radio receiver cannot be operated using the steering pad switch, and also the radio receiver itself cannot function. WIRING DIAGRAM Steering Pad SW LH Spiral Cable 12 A Volume- Volume+ Seek- 12 AU1 C13 Radio Receiver 7 R5 SW1 Seek+ 10 A EAU 11 A AU2 10 C13 6 R5 SWG MODE 11 C13 8 R5 SW2 E110885E07 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). AV AV–99 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 INSPECT RADIO RECEIVER Wire Harness View (10 Speaker System): R5 (a) Disconnect the radio receiver connector R5. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition SW1 - SWG No switch is pushed Approx. 100 kΩ SW1 - SWG SEEK+ switch: push Approx. 0 Ω SW1 - SWG SEEK- switch: push Approx. 0.3 kΩ SW1 - SWG VOL+ switch: push Approx. 1 kΩ SW1 - SWG VOL- switch: push Approx. 3.2 kΩ SW2 - SWG No switch is pushed Approx. 100 kΩ SW2 - SWG MODE switch: push Approx. 0 Ω SW2 NG SW1 Go to step 2 SWG Wire Harness View (6 Speaker System): R5 SW2 SW1 SWG E120024E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT STEERING PAD SWITCH LH (a) Disconnect the steering pad switch LH connector. (b) Measure the resistance according to the values in the table below. AV AV–100 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM A AU1 EAU AU2 I039169E04 Standard resistance Tester Connection Condition Specified Condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push Approx. 0 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.2 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push Approx. 0 Ω NG OK AV REPLACE STEERING PAD SWITCH LH AV–101 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: A EAU AU2 AU1 Tester Connection Spiral Cable Position EAU - EAU 2.5 rotations to the left Specified Condition Center Below 1 Ω 2.5 rotations to the right Center AU1 - AU1 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU2 - AU2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (See page RS-398). NG EAU AU2 AU1 REPLACE SPIRAL CABLE C13 E113447E07 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SPIRAL CABLE - RADIO RECEIVER) AV AV–14 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM PROBLEM SYMPTOMS TABLE • Before inspecting the suspected areas listed in the table below, check the fuse and relay. • Before inspecting the suspected areas listed in the table below, check for DTCs. • Methods used to verify the cause of the problem are listed in order of probability in the suspected area column. Audio Function: Symptom Pressing power switch does not turn on system. Panel switch does not function. No sound be heard from speakers. (Audio is mute.) (10 speaker system) No sound be heard from speakers. (Audio is mute.) (6 speaker system) Sound quality is bad in all modes. (Volume is too low.) (10 speaker system) AV Sound quality is bad in all modes. (Volume is too low.) (6 speaker system) ASL does not function. (10 speaker system) Suspected area See page 1. Proceed to "Pressing Power Switch does not Turn on System" AV-80 2. Radio receiver power source circuit AV-146 3. AVC-LAN circuit AV-128 4. Radio receiver AV-167 1. Steering pad switch circuit AV-97 2. AVC-LAN circuit AV-128 3. Radio receiver AV-167 1. Radio receiver power source circuit AV-146 2. Proceed to "No Sound can be Heard from Speakers" AV-81 3. Stereo component amplifier power source circuit AV-148 4. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-116 5. Speaker circuit AV-108 6. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-123 7. Proceed to "Mute Signal Circuit between Radio Receiver and Television Display Assembly" (*1) AV-125 8. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 9. Radio receiver AV-167 1. Radio receiver power source circuit AV-146 2. Proceed to "No Sound can be Heard from Speakers" AV-81 3. Speaker circuit AV-108 4. Proceed to "Mute Signal Circuit between Radio Receiver and Television Display Assembly" (*1) AV-125 5. Radio receiver AV-167 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" AV-92 2. Speaker circuit. AV-108 3. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-116 4. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-123 5. Proceed to "Mute Signal Circuit between Radio Receiver and Television Display Assembly" (*1) AV-125 6. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 7. Radio receiver AV-167 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" AV-92 2. Speaker circuit AV-108 3. Proceed to "Mute Signal Circuit between Radio Receiver and Television Display Assembly" (*1) AV-125 4. Radio receiver AV-167 Proceed to "Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter" AV-130 AV–15 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symptom ASL does not function. (6 speaker system) RSE sound cannot be heard or sound quality is bad. (*1) External device sound cannot be heard or sound quality is bad. (Stereo jack is used.) Abnormal noise occurs. (10 speaker system) Abnormal noise occurs. (6 speaker system) Radio broadcast cannot be received or poor reception. CD cannot be inserted/played or CD is ejected right after insertion. CD cannot be ejected. Suspected area See page Proceed to "Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter" AV-93 1. Radio receiver power source circuit AV-146 2. Television display assembly power source circuit AV-163 3. Proceed to "Sound Signal Circuit between Radio Receiver and Television Display Assembly" AV-118 4. Proceed to "Mute Signal Circuit between Radio Receiver and Television Display Assembly" AV-125 5. Radio receiver AV-167 6. Television display assembly AV-177 1. Radio receiver power source circuit AV-146 2. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter" AV-121 3. Stereo jack adapter AV-191 4. Radio receiver AV-167 1. Proceed to "Noise occurs" AV-78 2. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 3. Radio receiver AV-167 1. Proceed to "Noise occurs" AV-78 2. Radio receiver AV-167 Proceed to "Radio Broadcast cannot be Received or Poor Reception" AV-88 1. Radio receiver power source circuit AV-146 2. Proceed to "CD cannot be Inserted/Played or CD is Ejected Right After Insertion" AV-84 1. Radio receiver power source circuit AV-146 2. Proceed to "CD cannot be Ejected" AV-83 Sound quality is bad only when CD is played. (Volume is too low.) Proceed to "Sound Quality is Bad Only when CD is Played (Volume is Too Low)" AV-82 CD sound skips. Proceed to "CD Sound Skips" AV-86 1. Illumination circuit AV-101 2. Radio receiver AV-167 Radio receiver cannot be illuminated at night. *1: with Rear Seat Entertainment System Steering Pad Switch Function: Symptom Audio system cannot be operated with steering pad switch. Steering pad switch cannot be illuminated at night. Suspected area See page 1. Steering pad switch circuit AV-97 2. Radio receiver AV-167 1. Illumination circuit AV-101 2. Radio receiver AV-167 AV AV–102 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the radio receiver and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Steering Pad SW Spiral Cable 1 10 ILL+ EAU Radio Receiver 10 R2 (*1) 1 10 2 R1 ILL+ (*2) 6 R5 SWG 12 R1 ILL- TAIL Relay TAIL From J/B Fuse To Main Body ECU R13 Rheostat 5 E - 3 5 R3 (*1) (*2) *1: 6 Speaker System *2: 10 Speaker System E120025E01 INSPECTION PROCEDURE AV NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the supplemental restraint system (See page RS-1). AV–103 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 CHECK ILLUMINATION (a) Check if the illumination for the radio receiver, steering pad switch, glove box or others (hazard switch, cigarette lighter, etc.) comes on when the light control switch is turned to the HEAD or TAIL position. Result Result Proceed to Illumination comes on for all components except steering pad switch. A Illumination comes on for all components except radio receiver. B No illumination comes on (radio receiver, hazard switch, glove box, etc.). C Illumination comes on only for glove box and steering pad switch. D B Go to step 6 C GO TO LIGHTING SYSTEM D GO TO COMBINATION METER SYSTEM A 2 CHECK HARNESS AND CONNECTOR (BATTERY - SPIRAL CABLE) Spiral Cable Connector Front View: (a) Disconnect the spiral cable connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition ILL+ - Body ground Light control SW TAIL or HEAD 10 to 14 V ILL+ NG E121218E03 REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT STEERING PAD SWITCH LH (a) Disconnect the steering pad switch connector. (b) Connect the positive (+) lead to terminal ILL+ and the negative (-) lead to terminal EAU of the steering pad switch connector. AV AV–104 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Connector Front View: A E120027E01 (c) Check if the illumination for the steering pad switch comes on. OK: Illumination for the steering pad switch comes on. NG OK AV REPLACE STEERING PAD SWITCH LH AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–105 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: ILL+ EAU Tester Connection Spiral Cable Position EAU - EAU 2.5 rotations to the left Specified Condition Center Below 1 Ω 2.5 rotations to the right Center ILL+ - ILL+ 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (See page RS-398). Vehicle Side: NG REPLACE SPIRAL CABLE EAU ILL+ E113447E06 OK AV AV–106 5 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (SPIRAL CABLE - RADIO RECEIVER) Radio Receiver (10 Speaker System) Wire Harness View: R5 (a) Disconnect the connectors from the radio receiver and spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition SWG - EAU Always Below 1 Ω SWG - Body ground Always 10 kΩ or higher NG Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR SWG Radio Receiver (6 Speaker System) Wire Harness View: R5 SWG Spiral Cable Connector Front View: EAU E120029E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–107 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 6 CHECK HARNESS AND CONNECTOR (BATTERY - RADIO RECEIVER) Wire Harness View (10 Speaker System): (a) Disconnect the radio receiver connector R1 or R2. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V R1 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ILL+ Wire Harness View (6 Speaker System): R2 ILL+ E120030E03 OK AV AV–108 7 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - LIGHT CONTROL RHEOSTAT) Radio Receiver (10 Speaker System) Wire Harness View: R1 (a) Disconnect the radio receiver connector and light control rhepstat connector. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition ILL- - R13-3 Always Below 1 Ω ILL- - Body ground Always 10 kΩ or higher NG Specified Condition REPAIR OR REPLACE HARNESS OR CONNECTOR ILLRadio Receiver (6 Speaker System) Wire Harness View: R3 ILLLight Control Rheostat Wire Harness View: R13 R13-3 E120031E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–109 Speaker Circuit DESCRIPTION • When the vehicle has a built-in type amplifier, a sound signal is sent from the radio receiver to the speakers via the "6 Speaker System" circuit. • When the vehicle has a separate type amplifier, a sound signal from the radio receiver is amplified by the stereo component amplifier and then transmitted to the speaker via the "10 Speaker System" circuit. If there is a short in this circuit, the stereo component amplifier detects it and stops output to the speakers. Thus sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. AV AV–110 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM WIRING DIAGRAM 6 Speaker System: S20 Front No. 2 Speaker LH 2 D22 Front No. 1 Speaker LH 4 1 Radio Receiver 2 R2 FL+ 6 2 1 3 R2 FL- S21 Front No. 2 Speaker RH 2 D23 Front No. 1 Speaker RH 4 1 1 R2 FR+ 5 2 1 3 R2 FR- 2 1 R16 Rear Speaker LH R3 RL+ 6 2 R3 RL- 1 1 R17 Rear Speaker RH R3 RR+ 5 2 R3 RR- E121225E02 AV AV–111 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 10 Speaker System: Stereo Component Amplifier 1 4 S23 RL+ 2 13 S23 RL- 1 5 S23 RR+ 2 14 S23 RR- R16 Rear Speaker LH R17 Rear Speaker RH Woofer Box Speaker 2 WF+ W4 8 S23 WFL+ 4 WF- 19 S23 WFL- W4 9 S23 WFR+ 1 WF+ W4 3 20 S23 WFR- WF- W4 4 4 R19 Rear No. 2 Speaker LH 2 S23 DRS+ R20 Rear No. 2 Speaker RH 3 11 S23 DRS- 3 E119760E03 AV AV–112 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM C5 Front Stereo Component Speaker 3 3 S23 CTR+ 12 4 S23 CTR- S21 Front No. 2 Speaker RH 2 4 1 3 7 S23 FR+ 1 D23 Front No. 1 Speaker RH 2 18 S23 FR- S20 Front No. 2 Speaker LH 2 4 1 3 6 S23 FL+ 1 D22 Front No. 1 Speaker LH 2 17 S23 FL- E120023E03 AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–113 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR Stereo Component Amplifier (10 Speaker System) Wire Harness View: FR+ WFL+ WFR+ FL+ RR+ RL+ CTR+ DRS+ S23 WFRWFLFR- FL- RR- DRSCTRRL- Radio Receiver (6 Speaker System) Wire Harness View: R2 R3 FR+ RL+ FL+ RR+ FLRRRLFRFront No. 1 Speaker, Rear Speaker Connector Front View: D22 D23 R16 R17 Front No. 2 Speaker, Front Stereo Component Speaker (*1) Rear No. 2 Speaker (*1) Connector Front View: R19 (*1) R20 (*1) S20 C5 (*1) S21 *1: 10 Speaker System E120041E01 (a) Disconnect the connectors shown in the illustration from the stereo component amplifier or radio receiver and speakers. (b) 10 Speaker System: Measure the resistance between each of the front No. 2 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (c) 6 speaker System: Measure the resistance between each of the front No. 2 speakers and the radio receiver to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (d) Measure the resistance between each of the front No. 2 speakers and each of the front No. 1 speakers to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (e) 10 Speaker System: Measure the resistance between each of the rear speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (f) 6 Speaker System: Measure the resistance between each of the rear speakers and the radio receiver to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (g) 10 Speaker System: Measure the resistance between each of the rear No. 2 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (h) 10 Speaker System: Measure the resistance between the front stereo component speaker and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω AV AV–114 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (i) Woofer Box Speaker Connector Front View: W4 (j) E120044E02 10 Speaker System: Measure the resistance between the woofer box speaker and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω Measure the resistance between the each speaker and body ground to check for a short circuit in the wire harness. Standard resistance: 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT FRONT NO. 1 SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: 10 Speaker System: 4 to 6 Ω 6 Speaker System: Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER OK 3 INSPECT REAR SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. 10 Speaker System: Approximately 2.4 Ω 6 Speaker System: Approximately 4 Ω NG REPLACE REAR SPEAKER OK 4 AV INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when another speaker in good condition is installed. Standard: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speaker. AV–115 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • When there is a possibility that either the right or left front speaker is detective, inspect by interchanging the right one with the left one. • Perform the above inspection on both LH and RH sides. OK REPLACE FRONT NO. 2 SPEAKER NG 5 CONFIRM MODEL Result Result Proceed to 10 Speaker System A 6 Speaker System B B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A 6 INSPECT WOOFER BOX SPEAKER (a) Resistance check. (1) Measure the resistance according to the value(s) in the table below. NOTICE: The speaker should not be removed for checking. Standard resistance Tester Connection Condition Specified Condition 1-3 Always Approximately 1.2 Ω 2-4 Always Approximately 1.2 Ω E120044 NG REPLACE WOOFER BOX SPEAKER OK 7 INSPECT REAR NO. 2 SPEAKER (a) Check that the malfunction disappears when another speaker in good condition is installed. OK: Malfunction disappears. HINT: • Connect all the connectors to the rear No. 2 speaker. • When there is a possibility that either the right or left rear speaker is detective, inspect by interchanging the right one with the left one. OK REPLACE REAR NO. 2 SPEAKER AV AV–116 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG 8 INSPECT FRONT STEREO COMPONENT SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: 1.2 to 2.2 Ω NG REPLACE FRONT STEREO COMPONENT SPEAKER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–166 AUDIO / VISUAL – RADIO RECEIVER RADIO RECEIVER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY RADIO RECEIVER ASSEMBLY W/ BRACKET INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER AIR CONDITIONING CONTROL ASSEMBLY INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER CONSOLE UPPER REAR PANEL SUB-ASSEMBLY INSTRUMENT PANEL FINISH PLATE CONSOLE PANEL SUB-ASSEMBLY UPPER RADIO RECEIVER RADIO NO. 1 BRACKET AV RADIO NO. 2 BRACKET E115638E01 AUDIO / VISUAL – RADIO RECEIVER AV–167 REMOVAL 1. REMOVE INSTRUMENT PANEL FINISH PLATE (See page IP-6) 2. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-7) 3. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page IP-8) 4. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 5. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 6. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (See page IP-7) 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER (See page IP-8) 8. REMOVE RADIO RECEIVER (w/ Bracket) (a) Remove the 2 bolts. (b) Disconnect the connectors and remove the radio receiver assembly with bracket. 9. REMOVE RADIO NO. 1 BRACKET (a) Remove the 4 screws and radio No. 1 bracket. E115642 I033306 10. REMOVE RADIO NO. 2 BRACKET (a) Remove the 4 screws and radio No. 2 bracket. I033040 AV AV–117 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION The radio receiver sends a sound signal to the stereo component amplifier through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Stereo Component Amplifier 6 Radio Receiver (Shielded) (Shielded) 10 SLD S22 2 19 L- S22 R1 L- L+ 3 S22 9 R1 L+ R- 4 S22 18 R1 R- 5 8 R+ S22 R1 R1 SLD R+ E120032E03 AV AV–118 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the connectors from the radio receiver and stereo component amplifier. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View: R1 L+ SLD L- R+ R- Stereo Component Amplifier Wire Harness View: Tester Connection Condition Specified Condition L+ - L+ Always Below 1 Ω L- - L- Always Below 1 Ω R+ - R+ Always Below 1 Ω R- - R- Always Below 1 Ω SLD - SLD Always Below 1 Ω L+ - Body ground Always 10 kΩ or higher L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher R- - Body ground Always 10 kΩ or higher SLD - Body ground Always 10 kΩ or higher S22 NG R- REPAIR OR REPLACE HARNESS OR CONNECTOR L- SLD R+ L+ E120033E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–119 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Television Display Assembly DESCRIPTION The television display assembly sends a sound signal to the radio receiver through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier or radio receiver (built-in amplifier), and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio receiver, or speakers. WIRING DIAGRAM Television Display Assembly Radio Receiver (Shielded) 27 CSLD 1 R4 CDR+ 2 R4 R18 3 29 CDR- R4 CDL+ 4 R4 CDL- 5 R4 R18 SG1 28 R+ R18 R30 R18 L+ 31 R18 L- E120034E04 AV AV–120 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - TELEVISION DISPLAY ASSEMBLY) Radio Receiver (10 Speaker System) Wire Harness View: (a) Disconnect the connectors from the television display assembly and radio receiver. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition CDR+ - R+ Always Below 1 Ω R4 CDLCDL+ CSLD CDR+ CDRRadio Receiver (6 Speaker System) Wire Harness View: R4 CSLD CDR+ CDRTelevision Display Assembly Wire Harness View: R18 LL+ OK AV SG1 R- R+ E120035E05 Always Below 1 Ω Always Below 1 Ω CDL- - L- Always Below 1 Ω CSLD - SG1 Always Below 1 Ω R- - Body ground Always 10 kΩ or higher L+ - Body ground Always 10 kΩ or higher L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher SG1 - Body ground Always 10 kΩ or higher NG CDLCDL+ CDR- - RCDL+ - L+ REPAIR OR REPLACE HARNESS OR CONNECTOR AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–121 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Reconnect the television display assembly connector. (b) Check the waveform according to the conditions shown in the table below. Wire Harness View: R18 L- L+ R- R+ E120036E05 Standard Tester Connection Condition Specified Condition R+ - Body ground Voice sound is being produced A waveform synchronized with sound is output R- - Body ground Voice sound is being produced A waveform synchronized with sound is output L+ - Body ground Voice sound is being produced A waveform synchronized with sound is output L- - Body ground Voice sound is being produced A waveform synchronized with sound is output NG REPLACE TELEVISION DISPLAY ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–122 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter DESCRIPTION The stereo jack adapter sends an external device sound signal to the radio receiver through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier or radio receiver, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio receiver, or speakers. WIRING DIAGRAM Stereo Jack Adapter Radio Receiver 19 R5 AUXI 16 R5 ASGN 2 ARO S31 15 R5 ARI 1 ALO S31 17 R5 ALI 4 AUXO S31 3 ASGN S31 (Shielded) E121224E02 AV AV–123 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO JACK ADAPTER) (a) Disconnect the connectors from the stereo jack adapter and radio receiver. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Radio Receiver (10 Speaker System) R5 Tester Connection Condition Specified Condition AUXO - AUXI Always Below 1 Ω ASGN - ASGN Always Below 1 Ω ARO - ARI Always Below 1 Ω ALO - ALI Always Below 1 Ω ASGN AUXO - Body ground Always 10 kΩ or higher AUXI ASGN - Body ground Always 10 kΩ or higher ARO - Body ground Always 10 kΩ or higher ALO - Body ground Always 10 kΩ or higher ALI ARI Wire Harness View: Radio Receiver (6 Speaker System) NG REPAIR OR REPLACE HARNESS OR CONNECTOR R5 ASGN AUXI ARI ALI Connector Front View: Stereo Jack Adapter S31 AUXO ALO ARO ASGN E124113E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–124 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION This circuit sends a signal to the stereo component amplifier to mute noise. Because of that, the noise produced by changing the sound source ceases. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier is normal, no sound, or only an extremely small sound, can be produced. WIRING DIAGRAM Stereo Component Amplifier Radio Receiver 1 MUTE 7 R1 MUTE S22 E110892E16 INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: S22 MUTE AV Condition Specified Condition MUTE - Body ground Turn ignition switch to ACC, Audio system is playing → Changing Above 3.5 V → Below 1 V OK E120037E02 NG Tester Connection PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–125 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the radio receiver connector R1 and stereo component amplifier connector S22. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio Receiver Wire Harness View: R1 Tester Connection Condition Specified Condition MUTE - MUTE Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR MUTE Stereo Component Amplifier Wire Harness View: S22 MUTE E120033E04 OK 3 REPLACE WOOFER BOX SPEAKER ASSEMBLY (BUILT-IN STEREO COMPONENT AMPLIFIER) (a) Replace the stereo component amplifier and check if the audio system operates normally. OK: The audio system operates normally. OK END NG REPLACE RADIO RECEIVER AV AV–126 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Mute Signal Circuit between Radio Receiver and Television Display Assembly DESCRIPTION The radio receiver controls the volume according to the MUTE signal from the television display assembly. The MUTE signal is sent to reduce noise and a popping sound generated when switching the mode, etc. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the radio receiver is normal, no sound or, only an extremely small sound, can be produced. WIRING DIAGRAM Television Display Assembly Radio Receiver 26 6 R4 MUTE LMUT R18 E110892E17 INSPECTION PROCEDURE 1 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: R18 LMUT AV E120036E06 NG Tester Connection Condition Specified Condition LMUT - Body ground Turn ignition switch to ACC, RSE system is playing → Changing mode Above 3.5 V → Below 1 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–127 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - TELEVISION DISPLAY) Radio Receiver (10 Speaker System) Wire Harness View: (a) Disconnect the radio receiver connector R4 and television display assembly connector R18. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection R4 Condition Specified Condition MUTE - LMUT Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR MUTE Radio Receiver (6 Speaker System) Wire Harness View: R4 MUTE Television Display Assembly Wire Harness View: R18 LMUT E120035E06 OK 3 REPLACE TELEVISION DISPLAY ASSEMBLY (a) Replace the television display assembly and check if the audio system operates normally. OK: The audio system operates normally. OK END AV AV–128 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPLACE RADIO RECEIVER AV AV–129 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the audio system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the audio system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG REPLACE RADIO RECEIVER 6 Speaker System Wire Harness View: R4 TXM- TXM+ E119766E04 OK 2 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). AV AV–130 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Disconnect all connectors in all AVC-LAN circuits. (2) Check for an open or short in all AVC-LAN circuits. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 TXM+ R4 (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 TX- S22 9 R1 ATX+ (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 6 Speaker System: TXM+ R4 (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- E119767E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–131 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Leveliser) built into the stereo component amplifier. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio sound even when vehicle noise increases (as vehicle noise increases, the volume is turned up etc.). HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Stereo Component Amplifier 11 S22 SPD From A/C Control Assembly From Moon Roof Control ECU From ECM From 4WD Control ECU From Tire Pressure Monitor ECU 5 C9 From Main Body ECU Combination Meter From Speed Sensor E120038E04 AV AV–132 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG CHECK COMBINATION METER OK 2 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connector S22. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch to the ON position. Stereo Component Amplifier Wire Harness View: S22 SPD E120039E02 (4) Measure the voltage between terminal SPD of the stereo component amplifier and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. NG 4.5 to 14 V Below 2 V 0 AV Turn the wheel E110855E01 Go to step 3 AV–133 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK REPLACE WOOFER BOX SPEAKER ASSEMBLY (BUILT- IN STEREO COMPONENT AMPLIFIER) 3 CHECK HARNESS AND CONNECTOR (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the stereo component amplifier connector S22 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: S22 Tester Connection Condition Specified Condition SPD - C9-5 Ignition switch OFF Below 1 Ω NG SPD REPAIR OR REPLACE HARNESS OR CONNECTOR Combination Meter (Left Side of Vehicle) Connector Front View: C9-5 E120040E01 OK AV AV–134 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the stereo component amplifier connector S22 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: S22 SPD Combination Meter (Left Side of Vehicle) Connector Front View: C9-5 E120040E01 OK REPLACE COMBINATION METER AV Tester Connection Condition Specified Condition SPD - Body ground Ignition switch OFF 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OR CHECK EACH ECU AV–135 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Receiver Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 E110917E05 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the subcode in the example shown in the illustration. AV AV–136 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Stereo component amplifier (440) Stereo component amplifier power source circuit (See page AV-148) Television display assembly (1B0) Television display assembly power source circuit (See page AV-163) NEXT 3 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG 6 Speaker System Wire Harness View: R4 AV TXM- TXM+ E119766E04 REPLACE RADIO RECEIVER AV–137 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 4 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. (1) Disconnect all connectors between the radio receiver and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 TXM+ R4 (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 TX- S22 9 R1 ATX+ (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 TXM+ R4 6 Speaker System: (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- AV E119767E03 AV–138 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END AV REPLACE RADIO RECEIVER AV–16 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM TERMINALS OF ECU 1. RADIO RECEIVER (10 SPEAKER SYSTEM) R1 R5 R4 I035641E08 Wiring Color Terminal Description Condition Specification B (R1-1) - GND (R1-20) Symbols (Terminal No.) L-Y - BR Battery Always 10 to 14 V ILL+ (R1-2) - GND (R1-20) G - BR Illumination signal Light control switch OFF → TAIL Below 1 V → 10 to 14 V ATX+ (R1-5) - GND (R1-20) B - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V MUTE (R1-7) - GND (R1-20) W-R - BR MUTE signal Audio system is playing → Changing Above 3.5 V → Below 1 V R+ (R1-8) - GND (R1-20) B - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L+ (R1-9) - GND (R1-20) R - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output SLD (R1-10) - Body ground Shielded - Body ground Shield ground Always Below 1 V ACC (R1-11) - GND (R1-20) GR - BR Accessory (ON) Turn ignition switch to ACC 10 to14 V ILL- (R1-12) - GND (R1-20) W-G - BR Illumination (rheostat) signal Light control switch OFF → TAIL Below 1 V → Pulse generation ANT (R1-13) - GND (R1-20) B - BR Power source of antenna Radio switch ON and AM or FM 10 to 14 V ATX- (R1-15) - GND (R1-20) W - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V R- (R1-18) - GND (R1-20) W - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L- (R1-19) - GND (R1-20) G - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output GND (R1-20) - Body ground BR - Body ground Ground Always Below 1 V W-R - BR Steering pad switch ground Always Below 1 V 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V SWG (R5-6) - GND (R1-20) AV SW1 (R5-7) - GND (R1-20) V-W - BR Steering pad switch signal Steering pad switch not operated → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed SW2 (R5-8) - GND (R1-20) Y-B - BR Steering pad switch signal Steering pad switch not operated → MODE switch pushed 4 V or more → Below 2.5 V ARI (R5-15) - GND (R1-20) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ASGN (R5-16) - GND (R1-20) Shielded - BR Shield ground Always Below 1 V Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ALI (R5-17) - GND (R1-20) R - BR AV–17 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification AUXI (R5-19) - GND (R1-20) L - BR External device connection detection signal External device is connected Below 1 V CSLD (R4-1) - Body ground (*1) Shielded - Body ground Shielded ground Always Below 1 V CDR+ (R4-2) - GND (R1-20) (*1) B - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDR- (R4-3) - GND (R1-20) (*1) W - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDL+ (R4-4) - GND (R1-20) (*1) R - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDL- (R4-5) - GND (R1-20) (*1) G - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output MUTE (R4-6) - GND (R1-20) (*1) V - BR MUTE signal from RSE RSE system is playing → changing Above 3.5 V → Below 1 V TXM+ (R4-9) - GND (R1-20) (*1) R - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TXM- (R4-10) - GND (R1-20) (*1) G - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V 2. R2 *1: with Rear Seat Entertainment System RADIO RECEIVER (6 SPEAKER SYSTEM) R3 R4 R5 E119761E03 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification FR+ (R2-1) - GND (R2-7) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output FL+ (R2-2) - GND (R2-7) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output ACC (R2-3) - GND (R2-7) GR - BR Accessory (ON) Turn ignition switch OFF → ACC Below 1 V → 10 to 14 V +B (R2-4) - GND (R2-7) L-Y - BR Battery Always 10 to 14 V FR- (R2-5) - GND (R2-7) L - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output FL- (R2-6) - GND (R2-7) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output GND (R2-7) - Body ground BR - Body ground Ground Always Below 1 V 10 to 14 V ANT (R2-8) - GND (R2-7) B - BR Power source of antenna Radio switch ON and AM or FM ILL+ (R2-10) - GND (R2-7) G - BR Illumination signal Light control switch OFF → TAIL or HEAD Below 1 V → 10 to 14 V RR+ (R3-1) - GND (R2-7) R - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output RL+ (R3-2) - GND (R2-7) B - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR- (R3-3) - GND (R2-7) W - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output AV AV–18 Symbols (Terminal No.) AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Wiring Color Terminal Description Condition Specification ILL- (R3-5) - GND (R2-7) W-G - BR Illumination (rheostat) signal Light control switch OFF → TAIL or HEAD Below 1 V → Pulse generation RL- (R3-6) - GND (R2-7) Y - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output SPD (R5-3) - GND (R2-7) V-R - BR Speed signal from combination meter Turn ignition switch to ON. Turn drive wheels slowly. Pulse generation SWG (R5-6) - GND (R2-7) W-R - BR Steering pad switch ground Always Below 1 V 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V SW1 (R5-7) - GND (R2-7) V-W - BR Steering pad switch signal Steering pad switch not operated → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed SW2 (R5-8) - GND (R2-7) Y-B - BR Steering pad switch signal Steering pad switch not operated → MODE switch pushed 4 V or more → Below 2.5 V ARI (R5-15) - GND (R2-7) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ASGN (R5-16) - GND (R2-7) Shielded - BR Shield ground Always Below 1 V A waveform synchronized with sounds is output ALI (R5-17) - GND (R2-7) R - BR Sound signal (Left) External device is playing (When stereo jack is used) AUXI (R5-19) - GND (R2-7) L - BR External device connection detection signal External device is connected Below 1 V CSLD (R4-1) - Body ground (*1) Shielded - Body ground Shield ground Always Below 1 V CDR+ (R4-2) - GND (R2-7) (*1) B - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDR- (R4-3) - GND (R2-7) (*1) W - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDL+ (R4-4) - GND (R2-7) (*1) R - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output CDL- (R4-5) - GND (R2-7) (*1) G - BR Sound signal from RSE RSE system is playing A waveform synchronized with sounds is output MUTE (R4-6) - GND (R2-7) (*1) V - BR MUTE signal from RSE RSE system is playing → changing Above 3.5 V → Below 1 V TXM+ (R4-9) - GND (R2-7) (*1) R - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TXM- (R4-10) - GND (R2-7) (*1) G - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V 3. *1: with Rear Seat Entertainment System STEREO COMPONENT AMPLIFIER S23 S22 AV E120081E03 Symbols (Terminal No.) MUTE (S22-1) - GND2 (S23-15) Wiring Color Terminal Description Condition Specification W-R - BR Mute signal from radio receiver Audio system is playing → Changing Above 3.5 V → Below 1 V AV–19 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification L- (S22-2) - GND2 (S23-15) G - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output L+ (S22-3) - GND2 (S23-15) R - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output R- (S22-4) - GND2 (S23-15) W - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output R+ (S22-5) - GND2 (S23-15) B - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output SLD (S22-6) - Body ground Shielded - Body ground Shielded ground Always Below 1 V TX- (S22-7) - GND2 (S23-15) W - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX+ (S22-8) - GND2 (S23-15) B - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V SPD (S22-11) - GND2 (S23-15) V-R - BR Speed signal from combination meter Turn ignition switch to ON. Turn drive wheels slowly. Pulse generation ACC (S22-12) - GND2 (S23-15) GR - BR Accessory (ON) Turn ignition switch OFF → ACC Below 1 V → 10 to 14 V +B (S23-1) - GND2 (S23-15) W-L - BR Battery Always 10 to 14 V DRS+ (S23-2) - GND2 (S23-15) G-W - BR Sound signal (Rear No. 2 Speaker) Audio system is playing A waveform synchronized with sounds is output CTR+ (S23-3) - GND2 (S23-15) G - BR Sound signal (Front Center) Audio system is playing A waveform synchronized with sounds is output RL+ (S23-4) - GND2 (S23-15) B - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR+ (S23-5) - GND2 (S23-15) R - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output FL+ (S23-6) - GND2 (S23-15) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output FR+ (S23-7) - GND2 (S23-15) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output WFL+ (S23-8) - GND2 (S23-15) BR - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output WFR+ (S23-9) - GND2 (S23-15) L-B - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output +B2 (S23-10) - GND2 (S23-15) W-L - BR Battery Always A waveform synchronized with sounds is output DRS- (S23-11) - GND2 (S23-15) BR - BR Sound signal (Rear No. 2 Speaker) Audio system is playing 10 to 14 V CTR- (S23-12) - GND2 (S23-15) G-B - BR Sound signal (Front Center) Audio system is playing A waveform synchronized with sounds is output RL- (S23-13) - GND2 (S23-15) Y - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR- (S23-14) - GND2 (S23-15) W - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output GND2 (S23-15) - Body ground BR - Body ground Ground Always Below 1 V GND (S23-16) - Body ground BR - Body ground Ground Always Below 1 V FL- (S23-17) - GND2 (S23-15) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output FR- (S23-18) - GND2 (S23-15) L - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output WFL- (S23-19) - GND2 (S23-15) G-W - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output L-R - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output WFR- (S23-20) - GND2 (S23-15) 4. TELEVISION DISPLAY ASSEMBLY (See page AV-155) AV AV–20 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC CHECK / CLEAR HINT: If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication signals and repair or replace problem parts. (See page AV-128) 1. 10 Speaker System: SEEK TRACK 1 6 2. DISC 6 Speaker System: SEEK TRACK 1 DISC STARTING DIAGNOSTIC MODE (a) Turn the ignition switch to the ACC position. (b) Turn off the audio system. (c) While pressing the preset switches "1" and "6" at the same time, press the "DISC" switch 3 times. HINT: A beep is emitted 3 times and the diagnostic function is activated. The system enters the all element illumination mode and the switch check mode. ALL ELEMENT ILLUMINATION MODE AND SWITCH CHECK MODE HINT: Illumination status of all switches and operations of the panel switches can be checked. 6 E119763E01 (a) Check that all elements are on. (b) When pressing each panel switch, check that a beep is emitted. NOTICE: Pressing the "SEEK TRACK UP" switch transfers the screen to the stereo jack adapter connection check screen. Check the operation of this switch by confirming the transfer of the screen. Example: E119764E02 AV AV–21 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3. When a stereo jack adapter is connected: When a stereo jack adapter is not connected: 4. E119765E02 5. 6. STEREO JACK ADAPTER CONNECTION CHECK MODE (a) Press the "SEEK TRACK UP" switch. (b) Check if the stereo jack adapter is recognized. HINT: Vehicles that do not have a stereo jack adapter also have this function. NOTICE: This function is not to check connection information on an external device, but to check recognition information on a stereo jack adapter. SERVICE CHECK MODE (a) Press the "SEEK TRACK UP" switch. HINT: For details of the service check mode, refer to "6. CHECK DTC" and "7. DTC CLEAR/RECHECK". FINISHING DIAGNOSTIC MODE (a) Press the "DISC" switch for 2 seconds or more, or turn the ignition switch off. CHECK DTC HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. (a) Reference: In the system check mode, the system check and the diagnostic memory check are performed, and the check results are displayed in ascending order of the component codes (physical address). Terms Meaning Component code (Physical address) Three-digit code (in hexadecimal) given to each device comprising AVC-LAN. Corresponding to its function, individual symbol is provided. Logical address Two-digit code (in hexadecimal) given to each function and device unit in each device comprising AVC-LAN. (b) Service check result display Display good nCon ECHn Previous term Meaning Action to be taken Good (normal) No DTCs are detected in both "System Check Mode" and "Diagnostic Memory Mode". - No connection Exchange CHEC Check OLd Old version The system recognized the component when it was registered, but the component gives no response to the "Diagnostic Mode ON Request". Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). One or more DTCs for "Exchange" are detected in either "System Check Mode" or "Diagnostic Memory Mode". Go to the detailed information mode to check the trouble area referring to the DTC list. When no DTCs are detected for "Exchange", one or more DTCs for "Check" are detected in either "System Check Mode" or "Diagnostic Memory Mode". Go to the detailed information mode to check the trouble area referring to the DTC list. Old DTC application is identified and DTC is detected in either "System Check Mode" or "Diagnostic Memory Mode". - AV AV–22 Display nrES AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Previous term No response Meaning Action to be taken The device gives no response to any one of "System Check Mode ON Request", "System Check Result Request", and "Diagnostic Memory Request". Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). (c) Device name and physical address Physical address No. Name 190 Radio receiver 440 Stereo component amplifier 1B0 Television display assembly (d) Service check mode (1) Press the "SEEK TRACK" switch to see the check result of each component. (2) The component code (physical address) is displayed first, and then the check result follows. HINT: • If all check results are "good", the system judges that no DTC exists. • If the preset switch "1" is pressed in the service check mode, service check is performed again. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–23 Service Check Mode: (*1) (*2) (*3) (*1) (*2) (*4) (*1) (*2) (*3) (*1) PRESET SWITCH “2” (*2) Detailed Information Mode 1 (*4) (*1) (*2) PRESET SWITCH “3” (*3) (*1) PRESET SWITCH “2” (*2) Detailed Information Mode 2 (*4) (*1) (*2) PRESET SWITCH “3” Continues to display check result when more components are installed. (*1) (*1) (*2) (*5) (*2) PRESET SWITCH “5” (Press for 2 seconds or more) DTC Clear (*6) *1: SEEK TRACK DOWN *4: Result *2: SEEK TRACK UP *5: Up-to-date connection check number *3: P...Indicates physical address *6: Memory clear 190/440/1C6...Physical address E110920E07 (e) Detailed information mode 1 HINT: • "Detailed information mode 1" is displayed when there is no response to "System Check Result Request" and DTC is detected only in "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. AV AV–24 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch "2" to go to the "Detailed Information Mode 1". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch "3" to go to the "Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request" and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode" and "Diagnostic Memory Mode" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 1", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request" contains the information received from each ECU or stored in each ECU in the past. • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)" is displayed first, and then the logical address and DTC appear in order. • "Diagnostic Memory Request (COdE)" is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–25 Service Check Mode: (*1) PRESET SWITCH “3” Detailed Information Mode 1: (DTC is detected only in the response to “Diagnostic Memory Request”.) (*2) PRESET SWITCH “2” (*2) (*1) (*3) (*1) PRESET SWITCH “5” (*2) (*4) (*1) (*2) *1: SEEK TRACK DOWN (*5) (*1) (*2) (*1) (*2) (*7) (*1) *2: SEEK TRACK UP *3: P...Indicates physical address (*6) Detailed information of the first code is displayed. (Press for 2 seconds or more) (*2) 440...Physical address *4: “COdE” indicates the display start of the response to “Diagnostic Memory Request”. (*8) (*1) (*2) *5: 1...The first code (*9) (*1) (*2) 01...Logical address (*10) (*1) (*2) (*1) (*2) (*11) (*1) (*2) (*8) (*1) DC...DTC *7: Physical address appears as the sub-code. *8: Connection check number (*2) (*9) (*1) *6: 1...The first code d...Indicates DTC (*10) Detailed information of the second code is displayed. L...Indicates logical address *9: The number of times of occurrence (*2) Continues to display detailed information when more DTCs are detected. *10: 2...The second code *11: For DTCs without sub-codes, physical address is not displayed. AV (*1) (*2) E110919E06 AV–26 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (f) AV Detailed information mode 2 HINT: • "Detailed information mode 2" is displayed when DTCs are detected in the responses to both "System Check Result Request" and "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch "2" to go to the "Detailed Information Mode 2". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch "3" to go to the "Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request" and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode" and "Diagnostic Memory Mode" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 2", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request" contains the information received from each ECU or stored in each ECU in the past. • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)" is displayed first, and then the logical address and DTC appear in order. • "Diagnostic Memory Request (COdE)" is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–27 System Check Mode: PRESET SWITCH “3” PRESET SWITCH “2” Detailed Information Mode 2: (DTCs are detected in the responses to both “System Check Result Request” and “Diagnostic Memory Request”.) (*1) (*2) (*3) (*1) (*2) PRESET SWITCH “5” (Press 2 seconds or more) (*4) (*1) (*2) L...Indicates logical address (*5) Detailed information of the first code is displayed. (*1) (*2) 62...Logical address *6: 1...The first code (*6) (*1) *5: 1...The first code (*2) d...Indicates DTC 47...DTC Continues to display (*12) (*1) (*2) *7: “COdE” indicates the display start of the response to “Diagnostic Memory Request”. (*7) (*1) (*2) (*8) Detailed information of the second code is displayed. (*1) (*2) (*1) (*2) (*9) (*1) (*2) (*10) (*1) (*2) (*11) *1: SEEK TRACK DOWN (*1) *8: 2...The second code *9: Physical address appears as the sub-code. *10: Connection check number *11: The number of times of occurrence *12: Continues to display detailed information when more DTCs are detected in the response to “System Check Result Request”. (*2) *2: SEEK TRACK UP *3: P...Indicates physical address Continues to display (*13) 190...Physical address *4: “SyS” indicates the display start of the response to “System Check Result Request”. (*1) (*2) *13: Continues to display detailed information when more DTCs are detected in the response to “Diagnostic Memory Request”. AV E110918E05 AV–28 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 7. 10 Speaker System: 1 5 6 Speaker System: 1 5 E121228E01 AV DTC CLEAR/RECHECK (a) Clearing All DTC Memory (when clearing all the memory of the DTCs previously detected). (1) When the preset switch "5" is pressed for 2 seconds or more during "Service Check Mode", the DTCs for all components are cleared. ("CLr" is displayed at this time.) HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory for all the components is cleared, only the component codes (physical address) are displayed. • After the DTC memory is cleared, the "Service Check Mode" is restored. (b) Clearing Individual DTC Memory (when clearing the memory of the DTC previously detected individually). (1) When the preset switch "5" is pressed for 2 seconds or more during "Detailed Information Mode 1" or "Detailed Information Mode 2", the DTCs for the target component are cleared. HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory is cleared, only the component code (physical address) is displayed for the target component. • After the DTC memory is cleared, the "Service Check Mode" is restored. • To check DTCs, press the preset switch "1" and perform the system check again. (c) Press the preset switch "1" to perform the service check again, and check that no DTCs are displayed for all the component codes (physical address). AV–139 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 E110917E05 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the subcode in the example shown in the illustration. AV AV–140 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Television display assembly (1B0) Television display assembly power source circuit (See page AV-163) Radio receiver (190) Radio receiver power source circuit (See page AV-146) NEXT 3 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG 6 Speaker System Wire Harness View: R4 AV TXM- TXM+ E119766E04 REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–141 OK 4 CHECK HARNESS AND CONNECTOR (STEREO COMPONENT AMPLIFIER COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. (1) Disconnect all connectors between the stereo component amplifier and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. OK: There is no open or short circuit. AV AV–142 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 R1 ATX+ TXM+ R4 (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 S22 TX- 9 (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 6 Speaker System: TXM+ R4 (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- E119767E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG AV OK END REPLACE WOOFER BOX SPEAKER ASSEMBLY (BUILT-IN STEREO COMPONENT AMPLIFIER) AV–143 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Television Display Assembly Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. Example: Service Check Mode *2 *1 *2 *1 *2 *1 *2 *1 *2 Detailed Information Mode *3 *4 Continues to display check result when more components are installed. *1 *2 *1 *2 *1 *2 *1 *2 *2 *1 *1 *2 *1 *1 *1: SEEK TRACK DOWN *2 DTC Component shown by the sub-code Continues to display detailed information of the first code. *2: SEEK TRACK UP *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” *1 *2 Continues to display detailed information when more DTCs are detected. *1 *2 E110917E06 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component shown by the sub-code. HINT: • "190 (radio receiver)" is the component shown by the sub-code in the example shown in the illustration. AV AV–144 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Radio receiver (190) Radio receiver power source circuit (See page AV-146) Stereo component amplifier (440) Stereo component amplifier power source circuit (See page AV-148) NEXE 3 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG 6 Speaker System Wire Harness View: R4 AV TXM- TXM+ E119766E04 REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–145 OK 4 CHECK HARNESS AND CONNECTOR (TELEVISION DISPLAY ASSEMBLY - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the television display assembly and the component shown by the sub-code. (1) Disconnect all connectors between the television display assembly and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the television display assembly and the component shown by the sub-code. OK: There is no open or short circuit. AV AV–146 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 R1 ATX+ TXM+ R4 (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 S22 TX- 9 (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 6 Speaker System: TXM+ R4 (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- E119767E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK AV END REPLACE TELEVISION DISPLAY ASSEMBLY AUDIO / VISUAL – FRONT SIDE SPEAKER AV–169 FRONT SIDE SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS FRONT DOOR ARMLEST ASSEMBLY FRONT DOOR INSIDE HANDLE BEZEL LH FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH AV B120197E03 AV–170 AUDIO / VISUAL – FRONT SIDE SPEAKER FRONT DOOR LOWER FRAME BRACKET GARNISH LH 5.0 (51, 42 in.*lbf) FRONT NO. 2 SPEAKER 5.0 (51, 42 in.*lbf) 5.0 (51, 42 in.*lbf) FRONT NO. 1 SPEAKER AV N*m (kgf*cm, ft.*lbf) : Specified torque B120198E02 AV–147 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Receiver Power Source Circuit DESCRIPTION This circuit provides power to the radio receiver. WIRING DIAGRAM Radio Receiver RADIO No. 1 From Battery 4 R2 2 R1 (*1) (*2) 3 R2 R1 (*1) (*2) 7 R2 20 R1 (*1) (*2) B (*2) +B (*1) ACC CUT Relay From ACC Fuse 11 ACC GND *1: 6 Speaker System *2: 10 Speaker System E120046E01 AV AV–148 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER Wire Harness View (10 Speaker System): R1 (a) Disconnect the radio receiver connector R1 or R2. (b) Measure the resistance according to the value in the table below. Standard resistance Tester Connection Condition Specified Condition GND - Body ground Always Below 1 Ω (c) Measure the voltage according to the values in the table below. Standard voltage Tester Connection Condition Specified Condition +B - GND (*1) Always 10 to 14 V B - GND (*2) Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V B ACC GND *1: 6 Speaker *2: 10 Speaker Wire Harness View (6 Speaker System): NG REPAIR OR REPLACE HARNESS OR CONNECTOR R2 +B ACC GND E120030E04 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–149 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Stereo Component Amplifier Power Source Circuit DESCRIPTION This circuit provides power to the stereo component amplifier. WIRING DIAGRAM Stereo Component Amplifier RADIO No. 2 From Battery 1 S23 +B 10 S23 +B2 ACC CUT Relay From ACC Fuse 12 S23 ACC 15 S23 GND2 16 S23 GND E120047E01 AV AV–150 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connectors. (b) Measure the resistance according to the values in the table below. Standard resistance Wire Harness View: S23 S22 Tester Connection Condition Specified Condition GND - Body ground Always Below 1 Ω GND2 - Body ground Always Below 1 Ω (c) Measure the voltage according to the values in the table below. Standard voltage +B GND GND2 +B2 Tester Connection Condition Specified Condition +B - GND Always 10 to 14 V +B2 - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V ACC E120048E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–152 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM SYSTEM DESCRIPTION 1. 2. Television display assembly Radio and navigation assembly (*1) Radio receiver (*2) Remote Controller (Switch assembly) OUTLINE • As a unique feature of Rear Seat Entertainment (RSE) system, the front and rear seat occupants can enjoy different audio-visual modes at the same time. Thus, this system offers enhanced entertainment to the rear seat occupants. • The rear seat occupants can control the audio-visual modes with the remote controller (switch assembly), and listen to the audio using wireless headphones. • The RSE system is controlled by the television display assembly, and the communication between the audio head unit and the television display assembly is established via an AVC-LAN (Audio Visual Communication-Local Area Network). • The RSE system can play discs recorded entirely in the MP3 format, as well as music discs containing a mixture of CD data (CD-DA files) and MP3 data. HINT: MP3 is short for MPEG1 (Moving Picture Expert Group Phase 1) & 2 Audio Layer 3. It is an audio compression standard set by a working group (MPEG) of the ISO (International Standards Organization). MP3 is able to compress audio data to about 1/10 the level of a conventional disc. FUNCTION OF MAIN COMPONENTS • • • Displays DVD and Video images. Receives signals from the remote controller. Outputs audio signals to the wireless headphones in the form of infrared signals. • Receives audio signals from the television display assembly and outputs them to the stereo component amplifier. Enables or disables the function of the remote controller for the television display assembly. • Outputs various control signals of the RSE system to the television display assembly in the form of infrared signals. Wireless headphones • • Receives the audio signals from the television display assembly in the form of infrared signals. Volume adjustment of the wireless headphones can be done by using the volume control on the wireless headphones. VTR terminal This terminal is for connecting a video player's video and audio output terminals. *1: with Navigation System *2: without Navigation System AV AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM AV–153 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Interview the customer and confirm the trouble. (1) Confirm the problem by duplicating the conditions described by the customer. NEXT 3 BASIC INSPECTION (a) Basic inspection. (1) Measure the battery voltage. Standard voltage: 11 to 14 V (b) with Navigation system: Check the power supply to the radio and navigation assembly. (1) Turn the ignition switch to the ACC position. (2) Check whether the display appears on the radio and navigation assembly. (c) without Navigation system: Check the power supply to the radio receiver. (1) Turn the ignition switch to the ACC position. (2) Check whether the display appears on the radio receiver. DISPLAY DOES NOT APPEAR (GO TO "NAVIGATION SYSTEM" OR "AUDIO AND VISUAL SYSTEM"). DISPLAY APPEARS (Go to step 4). 4 PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table (See page AV154). NEXT AV AV–154 5 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM CIRCUIT INSPECTION AND PART INSPECTION NEXT 6 IDENTIFICATION OF PROBLEM NEXT 7 REPAIR OR REPLACE NEXT 8 NEXT END AV CONFIRMATION TEST AV–155 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM PROBLEM SYMPTOMS TABLE HINT: Inspect the "Fuse" and "Relay" before confirming the suspected area as shown in the table below. DISPLAY FUNCTION: Symptom Black screen (When a disc is inserted, or when the system is in the VTR mode.) Only the DVD screen is not displayed or not stable. Only display screen input from an external device is not displayed or not stable. Suspected area See page 1. Television display assembly power source circuit AV-163 2. AVC-LAN circuit (*1) AV-128 3. AVC-LAN circuit (*2) NS-201 4. Television display assembly AV-177 5. Radio receiver (*1) AV-167 6. Radio and navigation assembly (*2) NS-235 1. Television display assembly power source circuit AV-163 2. Television display assembly AV-177 1. Television display assembly power source circuit AV-163 2. Proceed to "Display Signal Circuit Between Video Terminal and Television Display Assembly" AV-160 3. Video terminal AV-188 4. Television display assembly AV-177 SOUND FUNCTION: Symptom Suspected area 1. Television display assembly power source circuit Quality of sound from wireless headphones is poor or no sound can be heard. Only DVD sound cannot be heard or the sound quality is poor. Only sound quality input from an external device is poor or no sound can be heard. See page AV-163 2. Wireless headphone - 3. Television display assembly AV-177 1. Television display assembly power source circuit AV-163 2. Television display assembly AV-177 1. Television display assembly power source circuit AV-163 2. Proceed to "Sound Signal Circuit between Video Terminal and Television Display Assembly" AV-157 3. Video terminal AV-188 4. Television display assembly AV-177 REMOTE CONTROL FUNCTION: Symptom Remote control system does not operate. Suspected area See page 1. Television display assembly power source circuit AV-163 2. Proceed to "A Remote Control System does not Operate" AV-156 3. AVC-LAN circuit (*1) AV-128 4. AVC-LAN circuit (*2) NS-201 5. Remote controller - 6. Television display assembly AV-177 *1: without Navigation System *2: with Navigation System AV AV–156 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM TERMINALS OF ECU 1. TELEVISION DISPLAY ASSEMBLY R18 E119739E02 AV Terminal Description Condition Specification Symbols (Terminal No.) Wiring Color NTS4 (R18-6) - GND6 (R18-12) G - BR Display Signal External device system is playing (When VTR jack is used) Pulse generation AUXR (R18-7) - GND6 (R18-12) V - BR Sound Signal External device system is playing (When VTR jack is used) A waveform synchronized with sound is output AUXL (R18-8) - GND6 (R18-12) LG - BR Sound Signal External device system is playing (When VTR jack is used) A waveform synchronized with sound is output SGN1 (R18-9) - GND6 (R18-12) Shielded - BR Shielded ground Always Below 1 V SG3 (R18-10) - GND6 (R18-12) L - BR Ground Always Below 1 V NTS1 (R18-11) - GND6 (R18-12) P - BR Display Signal DVD image is displayed GND6 (R18-12) - Body ground BR - Body ground Ground Always TX- (R18-13) - GND6 (R18-12) G - BR AVC-LAN communication signal Ignition switch ACC 2 to 3 V TX+ (R18-14) - GND6 (R18-12) L - BR AVC-LAN communication signal Ignition switch ACC 2 to 3 V Pulse generation Below 1 V ACC4 (R18-15) - GND6 (R18-12) GR - BR Ignition (ACC) Ignition switch ACC 10 to 14 V +B2 (R18-16) - GND6 (R18-12) L-Y - BR Battery Always 10 to 14 V SGN5 (R18-22) - GND6 (R18-12) R - BR SG7 (R18-23) - GND6 (R18-12) Shielded - BR Ground Always Below 1 V Shielded ground Always Below 1 V OPEN (R18-24) - GND6 (R18-12) G - BR VTR terminal detection Always Below 1 V LMUT (R18-26) - GND6 (R18-12) V - BR Mute signal RSE system is playing LMUT (R18-26) - GND6 (R18-12) V - BR Mute signal RSE system is changing SG1 (R18-27) - GND6 (R18-12) Shielded - BR Shielded ground Always Above 3.5 V Below 1 V Below 1 V R+ (R18-28) - GND6 (R18-12) B - BR RSE sound signal RSE system is playing A waveform synchronized with sound is output R- (R18-29) - GND6 (R18-12) W - BR RSE sound signal RSE system is playing A waveform synchronized with sound is output L+ (R18-30) - GND6 (R18-12) R - BR RSE sound signal RSE system is playing A waveform synchronized with sound is output L- (R18-31) - GND6 (R18-12) G - BR RSE sound signal RSE system is playing A waveform synchronized with sound is output AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM AV–157 A Remote Control System does not Operate INSPECTION PROCEDURE 1 CHECK SYSTEM (a) Check that the remote control operation of the rear system is not locked by the radio receiver or the radio and navigation assembly. (1) Check if "Rear System Locked" appears on the television display assembly. OK: The message does not appear. NG E119740 ENABLE THE REAR SEAT ENTERTAINMENT SYSTEM OK 2 CHECK BATTERY (REMOTE CONTROLLER) (a) Check the battery. (1) Check that the dry-cell battery used for the remote controller is not depleted. OK: It is not depleted. NG REPLACE BATTERY (REMOTE CONTROLLER) OK 3 CLEAN TELEVISION DISPLAY ASSEMBLY (INFRARED RAY EMITTING PORTION) (a) Clean the infrared ray emitting portion. (1) Clean the infrared ray emitting portion on the rear display assembly. (2) Check whether the same malfunction occurs. OK: The function returns to normal. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE E124109 OK END AV AV–158 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM Sound Signal Circuit between Video Terminal and Television Display DESCRIPTION This is the sound signal circuit from the video (video adapter) terminal to the television display assembly. WIRING DIAGRAM V14 Viedo Terminal Television Display Assembly (Shielded) SGND 3 AUXR 1 AUXL CE 2 8 23 R18 SG7 7 R18 AUXR 8 R18 AUXL 24 R18 OPEN E124110E01 AV AV–159 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (TELEVISION DISPLAY ASSEMBLY - VIDEO TERMINAL) Video Terminal Wire Harness View: V14 SGND (a) Disconnect the connectors from the video (video adapter) terminal and television display assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition SGND - SG7 Always Below 1 Ω AUXR - AUXR Always Below 1 Ω AUXL - AUXL Always Below 1 Ω AUXL AUXR CE Television Display Assembly Wire Harness View: CE - OPEN Always Below 1 Ω AUXR - Body ground Always 10 kΩ or higher AUXL - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR R18 AUXR AUXL SG7 OPEN E119743E03 OK 2 INSPECT VIDEO TERMINAL Video Terminal Wire Harness View: AUXL V14 AUXR E110048E05 (a) Reconnect the video (video adapter) terminal connector. (b) Using an oscilloscope, check the signal waveform between each terminal and body ground according to the conditions, as shown in the chart. HINT: An external device system is playing (When the video (video adapter) terminal is used). Signal waveform Tester Connection Condition Specified Condition AUXL - Body ground Sound is being produced A waveform synchronized with sound is output AUXR - Body ground Sound is being produced A waveform synchronized with sound is output AV AV–160 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM NG REPLACE VIDEO TERMINAL OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–161 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM Display Signal Circuit between Video Terminal and Television Display DESCRIPTION This is the display signal circuit from the video terminal to the television display assembly. WIRING DIAGRAM V14 Video Terminal Television Display Assembly (Shielded) SLD 7 NTSC 5 6 R18 NTS4 SGND 6 22 R18 SGN5 8 24 R18 OPEN CE E124111E01 AV AV–162 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (TELEVISION DISPLAY ASSEMBLY - VIDEO TERMINAL) Video Terminal Wire Harness View: V14 (a) Disconnect the connectors from the video terminal and television display assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition CE - OPEN Always Below 1 Ω NTSC CE SGND SLD Television Display Assembly Wire Harness View: NTSC - NTS4 Always Below 1 Ω SGND - SGN5 Always Below 1 Ω NTSC - Body ground Always 10 kΩ or higher SGND - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR R18 NTS4 SGN5 OPEN E119743E04 OK 2 INSPECT VIDEO TERMINAL Video Terminal Wire Harness View: Tester Connection Condition Specified Condition NTSC - SGND External device is playing A waveform synchronized with display signals is output HINT: The waveform pattern may differ from that shown in the illustration below due to differences in oscilloscope setting. A normal video terminal operating condition can be determined if any waveform is output. SGND V14 AV (a) Reconnect the video (video adapter) terminal connector. (b) Measure the waveform according to the table below. OK NTSC E110048E06 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM AV–163 (c) Oscilloscope waveform (1) Terminal: NTSC - Body ground Setting: 200mV/DIV, 10 µs/DIV Condition: DVD display is ON. GND NG REPLACE VIDEO TERMINAL E119745E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–164 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM Television Display Power Source Circuit DESCRIPTION This is the power source circuit to operate the television display assembly. AV AV–165 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM WIRING DIAGRAM Television Display Assembly Short Pin RADIO No. 1 I18 Ignition SW ACC AM1 ALT ACC CUT Relay 16 R18 +B2 15 R18 ACC4 12 R18 GND6 Battery E119746E01 AV AV–166 AUDIO / VISUAL – REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Disconnect the connector from the television display assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Television Display Assembly Wire Harness View: R18 +B2 Tester Connection Condition Specified Condition GND6 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition +B2 - GND Always 10 to 14 V ACC4 - GND Ignition SW ACC 10 to 14 V ACC4 GND6 E113507E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–168 AUDIO / VISUAL – RADIO RECEIVER INSTALLATION 1. INSTALL RADIO NO. 2 BRACKET 2. INSTALL RADIO NO. 1 BRACKET 3. INSTALL RADIO RECEIVER (w/ Bracket) 4. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER 5. INSTALL AIR CONDITIONING CONTROL ASSEMBLY 6. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 7. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 8. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 9. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 10. INSTALL INSTRUMENT PANEL FINISH PLATE AV AV–29 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DIAGNOSTIC TROUBLE CODE CHART COMMUNICATION DIAGNOSIS: DTC No. 01-21 Detection Item Trouble Area ROM Error Radio receiver See page AV-32 01-22 RAM Error Radio receiver AV-32 01-D5 Absence of Registration Unit 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 01-D6 No Master 1. Radio receiver power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio receiver and the component which has stored this code 4. Component which has stored this code 5. Radio receiver AV-35 01-D7 Connection Check Error 1. Radio receiver power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio receiver and the component which has stored this code 4. Component which has stored this code 5. Radio receiver AV-35 01-D8 No Response for Connection Check 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 01-D9 Last Mode Error 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 01-DA No Response Against ON / OFF Command 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 AV AV–30 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Trouble Area See page 01-DB Mode Status Error Detection Item 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 01-DC Transmission Error If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code AV-40 01-DD Master Reset 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-43 01-DE Slave Reset 1. Power source circuit of the component shown by the subcode 2. AVC-LAN circuit between the radio receiver and the component shown by the sub-code 3. Component shown by the subcode AV-33 01-DF Master Error 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-48 01-E0 Registration Complete Indication Error - AV-53 01-E1 Voice Processing Device ON Error 1. Radio receiver power source circuit 2. AVC-LAN circuit between the radio receiver and the component which has stored this code 3. Radio receiver 4. Component which has stored this code AV-43 01-E2 ON / OFF Indication Parameter Error Radio receiver AV-54 01-E3 Registration Demand Transmission - AV-53 01-E4 Multiple Frame Incomplete - AV-53 DVD PLAYER: DTC No. AV Detection Item 44-10 DVD Player Mechanical Error Trouble Area See page Television display assembly AV-55 44-11 DVD Insertion and Eject Error Television display assembly AV-55 44-12 DVD Reading Abnormal Television display assembly AV-55 44-41 Wrong Disc 1. DVD 2. Television display assembly AV-56 44-42 Disc cannot be Read 1. DVD 2. Television display assembly AV-56 AV–31 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Detection Item Trouble Area See page 44-43 DVD-ROM Abnormal 1. DVD 2. Television display assembly AV-58 44-44 DVD Error Television display assembly AV-59 44-45 Eject Error Television display assembly AV-60 44-46 Scratched / Reversed Disc 1. DVD 2. Television display assembly AV-61 44-47 High Temperature Television display assembly AV-63 44-48 Excess Current Television display assembly AV-59 44-50 Tray Insertion / Ejection Error Television display assembly AV-59 44-51 Elevator Error Television display assembly AV-60 44-52 Clamp Error Television display assembly AV-60 44-78 DSP Error - AV-64 44-7D Disc cannot be Played 1. DVD 2. Television display assembly AV-65 44-7E No Playable Files 1. DVD 2. Television display assembly AV-65 44-7F Copyright Protection Error 1. DVD 2. Television display assembly AV-65 CD PLAYER DTC No. 62-10 Detection Item Trouble Area See page CD Player Mechanical Error Radio receiver AV-66 62-11 CD Insertion and Eject Error Radio receiver AV-66 62-12 CD Reading Abnormal Radio receiver AV-66 62-41 Wrong Disc 1. CD 2. Radio receiver AV-67 62-42 Disc cannot be Read 1. CD 2. Radio receiver AV-67 62-43 CD-ROM Abnormal 1. CD 2. Radio receiver AV-69 62-44 CD Abnormal Radio receiver AV-71 62-45 Eject Error Radio receiver AV-72 62-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-73 62-47 High Temperature Radio receiver AV-75 62-48 Excess Current Radio receiver AV-71 62-50 Tray Insertion / Ejection Error Radio receiver AV-71 62-51 Elevator Error Radio receiver AV-72 62-52 Clamp Error Radio receiver AV-72 62-78 DSP Error - AV-76 62-7D Disc cannot be Played 1. CD 2. Radio receiver AV-77 62-7E No Playable Files 1. CD 2. Radio receiver AV-77 62-7F Copyright Protection Error 1. CD 2. Radio receiver AV-77 IN-DASH CD CHANGER DTC No. Detection Item Trouble Area See page 63-10 CD Changer Mechanical Error Radio receiver AV-66 63-11 CD Insertion and Eject Error Radio receiver AV-66 63-12 CD Reading Abnormal Radio receiver AV-66 63-41 Wrong Disc 1. CD 2. Radio receiver AV-67 AV AV–32 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. AV Detection Item Trouble Area See page 63-42 Disc cannot be Read 1. CD 2. Radio receiver AV-67 63-43 CD-ROM Abnormal 1. CD 2. Radio receiver AV-69 63-44 CD Abnormal Radio receiver AV-71 63-45 Eject Error Radio receiver AV-72 63-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-73 63-47 High Temperature Radio receiver AV-75 63-48 Excess Current Radio receiver AV-71 63-50 Tray Insertion / Ejection Error Radio receiver AV-71 63-51 Elevator Error Radio receiver AV-72 63-52 Clamp Error Radio receiver AV-72 63-78 DSP Error - AV-76 63-7D Disc cannot be Played 1. CD 2. Radio receiver AV-77 63-7E No Playable Files 1. CD 2. Radio receiver AV-77 63-7F Copyright Protection Error 1. CD 2. Radio receiver AV-77 AUDIO / VISUAL – FRONT SIDE SPEAKER AV–171 ON-VEHICLE INSPECTION 1. INSPECT FRONT NO. 1 SPEAKER HINT: Remove interior parts so that the front No. 1 speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the front No. 1 speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the front No. 1 speaker. (c) Speaker resistance check (1) Disconnect the front No. 1 speaker connector. (2) Measure the resistance between the terminals of the speaker. Standard resistance: 6 Speaker System: Approximately 4 Ω 10 Speaker System: 4 to 6 Ω If the result is not as specified, replace the front No. 1 speaker. 2. INSPECT FRONT NO. 2 SPEAKER HINT: Remove interior parts so that the front No. 2 speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the front No. 2 speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the front No. 2 speaker. AV AV–172 AUDIO / VISUAL – FRONT SIDE SPEAKER REMOVAL 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-28) 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-28) 3. REMOVE FRONT ARMREST ASSEMBLY LH (See page ED-28) 4. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-28) 5. REMOVE FRONT NO. 1 SPEAKER (a) Disconnect the connector. (b) Remove the 4 screws and front No. 1 speaker. 6. REMOVE FRONT NO. 2 SPEAKER (a) Disconnect the connector and remove the 2 bolts. (b) Remove the front No. 2 speaker from speaker mounting bracket No. 1. I031482 I033307 AV AUDIO / VISUAL – FRONT SIDE SPEAKER AV–173 INSTALLATION 1. INSTALL FRONT NO. 2 SPEAKER (a) Align a claw with the notch of the speaker mounting bracket No. 1, and install the front No. 2 speaker with 2 bolts. (b) Connect the connector. 2. INSTALL FRONT NO. 1 SPEAKER (a) Install the front No. 1 speaker with the 4 crews. NOTICE: Install them in the order shown in the illustration. (b) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH 4. INSTALL FRONT ARMREST ASSEMBLY LH 5. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH 6. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH AV AUDIO / VISUAL – FRONT CENTER SPEAKER AV–173 FRONT CENTER SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY AV B120192E04 AV–174 AUDIO / VISUAL – FRONT CENTER SPEAKER FRONT STEREO COMPONENT SPEAKER AV E115640E01 AUDIO / VISUAL – FRONT CENTER SPEAKER AV–175 ON-VEHICLE INSPECTION 1. INSPECT FRONT STEREO COMPONENT SPEAKER HINT: Remove interior parts so that the front stereo component speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the front stereo component speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the front stereo component speaker. (c) Speaker resistance check (1) Disconnect the front stereo component speaker connector. (2) Measure the resistance between the terminals of the speaker. Standard resistance: 1.2 to 2.2 Ω If the result is not as specified, replace the front stereo component speaker. AV AV–176 AUDIO / VISUAL – FRONT CENTER SPEAKER REMOVAL I033308 AV 1. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the instructions for removal of the instrument panel sub-assembly (See page IP-6). 2. REMOVE FRONT STEREO COMPONENT SPEAKER (a) Disconnect the connector. (b) Remove the 2 screw and front stereo component speaker. AUDIO / VISUAL – FRONT CENTER SPEAKER AV–177 INSTALLATION 1. INSTALL FRONT STEREO COMPONENT SPEAKER 2. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the installation procedures of the instrument panel safety pad sub-assembly (See page IP-12). AV AV–178 AUDIO / VISUAL – TELEVISION DISPLAY INSTALLATION AV 1. INSTALL TELEVISION DISPLAY ASSEMBLY 2. INSTALL DOME LIGHT ASSEMBLY 3. INSTALL DOME LIGHT LENS RH 4. INSTALL DOME LIGHT LENS LH AUDIO / VISUAL – RADIO ANTENNA CORD AV–181 REMOVAL 1. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the instructions for removal of the instrument panel sub-assembly (See page IP-6). 2. REMOVE ANTENNA CORD SUB-ASSEMBLY (a) Remove the 4 clamps and antenna cord subassembly. 4 Clamps I033314E01 AV AV–182 AUDIO / VISUAL – RADIO ANTENNA CORD INSTALLATION AV 1. INSTALL ANTENNA CORD SUB-ASSEMBLY 2. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the installation procedures of the instrument panel safety pad sub-assembly (See page IP-12). AV–184 AUDIO / VISUAL – AMPLIFIER ANTENNA REMOVAL 4 Clamps 1. REMOVE SUN ROOF OR REMOVABLE ROOF HEADLINING ASSEMBLY HINT: Refer to the instructions for removal of the sun roof or removable roof headlining assembly (See page IR-7). 2. REMOVE AMPLIFIER ANTENNA (a) Disconnect the connectors and remove the 2 bolts. (b) Remove the 17 clamps and amplifier antenna. Clamp 11 Clamps Clamp I034049E02 AV AUDIO / VISUAL – AMPLIFIER ANTENNA AV–185 INSTALLATION 1. INSTALL AMPLIFIER ANTENNA 2. INSTALL SUN ROOF OR REMOVABLE ROOF HEADLINING ASSEMBLY HINT: Refer to the installation procedures of the roof headlining assembly (See page IR-14). AV AV–188 AUDIO / VISUAL – VIDEO TERMINAL REMOVAL E115645 AV 1. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 2. REMOVE VIDEO TERMINAL (a) Disconnect the connector. (b) Disengage the wire harness clamp. (c) Disengage the 4 claws and remove the video (video adapter) terminal. AUDIO / VISUAL – VIDEO TERMINAL AV–189 INSTALLATION 1. INSTALL VIDEO TERMINAL 2. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER AV AV–33 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition 01-21 A malfunction exists in ROM. 01-22 A malfunction exists in RAM. Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO RECEIVER NEXT END AV AV–34 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset DESCRIPTION DTC No. DTC Detection Condition 01-D5 *1, *3 A device that the sub-code shows is (was) disconnected from the system when turning the ignition switch to the ON or ACC position. The communication condition with the device that the code shows cannot be obtained when the engine starts. 01-D8 *2, *3 The device indicated by the sub-code is (was) disconnected from the system after the engine starts. 01-D9 *1, *3 The device that had functioned before the engine stopped is (was) disconnected from the system when the engine switch is (was) in the ON or ACC position. 01-DA *3 No response is identified when changing mode. Sound and image do not change by switch operation. 01-DB *1, *3 A dual alarm is detected. 01-DE *3, *4 A slave device has been disconnected after the engine starts Trouble Area • • • Power source circuit of the component shown by the sub-code AVC-LAN circuit between the radio receiver and the component shown by the sub-code Component shown by the sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: If the power connector is disconnected after the engine starts, this code is stored after 180 seconds. • *3: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. • *4: This code may be stored if the engine is started and the ignition switch is turned to the START position again. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. AV INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 AV–35 CHECK "RADIO RECEIVER COMMUNICATION ERROR" IN FLOW CHART Refer to the radio receiver communication error (See page AV-134). NEXT END AV AV–176 AUDIO / VISUAL – TELEVISION DISPLAY TELEVISION DISPLAY BODY ELECTRICAL AUDIO / VISUAL COMPONENTS TELEVISION DISPLAY ASSEMBLY DOME LIGHT ASSEMBLY AV E115641E06 AUDIO / VISUAL – TELEVISION DISPLAY AV–177 REMOVAL 1. REMOVE DOME LIGHT LENS LH (a) Disengage the 4 claws and remove the dome the light lens LH. HINT: Tape the screwdriver tip before use. 2. REMOVE DOME LIGHT LENS RH (a) Disengage the 4 claws and remove the dome light lens RH. HINT: Tape the screw driver tip before use. 3. REMOVE DOME LIGHT ASSEMBLY (a) Remove the 2 screws. E115648 E115649 E115650 (b) Disengage the 4 clips. (c) Disconnect the connector and remove the dome light assembly. E116107 4. REMOVE TELEVISION DISPLAY ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts. (c) Disengage the 2 clips and remove television display assembly. AV E116108 AV–36 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error DESCRIPTION DTC No. DTC Detection Condition 01-D6 *1 When either of the following conditions is met: • The device that stores (stored) the code has (had) been disconnected when the ignition switch is in the ACC or ON position • The master device has (had) been disconnected when this code is stored 01-D7 *2 When either of the following conditions is met: • The device that stored the code has (had) been disconnected after the engine starts (started) • The master device has (had) been disconnected when this code is (was) stored Trouble Area • • • • • Radio receiver power source circuit Power source circuit of the component which has stored this code AVC-LAN circuit between the radio receiver and the component which has stored this code Component which has stored this code Radio receiver HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch in the ACC or ON position, this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-146). If the power source circuit is operating normally, proceed to the next step. NEXT 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV AV–37 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: (*1) Service Check Mode (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component Physical address Stereo component amplifier 440 Television display assembly 1B0 HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AV AV–38 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Stereo component amplifier Stereo component amplifier power source circuit (See page AV-148) Television display assembly Television display assembly power source circuit (See page AV-163) NEXT 4 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG 6 Speaker System Wire Harness View: R4 TXM- TXM+ AV E119766E04 OK REPLACE RADIO RECEIVER AV–39 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 R1 ATX+ TXM+ R4 (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 TX- S22 9 (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 6 Speaker System: TXM+ R4 (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- E119767E03 NG REPAIR OR REPLACE HARNESS OR CONNECTOR AV AV–40 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 6 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END AV REPLACE RADIO RECEIVER AUDIO / VISUAL – RADIO ANTENNA CORD AV–179 RADIO ANTENNA CORD BODY ELECTRICAL AUDIO / VISUAL COMPONENTS INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY AV B120192E05 AV–180 AUDIO / VISUAL – RADIO ANTENNA CORD ANTENNA CORD SUB-ASSEMBLY AV E115641E07 AV–41 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DC Transmission Error DESCRIPTION DTC No. 01-DC *1 DTC Detection Condition Trouble Area Transmission to component shown by sub-code failed (Detecting this DTC does not always mean actual failure) If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code HINT: *1: This code may be stored if the engine is started, idled for 60 seconds and then started again. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. Result Result Proceed to "01-DC" is output and the same physical address is displayed A "01-DC" is not output or the same physical address is not displayed B HINT: For the list of the components shown by sub-codes, refer to the table in step 2. B Go to step 4 A 2 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV AV–42 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: (*1) Service Check Mode (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table: Component AV Physical address Stereo component amplifier 440 Television display assembly 1B0 Radio receiver 190 HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–43 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component Table: Component Proceed to Stereo component amplifier Stereo component amplifier communication error (See page AV-138) Television display assembly Television display assembly communication error (See page AV-142) Radio receiver Radio receiver communication error (See page AV-134) NEXT END 4 CLEAR DTC (a) Clear the DTCs (See page AV-19). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble code occurs again. OK: Malfunction disappears. NG Go to step 3 OK END AV AV–182 AUDIO / VISUAL – AMPLIFIER ANTENNA AMPLIFIER ANTENNA BODY ELECTRICAL AUDIO / VISUAL COMPONENTS SUN ROOF OR REMOVABLE ROOF HEADLINING ASSEMBLY AV B120189E02 AUDIO / VISUAL – AMPLIFIER ANTENNA AV–183 AMPLIFIER ANTENNA AV E115641E08 AV–44 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-DD *1 The device that should be the master has been disconnected after engine start • • 01-E1 *2 The AMP device records that the AMP output does not function even while the source device operates • • Radio receiver power source circuit AVC-LAN circuit between the radio receiver and the component which has stored this code Radio receiver Component which has stored this code HINT: *1: This code may be stored if the engine is started and the ignition switch is turned to START position again. *2: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio receiver is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO RECEIVER POWER SOURCE CIRCUIT Refer to the radio receiver power source circuit (See page AV-146). If the power source circuit is operating normally, proceed to the next step. NEXT AV AV–45 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 INSPECT RADIO RECEIVER 10 Speaker System Wire Harness View: R1 R4 ATX+ ATX- TXM- TXM+ (a) Disconnect the radio receiver connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition ATX+ (R1-5) - ATX- (R115) (*1) Always 60 to 80 Ω TXM+ (R4-9) - TXM- (R410) Always 60 to 80 Ω *1: 10 Speaker System NG REPLACE RADIO RECEIVER 6 Speaker System Wire Harness View: R4 TXM- TXM+ E119766E04 OK 3 IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. AV AV–46 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Example: (*1) Service Check Mode (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) Detailed Information Mode Component which has stored this code (*3) (*4) Continues to display check result when more components are installed. (*1) (*1) (*2) (*1) (*2) (*1) (*2) (*1) (*2) (*2) (*2) (*1) *1: SEEK TRACK DOWN *2: SEEK TRACK UP DTC Continues to display detailed information of the first code. (*1) (*2) Continues to display detailed information when more DTCs are detected. *3: PRESET SWITCH “2” *4: PRESET SWITCH “3” (*1) (*2) E110915E04 (b) Press the preset switch "3" to change to "Detailed Information Mode". (c) Identify the component which has stored this code. Component Table Component AV Physical address Stereo component amplifier 440 Television display assembly 1B0 HINT: • "440 (stereo component amplifier)" is the component which has stored this code in the example shown in the illustration. • For details of the DTC display, refer to "DTC CHECK/ CLEAR" (See page AV-19). AV–47 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 4 CHECK HARNESS AND CONNECTOR (RADIO RECEIVER - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page AV-15). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component which has stored this code. (1) Disconnect all connectors between the radio receiver and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component which has stored this code. OK: There is no open or short circuit. AVC-LAN WIRING DIAGRAM *1: Master Unit *2: Slave Unit *3: with Rear Seat Entertainment System 10 Speaker System: (*2) 8 TX+ S22 5 R1 ATX+ (*3) 14 T18 TX+ Radio Receiver Stereo Component Amplifier 7 TX- S22 9 TXM+ R4 (*1) 15 R1 ATX- Television Display Assembly 10 TXM- R4 9 TXM+ R4 6 Speaker System: (*3) (*3) 13 T18 TX- 14 T18 TX+ Radio Receiver (*2) (*3) Television Display Assembly (*1) 10 TXM- (*2) (*3) R4 (*3) 13 T18 TX- AV E119767E03 AV–48 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO RECEIVER (a) Replace the radio receiver with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END AV REPLACE COMPONENT WHICH HAS STORED THIS CODE AV–186 AUDIO / VISUAL – VIDEO TERMINAL VIDEO TERMINAL BODY ELECTRICAL AUDIO / VISUAL COMPONENTS CONSOLE PANEL SUB-ASSEMBLY UPPER AV B120191E04 AUDIO / VISUAL – VIDEO TERMINAL AV–187 VIDEO TERMINAL AV E115639E03 AUDIO / VISUAL – AUDIO TERMINAL AV–191 REMOVAL 1. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 2. REMOVE STEREO JACK ADAPTER (a) Disconnect the connector. (b) Disengage the wire harness clamp. (c) Disengage the 2 claws remove the stereo jack adapter assembly. E115647 AV AV–192 AUDIO / VISUAL – AUDIO TERMINAL INSTALLATION AV 1. INSTALL STEREO JACK ADAPTER 2. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER AV–194 AUDIO / VISUAL – STEERING PAD SWITCH REMOVAL 1. SEPARATE BATTERY NEGATIVE TERMINAL (See page RS-387) 2. REMOVE STEERING WHEEL COVER LOWER NO. 2 (See page RS-388) 3. REMOVE STEERING WHEEL COVER LOWER NO. 3 (See page RS-387) 4. REMOVE STEERING PAD ASSEMBLY (See page RS388) 5. REMOVE STEERING PAD SWITCH (a) Disconnect the connector. (b) Disconnect the connector of cruise control main switch. (c) Remove the screw. E062430 (d) Disengage the meshing of 2 pins remove the steering pad switch LH. 2 Pins 2 Pins AV I033301E02 AV–195 AUDIO / VISUAL – STEERING PAD SWITCH INSPECTION 1. INSPECT STEERING PAD SWITCH LH (a) Measure the resistance according to the values in the table below. AU1 EAU AU2 I039169E02 Standard resistance Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push Approx. 0 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push Approx. 0 Ω If the result is not as specified, replace the steering pad switch LH. AV AV–196 AUDIO / VISUAL – STEERING PAD SWITCH 2. INSPECT STEERING PAD SWITCH RH (w/ Navigation System) (a) Inspect steering pad switch assembly. (1) Measure the resistance according to the values in the table below. Connector Front View: A EAU AU2 AU1 E120112E01 Standard resistance Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push Approx. 0 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push Approx. 0 Ω AU2 - EAU VOICE switch: push Approx. 3.1 kΩ AU2 - EAU ON HOOK switch: push Approx. 0.3 kΩ AU2 - EAU OFF HOOK switch: push Approx. 1 kΩ (b) Inspect steering pad switch cable. B 21 3 4 5 6 78 C 12 3 4 5 6 87 AV E120113E02 AV–197 AUDIO / VISUAL – STEERING PAD SWITCH (1) Measure the resistance according to the values in the table below. Standard resistance Tester connection Condition Specified condition B-1 - C-1 Always Below 1 Ω B-2 - C-2 Always Below 1 Ω B-3 - C-3 Always Below 1 Ω B-4 - C-4 Always Below 1 Ω B-5 - C-5 Always Below 1 Ω B-6 - C-6 Always Below 1 Ω B-7 - C-7 Always Below 1 Ω B-8 - C-8 Always Below 1 Ω B-1 - Body ground Always 10 kΩ or higher B-2 - Body ground Always 10 kΩ or higher B-3 - Body ground Always 10 kΩ or higher B-4 - Body ground Always 10 kΩ or higher B-5 - Body ground Always 10 kΩ or higher B-6 - Body ground Always 10 kΩ or higher B-7 - Body ground Always 10 kΩ or higher B-8 - Body ground Always 10 kΩ or higher If the result is not as specified, replace the steering pad switch cable. (c) Inspect steering pad switch RH. Connector Front View: Opposite Side: AU2 (B-5) AU2 (B-4) B EAU (B-3) EAU (B-2) E120114E01 AV AV–198 AUDIO / VISUAL – STEERING PAD SWITCH (1) Measure the resistance according to the values in the table below. Standard resistance Tester connection Condition Specified condition No switch is pushed 10 kΩ or higher VOICE switch: push Approx. 3.1 kΩ ON HOOK switch: push Approx. 0.3 kΩ OFF HOOK switch: push Approx. 1 kΩ AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) If the result is not as specified, replace the steering pad switch RH. AV AUDIO / VISUAL – AUDIO TERMINAL AV–189 AUDIO TERMINAL BODY ELECTRICAL AUDIO / VISUAL COMPONENTS CONSOLE PANEL SUB-ASSEMBLY UPPER AV B120191E05 AV–190 AUDIO / VISUAL – AUDIO TERMINAL STEREO JACK ADAPTER AV E115639E04 AUDIO / VISUAL – STEERING PAD SWITCH AV–199 INSTALLATION 1. INSTALL STEERING PAD SWITCH 2. INSTALL STEERING PAD ASSEMBLY (See page RS388) 3. INSTALL STEERING WHEEL COVER LOWER NO. 3 (See page RS-388) 4. INSTALL STEERING WHEEL COVER LOWER NO. 2 (See page RS-388) 5. CONNECT BATTERY NEGATIVE TERMINAL 6. INSPECT STEERING PAD ASSEMBLY (See page RS389) 7. INSPECT SRS WARNING LIGHT (See page RS-389) AV AV–192 AUDIO / VISUAL – STEERING PAD SWITCH STEERING PAD SWITCH BODY ELECTRICAL AUDIO / VISUAL COMPONENTS STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER LOWER NO. 2 AV STEERING PAD ASSEMBLY C C131315E04 AUDIO / VISUAL – STEERING PAD SWITCH AV–193 STEERING PAD SWITCH AV E115639E05 AUDIO / VISUAL – MICROPHONE AMPLIFIER AV–201 REMOVAL 1. REMOVE ROOF CONSOLE BOX ASSEMBLY (See page IR-12) 2. REMOVE MICROPHONE AMPLIFIER (a) Remove the 4 screws. E116109 (b) Disconnect the connector. (c) Disengage the 2 claws remove the amplifier microphone assembly. E116240 AV AV–202 AUDIO / VISUAL – MICROPHONE AMPLIFIER INSTALLATION AV 1. INSTALL MICROPHONE AMPLIFIER 2. INSTALL ROOF CONSOLE BOX ASSEMBLY (See page IR-15) AUDIO / VISUAL – MICROPHONE AMPLIFIER AV–199 MICROPHONE AMPLIFIER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS ROOF CONSOLE BOX ASSEMBLY AV B120189E03 AV–200 AUDIO / VISUAL – MICROPHONE AMPLIFIER MICROPHONE AMPLIFIER AV E115641E09 AV–206 AUDIO / VISUAL – REAR SPEAKER REMOVAL 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-41) 2. REMOVE REAR ARMREST ASSEMBLY LH (See page ED-41) 3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-41) 4. REMOVE REAR SPEAKER (a) Disconnect the connector. (b) Remove the 3 screws and rear speaker. I033309 INSTALLATION 1. INSTALL REAR SPEAKER (a) Install the rear speaker with the 3 screws. NOTICE: Install them in the order shown in the illustration. (b) Connect the connector. 2. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH 3. INSTALL REAR ARMREST ASSEMBLY LH 4. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH I033309 AV AV–202 AUDIO / VISUAL – WINDOW GLASS ANTENNA WIRE WINDOW GLASS ANTENNA WIRE BODY ELECTRICAL AUDIO / VISUAL COMPONENTS WINDOW GLASS ANTENNA WIRE AV E115641E10 AUDIO / VISUAL – WINDOW GLASS ANTENNA WIRE AV–203 INSPECTION 1. INSPECT WINDOW GLASS ANTENNA WIRE NOTICE: When cleaning the glass, use a soft dry cloth and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the foil negative probe and press the foil against the wire with your finger, as shown in the illustration. (a) Inspect the continuity, at the center of each antenna wire, as shown in the illustration. E032576 REPAIR Repair Point 1. Broken Wire REPAIR WINDOW GLASS ANTENNA WIRE (a) Clean the broken wire tips with a grease, wax and silicone remover. (b) Place the masking tape along both sides of the wire to be repaired. (c) Thoroughly mix the repair agent (Dupont+. paste No. 4817). Masking Tape BE00150E08 Fine Tip Brush (d) Using a fine tip brush, apply a small amount to the wire. (e) After a few minutes, remove the masking tape. (f) Do not repair the defogger were for at least 24 hours. Repair Point Glass BE00151E06 AV AV–210 AUDIO / VISUAL – REAR NO. 2 SPEAKER ON-VEHICLE INSPECTION 1. AV INSPECT REAR NO. 2 SPEAKER HINT: Remove interior parts so that the rear No. 2 speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the rear No. 2 speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the rear No. 2 speaker. AUDIO / VISUAL – REAR NO. 2 SPEAKER AV–211 REMOVAL 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE BACK DOOR WEATHERSTRIP 3. REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-7) 4. REMOVE DECK BOARD ASSEMBLY (See page IR-7) 5. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-7) 6. REMOVE DECK FLOOR BOX LH (See page IR-8) 7. REMOVE DECK TRIM COVER REAR (See page IR-8) 8. REMOVE DECK TRIM SIDE BOARD UPR LH (See page IR-8) 9. REMOVE SIDE TRIM BOX ASSEMBLY LH (See page IR-8) 10. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-8) 11. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 12. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-9) 13. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER LH (See page IR-10) 14. REMOVE REAR NO. 2 SPEAKER (a) Disconnect the connector. (b) Remove the 2 bolts and rear No. 2 speaker. I033310 AV AV–204 AUDIO / VISUAL – REAR SPEAKER REAR SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS REAR DOOR INSIDE HANDLE BEZEL LH REAR SPEAKER REAR ARMREST ASSEMBLY LH AV REAR DOOR TRIM BOARD SUB-ASSEMBLY LH B120199E02 AUDIO / VISUAL – REAR SPEAKER AV–205 ON-VEHICLE INSPECTION 1. INSPECT REAR SPEAKER HINT: Remove interior parts so that the rear speaker can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the rear speaker. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the rear speaker. (c) Speaker resistance check (1) Disconnect the rear speaker connector. (2) Measure the resistance between the terminals of the speaker. Standard resistance: 6 Speaker System: Approximately 4 Ω 10 Speaker System: Approximately 2.4 Ω If the result is not as specified, replace the rear speaker. AV AV–212 AUDIO / VISUAL – REAR NO. 2 SPEAKER INSTALLATION 1. INSTALL REAR NO. 2 SPEAKER 2. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER LH (See page IR-16) 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-16) 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-17) 6. INSTALL SIDE TRIM BOX ASSEMBLY LH (See page IR-18) 7. INSTALL DECK TRIM SIDE BOARD UPR LH (See page IR-18) 8. INSTALL DECK TRIM COVER REAR 9. INSTALL DECK FLOOR BOX LH (See page IR-18) 10. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-18) 11. INSTALL DECK BOARD ASSEMBLY (See page IR-18) 12. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-18) 13. INSTALL BACK DOOR WEATHERSTRIP 14. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY AV AUDIO / VISUAL – REAR NO. 2 SPEAKER AV–207 REAR NO. 2 SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS DECK TRIM COVER REAR DECK BOARD SUB-ASSEMBLY AV B120186E04 AV–208 AUDIO / VISUAL – REAR NO. 2 SPEAKER BACK DOOR WEATHERSTRIP REAR FLOOR MAT SUPPORT PLATE REAR DECK BOARD SUB-ASSEMBLY DECK TRIM COVER REAR DECK FLOOR BOX LH ROOF SIDE GARNISH ASSEMBLY INNER LH DECK TRIM SIDE PANEL ASSEMBLY LH REAR DOOR SCUFF PLATE LH REAR DOOR OPENING TRIM WEATHERSTRIP LH B120187E04 AV AV–209 AUDIO / VISUAL – REAR NO. 2 SPEAKER REAR NO. 2 SPEAKER AV E115641E04 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX AV–215 ON-VEHICLE INSPECTION 1. INSPECT NO. 1 SPEAKER WITH BOX HINT: Remove interior parts so that the No. 1 speaker with box can be seen. (a) Check the speaker installation. OK: The speaker is securely installed. If the result is not as specified, reinstall the No. 1 speaker with box. (b) Visually check the speaker. OK: The cone paper of the speaker is not torn. If the result is not as specified, replace the No. 1 speaker with box. (c) Resistance check. (1) Measure the resistance according tot the value(s) in the table below. NOTICE: The speaker should not be removed for checking. Standard resistance I034673 Tester connection Condition Specified condition 1-3 Always Approximately 1.2 Ω 2-4 Always Approximately 1.2 Ω If the result is not as specified, replace the No. 1 speaker with box. AV AV–216 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX REMOVAL 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE BACK DOOR WEATHERSTRIP 3. REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-7) 4. REMOVE DECK BOARD ASSEMBLY (See page IR-7) 5. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-7) 6. REMOVE DECK FLOOR BOX RH (See page IR-8) 7. REMOVE DECK TRIM COVER REAR (See page IR-8) 8. REMOVE DECK TRIM SIDE BOARD UPR RH (See page IR-8) 9. REMOVE SIDE TRIM BOX ASSEMBLY RH (See page IR-8) 10. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-8) 11. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 12. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-9) 13. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH (See page IR-10) 14. REMOVE WOOFER BOX SPEAKER ASSEMBLY (a) Disconnect the connectors. (b) Remove the 5 bolts and woofer box speaker assembly. I033311 AV AV–212 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX NO. 1 SPEAKER WITH BOX BODY ELECTRICAL AUDIO / VISUAL COMPONENTS REAR DOOR OPENING TRIM WEATHERSTRIP RH DECK TRIM COVER REAR ROOF SIDE GARNISH ASSEMBLY INNER RH DECK FLOOR BOX RH SIDE DECK TRIM PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH DECK BOARD SUB-ASSEMBLY AV B120186E05 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX AV–213 BACK DOOR WEATHERSTRIP DECK TRIM COVER REAR RH REAR FLOOR MAT SUPPORT PLATE REAR DECK BOARD ASSEMBLY DECK TRIM COVER REAR B120187E06 AV AV–214 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX WOOFER BOX SPEAKER ASSEMBLY AV E115641E05 AUDIO / VISUAL – NO. 1 SPEAKER WITH BOX AV–217 INSTALLATION 1. INSTALL WOOFER BOX SPEAKER ASSEMBLY 2. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH (See page IR-16) 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-16) 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 5. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-17) 6. INSTALL SIDE TRIM BOX ASSEMBLY RH (See page IR-18) 7. INSTALL DECK TRIM SIDE BOARD UPR RH (See page IR-18) 8. INSTALL DECK TRIM COVER REAR (See page IR-18) 9. INSTALL DECK FLOOR BOX RH (See page IR-18) 10. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR (See page IR-18) 11. INSTALL DECK BOARD ASSEMBLY (See page IR-18) 12. INSTALL DECK BOARD SUB-ASSEMBLY (See page IR-18) 13. INSTALL BACK DOOR WEATHERSTRIP 14. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY AV NAVIGATION – NAVIGATION SYSTEM NS–3 SYSTEM DESCRIPTION 1. Radio and navigation assembly outline (a) Conventionally, 2 separate devices, a "radio and display" and a "navigation ECU" are used. This model has adopted a new type, combining these devices into a single unit. Radio and Disdplay Radio and Navigation Assembly Navigation ECU E120051E01 NS NS–4 NAVIGATION – NAVIGATION SYSTEM 2. Navigation system outline (a) Vehicle position tracking methods It is essential that the navigation system correctly tracks the current vehicle position and displays it on the map. There are 2 methods to track the current vehicle position: autonomous (dead reckoning) and GPS* (satellite) navigation. Both navigation methods are used in conjunction with each other. *GPS (Global Positioning System) GPS satellite Location by autonomous navigation Navigation Gyro Sensor GPS Antenna Location by GPS navigation Vehicle Speed Sensor Radio and Navigation Assembly GPS Antenna Receive satellite radio wave ECU Detect the measurement position GPS correction Vehicle Speed Sensor Detect vehicle running distance Create the current vehicle position tracking data Navigation screen Detect direction change Gyro Sensor Map matching correction Map disc Map and current vehicle position data processing Map scrolling Map scale switching NS E120052E01 NS–5 NAVIGATION – NAVIGATION SYSTEM Operation Description Vehicle Position Calculation The radio and navigation assembly calculates the current vehicle position (direction and current position) using the direction deviation signal from the gyro sensor and the running distance signal from the vehicle speed sensor and creates the driving route. Map Display Processing The radio and navigation assembly displays the vehicle track on the map by processing the vehicle position data, vehicle running track, and map data from the map disc. Map Matching The map data from the map disc is compared to the vehicle position and running track data. Then, the vehicle position is matched with the nearest road. GPS Correction The vehicle position is matched to the position measured by GPS. Then, the measurement position data from the GPS unit is compared with the vehicle position and running track data. If the position is widely different, the GPS measurement position is used. Distance Correction The running distance signal from the vehicle speed sensor includes the error caused by tire wear and slippage between the tires and road surface. Distance correction is performed to account for this. The radio and navigation assembly automatically offsets the running distance signal to make up for the difference between it and the distance data of the map. The offset is automatically updated. Navigation is performed even where the GPS radio wave does not reach. GPS Satellite In a tunnel In an indoor parking lot Between tall buildings Under an overpass On a forest or tree-lined path Autonomous Navigation Autonomous Navigation and GPS Wave Navigation I100028E07 NS NS–6 NAVIGATION – NAVIGATION SYSTEM HINT: The combination of autonomous and GPS navigation makes it possible to display the vehicle position even when the vehicle is in places where the GPS radio wave cannot receive a signal. When only autonomous navigation is used, however, the mapping accuracy may slightly decline. (b) Autonomous navigation This method determines the relative vehicle position based on the running track determined by the gyro and vehicle speed sensors located in the radio and navigation assembly. (1) Gyro sensor Calculates the direction by detecting angular velocity. It is located in the radio and navigation assembly. (2) Vehicle speed sensor Used to calculate the vehicle running distance. NS NS–7 NAVIGATION – NAVIGATION SYSTEM (c) GPS navigation (Satellite navigation) This method detects the absolute vehicle position using radio waves from a GPS satellite. * GPS satellites were launched by the U.S. Department of Defence for military purposes. Current longitude/latitude/altitude is determined using the radio wave arrival time from four satellites. GPS I100029E03 Number of satellites Measurement Description 2 or less Measurement impossible Vehicle position cannot be obtained because the number of satellites is not enough. 3 2-dimensional measurement is possible Vehicle position is obtained based on the current longitude and latitude. (This is less precise than 3-dimensional measurement.) 4 3-dimensional measurement is possible Vehicle position is obtained based on the current longitude, latitude and altitude. NS NS–8 NAVIGATION – NAVIGATION SYSTEM (d) Map matching The current driving route is calculated by autonomous navigation (according to the gyro sensor and vehicle speed sensor) and GPS navigation. This information is then compared with possible road shapes from the map data in the map disc and the vehicle position is set onto the most appropriate road. Start Actual driving route Driving route on the display (Route by estimation) L1 L 1 A L 2 L2 L3 Roads L 3 The system compares the shape of the roads L1, L2 and L3 to the estimated running track after the vehicle makes a right turn. At point A, the vehicle position differs enough from the shape of L1 that the display switches to the road L2. Map Matching NS I100030E07 NS–9 NAVIGATION – NAVIGATION SYSTEM (e) Touch switch Touch switches are touch-sensitive (interactive) switches operated by touching the screen. When a switch is pressed, the outer glass bends in to contact the inner glass at the pressed position. By doing this, the voltage ratio is measured and the pressed position is detected. Outer Glass Inner Vx1 (Vy1) Vy1 Contact Vx1 Vx2 Vx2 (Vy2) Vy2 Touch-sensitive switch position The touch switch detects the voltage ratio and calculates the position on the screen. E106414E03 3. DVD (Digital Versatile Disc) player outline (for navigation map) (a) The radio and navigation assembly (built-in navigation ECU) uses a laser pickup to read the digital signals recorded on a DVD. HINT: • Do not disassemble any part of the radio and navigation assembly (built-in navigation ECU). • Do not apply oil to the radio and navigation assembly (built-in navigation ECU). • Do not insert anything but a DVD into the radio and navigation assembly (built-in navigation ECU). NS NS–10 NAVIGATION – NAVIGATION SYSTEM 4. CAUTION: Do not look directly at the laser pickup because the radio and navigation assembly (built-in navigation ECU) uses an invisible laser beam. Be sure to only operate the navigation system as instructed. CD (Compact Disc) player outline (a) A compact disc player uses a laser pickup to read digital signals recorded on a compact disc (CD). By converting the digital signals to analog, it can play music and other things. NOTICE: • Do not disassemble any part of the CD player. • Do not apply oil to the CD player. • Do not insert anything but a CD into the CD player. CAUTION: Do not look directly at the laser pickup because the CD player uses an invisible laser beam. Be sure to only operate the player as instructed. (b) Usable discs (1) This player can only play audio CDs, CD-Rs (CD-Recordable), and CD-RWs (CDReWritable) that have any of the following marks: E119759 NS (c) Precautions for use of discs NOTICE: • Copy-protected CDs cannot be played. • CD-Rs and CD-RWs may not be played depending on the recording conditions or characteristics of the discs, or due to damage, dirt, or deterioration caused by leaving the discs in the cabin for a long time. • Unfinalized CD-Rs and CD-RWs cannot be played. • Dualdiscs that mate DVD recorded material on one side with CD digital audio material on the other cannot be played. • Keep the discs away from dirt. Be careful not to damage the discs or leave your fingerprints on them. • Hold discs by the outer edge and center hole with the label side up. NAVIGATION – NAVIGATION SYSTEM NS–11 • Leaving the disc exposed halfway out of the slot for a long time after pressing the disc eject button may cause deformation of the disc, making the disc unusable. • If discs have adhesive tape, stickers, CDR labels, or any traces of such labels attached, the discs may not be ejected or player malfunctions may result. • Keep the discs away from direct sunlight. (Exposure to direct sunlight may cause deformation of the disc, making the disc unusable.) • Do not use odd-shaped CDs because these may cause player malfunctions. • Do not use discs whose recording portion is transparent or translucent because they may not be inserted, ejected, or played normally. HINT: • When it is cold or it is raining, if the windows mist up, mist and also dew may form in the player. In such a case, the CD may skip or the CD may stop in the middle of play. Ventilate or dehumidify the cabin for a while before using the player. • The CD may skip if the player experiences strong vibrations when the vehicle is driven on rough road or similar uneven surface(s). I100151 5. (d) Cleaning NOTICE: Do not use a lens cleaner because it may cause a malfunction in the pickup portion of the player. (1) If dirt is on the disc surface, wipe it clean with a soft dry cloth such as an eyeglass cleaner for plastic lenses from the inside to the outside in a radial direction. NOTICE: • Pressing on the disc by hand or rubbing the disc with a hard cloth may scratch the disc surface. • Use of solvent such as a record spray, antistatic agent, alcohol, benzine, and thinner, or a chemical cloth may cause damage to the disc, making the disc unusable. MP3 / WMA OUTLINE (a) Playable MP3 file standards Compatible standard Compatible sampling frequency Compatible bit rate Compatible channel mode MP3 (MPEG1 LAYER3, MPEG2 LSF LAYER 3) • • MPEG1 LAYER3: 32, 44.1, 48 (kHz) MPEG2 LSF LAYER3: 16, 22.05, 24 (kHz) • MPEG1 LAYER3: 64, 80, 96, 112, 128, 160, 192, 224, 256, 320 (kbps) MPEG2 LSF LAYER3: 64, 80, 96, 112, 128, 144, 160 (kbps) Compatible with VBR • • Stereo, joint stereo, dual channel, monaural NS NS–12 NAVIGATION – NAVIGATION SYSTEM (b) Playable WMA file standards Compatible standard WMA Ver. 7, 8, and 9 Compatible sampling frequency 32, 44.1, 48 (kHz) Compatible bit rate • • • Ver. 7, 8: CBR48, 64, 80, 96, 128, 160, 192 (kbps) Ver. 9: CBR48, 64, 80, 96, 128, 160, 192, 256, 320 (kbps) Compatible with playback of channel 2 only (c) ID3 tag and WMA tag (1) Additional textual information called ID3 tag can be input to MP3 files. Information such as song titles and artist names can be stored. HINT: This player is compatible with the ID3 tags of ID3 Ver. 1.0 and 1.1, and ID3 Ver. 2.2 and 2.3. (Number of characters complies with ID3 Ver. 1.0 and 1.1.) (2) Additional textual information called WMA tag can be input to WMA files. Information such as song titles and artist names can be stored. (d) Usable media (1) Only CD-ROMs, CD-Rs (CD-Recordable), and CD-RWs (CD-ReWritable) only can be used to play MP3/WMA files. NOTICE: • CD-Rs and CD-RWs are more easily affected by a hot and humid environment than discs used for normal audio CDs. For this reason, some CD-Rs and CD-RWs may not be played. • If there are fingerprints or scratches on the disc, the disc may not be played or the CD may skip. • Some CD-Rs and CD-RWs deteriorate if they are left in the cabin for a long time. • Keep CD-Rs and CD-RWs in a storage case that is impenetrable to light. (e) Usable media format (1) Usable media format NS Disc format CD-ROM Mode 1, CD-ROM XA Mode 2 Form 1 File format ISO9660 Level 1 and Level 2 (Joliet, Romeo) HINT: • As for MP3/WMA files written in any format other than those above, the contents of the files may not be played normally or the file names or folder names may not be displayed correctly. • This player is compatible with multi-session discs and can play CD-Rs and CD-RWs on which MP3/WMA files are added. However, only the first session can be played. • Discs whose first session includes both music data and MP3 or WMA format data cannot be played. NAVIGATION – NAVIGATION SYSTEM NS–13 (2) Standard and restrictions Maximum directory levels 8 levels Maximum number of characters for a folder name/file name 16 two-byte characters (or 32 one-byte characters) Maximum number of folders 192 (Including empty folders, route folders, and folders that do not contain MP3 / WMA files) Maximum number of files in a disc 255 (Including non-MP3 / WMA files) (f) 6. File names (1) Only files with an extension of ".mp3" or ".wma" can be recognized and played as MP3 or WMA files. (2) Save MP3 or WMA files with an extension of ".mp3" or ".wma". NOTICE: If saving non-MP3 or non-WMA files with an extension of ".mp3" or ".wma", those files are wrongly recognized as MP3 orWMA files and played. A loud noise may occur and damage to the speaker may result. AVC-LAN Description (a) What is AVC-LAN? AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. Example: Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100032E09 NS NS–14 NAVIGATION – NAVIGATION SYSTEM 7. 8. NS (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short to +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. • If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the radio and navigation assembly is equipped, it is the master unit. • The radio and navigation assembly contains a resistor that is necessary to enable communication on the different AVC-LAN circuits. • The car audio system with an AVC-LAN circuit has a diagnostic function. • Each component has a specified number (3digit) called a physical address. Each function has a number (2-digit) called a logical address. Communication system outline (a) Components of the navigation system communicate with each other via the AVC-LAN. (b) The radio and navigation assembly has enough resistance (60 to 80 Ω) necessary for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the navigation system will stop functioning. Diagnostic function outline (a) The audio system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. NAVIGATION – NAVIGATION SYSTEM 9. E100921 Example: NS–15 "Bluetooth" outline (a) "Bluethooth" is a trademark owned by Bluetooth SIG. Inc. (b) "Bluetooth" is a new wireless connection technology that uses the 2.4 GHz frequency band. This makes it possible to connect a cellular phone ("Bluetooth" compatible phone *1) to the radio and navigation assembly (the "Bluetooth" system is built in), and use the handsfree function of the cellular phone, even if it is in a pocket or bag. As a result, it is not necessary to use a connector attached directly to the cellular phone. *1: Some versions of "Bluetooth" compatible cellular phones may not function. Radio and Navigation Assembly (Built-in Bluetooth receiver antenna) Cellular Phone (Bluetooth type) Cellular Tower E121227E01 HINT: The communication performance of "Bluetooth" may vary depending on obstructions or radio wave conditions between communication devices, electromagnetic radiation, communication device sensitivity, or antenna capacity. NS NS–16 NAVIGATION – NAVIGATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT INTO A WORKSHOP NEXT 2 DIAGNOSTIC QUESTIONING AND SYMPTOM CONFIRMATION (a) Ask the customer about symptoms and confirm malfunctions. THE SCREEN DISPLAYS NOTHING (GO TO STEP 8, AND PROCEED TO "BLACK SCREEN") OTHER SYMPTOMS (GO TO STEP 3) 3 CONFIRM THE SYSTEM NORMAL CONDITION APPLICABLE (THIS IS NOT A MALFUNCTION) NOT APPLICABLE (GO TO STEP 4) 4 CHECK DTC HINT: If the system cannot enter the diagnosis mode, inspect each AVC-LAN communication signal and repair or replace problem parts. A CODE IS OUTPUT (GO TO STEP 5) A CODE IS NOT OUTPUT (GO TO STEP 8) 5 DTC CLEAR (a) Clear the DTCs and finish the diagnostic mode. HINT: The currently output DTCs may not indicate actual malfunctions depending on the vehicle conditions. NEXT NS NAVIGATION – NAVIGATION SYSTEM 6 NS–17 RECHECK DTC HINT: • If the system cannot enter the diagnosis mode, inspect the AVC-LAN and all the components that connect to the AVCLAN for short circuits. • Even if the malfunction symptom is not confirmed, check for diagnostic trouble codes. This is because the system stores past diagnostic trouble codes. • Refer to the detailed description on the diagnostic screen, as necessary (See page NS-30). • Check the diagnostic trouble code and inspect the area the code indicates. A CODE IS OUTPUT (GO TO STEP 7) A CODE IS NOT OUTPUT (GO TO STEP 8) 7 DIAGNOSTIC TROUBLE CODE CHART (a) Find the output code on the diagnostic trouble code chart. NEXT 8 GO TO STEP 10 PROBLEM SYMPTOMS TABLE (a) Find the applicable symptom code in the problem symptoms table. HINT: If the symptom does not recur and no code is output, perform the symptom reproduction method (See page NS-41). THERE IS AN APPLICABLE SYMPTOM CODE IN THE TABLE (GO TO STEP 10) THERE IS NO APPLICABLE SYMPTOM CODE IN THE TABLE (GO TO STEP 9) 9 CHECK THE ECU TERMINAL ARRANGEMENT BASED ON THE MALFUNCTION SYMPTOM NEXT 10 CHECK THE CIRCUIT (a) Adjust, repair, or replace as necessary. NS NS–18 NAVIGATION – NAVIGATION SYSTEM NEXT 11 RECHECK THE DIAGNOSTIC TROUBLE CODE HINT: After deleting the DTCs, recheck for diagnostic trouble codes. NEXT 12 NEXT END NS PERFORM CONFIRMATION TEST NS–19 NAVIGATION – NAVIGATION SYSTEM IDENTIFICATION OF NOISE SOURCE 1. Frequency 300 kHz 30 kHz Designation Radio Description (a) Radio frequency band (1) Radio broadcasts use the radio frequency bands shown in the table below. LF MF Modulation HF VHF FM Amplitude modulation MF: Medium Frequency 300 MHz 30 MHz AM Radio Wave LF: Low Frequency 30 MHz HF: High Frequency Frequency modulation VHF: Very High Frequency E108734E01 (b) Service area (1) The service areas of AM and FM broadcasts are vastly different. Sometimes an AM broadcast can be received very clearly but an FM stereo cannot. FM stereo has the smallest service area, and is prone to pick up static and other types of interference such as noise. (c) Radio reception problems HINT: In addition to static, other problems such as "phasing", "multipath", and "fade out" exist. These problems are not caused by electrical noise, but by the radio signal propagation method itself. FM (Stereo) FM (Monaural) AM E108735E01 Phasing Ionosphere (1) Phasing AM broadcasts are susceptible to electrical interference and another kind of interference called phasing. Occurring only at night, phasing is the interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off the ionosphere and the other signal is received directly from the transmitter. I100011E02 NS NS–20 NAVIGATION – NAVIGATION SYSTEM (2) Multipath Multipath is a type of interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off buildings or mountains and the other signal is received directly from the transmitter. Multipath I100012E02 (3) Fade out Fade out is caused by objects (buildings, mountains, and other large obstacles) that deflect away part of a signal, resulting in a weaker signal when the object is between the transmitter and vehicle. High frequency radio waves, such as FM broadcasts, are easily deflected by obstructions. Low frequency radio waves, such as AM broadcasts, are much more difficult to deflect. (d) Noise problem Technicians must have a clear understanding about each customer's noise complaint. Use the following table to diagnose noise problems. Fade Out I100013E02 Radio Frequency Noise Occurrence Condition Presumable Cause AM Noise occurs in a specified area Foreign noise AM Noise occurs when listening to an intermittent broadcast An identical program transmitted from multiple towers can cause noise where the signals overlap AM Noise occurs only at night Music beat from a distant broadcast FM Noise occurs while driving in a specified area Multipath or phasing noise resulting from a change in FM frequency HINT: If the noise does not match the examples above, refer to the descriptions about phasing and multipath. NS NS–67 NAVIGATION – NAVIGATION SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error DESCRIPTION DTC No. DTC Detection Condition 01-D6 *1 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected when the ignition switch is in the ACC or ON position. • The master device has (had) been disconnected when this code is stored. 01-D7 *2 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected after the engine starts (started). • The master device has (had) been disconnected when this code is (was) stored. Trouble Area • • • • • Radio and navigation assembly power source circuit Power source circuit of the component which has stored this code AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code Component which has stored this code Radio and navigation assembly HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch is in the ACC or ON position, this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-229). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–68 2 NAVIGATION – NAVIGATION SYSTEM IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display Component Rr-TV Television display assembly DSP-AMP Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E121199E01 NEXT 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component NS Proceed to Television display assembly (Rr-TV) Television display assembly power source circuit (See page NS-231) Stereo component amplifier (DSP-AMP) Stereo component amplifier power source circuit (See page NS-227) NEXT NS–69 NAVIGATION – NAVIGATION SYSTEM 4 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 TXM+ ATX+ ATX- Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK 5 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. OK: There is no open or short circuit. NS NS–70 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–71 NAVIGATION – NAVIGATION SYSTEM DTC 01-DC Transmission Error DESCRIPTION DTC No. 01-DC *1 DTC Detection Condition Trouble Area Transmission to component shown by sub-code failed. (Detecting this DTC does not always mean actual failure.) If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code HINT: *1: This code may be stored if the engine is started, idled for 60 seconds and then the ignition switch is turned to the START position again. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. HINT: For the list of the components shown by sub-codes, refer to the table in step 2. Result Result Proceed to "01-DC" is output and the same physical address is displayed A "01-DC" is not output or the same physical address is not displayed B B Go to step 4 A NS NS–72 2 NAVIGATION – NAVIGATION SYSTEM IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display Component Rr-TV (1B0) Television display assembly DSP-AMP (440) Stereo component amplifier AVN (140) Radio and navigation assembly HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC Component shown by sub-code E121199E02 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component Table: Component Radio and navigation assembly (AVN) Radio and navigation assembly communication error (See page NS-221) Television display assembly (Rr-TV) Television display assembly communication error (See page NS-224) Stereo component amplifier (DSP-AMP) Stereo component amplifier communication error (See page NS-218) NEXT NS Proceed to END NAVIGATION – NAVIGATION SYSTEM 4 NS–73 CLEAR DTC (a) Clear the DTCs (See page NS-49). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG Go to step 3 OK END NS NS–1 NAVIGATION – NAVIGATION SYSTEM NAVIGATION SYSTEM BODY ELECTRICAL NAVIGATION PARTS LOCATION OVERHEAD J/B RADIO AND NAVIGATION ASSEMBLY - MICROPHONE FRONT CENTER SPEAKER FRONT SIDE SPEAKER - FRONT NO. 2 SPEAKER TELEVISION DISPLAY ASSEMBLY (*1) - FRONT STEREO COMPONENT SPEAKER STEREO JACK ADAPTER WINDOW GLASS ANTENNA WIRE FRONT SIDE SPEAKER - FRONT NO. 1 SPEAKER ENGINE ROOM R/B - ACC CUT RELAY - AM1 FUSE - ALT FUSE REAR SPEAKER NO. 1 SPEAKER WITH BOX - EFI FUSE - WOOFER BOX SPEAKER ASSEMBLY - RADIO NO. 1 FUSE - RADIO NO. 2 FUSE COMBINATION METER STEREO COMPONENT AMPLIFIER - DOME FUSE STEERING PAD SWITCH RH SPIRAL CABLE STEERING PAD SWITCH LH *1: with Rear Seat Entertainment System E120049E01 NS NS–2 NAVIGATION – NAVIGATION SYSTEM SYSTEM DIAGRAM Steering Pad Switch Combination Meter Vehicle Speed Signal Stereo Component Amplifier (Built-in Woofer Box Speaker) Speakers Park / Neutral Position Switch Reverse Signal Parking Brake Switch Parking Brake Signal Microphone Assembly Microphone Voice Signal Radio and Navigation Assembly Stereo Jack Adapter External Device Sound Signal Radio Antenna GPS Antenna (*1) *1: with Rear Seat Entertainment System Television Display Assembly (*1) (*1) (*1) : Display Signal : Sound Signal : AVC-LAN E120050E04 NS NS–74 NAVIGATION – NAVIGATION SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION DTC No. 01-DD *1 DTC Detection Condition The device that should be the master has been disconnected after the engine starts. Trouble Area • • 01-E1 *2 The AMP device records that the AMP output does not function even while the source device is operating. • • Radio and navigation assembly power source circuit AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code Radio and navigation assembly Component which has stored this code HINT: • *1: This code may be stored if the engine is started and the ignition switch is turned to the START position again. • *2: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-229). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–75 NAVIGATION – NAVIGATION SYSTEM 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 TXM+ ATX+ ATX- Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK NS NS–76 3 NAVIGATION – NAVIGATION SYSTEM IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display Component Rr-TV Television display assembly DSP-AMP Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E111829E03 NEXT 4 NS CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. NS–77 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO AND NAVIGATION ASSEMBLY (a) Replace the radio and navigation assembly with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE COMPONENT WHICH HAS STORED THIS CODE OK END NS NS–78 NAVIGATION – NAVIGATION SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • 01-DF *1 • The device with a display fails and the master is switched to the audio device. A communication error between sub-master (radio receiver) and master occurs. • • • • Radio and navigation assembly power source circuit AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code AVC-LAN circuit between the radio and navigation assembly and the radio receiver Radio and navigation assembly Component which has stored this code HINT: *1: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the ignition switch in the ACC or ON position, this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK RADIO AND NAVIGATION ASSEMBLY POWER SOURCE CIRCUIT Refer to the radio and navigation assembly power source circuit (See page NS-229). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–79 NAVIGATION – NAVIGATION SYSTEM 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 TXM+ ATX+ ATX- Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK NS NS–80 3 NAVIGATION – NAVIGATION SYSTEM IDENTIFY THE COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component Table: Example: Display Component Rr-TV Television display assembly DSP-AMP Stereo component amplifier HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. Component which has stored this code DTC E121199E04 NEXT 4 NS CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. (1) Disconnect all connectors between the radio and navigation assembly and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code. NS–81 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE RADIO AND NAVIGATION ASSEMBLY (a) Replace the radio and navigation assembly with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE COMPONENT WHICH HAS STORED THIS CODE OK END NS NS–82 NAVIGATION – NAVIGATION SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from the master device cannot be received. - 01-E3 The registration demand signal from the slave device is output. Or the registration demand signal is output by receiving connection confirmation signal from the submaster device. - 01-E4 The multiple frame transmission is incomplete. - HINT: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. INSPECTION PROCEDURE HINT: • After the inspection is completed, clear the DTCs. • These DTCs do not indicate a malfunction. NS NS–83 NAVIGATION – NAVIGATION SYSTEM DTC 01-E2 ON / OFF Indication Parameter Error DESCRIPTION DTC No. 01-E2 DTC Detection Condition The signal for ON/OFF control from the master device has a problem. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–84 NAVIGATION – NAVIGATION SYSTEM DTC 21-10 Panel Switch Error DTC 21-11 Touch Switch Error DTC 23-10 Panel Switch Error DTC 23-11 Touch Switch Error DTC 24-10 Panel Switch Error DTC 24-11 Touch Switch Error DTC 25-10 Panel Switch Error DTC 25-11 Touch Switch Error DESCRIPTION DTC No. 21-10 DTC Detection Condition 21-11 The touch panel switch has a problem. 23-10 The panel switch detection circuit has a problem. 23-11 The touch panel switch has a problem. 24-10 The panel switch detection circuit has a problem. 24-11 The touch panel switch has a problem. 25-10 The panel switch detection circuit has a problem. 25-11 The touch panel switch has a problem. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS Trouble Area The panel switch detection circuit has a problem. REPLACE RADIO AND NAVIGATION ASSEMBLY Radio and navigation assembly NS–85 NAVIGATION – NAVIGATION SYSTEM DTC 34-10 Error in Picture Circuit DTC 34-11 No Current in Back-light DTC 34-12 Excess Current in Back-light DESCRIPTION DTC No. DTC Detection Condition 34-10 Error in power supply system for picture circuit 34-11 Decline in power output from inverter circuit for backlight 34-12 Excess power output from inverter circuit for back-light Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–86 NAVIGATION – NAVIGATION SYSTEM DTC 44-10 DVD Player Mechanical Error DTC 44-11 DVD Insertion and Ejection Error DTC 44-12 DVD Reading Abnormal DESCRIPTION TC No. DTC Detection Condition 44-10 A mechanical error in the DVD player is detected while the DVD is not being inserted or ejected. 44-11 DVD insertion or ejection is failed. 44-12 DVD read problem occurs. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE TELEVISION DISPLAY ASSEMBLY Trouble Area Television display assembly NS–87 NAVIGATION – NAVIGATION SYSTEM DTC 44-41 Wrong Disc DTC 44-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detection Condition 44-41 An unsuitable disc is inserted. 44-42 The disc cannot be read. Trouble Area • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NEXT 3 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT NS NS–88 4 NAVIGATION – NAVIGATION SYSTEM RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS REPLACE TELEVISION DISPLAY ASSEMBLY NS–89 NAVIGATION – NAVIGATION SYSTEM DTC 44-43 DVD-ROM Abnormal DESCRIPTION DTC No. 44-43 DTC Detection Condition DVD-ROM operation is abnormal. Trouble Area • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER DVD IS INSERTED (a) Make sure that the DVD is a video DVD or a CD with an MP3 file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal DVD or CD HINT: • Translucent or uniquely-shaped DVDs or CDs cannot be played. • For details on playable DVDs or CDs, refer to the Owner's Manual. NG DISC IS FAULTY OK 2 CHANGE DISC (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END NS NS–90 NAVIGATION – NAVIGATION SYSTEM DTC 44-44 DVD Error DTC 44-48 Excess Current DTC 44-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. 44-44 DTC Detection Condition Trouble Area Operation error in the DVD mechanism 44-48 Excess current is present in the DVD player. 44-50 Malfunction in insertion/ejection system Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the television display assembly. OK: Malfunction disappears. NG OK END NS REPLACE TELEVISION DISPLAY ASSEMBLY NS–91 NAVIGATION – NAVIGATION SYSTEM DTC 44-45 Eject Error DTC 44-51 Elevator Error DTC 44-52 Clamp Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 44-45 Disc cannot be ejected. 44-51 Mechanical error occurs during elevator operation. 44-52 Error occurs in DVD player clamp. Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK TELEVISION DISPLAY ASSEMBLY (a) Check if a disc can be changed, inserted or ejected normally. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END NS NS–92 NAVIGATION – NAVIGATION SYSTEM DTC 44-46 Scratched / Reversed Disc DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 44-46 Scratches or dirt is found on DVD surface or DVD is set upside down. • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT DISC IS INSERTED PROPERLY (a) Check whether or not the disc is inserted upside down. OK: Disc is properly inserted. NG REINSERT DISC OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 3 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NS NEXT NAVIGATION – NAVIGATION SYSTEM 4 NS–93 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END NS NS–94 NAVIGATION – NAVIGATION SYSTEM DTC 44-47 High Temperature DESCRIPTION DTC No. DTC Detection Condition Trouble Area 44-47 Sensor detects that DVD unit temperature is high (Over 80°C). Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK TELEVISION DISPLAY ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the television display assembly has become sufficiently low, and start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG OK END NS REPLACE TELEVISION DISPLAY ASSEMBLY NS–95 NAVIGATION – NAVIGATION SYSTEM DTC 44-78 DSP Error DESCRIPTION DTC No. 44-78 DTC Detection Condition Trouble Area An error occurs during the decode process (MP3 / WMA). - INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NOTICE: • This code may be output even if there is no malfunction. • If this code is output frequently, replace the television display assembly. 1 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END NS NS–21 NAVIGATION – NAVIGATION SYSTEM SYSTEM NORMAL CONDITION CHECK 1. CHECK NORMAL CONDITION (a) If the symptom is applicable to any of the following, it is intended behavior, and not a malfunction. Symptom Answer A longer route than expected is chosen. Depending on the road conditions, the radio and navigation assembly may determine that a longer route is quicker. Even when distance priority is high, the shortest route is not shown. Some paths may not be advised due to safety concerns. When the vehicle is put into motion immediately after the engine starts, the navigation system deviates from the actual position. If the vehicle starts before the navigation system activates, the system may not react. When running on certain types of roads, especially new roads, the vehicle position deviates from the actual position. When the vehicle is driving on new roads not available on the map disc, the system attempts to match it to another nearby road, causing the position mark to deviate. (b) The following symptoms are not a malfunction, but are caused by errors inherent in the GPS, gyro sensor, speed sensor, and radio and navigation assembly. (1) The current position mark may be displayed on a nearby parallel road. I100066 (2) Immediately after a fork in the road, the current vehicle position mark may be displayed on the wrong road. I100067 (3) When the vehicle turns right or left at an intersection, the current vehicle position mark may be displayed on a nearby parallel road. I100068 NS NS–22 NAVIGATION – NAVIGATION SYSTEM (4) When the vehicle is carried, such as on a ferry, and the vehicle itself is not running, the current vehicle position mark may be displayed in the position where the vehicle was until a measurement can be performed by GPS. I100069 (5) When the vehicle runs on a steep hill, the current vehicle position mark may deviate from the correct position. I100070 (6) When the vehicle makes a continuous turn of 360, 720, 1,080, etc. degrees, the current vehicle position mark may deviate from the correct position. I100071 (7) When the vehicle moves erratically, such as constant lane changes, the current vehicle position mark may deviate from the correct position. I100072 (8) When the ignition switch is turned to the ACC or ON position on a turntable before parking, the current vehicle position mark may not point in the correct direction. The same will occur when the vehicle comes out of parking. NS I038146 NAVIGATION – NAVIGATION SYSTEM NS–23 (9) When the vehicle runs on a snowy road or a mountain path with the chains installed or using a spare tire, the current vehicle position mark may deviate from the correct position. I100074 (10)When a tire is changed, the current vehicle position mark may deviate from the correct position. HINT: • Diameter of the tire may change, causing a speed sensor error. • Performing the "tire change" in calibration mode will allow the system to correct the current vehicle position faster. I100075 NS NS–96 NAVIGATION – NAVIGATION SYSTEM DTC 44-7D Disc cannot be Played DTC 44-7E No Playable Files DTC 44-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detecting Condition Trouble Area • • An incompatible MP3/WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 44-7E • • A disc with no music data is used. Playable files are not on the disc (MP3/WMA). 44-7F A copy-protected file, which cannot be played, is used. 44-7D • • DVD Television display assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG OK END NS REPLACE TELEVISION DISPLAY ASSEMBLY NS–97 NAVIGATION – NAVIGATION SYSTEM DTC 57-47 Bluetooth Module Initialization Failed DESCRIPTION DTC No. 57-47 DTC Detection Condition • • • Bluetooth module is not installed. Problem with Bluetooth module Problem in communication line to Bluetooth module Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–98 NAVIGATION – NAVIGATION SYSTEM DTC 58-10 Gyro Error DTC 80-10 Gyro Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-10 Ground short, power supply short, or open circuit in the gyro signal 80-10 Ground short, power supply short, or open circuit in the gyro signal • • Gyro sensor Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) Check the gyro voltage. Standard voltage: 0.1 to 4.5 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY E120088 OK 2 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 3 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio and navigation assembly. OK: Malfunction disappears. NG NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–99 OK END NS NS–234 NAVIGATION – NAVIGATION RECEIVER NAVIGATION RECEIVER BODY ELECTRICAL NAVIGATION COMPONENTS RADIO AND NAVIGATION ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY INSTRUMENT PANEL FINISH PLATE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY CONSOLE PANEL SUB-ASSEMBLY UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER W/ NAVIGATION: RADIO AND NAVIGATION ASSEMBLY RADIO NO. 2 BRACKET NS RADIO NO. 1 BRACKET E115638E02 NAVIGATION – NAVIGATION RECEIVER NS–235 REMOVAL 1. REMOVE INSTRUMENT PANEL FINISH PLATE (See page IP-6) 2. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-7) 3. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page IP-8) 4. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (See page IP-7) 5. REMOVE CONSOLE PANEL SUB-ASSEMBLY UPPER (See page IP-7) 6. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (See page IP-7) 7. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER (See page IP-8) 8. REMOVE RADIO AND NAVIGATION ASSEMBLY (w/ Bracket) (a) Remove the 2 bolts. (b) Disconnect the connectors and remove the radio and navigation assembly w/ bracket. 9. REMOVE RADIO NO. 1 BRACKET (a) Remove the 4 screws and radio No. 1 bracket. E133061 I033306 10. REMOVE RADIO NO. 2 BRACKET (a) Remove the 4 screws and radio No. 2 bracket. I033040 NS NS–100 NAVIGATION – NAVIGATION SYSTEM DTC 58-11 GPS Receiver Error DTC 80-11 GPS Receiver Error DESCRIPTION DTC No. DTC Detection Condition • 58-11 • • 80-11 • RTC, ROM, and RAM of the GPS receiver and TCXO error GPS receiver is failed. RTC, ROM, and RAM of the GPS receiver and TCXO error GPS receiver is failed. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE RADIO AND NAVIGATION ASSEMBLY Trouble Area Radio and navigation assembly NS–101 NAVIGATION – NAVIGATION SYSTEM DTC 58-40 GPS Antenna Error DTC 58-41 GPS Antenna Power Source Error DTC 80-40 GPS Antenna Error DTC 80-41 GPS Antenna Power Source Error DESCRIPTION DTC No. DTC Detection Condition 58-40 GPS antenna error 58-41 Error of the power source to the GPS antenna 80-40 GPS antenna error 80-41 Error of the power source to the GPS antenna Trouble Area • • • Wire harness GPS antenna Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK HARNESS AND CONNECTOR (GPS ANTENNA - RADIO AND NAVIGATION ASSEMBLY) (a) Check that the GPS antenna cord is securely connected to the radio and navigation assembly connector. OK: The cord is securely connected. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 REPLACE GPS ANTENNA (a) Replace the GPS antenna with a normal one and check if the same problem occurs again. (1) Clear the DTCs (See page NS-49). (2) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–102 NAVIGATION – NAVIGATION SYSTEM DTC 58-42 Map Disc Read Error DTC 80-42 Map Disc Read Error DESCRIPTION DTC No. DTC Detection Condition 58-42 • • • Player error Scratches or dirt on the disc Access to an invalid address due to software error 80-42 • • • Player error Scratches or dirt on the disc Access to an invalid address due to software error Trouble Area • • Map disc Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG Go to step 4 I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100201E04 NEXT NS 3 DTC CLEAR AND RECHECK (a) Clear the DTCs (See page NS-49). NAVIGATION – NAVIGATION SYSTEM NS–103 (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK END NG 4 REPLACE MAP DISC (a) Replace the map disc. (b) Clear the DTCs and recheck for DTCs. (c) Check if the same trouble occurs again. OK: Same problem does not occur. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–104 NAVIGATION – NAVIGATION SYSTEM DTC 58-43 SPD Signal Error DTC 80-43 SPD Signal Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-43 A difference between the GPS speed and SPD pulse is detected. 80-43 A difference between the GPS speed and SPD pulse is detected. • • Speed signal circuit Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "SPD" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. OK E120089 REPLACE RADIO AND NAVIGATION ASSEMBLY NG 2 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE Refer to "Speed signal does not change in the navigation check mode" in the problem symptoms table (See page NS41). NEXT END NS NS–105 NAVIGATION – NAVIGATION SYSTEM DTC 58-44 Player Error DTC 80-44 Player Error DESCRIPTION DTC No. DTC Detection Condition 58-44 Map player error is detected. 80-44 Map player error is detected. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc can be inserted or ejected normally. OK: A disc can be inserted or ejected normally. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 2 DTC CLEAR AND RECHECK (a) Clear the DTCs (See page NS-49). (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–106 NAVIGATION – NAVIGATION SYSTEM DTC 58-45 High Temperature DTC 80-45 High Temperature DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-45 High map disc player temperature is detected (Over 80°C). 80-45 High map disc player temperature is detected (Over 80°C). Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio and navigation assembly has becomes sufficiently low, then start the engine to verify the malfunction symptom. OK: Same problem does not occur. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–107 NAVIGATION – NAVIGATION SYSTEM DTC 5C-40 Camera Picture Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • • Synchronous signal from the camera cannot be transmitted. 5C-40 Wire harness Television camera assembly Radio and navigation assembly WIRING DIAGRAM T11 Television Camera Assembly CV+ CGND Radio and Navigation Assembly 4 22 R26 V+ 2 21 R26 CGND 24 R26 CA+ CB+ 1 CV- 3 (*1) (*1) (*1) (*1) 23 R26 V- *1: Shielded E120090E01 INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY TELEVISION CAMERA ASSEMBLY) (a) Disconnect the R26 connector from the radio and navigation assembly. (b) Disconnect the T11 connector from the television camera assembly. NS NS–108 NAVIGATION – NAVIGATION SYSTEM Radio and Navigation Assembly: R26 Television Camera Assembly: CGND CB+ T11 CA+ V- V+ CGND CV- CV+ E120091E01 (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection (Terminal No.) Condition Specified Condition CB+ (T11-1) - CA+ (R26-24) Always Below 1 Ω CGND (T11-2) - CGND (R26-21) Always Below 1 Ω CV+ (T11-4) - V+ (R26-22) Always Below 1 Ω CV- (T11-3) - V- (R26-23) Always Below 1 Ω CB+ (T11-1) - Body ground Always 10 kΩ or higher CGND (T11-2) - Body ground Always 10 kΩ or higher CV+ (T11-4) - Body ground Always 10 kΩ or higher CV- (T11-3) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Reconnect the radio and navigation assembly connector. NS NS–109 NAVIGATION – NAVIGATION SYSTEM Television Camera Assembly: CGND CB+ T11 E126215E01 (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection (Terminal No.) Condition Specified Condition CB+ (T11-1) - CGND (T11-2) IG SW ON, shift lever R position Approx. 6 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 3 INSPECT TELEVISION CAMERA ASSEMBLY (a) Reconnect the radio and navigation assembly R26 connector and the television camera assembly T11 connector. NS NS–110 NAVIGATION – NAVIGATION SYSTEM Television Camera Assembly: T11 CV+ CV- E120092E01 (b) Check the waveform of the television camera assembly using an oscilloscope. (1) Measurement terminal: CV+ - CVMeasurement setting: 0.2 V/DIV, 0.2 µs/DIV Condition: Ignition switch ON, Shift lever in R range OK: Pulses as shown in the illustration. GND NG E119731E02 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS REPLACE TELEVISION CAMERA ASSEMBLY NS–111 NAVIGATION – NAVIGATION SYSTEM DTC 63-10 CD Changer Mechanical Error DTC 63-11 CD Insertion and Ejection Error DTC 63-12 CD Reading Abnormal DESCRIPTION DTC No. DTC Detection Condition 63-10 A mechanical error in the CD changer is detected while the CD is not being inserted or ejected. 63-11 CD insertion or ejection is failed. 63-12 CD read problem occurs. Trouble Area Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE RADIO AND NAVIGATION ASSEMBLY NEXT END NS NS–112 NAVIGATION – NAVIGATION SYSTEM DTC 63-41 Wrong Disc DTC 63-42 Disc cannot be Read DESCRIPTION DTC No. DTC Detection Condition 63-41 An unsuitable disc is inserted. 63-42 The disc cannot be read. Trouble Area • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformations or cracks on the disc. NG CHANGE DISC I100152 OK 2 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to outside in a radial direction. NOTICE: Do not use a conventional record cleaner or anti-static preservative. I100151 NEXT 3 CLEAR DTC (a) Clear the DTCs (See page NS-49). NS NEXT NAVIGATION – NAVIGATION SYSTEM 4 NS–113 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–114 NAVIGATION – NAVIGATION SYSTEM DTC 63-43 CD-ROM Abnormal DESCRIPTION DTC No. 63-43 DTC Detection Condition Trouble Area • • CD-ROM operation is abnormal. CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • CD with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CD IS FAULTY OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with another and recheck. (1) Replace the CD with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK NS END REPLACE RADIO AND NAVIGATION ASSEMBLY NS–115 NAVIGATION – NAVIGATION SYSTEM DTC 63-44 CD Abnormal DTC 63-48 Excess Current DTC 63-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. 63-44 DTC Detection Condition Trouble Area Operation error in the CD mechanism 63-48 Excess current is present in the CD changer. 63-50 Malfunction in insertion/ejection system Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio and navigation assembly. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–116 NAVIGATION – NAVIGATION SYSTEM DTC 63-45 Eject Error DTC 63-51 Elevator Error DTC 63-52 Clamp Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 63-45 Magazine cannot be ejected. 63-51 Mechanical error occurs during elevator operation. 63-52 Error occurs in CD changer clamp. Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc can be changed, inserted, or ejected normally. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–117 NAVIGATION – NAVIGATION SYSTEM DTC 63-46 Scratched / Reversed Disc DESCRIPTION DTC No. 63-46 DTC Detection Condition Trouble Area Scratches or dirt is found on CD surface or CD is set upside down. • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT CD IS INSERTED PROPERLY (a) Check that the CD is not inserted upside down. OK: CD is properly inserted. NG INSERT CD PROPERLY OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformations or cracks on the disc. NG CHANGE DISC I100152 OK 3 DISC CLEANING (a) Disc cleaning (1) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to outside in a radial direction. NOTICE: Do not use conventional record cleaner or antistatic preservative. I100151 NEXT NS NS–118 4 NAVIGATION – NAVIGATION SYSTEM CLEAR DTC (a) Clear the DTCs (See page NS-49). NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REPLACE DISC WITH ANOTHER AND RECHECK (a) Replace the disc with another and recheck. (1) Replace the disc with another normal one. (2) Clear the DTCs (See page NS-49). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–119 NAVIGATION – NAVIGATION SYSTEM DTC 63-47 High Temperature DESCRIPTION DTC No. 63-47 DTC Detection Condition Trouble Area Sensor detects that CD unit temperature is high (Over 80°C). Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio and navigation assembly becomes sufficiently low, then start the engine. Check that the malfunction disappears. OK: Malfunction disappears. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK END NS NS–120 NAVIGATION – NAVIGATION SYSTEM DTC 63-78 DSP Error DESCRIPTION DTC No. 63-78 DTC Detection Condition Trouble Area An error occurs during the decode process (MP3 / WMA). - INSPECTION PROCEDURE HINT: After the inspection completed, clear the DTCs. NOTICE: • This code may be output even if there is no malfunction. • If this code is output frequently, replace the radio and navigation assembly. 1 CLEAR DTC (a) Clear the DTCs (See page NS-49). HINT: These DTCs do not indicate a malfunction. NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–24 NAVIGATION – NAVIGATION SYSTEM DISPLAY CHECK MODE HINT: • This mode checks the color display on the display. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-49) 2. DISPLAY CHECK (a) Select "Display Check" from the "Diagnosis MENU" screen. 3. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Display Check" screen. E120055E02 E120053E07 (b) Select a color bar from the "Color Bar Check Mode" screen. (c) Check the display color. HINT: • The entire screen turns to the color or stripe selected. • Touching the display will return to the "Color Bar Check" screen. NS E120102 NS–25 NAVIGATION – NAVIGATION SYSTEM 4. TOUCH SWITCH CHECK (a) Select "Touch Switch Check" from the "Display Check" screen. E125809E02 (b) Touch the display anywhere in the open area to perform the check when the "Touch Switch Check" screen is displayed. HINT: • A "+" mark is displayed where the display is touched. • The "+" mark remains on the display even after the finger is removed. E120103 5. PANEL SWITCH CHECK (a) Select "Panel Switch Check" from the "Display Check" screen. E125809E03 (b) Operate each switch and check that the switch name and condition are correctly displayed. *1 *2 *3 I100041E07 Display Push switch name/*1 Rotary switch name/*2 Rotary switch direction/*3 Contents • • Name of the pressed switch is displayed. If more than one switch is pressed, "MULTIPLE" is displayed. Name of the rotary switch is displayed. Direction of the rotary switch is displayed. NS NS–26 NAVIGATION – NAVIGATION SYSTEM 6. VEHICLE SIGNAL CHECK (a) Select "Vehicle Signal Check" from the "Display Check" screen. E125809E04 (b) When the "Vehicle Signal Check Mode" screen is displayed, check all the vehicle signal conditions. HINT: • Only conditions having inputs are displayed. • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). E125810 7. E120057 NS CAN CHECK (a) Select "CAN check" from the "Display check" screen. (b) Check the CAN connection check result. HINT: • This function operates only for the systems connected to the CAN system. • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). NAVIGATION – NAVIGATION SYSTEM NS–27 BLUETOOTH TEL CHECK MODE HINT: Illustration may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed area may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-49) 2. "BLUETOOTH" TEL CHECK (a) Select ""Bluetooth" TEL Check" from the "Diagnosis MENU" screen. 3. "BLUETOOTH" CHECK (a) Select ""Bluetooth" Check" from the ""Bluetooth" Handsfree Check Menu" screen. E120062E01 E120063 (b) Select "Serial Communication Log" from the ""Bluetooth" Check Menu" screen. E120064 (1) The communication log data in the display ECU are displayed on this screen. HINT: The displayed data can be used as a reference. E120065 NS NS–28 NAVIGATION – NAVIGATION SYSTEM (c) Select "Software Version" from the ""Bluetooth" Check Menu" screen. E120066 (1) Check the software version of the "Bluetooth" module. *1 *2 *3 *4 E120067E02 Screen Description: Display Contents General Version / *1 • • General software version of "Bluetooth" module If any of the API version, upper stack version, and low stack version is updated, the general version is upgraded. API Version / *2 API software version is displayed. Upper Stack Version / *3 Upper Stack version is displayed. Lower Stack Version / *4 Lower Stack version is displayed. HINT: This function is controlled by the built-in display ECU. 4. E120068 NS HANDSFREE VOICE QUALITY SET (a) Select "Handsfree Voice Quality Set" from the ""Bluetooth" Handsfree check Menu" screen. NS–29 NAVIGATION – NAVIGATION SYSTEM (b) Check the handsfree voice level. *1 *2 E120069E01 Screen Description: Display Contents Received voice level adjustment / *1 Setting possible for the voice level received from "Bluetooth" compatible phones. Sent voice level adjustment / *2 Setting possible for the voice set to "Bluetooth" compatible phones. HINT: This function is controlled by the built-in display ECU. NOTICE: "Voice Quality Type" should not be changed. NS NS–121 NAVIGATION – NAVIGATION SYSTEM DTC 63-7D Disc cannot be Played DTC 63-7E No Playable Files DTC 63-7F Copyright Protection Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area • • An incompatible MP3 / WMA file is used. Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. 63-7E • • A disc with no music data is used. Playable files are not on the disc (MP3 / WMA). 63-7F A copy-protected file, which cannot be played, is used. 63-7D • • CD Radio and navigation assembly INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK DISC IS FAULTY NS NS–122 NAVIGATION – NAVIGATION SYSTEM Noise Occurs INSPECTION PROCEDURE 1 NOISE CONDITION (a) Check in which direction the noise comes from (front left or right, or rear left or right). (1) Check in which direction the noise comes from. OK: The location of the noise source can be determined. NG Go to step 3 OK 2 CHECK SPEAKERS (a) Check the installation conditions of the speaker units that are located near the noise source and that there are no cracks, scratches, deformation, or other failures. Result Condition Proceed to A speaker is installed incorrectly A Foreign objects are in the speaker B A speaker cone paper is broken C No malfunction is found D A REINSTALL SPEAKER B REMOVE FOREIGN OBJECT C REPLACE SPEAKER D 3 CHECK NOISE CONDITIONS (a) Check the noise condition. HINT: The radio has a noise prevention function to reduce noise when listening to the radio. If a loud noise occurs, check whether the ground at the antenna mounting base and the noise prevention unit are installed and wired correctly. Conditions under which noise occurs NS Noise increases when the accelerator pedal is depressed, but stops when the engine is stopped. Noise occurs during A/C or heater operation. Noise occurs when the vehicle accelerates rapidly on an unpaved road or after the ignition switch is turned ON or ACC. Noise Source Generator Blower motor Fuel pump NS–123 NAVIGATION – NAVIGATION SYSTEM Conditions under which noise occurs Noise Source Noise occurs when the horn switch is pressed and released or when pressed and held. Horn Noise occurs synchronously with the blink of the turn signal. Flasher Noise occurs during window washer operation. Washer Noise occurs while the engine is running, and continues even after the engine is stopped. Noise occurs during wiper operation. Water temperature sensor Wiper Noise occurs when the brake pedal is depressed. Stop light switch Others Static electricity HINT: • In the chart's left column, find the situation that matches the customer's complaint. Then, in the right column, find the part that is causing the noise. Check the noise filter on or for the part. • To save time and avoid a misdiagnosis, first make sure that the noise is not coming from outside the vehicle. • Noise should be removed in descending order of loudness. • Setting the radio to a frequency where no signal is received may make recognition of the noise problem easier. OK: The noise source can not be determined. NG REPAIR OR REPLACE NOISE SOURCE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–124 NAVIGATION – NAVIGATION SYSTEM Pressing Power Switch does not Turn on System INSPECTION PROCEDURE 1 CHECK CABIN (a) Check that conditions in the cabin are not likely to cause condensation. HINT: This problem occurs when the cabin is humid and the temperature rapidly changes. This condition may produce condensation, resulting in a short circuit. OK: Condensation is not likely to occur. NG DRY CABIN AND RECHECK CONDITIONS OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–125 No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Enter the sound adjustment screen by pressing the "SOUND" switch on the AUDIO display. (b) Set volume, fader, and balance to the initial values and check that sound is normal. OK: Audio system returns to normal. HINT: Sound quality adjustment items vary depending on the type of the amplifier. E120098 OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION ANTENNA NS–237 NAVIGATION ANTENNA BODY ELECTRICAL NAVIGATION COMPONENTS INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY B120192E06 NS NS–238 NAVIGATION – NAVIGATION ANTENNA NAVIGATION ANTENNA NS E115640E02 NS–126 NAVIGATION – NAVIGATION SYSTEM CD cannot be Ejected INSPECTION PROCEDURE 1 CHECK OPERATION (a) Press the disc eject switch of the radio receiver for 5 seconds or more and check that the CD is ejected. OK: CD is ejected. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 2 REPLACE CD WITH ANOTHER AND RECHECK (a) Insert another CD and check if it is ejected. OK: CD is ejected. NG OK CD IS FAULTY NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–127 CD cannot be Inserted / Played or CD is Ejected Right After Insertion INSPECTION PROCEDURE 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CD IS FAULTY OK 2 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG SET CD PROPERLY OK 3 CHECK CD (a) Clean the disc by wiping it with a soft cloth from the inside to the outside in a radial direction. OK: Malfunction disappears. NOTICE: Do not use a conventional record cleaner or antistatic preservative. OK CD WAS DIRTY I100151 NG NS NS–128 4 NAVIGATION – NAVIGATION SYSTEM REPLACE CD WITH ANOTHER AND RECHECK (a) Replace the CD with a normal one and check that the malfunction disappears. OK: Malfunction disappears. NG OK CD IS FAULTY NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–129 CD Sound Skips INSPECTION PROCEDURE 1 CHECK CD (a) Check the CD. OK: The CD is clean. HINT: If dirt is on the CD surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NG CLEAN CD OK 2 CHECK CD (a) Check that the CD is not deformed or cracked. OK: No deformation or cracks on the CD. NG CD IS FAULTY I100152 OK 3 CHECK OPERATION USING ANOTHER CD (a) Check using another CD. (1) Check if the problem recurs using another CD. OK: The problem does not occur. OK CD IS FAULTY NG 4 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check the radio and navigation assembly installation condition. (1) Check that the radio and navigation assembly is properly installed. NS NS–130 NAVIGATION – NAVIGATION SYSTEM OK: Radio and navigation assembly is properly installed. NG OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS REINSTALL RADIO AND NAVIGATION ASSEMBLY NS–131 NAVIGATION – NAVIGATION SYSTEM Radio Broadcast cannot be Received or Poor Reception INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check the radio's automatic station search function. (1) Check the radio's automatic station search function by activating it. OK: The radio's automatic station search function works properly. OK REPLACE RADIO AND NAVIGATION ASSEMBLY NG 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R12. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: Tester Connection Condition Specified Condition ANT - Body ground Ignition SW ON Radio SW ON 10 to 14 V NG R12 REPLACE RADIO AND NAVIGATION ASSEMBLY ANT E120099E02 OK 3 CHECK OPTIONAL COMPONENTS (a) Check optional components (sun-shade film, telephone antenna, etc.). (1) Check if any optional components, such as sunshade film or telephone antenna that may decrease reception capacity, are installed. OK: Optional components are installed. NOTICE: Do not remove any optional components installed by the customer without his or her consent. NS NS–132 NAVIGATION – NAVIGATION SYSTEM OK REMOVE AND RECHECK OPTIONAL COMPONENTS (SEE NOTICE ABOVE) NG 4 CHECK RADIO AND NAVIGATION ASSEMBLY E050367E01 (a) Preparation for check (1) Remove the antenna plug from the radio and navigation assembly. (b) Check for noise (1) Turn the ignition switch to the ACC position with the radio and navigation assembly connector connected. (2) Turn the radio on and put into AM mode. (3) Place a screwdriver, thin wire, or other metal object on the radio receiver's antenna jack and check that noise can be heard from the speaker. OK: Noise occurs. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 5 CHECK GLASS ANTENNA (a) Check for continuity of the antenna. HINT: Check for continuity at the center of each antenna wire as shown in the illustration. NOTICE: When cleaning the glass, wipe it in the direction of the wire with a soft dry cloth. Take care not to damage the wire. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wrap a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. Tester Probe Tin Foil Antenna Wire NG E111994E02 NS OK REPAIR GLASS ANTENNA NAVIGATION – NAVIGATION SYSTEM 6 NS–133 REPLACE ANTENNA AMPLIFIER (a) Replace the antenna amplifier and check that it operates normally. OK: The antenna amplifier operates normally. OK END NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–134 NAVIGATION – NAVIGATION SYSTEM Illumination for Panel Switch does not Come on with Tail Switch ON INSPECTION PROCEDURE 1 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (See page NS-22). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK Light Control Switch I038223E01 TAIL or ON ON OFF OFF HINT: This display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. NG OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS Display PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–135 NAVIGATION – NAVIGATION SYSTEM Display does not Dim when Light Control Switch is Turned ON INSPECTION PROCEDURE 1 CHECK IMAGE QUALITY SETTING (a) Enter the display adjustment screen by pressing the "DISPLAY" switch. (b) Turn the light control switch to the TAIL position. (c) Check if "DAY MODE" on the display adjustment is ON. OK: "DAY MODE" is ON. NG Go to step 2 E125813 OK TURN "DAY MODE" SETTING OFF 2 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check) (See page NS-22). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK Light Control Switch E125810E01 Display TAIL or ON ON OFF OFF HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–136 NAVIGATION – NAVIGATION SYSTEM Panel Switches do not Function INSPECTION PROCEDURE 1 CHECK PANEL SWITCH (a) Check for foreign matter around the switches that might prevent operation. OK: No foreign matter is found. NG REMOVE ANY FOREIGN MATTER FOUND OK 2 CHECK PANEL SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Panel Switch Check) (See page NS-22). (b) Operate the abnormal switch and check if the switch name and status are correctly displayed. OK: The switch name and status are correctly displayed as operated. NG I100041 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–137 Touch Panel Switch does not Function INSPECTION PROCEDURE 1 CHECK TOUCH PANEL (a) Check for foreign matter on the display. OK: The display is clean. NG CLEAN DISPLAY AND RECHECK TOUCH PANEL OK 2 CHECK TOUCH SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Touch Switch Check) (See page NS-22). (b) Touch the display in the area where the switch malfunction occurs. OK: A "+" mark appears at the touched position. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE I100039E04 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–138 NAVIGATION – NAVIGATION SYSTEM Display Panel does not Open, Tilt or Tilts Improperly INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check for foreign matter or obstructions caught in the moving parts of the panel. OK: No obstruction or foreign matter found. NG REMOVE ANY OBSTRUCTION OR FOREIGN MATTER FOUND E120094 OK 2 CHECK OPERATION (a) Check if the navigation and audio systems function properly. OK: Navigation and audio systems function properly. OK REPLACE RADIO AND NAVIGATION ASSEMBLY NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–139 Screen Flicker or Color Distortion INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Enter the display adjustment screen by pressing the "DISPLAY" switch. (b) Reset display settings (contrast, brightness) and check that the screen appears normal. E120095 (c) Press the "INFO" switch and then select "Screen Setting." E120096E03 (d) Set the "Switch Color" to "Green" (initial setting) and check if the display returns to normal. OK: Returns to normal. NG Go to step 2 E120097 OK END 2 CHECK CABIN (a) Check that the cabin temperature is warmer than -20°C (-4.0°F). OK: Cabin is warmer than -20°C (-4.0°F). NG HEAT CABIN AND RECHECK TEMPERATURE NS NS–140 NAVIGATION – NAVIGATION SYSTEM OK 3 CHECK COLOR BAR (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Color Bar Check) (See page NS-22). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. NG REPLACE RADIO AND NAVIGATION ASSEMBLY I100037E05 OK 4 CHECK NAVI COLOR BAR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (NAVI Color Bar Check) (See page NS-27). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. NG REPLACE RADIO AND NAVIGATION ASSEMBLY I100050E04 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–141 Poor Sound Quality in All Modes (Low Volume) INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Set "BASS", "MID" and "TREB" to the initial values and check that sound is normal. OK: Malfunction disappears. OK END NG 2 COMPARE WITH ANOTHER VEHICLE OF SAME MODEL (a) Compare with another vehicle of the same model. (1) Compare with another vehicle of the same model which does not have trouble to see if there is any difference in the sound quality. OK: No difference is found. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–142 NAVIGATION – NAVIGATION SYSTEM MAP Disc cannot be Inserted INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a disc is inserted into the MAP disc slot. (1) Check if "DISC IN" is displayed. OK: "DISC IN" is displayed. NG EJECT DISC E125111 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–143 NAVIGATION – NAVIGATION SYSTEM Vehicle Position Mark Deviates Greatly INSPECTION PROCEDURE 1 CHECK GPS MARK (a) Check that the GPS mark is displayed. OK: GPS mark is displayed. NG GO TO "GPS MARK IS NOT DISPLAYED" IN PROBLEM SYMPTOMS TABLE E125110E01 OK 2 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check that these readings are almost equal. OK: The readings are almost equal. NG E120089 GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Check that the display changes between ON and OFF according to the shift lever operation (P and R). OK E120101E01 Shift Lever Position Display P OFF R ON HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG GO TO "REVERSE SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE NS NS–144 NAVIGATION – NAVIGATION SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–30 NAVIGATION – NAVIGATION SYSTEM NAVIGATION CHECK MODE HINT: • This mode displays GPS satellite information. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-49 ) 2. NAVIGATION CHECK (a) Select "Navigation Check" from the "Diagnosis MENU" screen. 3. GPS INFORMATION (a) Select "GPS Information" from the "Navigation Check" screen. E120058E01 E120059E15 (b) When GPS information is displayed, check the GPS conditions. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). I102403 4. NS E120059E16 VEHICLE SENSORS (a) Select "Vehicle Sensors" from the "Navigation Check" screen. NAVIGATION – NAVIGATION SYSTEM NS–31 (b) Check all the signals and sensors when vehicle signal information is displayed. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • This screen displays vehicle signals input to the built-in navigation ECU. • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). E120060 5. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Navigation Check" screen. E120059E17 (b) Check each color of the color bar when the "NAVI Color Bar Check" screen is displayed. HINT: • Colors will not be displayed full-screen as in "Display Check Mode". • This screen displays the built-in navigation ECU display color. I100050 6. MEMORY COPY/PASTE CHECK HINT: This function cannot be used. 7. PARTS INFORMATION (a) Select "Parts Information" from the "Navigation Check" screen. E120059E18 NS E120059E19 NS–32 NAVIGATION – NAVIGATION SYSTEM (b) Check the navigation and disc information when the "Parts Information" screen is displayed. *1 *2 *3 *4 I100052E02 Screen Description: Display Contents Navigation Manufacturer/*1 Radio and navigation assembly manufacturer is displayed. Navigation Version/*2 Radio and navigation assembly version is displayed. Disc Manufacturer/*3 Map disc manufacturer is displayed. Disc Version/*4 Map disc version is displayed. 8. MIC & VOICE RECOGNITION CHECK (a) Select "Mic & Voice Recognition Check" on the "Display Check" screen to display "MICROPHONE & VOICE RECOGNITION CHECK" screen. E120059E20 Microphone Input Level Meter Recording Switch Play Switch Stop Switch Recording Indicator E120056E04 NS (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally. HINT: • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). • This function is controlled by the built-in navigation ECU. NAVIGATION – NAVIGATION SYSTEM 9. NS–33 DVD PLAYER INFORMATION CHECK (a) Select "DVD Player Information" from the "Navigation Check" screen. E120059E21 (b) Check for DTCs. HINT: • This is a DVD player check function in the radio and navigation assembly (built-in navigation ECU). • For details of this function, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS-30). Trouble code E120061E01 NS NS–34 NAVIGATION – NAVIGATION SYSTEM DIAGNOSIS DISPLAY DETAILED DESCRIPTION HINT: • This section contains a detailed description of displays within diagnostic mode. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. SYSTEM CHECK (a) System Check Mode Screen *1 *2 *3 *1 *2 *4 I100055E08 (1) Device Names and Hardware Address/*1 HINT: • Registered device names are displayed. • If a device name is unknown to the system, its physical address is shown instead. Address No. NS Name Address No. Name 110 EMV 120 AVX 128 1DIN TV 140 AVN 144 G-BOOK 178 NAVI 17C MONET 190 AUDIO H/U 1AC CAMERA-C 1B0 Rr-TV 1C0 Rr-CONT 19D BT-HF 1C4 PANEL 1C6 G/W 1C8 FM-M-LCD 1D8 CONT-SW 1EC Body 118 EMVN 1F1 XM 1F2 SIRIUS 230 TV-TUNER 240 CD-CH2 250 DVD-CH 280 CAMERA 360 CD-CH1 3A0 MD-CH NS–35 NAVIGATION – NAVIGATION SYSTEM Address No. 17D Name Address No. TEL 440 Name DSP-AMP 530 ETC 1F6 RSE 1A0 DVD-P 1D6 CLOCK 238 DTV 480 AMP (2) Check Result/*2 HINT: Result codes for all devices are displayed. Result Meaning Action OK The device did not respond with a DTC (excluding communication DTCs from the AVC-LAN). EXCH The device responds with a "replace"-type DTC. Look up the DTC in "Unit Check Mode" and replace the device. CHEK The device responds with a "check"-type DTC. Look up the DTC in "Unit Check Mode". NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old The device responds with an "old"-type DTC. Look up the DTC in "Unit Check Mode". The device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. NRES - (3) Code Clear/*3 • Present DTCs are cleared. • Press the "Code CLR" switch for 3 seconds. (4) Memory Clear/*4 • Present and past DTCs and registered connected device names are cleared. • Press the "Memory CLR" switch for 3 seconds. (b) Diagnosis MENU Screen NS E120070E01 NS–36 NAVIGATION – NAVIGATION SYSTEM HINT: Each item is grayed out or not displayed based on the device settings. (c) Unit Check Mode Screen *1 *6 *5 *2 *3 *4 *7 E120071E03 Screen Description: Display Device name/*1 Segment/*2 DTC/*3 Timestamp/*4 Present Code/*5 Past Code/*6 Diagnosis Clear Switch/*7 NS Contents Target device Target device logical address DTC (Diagnostic Trouble Code) The time and date of past DTCs are displayed. (The year is displayed in 2-digit format.) DTCs output at the service check are displayed. Diagnostic memory results and recorded DTCs are displayed. Pushing this switch for 3 seconds clears the diagnostic memory data of the target device. (Both response to diagnostic system check result and the displayed data are cleared.) NS–37 NAVIGATION – NAVIGATION SYSTEM (d) LAN Monitor (Original) Screen *1 I100058E04 (1) Check Result/*1 HINT: Check results of all the devices are displayed. Result No Err (OK) Meaning There are no communication DTCs. Action - CHEK The device responds with a "check"-type DTC. Look up the DTC in "Unit Check Mode". NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. The device responded with an "old"-type DTC. Look up the DTC in "Unit Check Mode". The device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old NRES NS NS–38 NAVIGATION – NAVIGATION SYSTEM (e) LAN Monitor (Individual) Screen *1 *2 *3 *4 *5 *7 *6 E120072E01 Screen Description: Display Device name/*1 Segment/*2 DTC/*3 Sub-code (device address)/*4 Connection check No./*5 DTC occurrence/*6 Diagnosis Clear Switch/*7 NS Contents Target device Target logical address DTC (Diagnostic Trouble Code) Physical address stored with DTC (If there is no address, nothing is displayed.) Connection check number stored with DTC Number of times the same DTC has been recorded Pushing this switch for 3 seconds clears the diagnostic memory data of the target device. (Both response to diagnostic system check result and the displayed data are cleared.) NS–39 NAVIGATION – NAVIGATION SYSTEM 2. DISPLAY CHECK (a) Vehicle Signal Check Mode Screen E120073 Screen Description: Name Battery Contents Battery voltage is displayed. PKB Parking brake ON/OFF state is displayed. REV Reverse signal ON/OFF state is displayed. IG TAIL SPEED IG switch ON/OFF state is displayed. TAIL signal (Light control switch) ON/OFF state is displayed. Vehicle speed is displayed in km/h. HINT: • Only items sending a vehicle signal will be displayed. • This screen is updated once per second when input signals to the vehicle are changed. NS NS–40 NAVIGATION – NAVIGATION SYSTEM (b) CAN Connection Check Screen *1 E120075E01 Screen Description: Name Contents • • CAN Connection check result/*1 • • For systems connected to the CAN system, the results of the CAN connection check are displayed. "NG" - The ignition switch is ACC or ON and the CAN communication lines are malfunctioning or the CAN bus lines are not connected. "OK" - The ignition switch is ACC or ON and the CAN communication lines are normal. Blank - CAN connection check is performed with the ignition switch is ACC or off. HINT: • This function operates only for the systems connected to the CAN system. • When the ignition switch is turned off, the bus lines are disconnected, or a malfunction occurs in the bus lines while the CAN connection check result is being displayed, the problem will be reflected on the screen in real time. HINT: When the ignition switch is turned off, the bus lines are disconnected, or a malfunction occurs in the bus lines while the CAN connection check result is being displayed, the problem will be reflected on the screen in real time. NS NS–41 NAVIGATION – NAVIGATION SYSTEM 3. NAVIGATION CHECK (a) Navigation Check Screen E120076E01 HINT: Each item is grayed out or not displayed based on the device settings. (b) GPS Information Screen *1 *1 *2 *2 *5 *3 *4 I102405E01 (1) Satellite information/*1 Information from a maximum of 12 satellites is displayed on the screen. This information includes the target GPS satellite number, elevation angle, direction, and signal level. NS NS–42 NAVIGATION – NAVIGATION SYSTEM (2) Receiving condition/*2 (DENSO model): Display Contents T The system is receiving a GPS signal, but is not using it for location. P The system is using the GPS signal for location. - The system cannot receive a GPS signal. (AISIN AW model): Display Contents 01H The system cannot receive a GPS signal. 02H The system is tracing a satellite. 03H The system is receiving a GPS signal, but is not using it for location. 04H The system is using the GPS signal for location. Measurement information/*3: Display Contents 2D 2-dimensional location method is being used. 3D 3-dimensional location method is being used. NG Location data cannot be used. Error - Reception error has occurred. Any other state. Position information/*4 Display Contents Position Latitude and longitude information on the current position is displayed. Display Contents Date information/*5: Date The date/time information obtained from GPS signal is displayed in Greenwich mean time (GMT). The last 4 digits are displayed. (c) Vehicle Sensors Screen *1 *2 *3 NS E120077E01 NS–43 NAVIGATION – NAVIGATION SYSTEM Vehicle signal: Display Contents REV/*1 REV signal ON/OFF state is displayed. SPD/*2 SPD signal condition is displayed. Sensor signal: Display Contents Gyro sensor output condition is displayed (when the vehicle runs straight or is stationary, the voltage is approximately 2.5 V). Gyro sensor/*3 HINT: Signals are updated once per second only when vehicle sensor signals are changed. (d) Microphone & Voice Recognition Check Screen *1 *2 *3 *4 *5 E125119E01 Screen Description: Display Microphone input level meter/*1 Contents Monitors the microphone input level every 100 ms and displays the results in 8 different levels. Recording switch/*2 Starts recording. Stop switch/*3 Stops recording. Play switch/*4 Plays the recorded voice. Recording indicator/*5 Comes on while recording. HINT: • The microphone input function is on at all times when this screen is displayed. • While recording or playing, the switches other than the stop switch cannot be pushed. • When no voice is recorded, the play switch cannot be pushed. • Recording will stop after 5 seconds or by pushing the stop switch. NS NS–44 NAVIGATION – NAVIGATION SYSTEM (e) DVD Player Information Screen *2 *1 *3 *4 *5 E120078E01 Screen Description: Display Contents Trouble code/*1 Each code corresponding to the malfunctions is displayed. For details, refer to "Trouble Code Description". • Occurrence time/*2 • The date (year, month, day) and time (hour, minute, second) when the trouble code was detected are displayed as a time stamp. (Greenwich mean time) The time data to be displayed are received from the GPS receiver. All code data being displayed are cleared by pushing this switch for 3 seconds. Trouble code clear switch/*3 Returning switch/*4 The previous page is displayed. If the current displayed page is the first page, this switch cannot be operated. Proceeding switch/*5 The next page is displayed. If the current displayed page is the last page, this switch cannot be operated. Trouble Code Description: Code 01 03 Malfunction Countermeasure Cannot be recognized Replace radio and navigation assembly. Cannot be read Follow the inspection procedure for DTC 58-42 (See page NS-97). HINT: This is a DVD player check function in the radio and navigation assembly (built-in navigation ECU). NS NAVIGATION – NAVIGATION SYSTEM NS–145 Cursor or MAP Rotates when Vehicle Stopped INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check with the customer if the vehicle has been turned by a turntable. OK: Vehicle has not been turned by turntable. HINT: If the vehicle is turned on a turntable with the ignition switch on, the system may store the angular velocity. As a result, the vehicle position cursor may deviate. E106418 NG TURN IGNITION SWITCH TO ON POSITION WHEN VEHICLE IS COMPLETELY STOPPED OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–146 NAVIGATION – NAVIGATION SYSTEM Vehicle Position Mark is not Updated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK MAP DISPLAY (a) Check if a touch scroll can be performed on the map display. OK: Touch scroll can be performed. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (See page NS-27). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. NG E120089 GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–147 Current Position Display does not Appear INSPECTION PROCEDURE 1 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check if a map disc is inserted into the map disc slot. OK: A map disc is inserted. NG INSERT MAP DISC IN MAP SIDE SLOT E125111 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–148 NAVIGATION – NAVIGATION SYSTEM GPS Mark is not Displayed INSPECTION PROCEDURE 1 CHECK CABIN (a) Check the cabin for any object that might interrupt radio reception on the instrument panel. If such an object exists, remove it and check if the GPS mark reappears. HINT: The GPS uses extremely faint radio waves originating from satellites. If the signal is interrupted by obstructions or other radio waves, the GPS may not be able to properly receive the signal. OK: Mark appears. NG Go to step 2 OK NORMAL OPERATION 2 CHECK SURROUNDINGS (a) Check if the vehicle is in a location where GPS signal reception is poor. If the vehicle is in such a place, relocate the vehicle and check if the GPS mark reappears. HINT: The GPS uses 24 satellites in 6 orbits. At any point in time, 4 satellites should be able to pinpoint your vehicle. However, GPS signals may not reach the vehicle due to influence from the surroundings, vehicle direction, and time. For illustrated examples, see below. NS NS–149 NAVIGATION – NAVIGATION SYSTEM In a tunnel In a building Under an overpass Between tall buildings On a forest or tree-lined path Under a cliff, overhang I100196E03 OK: GPS mark is displayed. NG Go to step 3 OK SYSTEM RETURN TO NORMAL 3 CHECK GPS INFORMATION (NAVIGATION CHECK MODE) I102403E01 (a) Enter the "Navigation Check" mode (GPS Information) (See page NS-27). (b) Check how many of the following codes appear in the "STS" column. For DENSO Made: T, P For AISIN AW Made: 08H, 04H OK: At least 3 codes appear. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–150 NAVIGATION – NAVIGATION SYSTEM OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NAVIGATION – NAVIGATION SYSTEM NS–151 Voice Guidance does not Function INSPECTION PROCEDURE 1 CHECK NAVIGATION SYSTEM SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Volume". E120104E02 (c) Check that "OFF" is not selected. OK: "OFF" is not selected. NG TURN VOICE GUIDANCE VOLUME UP TO 4 USING VOICE ADJUSTMENT SWITCHES E120106 OK 2 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Set up". E120104E03 NS NS–152 NAVIGATION – NAVIGATION SYSTEM (c) Check that "Voice Guidance in All Modes" is not OFF. OK: Voice guidance in all modes is not OFF. NG TURN VOICE GUIDANCE IN ALL MODES "ON" E120105E01 OK 3 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". E120104E03 (c) Check that "Auto Voice Guidance" is not OFF. OK: Auto voice guidance is not OFF. NG TURN AUTO VOICE GUIDANCE "ON" E120107 OK 4 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG NS I100152E12 REPLACE MAP DISC NAVIGATION – NAVIGATION SYSTEM NS–153 OK 5 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Check that audio sound can be heard from the driver side speaker. OK: Audio sound can be heard. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–154 NAVIGATION – NAVIGATION SYSTEM MAP Display Incomplete INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK DISPLAY (a) Check that displays other than the navigation display are complete. OK: No other incomplete displays are found. OK NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–155 Route cannot be Calculated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 SET DESTINATION (a) Set another destination and check if the system can calculate the route correctly. OK: Route can be correctly calculated. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK NORMAL OPERATION NS NS–156 NAVIGATION – NAVIGATION SYSTEM Voice Recognition Difficulty INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check if the system's voice recognition level is low by using only one particular voice. OK: System's voice recognition level is low with any voice. NG SYSTEM'S VOICE RECOGNITION LEVEL VARIES DEPENDING ON VOICE AND PRONUNCIATION. THIS IS NOT A MALFUNCTION. OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 3 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc's surface radially with a soft cloth. I100201E04 OK NS NG CLEAN MAP DISC NAVIGATION – NAVIGATION SYSTEM 4 NS–157 CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK END NS NS–158 NAVIGATION – NAVIGATION SYSTEM Voice is not Recognized INSPECTION PROCEDURE 1 CHECK NAVIGATION SETTINGS (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". E120104E03 (c) Check that "Voice Recognition Guidance" is not OFF. OK: Voice Recognition Guidance is not OFF. NG TURN VOICE RECOGNITION GUIDANCE "ON" E120105E02 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG I100152E12 OK NS REPLACE MAP DISC NAVIGATION – NAVIGATION SYSTEM 3 NS–159 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on the map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc's surface radially with a soft cloth. I100201E04 NG CLEAN MAP DISC OK 4 CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–160 NAVIGATION – NAVIGATION SYSTEM Cellular Phone Registration Failure, Phone Directory Transfer Failure INSPECTION PROCEDURE 1 CHECK CURRENT CONDITIONS (a) Proceed to the next step according to the table below. RESULT Conditions Proceed To Another "Bluetooth" compatible cellular phone is present. A Another "Bluetooth" compatible vehicle is present. B None of the above C B Go to step 3 C Go to step 4 A 2 CHECK USING ANOTHER CELLULAR PHONE (a) Check if the system functions using another "Bluetooth" compatible cellular phone. HINT: • Confirm that either the same or a different version of another "Bluetooth" compatible cellular phone complies with the system. • Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 3 NS CHECK USING ANOTHER "BLUETOOTH" COMPATIBLE VEHICLE (a) Register the cellular phone with another vehicle and check if the system functions normally. HINT: Depending on the version, some "Bluetooth" compatible cellular phones cannot be used. OK: The system functions. NAVIGATION – NAVIGATION SYSTEM OK NS–161 REPLACE RADIO AND NAVIGATION ASSEMBLY NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE 4 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: The phone is "Bluetooth" compatible. NG USE A "BLUETOOTH" COMPATIBLE CELLULAR PHONE OK 5 CHECK CELLULAR PHONE (a) Check if a call can be made from the cellular phone. HINT: When the battery is low, registration or directory transfer cannot be done. OK: A call can be made from the cellular phone. NG REPAIR OR REPLACE CELLULAR PHONE OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–162 NAVIGATION – NAVIGATION SYSTEM Cellular Phone cannot Send / Receive INSPECTION PROCEDURE 1 CHECK "BLUETOOTH" SETTINGS (a) Check if the "Bluetooth" settings are correct. OK: "Bluetooth" settings are correct. NG SET SETTINGS CORRECTLY OK 2 CHECK CELLULAR PHONE (a) Check if the cellular phone is "Bluetooth" compatible. HINT: Some versions of "Bluetooth" compatible cellular phones may not function. OK: Phone is "Bluetooth" compatible. NG END (ONLY A "BLUETOOTH" COMPATIBLE CELLULAR PHONE CAN BE USED) OK 3 CHECK SETTINGS (a) Check if the cellular phone functions. HINT: The cellular phone is unable to call under any of the following conditions. • The cellular phone is locked. • The directory is being transferred. • The line is crossed. • Transmission is regulated. • The power is off. • The cellular phone is not connected to "Bluetooth" ("BT" is displayed while connected). OK: None of the above conditions exist. NG SET SETTINGS CORRECTLY OK 4 NS CHECK CELLULAR PHONE (a) Check if the cellular phone can make a call. NAVIGATION – NAVIGATION SYSTEM NS–163 HINT: When the battery is low, calls cannot be made or received. OK: Cellular phone can make a call. NG REPAIR OR REPLACE CELLULAR PHONE OK 5 CHECK RECEPTION (a) Set the cellular phone so that it can receive calls. (b) Place the cellular phone close to the radio and navigation assembly. (c) Check if the cellular phone has reception according to the radio and navigation assembly. OK: Cellular phone has reception. NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–164 NAVIGATION – NAVIGATION SYSTEM Cannot Call in a Certain Place INSPECTION PROCEDURE 1 CHECK SURROUNDING CONDITIONS (a) Check if the cellular phone can make calls in a certain place. OK: It can make calls. NG END (CELLULAR PHONES CAN ONLY FUNCTION IN CELLULAR SERVICE AREAS) OK 2 CHECK RECEPTION (a) Enter the "Information" screen by pressing the "INFO" switch. (b) Select "Telephone". E120096E02 (c) Check the "Bluetooth" connection indicator (BT indicator). E120108E01 Result NEXT NS END Condition Procedure Yellow color Bring the cellular phone to a location where the BT mark turns blue. Blue color Replace radio and navigation assembly. No connection mark is displayed Select a registered cellular phone or register a "Bluetooth" compatible phone. NAVIGATION – NAVIGATION SYSTEM NS–165 The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the voice on the other side can be heard using a cellular phone. OK: Voice can be heard. NG REPAIR OR REPLACE CELLULAR PHONE OK 2 CHECK NAVIGATION SYSTEM (a) Check that navigation sound can be heard from the driver side speaker. OK: Audio sound can be heard. NG GO TO "VOICE GUIDANCE DOES NOT FUNCTION" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK SETTINGS (a) Check if the volume level is set to low on the CALL screen. OK: The level is not set low. NG SET VOLUME TO HIGH E120109E02 OK NS NS–166 4 NAVIGATION – NAVIGATION SYSTEM CHECK SETTINGS E120069E02 (a) Enter the "Handsfree Voice Quality Set" mode (See page NS-25). (b) Check if the Receive Voice Level is set to "0". HINT: The Receive Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Receive Voice Level is set to the minimum or maximum level. HINT: When the Receive Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Receive Voice Level is set to "0". NG SET RECEIVE VOICE LEVEL TO "0" OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–167 The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the other side can hear your voice properly. OK: Your voice can be heard correctly. NG REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the mute switch is set to ON. OK: Mute switch is not set to ON. NG TURN MUTE SWITCH OFF E120109E03 OK 3 CHECK SETTINGS E120069E06 (a) Enter the "Handsfree Voice Quality Set" mode (See page NS-25). (b) Check if the Send Voice Level is set to "0". HINT: The Send Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Send Voice Level minimum or maximum level. HINT: When the Send Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Send Voice Level is set to "0". NG OK SET SEND VOICE LEVEL TO "0" NS NS–168 4 NAVIGATION – NAVIGATION SYSTEM CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Recording Indicator Stop Switch (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (See page NS-27). (b) When voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: Voice can be recorded up to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E120056E03 OK REPLACE RADIO AND NAVIGATION ASSEMBLY NS PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–45 NAVIGATION – NAVIGATION SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Before inspecting the suspected areas listed in the table below, check the fuse and relay. • Before inspecting the suspected areas listed in the table below, check the DTCs. • Methods used to verify the cause of the problem are listed in order of probability in the suspected area column. Display function: Symptom Pressing PWR switch does not turn on system. Black screen (No image appears on navigation/audio screen). Illumination for panel switch does not come on with TAIL switch on. Display does not dim (Night Screen) with TAIL switch on. Power does not turn off (The screen remains on). Panel switches do not function. Touch panel switch does not function. Display panel does not open, tilt, or tilts improperly. Screen is distorted. Screen flicker or color distortion. DVD image cannot be displayed on front screen. (Parking brake is on.) (*1) Navigation function switches can be operated while vehicle is running. Suspected area See page 1. Proceed to "Pressing Power Switch does not Turn ON System" NS-119 2. Radio and navigation assembly power source circuit NS-229 3. AVC-LAN circuit NS-201 4. Radio and navigation assembly NS-235 1. Proceed to "Black Screen" NS-164 2. Illumination circuit NS-175 3. AVC-LAN circuit NS-201 4. Radio and navigation assembly NS-235 1. Proceed to "Illumination for Panel Switch does not Come on with TAIL Switch ON" NS-129 2. Illumination circuit NS-175 3. Radio and navigation assembly NS-235 1. Proceed to "Display does not DIM with Light Control Switch is Turned ON" NS-130 2. Illumination circuit NS-175 3. Radio and navigation assembly NS-235 1. Radio and navigation assembly power source circuit NS-229 2. Radio and navigation assembly NS-235 1. Proceed to "Panel Switches do not Function" NS-131 2. Steering pad switch circuit NS-169 3. Radio and navigation assembly power source circuit NS-229 4. Radio and navigation assembly NS-235 1. Proceed to "Touch Panel Switch does not Function" NS-132 2. Steering pad switch circuit NS-169 3. Radio and navigation assembly power source circuit NS-229 4. Radio and navigation assembly NS-235 1. Proceed to "Display Panel does not Open, Tilt, or Tilts Improperly" NS-133 2. Radio and navigation assembly power source circuit NS-229 3. Radio and navigation assembly NS-235 1. Radio and navigation assembly power source circuit NS-229 2. Radio and navigation assembly NS-235 1. Proceed to "Screen Flicker or Color Distortion" NS-134 2. Radio and navigation assembly power source circuit NS-229 3. Radio and navigation assembly NS-235 1. Proceed to "Display Signal Circuit between Television Display Assembly and Radio and Navigation Assembly" NS-212 2. Parking brake switch circuit NS-183 3. Radio and navigation assembly NS-235 Proceed to "Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter" NS-165 NS NS–46 NAVIGATION – NAVIGATION SYSTEM *1: with Rear Seat Entertainment System Audio function: Symptom No sound can be heard from speakers (audio is mute). Suspected area See page 1. Proceed to "No Sound can be Heard from Speakers" NS-120 2. Stereo component amplifier power source circuit NS-227 3. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Television Display Assembly" (*1) NS-197 4. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-199 5. Proceed to "Sound Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-193 6. Speaker circuit NS-185 7. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 8. Radio and navigation assembly NS-235 Radio broadcast cannot be received or poor reception. Proceed to "Radio Broadcast cannot be Received or Poor Reception" NS-126 CD cannot be inserted/played or CD is ejected right after insertion. Proceed to "CD cannot be Inserted/Played or CD is Ejected Right After Insertion" NS-122 CD cannot be ejected. Proceed to "CD cannot be Ejected" NS-121 CD sound skips. Proceed to "CD Sound Skips" NS-124 Abnormal noise occurs. Proceed to "Noise Occurs" NS-117 1. Proceed to "Poor Sound Quality in All Modes (Low Volume)" NS-136 2. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Television Display Assembly" (*1) NS-197 3. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-199 4. Stereo component amplifier power source circuit NS-227 5. Radio and navigation assembly power source circuit NS-229 6. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 7. Radio and navigation assembly NS-235 1. Television display assembly power source circuit NS-231 2. Proceed to "Sound Signal Circuit between Radio and Navigation Assembly and Television Display Assembly" NS-190 3. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Television Display Assembly" NS-197 4. Radio and navigation assembly NS-235 5. Television display assembly AV-177 1. Proceed to "Sound Signal Circuit between Radio and Navigation Assembly and Stereo Jack Adapter" NS-195 2. Stereo jack adapter AV-191 3. Radio and navigation assembly NS-235 Proceed to "Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter" NS-203 Poor sound quality in all modes (low volume). RSE sound cannot be heard or sound quality is bad. External device sound cannot be heard or sound quality is bad (Stereo jack is used). ASL does not function. *1: with Rear Seat Entertainment System Navigation function: Symptom Map disc cannot be inserted. NS Map disc cannot be ejected. Suspected area See page 1. Proceed to "Map Disc cannot be Inserted" NS-137 2. Radio and navigation assembly power source circuit NS-229 3. Radio and navigation assembly NS-235 1. Radio and navigation assembly power source circuit NS-229 2. Radio and navigation assembly NS-235 NS–47 NAVIGATION – NAVIGATION SYSTEM Symptom Vehicle position mark deviates. Cursor or map rotates when vehicle is stopped. Vehicle position mark is not updated. Current position display does not appear. GPS mark is not displayed. Voice guidance does not function. Map display incomplete. Route cannot be calculated. Voice recognition difficulty. Suspected area See page 1. Proceed to "Vehicle Position Mark Deviates Greatly" NS-138 2. GPS antenna NS-239 3. Radio and navigation assembly NS-235 1. Proceed to "Cursor or Map Rotates When Vehicle is Stopped" NS-140 2. Radio and navigation assembly NS-235 1. Proceed to "Vehicle Position Mark is not Updated" NS-141 2. Map disc - 3. Radio and navigation assembly NS-235 1. Proceed to "Current Position Display does not Appear" NS-142 2. Map disc - 3. GPS antenna NS-239 4. Radio and navigation assembly NS-235 1. Proceed to "GPS Mark is not Displayed" NS-143 2. GPS antenna NS-239 3. Radio and navigation assembly NS-235 1. Proceed to "Voice Guidance does not Function" NS-146 2. Proceed to "Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier" NS-199 3. Navigation Voice Circuit NS-210 4. Speaker Circuit NS-185 5. Map disc - 6. Radio and navigation assembly NS-235 7. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 1. Proceed to "Map Display Incomplete" NS-149 2. Map disc - 3. Radio and navigation assembly NS-235 1. Proceed to "Route cannot be Calculated" NS-150 2. Map disc - 3. Radio and navigation assembly NS-235 1. Proceed to "Voice Recognition Difficulty" NS-151 2. Radio and navigation assembly NS-235 1. Proceed to "Voice is not Recognized" NS-153 2. Proceed to "Microphone Circuit between Microphone and Radio and Navigation Assembly" NS-215 3. Steering Pad Switch Circuit NS-169 4. Microphone AV-201 5. Radio and navigation assembly NS-235 Speed signal does not change in the navigation check mode. Proceed to "Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter" NS-165 Reverse signal does not change in the navigation check mode. Proceed to "Reverse Signal Circuit" NS-207 Voice is not recognized. Steering pad switch function: Symptom Suspected area See page The system cannot be operated by the steering pad switch. 1. Steering Pad Switch Circuit NS-169 2. Radio and navigation assembly NS-235 Illumination for steering pad switch does not come on with TAIL switch on. 1. Illumination Circuit NS-175 2. Radio and navigation assembly NS-235 NS NS–48 NAVIGATION – NAVIGATION SYSTEM "Bluetooth" function: Symptom See page Cellular phone registration failure, phone directory transfer failure. Proceed to "Cellular Phone Registration Failure, Phone Directory Transfer Failure" NS-155 1. Proceed to "Cellular Phone cannot Send/Receive" NS-157 Cellular phone cannot send/receive. 2. Steering Pad Switch Circuit NS-169 3. Radio and navigation assembly NS-235 Cannot call in a certain place. Proceed to "Cannot Call in a Certain Place" NS-159 1. Proceed to "The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted" NS-160 2. Navigation Voice Circuit NS-210 3. Radio and navigation assembly NS-235 4. Woofer box speaker assembly (Built-in stereo component amplifier) AV-215 1. Proceed to "The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted" NS-162 2. Proceed to "Microphone Circuit between Microphone and Radio and Navigation Assembly" NS-215 The other caller's voice cannot be heard, is too quiet, or distorted. The other caller cannot hear your voice, or your voice is too quiet or distorted. NS Suspected area 3. Microphone - 4. Radio and navigation assembly NS-235 NAVIGATION – NAVIGATION SYSTEM NS–169 Black Screen INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Check that the display is not in "Screen OFF" mode. OK: The display setting is not in "Screen OFF" mode. NG CHANGE SCREEN TO "SCREEN ON" MODE OK 2 CHECK IMAGE QUALITY SETTING (a) Check that the screen color quality can be set. OK: Setting is possible. NG Go to step 3 OK PRESS PANEL SWITCH "DISPLAY" AND SET SCREEN COLOR QUALITY TO NORMAL 3 CHECK CABIN (a) Check that condensation is not likely to occur in the cabin, and that the temperature is not high or extremely low in the cabin. HINT: • A humid cabin and a rapid change in temperature may lead to condensation. Condensation in the cabin may short circuit the screen. • The appropriate cabin temperature is 20 to 30°C (68 to 86°F). OK: Condensation is not likely and temperature is not high or extremely low. NG SET CABIN TO APPROPRIATE TEMPERATURE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–170 NAVIGATION – NAVIGATION SYSTEM Vehicle Speed Signal Circuit between Radio and Navigation Assembly and Combination Meter DESCRIPTION The radio and navigation assembly receives a vehicle speed signal from the combination meter and information about the GPS antenna, and then adjusts vehicle position. HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Radio and Navigation Assembly 3 R9 From A/C Control Assembly From Moon Roof Control ECU SPD From ECM From 4WD Control ECU From Tire Pressure Monitor ECU 5 C9 From Main Body ECU Combination Meter From Speed Sensor E120038E03 NS NAVIGATION – NAVIGATION SYSTEM NS–171 INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO COMBINATION METER SYSTEM OK 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R9. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch to the ON position. Radio and Navigation Assembly Wire Harness View: SPD R9 E113510E03 (4) Measure the voltage between terminal SPD of the radio and navigation assembly and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V REPLACE RADIO AND NAVIGATION ASSEMBLY Below 2 V 0 Turn the wheel E110855E01 NG NS NS–172 3 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector R9 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SPD Tester connection Condition Specified condition SPD - C9-5 Ignition switch off Below 1 Ω NG R9 Combination Meter (Left Side of Vehicle) Connector Front View: C9-5 E120119E01 OK NS REPAIR OR REPLACE HARNESS OR CONNECTOR NS–173 NAVIGATION – NAVIGATION SYSTEM 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector R9 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SPD Tester connection Condition Specified condition SPD - Body ground Ignition switch off 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU. R9 NG Combination Meter (Left Side of Vehicle) Connector Front View: REPAIR OR REPLACE HARNESS OR CONNECTOR OR CHECK EACH ECU C9-5 E120119E01 OK REPLACE COMBINATION METER NS NS–174 NAVIGATION – NAVIGATION SYSTEM Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio and navigation assembly. If there is an open in the circuit, the navigation system cannot be operated using the steering pad switch. If there is a short in the circuit, the resulting condition is the same as if the switch were continuously depressed. Therefore, the radio and navigation assembly cannot be operated using the steering pad switch, and the radio and navigation assembly itself cannot function. WIRING DIAGRAM Steering Pad Switch LH 12 AU1 Volume- Volume+ Seek- Seek+ A EAU MODE 11 AU2 B B AU2 EAU C C AU2 AU1 10 A EAU Radio and Navigation Assembly Spiral Cable A 12 C13 10 EAU AU2 C13 11 C13 7 R10 SW1 6 R10 SWG 8 R10 SW2 Steering Pad Switch RH ON HOOK OFF HOOK Voice E120111E03 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) such as the airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). NS NS–175 NAVIGATION – NAVIGATION SYSTEM 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R10. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: SW1 SW2 R10 SWG Tester connection E113509E02 Condition Specified condition SW1 - SWG No switch is pushed Approx. 100 kΩ SW1 - SWG SEEK+ switch: push Approx. 0 Ω SW1 - SWG SEEK- switch: push Approx. 0.3 kΩ SW1 - SWG VOL+ switch: push Approx. 1 kΩ SW1 - SWG VOL- switch: push Approx. 3.1 kΩ SW2 - SWG No switch is pushed Approx. 100 kΩ SW2 - SWG MODE switch: push Approx. 0 Ω SW2 - SWG VOICE switch: push Approx. 3.1 kΩ SW2 - SWG ON HOOK switch: push Approx. 0.3 kΩ SW2 - SWG OFF HOOK switch: push Approx. 1 kΩ NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 2 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch assembly connector A. Connector Front View: A EAU AU2 AU1 E120112E01 (b) Measure the resistance according to the value(s) in the table below. NS NS–176 NAVIGATION – NAVIGATION SYSTEM Standard resistance Tester connection Condition Specified condition AU1 - EAU No switch is pushed Approx. 100 kΩ AU1 - EAU SEEK+ switch: push Approx. 0 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.1 kΩ AU2 - EAU No switch is pushed Approx. 100 kΩ AU2 - EAU MODE switch: push Approx. 0 Ω AU2 - EAU VOICE switch: push Approx. 3.1 kΩ AU2 - EAU ON HOOK switch: push Approx. 0.3 kΩ AU2 - EAU OFF HOOK switch: push Approx. 1 kΩ NG Go to step 4 OK 3 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch assembly and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: EAU AU2 AU1 Tester connection Spiral Cable Position Specified condition Center EAU - EAU 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU1 - AU1 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Center AU2 - AU2 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right Vehicle Side: NG EAU AU2 AU1 NS NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (See page RS-398). E113447E03 REPLACE SPIRAL CABLE NS–177 NAVIGATION – NAVIGATION SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SPIRAL CABLE - RADIO AND NAVIGATION ASSEMBLY) 4 INSPECT STEERING PAD SWITCH CABLE (a) Disconnect the steering pad switch LH and the steering pad switch RH. B C 21 3 4 5 6 78 12 3 4 5 6 87 E120113E02 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition B-1 - C-1 Always Below 1 Ω B-2 - C-2 Always Below 1 Ω B-3 - C-3 Always Below 1 Ω B-4 - C-4 Always Below 1 Ω B-5 - C-5 Always Below 1 Ω B-6 - C-6 Always Below 1 Ω B-7 - C-7 Always Below 1 Ω B-8 - C-8 Always Below 1 Ω B-1 - Body ground Always 10 kΩ or higher B-2 - Body ground Always 10 kΩ or higher B-3 - Body ground Always 10 kΩ or higher B-4 - Body ground Always 10 kΩ or higher B-5 - Body ground Always 10 kΩ or higher B-6 - Body ground Always 10 kΩ or higher B-7 - Body ground Always 10 kΩ or higher B-8 - Body ground Always 10 kΩ or higher NG OK REPLACE STEERING PAD SWITCH CABLE NS NS–178 5 NAVIGATION – NAVIGATION SYSTEM INSPECT STEERING PAD SWITCH RH (a) Reconnect the steering pad switch RH. Connector Front View: Opposite Side: AU2 (B-5) AU2 (B-4) B EAU (B-3) EAU (B-2) E120114E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition No switch is pushed 10 kΩ or higher VOICE switch: push Approx. 3.2 kΩ ON HOOK switch: push Approx. 0.3 kΩ OFF HOOK switch: push Approx. 1 kΩ AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) AU2 (B-4) - EAU (B-2) AU2 (B-5) - EAU (B-3) AU2 (B-5) - EAU (B-2) AU2 (B-4) - EAU (B-3) NG NS REPLACE STEERING PAD SWITCH RH NAVIGATION – NAVIGATION SYSTEM NS–179 OK REPLACE STEERING PAD SWITCH LH NS NS–180 NAVIGATION – NAVIGATION SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the radio and navigation assembly and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Radio and Navigation Assembly Steering Pad Switch Spiral Cable LH 1 A ILL+ 1 C13 2 R12 ILL+ 10 A EAU 10 C13 6 R10 SWG RH Other Illuminations TAIL Relay TAIL From J/B Fuse To Main Body ECU R13 Rheostat 5 E - 3 12 R12 ILL- E121201E01 INSPECTION PROCEDURE NS NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) such as the airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (See page RS-1). NS–181 NAVIGATION – NAVIGATION SYSTEM 1 CHECK ILLUMINATION (a) Check if the illumination for the radio and navigation assembly, steering pad switch, glove box or others (hazard switch, cigarette lighter, etc.) comes on when the light control switch is turned to the HEAD or TAIL position. Result Condition Proceed to Illumination comes on for all components except steering pad switch. A Illumination comes on for all components except radio and navigation assembly. B No illumination comes on (radio receiver, hazard switch, glove box, etc.) C Illumination comes on only for glove box and steering pad switch. D B Go to step 7 C GO TO LIGHTING SYSTEM D GO TO COMBINATION METER SYSTEM A 2 CHECK HARNESS AND CONNECTOR (BATTERY - SPIRAL CABLE) Spiral Cable Connector Front View: C13 (a) Disconnect the spiral connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR ILL+ E120026E06 OK 3 CHECK STEERING PAD SWITCH ASSEMBLY (a) Disconnect the steering pad switch assembly connector. NS NS–182 NAVIGATION – NAVIGATION SYSTEM A + - E120115E02 (b) Disconnect the steering pad switch connector. (c) Connect the positive (+) lead to terminal ILL+ and the negative (-) lead to terminal EAU of the steering pad switch connector. (d) Check if the illumination for the steering pad switch comes on. Result Proceed to Illumination comes on for steering pad switch LH and RH. A Illumination comes on for only the steering pad switch LH. B Illumination comes on for only the steering pad switch RH. C B C A NS Go to step 6 REPLACE STEERING PAD SWITCH LH NS–183 NAVIGATION – NAVIGATION SYSTEM 4 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch and spiral cable connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Pad Switch Side: ILL+ EAU Tester Connection Spiral Cable Position EAU - EAU 2.5 rotations to the left Specified Condition Center Below 1 Ω 2.5 rotations to the right Center ILL+ - ILL+ 2.5 rotations to the left Below 1 Ω 2.5 rotations to the right NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (See page RS-398). Vehicle Side: NG REPLACE SPIRAL CABLE EAU ILL+ E113447E04 OK NS NS–184 5 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (SPIRAL CABLE - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the connectors from the radio and navigation assembly and spiral cable. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SWG R10 Tester connection Condition Specified condition SWG - EAU Always Below 1 Ω SWG - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Spiral Cable Connector Front View: C13 EAU E120116E02 OK REPLACE RADIO AND NAVIGATION ASSEMBLY 6 INSPECT STEERING PAD SWITCH CABLE (a) Disconnect the steering pad switch LH and the steering pad switch RH. NS NS–185 NAVIGATION – NAVIGATION SYSTEM LH RH 21 3 4 5 6 78 12 3 4 5 6 87 E120113E03 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition LH-1 - RH-1 Always Below 1 Ω LH-2 - RH-2 Always Below 1 Ω LH-3 - RH-3 Always Below 1 Ω LH-4 - RH-4 Always Below 1 Ω LH-5 - RH-5 Always Below 1 Ω LH-6 - RH-6 Always Below 1 Ω LH-7 - RH-7 Always Below 1 Ω LH-8 - RH-8 Always Below 1 Ω LH-1 - Body ground Always 10 kΩ or higher LH-2 - Body ground Always 10 kΩ or higher LH-3 - Body ground Always 10 kΩ or higher LH-4 - Body ground Always 10 kΩ or higher LH-5 - Body ground Always 10 kΩ or higher LH-6 - Body ground Always 10 kΩ or higher LH-7 - Body ground Always 10 kΩ or higher LH-8 - Body ground Always 10 kΩ or higher NG REPLACE STEERING PAD SWITCH CABLE OK REPLACE STEERING PAD SWITCH RH NS NS–186 7 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (BATTERY - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector R12. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: ILL+ Tester connection Condition Specified condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V NG R12 REPAIR OR REPLACE HARNESS OR CONNECTOR E113513E03 OK 8 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - LIGHT CONTROL RHEOSTAT) (a) Disconnect the radio and navigation assembly and light control rheostat connectors. (b) Measure the resistance according to the value(s) in the table below. Standard voltage Wire Harness View: ILL- R12 Condition Specified condition ILL- - C13-3 Always Below 1 Ω ILL- - Body ground Always 10 kΩ or higher NG Light Control Rheostat Wire Harness View: R13 R13-3 NS Tester connection E120117E01 REPAIR OR REPLACE HARNESS OR CONNECTOR NAVIGATION – NAVIGATION SYSTEM NS–187 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–188 NAVIGATION – NAVIGATION SYSTEM Parking Brake Switch Circuit DESCRIPTION This circuit is from the parking brake switch to the radio and navigation assembly. WIRING DIAGRAM Radio and Navigation Assembly P4 Parking Brake SW 1 R9 1 PKB E111727E07 INSPECTION PROCEDURE 1 CHECK BRAKE WARNING LIGHT (a) Check that the brake warning light comes on when the parking brake is applied and goes off when it is released. OK: The brake warning light operates as specified above. OK NG NS Go to step 3 NS–189 NAVIGATION – NAVIGATION SYSTEM 2 INSPECT PARKING BRAKE SWITCH (a) Disconnect the parking brake switch. (b) Measure the resistance according to the value(s) in the table below. Standard resistance ON OFF Tester connection Condition Specified condition Switch connector Switch body ON (When shaft is not pressed) Below 1 Ω Switch connector Switch body OFF (When shaft is pressed) 10 kΩ or higher E071372E01 NG REPLACE PARKING BRAKE SWITCH OK 3 CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the radio and navigation assembly connector R9 and parking brake switch connector P4. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: PKB Tester connection Condition PKB - P4-1 Always Below 1 Ω PKB - Body ground Always 10 kΩ or higher NG R9 Specified condition REPAIR OR REPLACE HARNESS OR CONNECTOR Parking Brake Switch Connector Front View: P4 E120118E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–190 NAVIGATION – NAVIGATION SYSTEM Speaker Circuit DESCRIPTION The sound signal that has been amplified by the stereo component amplifier is sent to the speakers from the stereo component amplifier through this circuit. If there is a short in this circuit, the stereo component amplifier detects it and stops output to the speakers. Thus sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. When a short is detected in the speaker circuit, no sound can be heard from the speakers. NS NS–191 NAVIGATION – NAVIGATION SYSTEM WIRING DIAGRAM Stereo Component Amplifier 1 4 S23 RL+ 2 13 S23 RL- 1 5 S23 RR+ 2 14 S23 RR- R16 Rear Speaker LH R17 Rear Speaker RH S20 Front No. 2 Speaker LH 1 D22 Front No. 1 Speaker LH 2 D23 Front No. 1 Speaker RH 2 4 3 1 S21 Front No. 2 Speaker RH 2 1 2 1 C5 Front Stereo Component Speaker Woofer Box Speaker 4 3 4 3 6 S23 FL+ 17 S23 FL7 S23 FR+ 18 S23 FR3 S23 CTR+ 12 S23 CTR- 1 WF+ W4 9 S23 WFR+ 3 W4 20 S23 WFR- 2 WF+ W4 8 S23 WFL+ 4 W4 19 S23 WFL- WF- WF- E121189E01 NS NS–192 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR Stereo Component Amplifier Wire Harness View: FR+ WFL+ FL+ RR+ RL+ CTR+ WFR+ S23 WFRWFL- FR- FL- RR- RL- CTR- Front No. 2 Speaker, Front Stereo Component Speaker Connector Front View: S20 S21 C5 Front No. 1 Speaker, Rear Speaker Connector Front View: D23 D22 (a) Disconnect the connectors shown in the illustration on the left from the stereo component amplifier and speakers. (b) Measure the resistance between the front No. 2 speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (c) Measure the resistance between rear speakers and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (d) Measure the resistance between the front stereo component speaker and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (e) Measure the resistance between the woofer box speaker and the stereo component amplifier to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (f) Measure the resistance between the front No. 1 speaker and the front No. 2 speaker to check for an open circuit in the wire harness. Standard resistance: Below 1 Ω (g) Measure the resistance between each speaker and body ground to check for a short circuit in the wire harness. Standard resistance: 10 kΩ or higher NG R16 R17 Woofer Box Speaker Connector Front View: W4 NS E121190E01 REPAIR OR REPLACE HARNESS OR CONNECTOR NS–193 NAVIGATION – NAVIGATION SYSTEM OK 2 INSPECT WOOFER BOX SPEAKER (a) Resistance check. (b) Measure the resistance according to the value(s) in the table below. NOTICE: The speaker should not be removed for checking. Standard resistance Tester connection Condition Specified condition 1-3 Always Approximately 1.2 Ω 2-4 Always Approximately 1.2 Ω E120044 NG REPLACE WOOFER BOX SPEAKER OK 3 INSPECT FRONT NO. 1 SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: 4 to 6 Ω NG REPLACE FRONT NO. 1 SPEAKER OK 4 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when another speaker in good condition is installed. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speakers. • When there is a possibility that either right or left front speaker is defective, inspect by interchanging the right one with the left one. OK REPLACE FRONT NO. 2 SPEAKER NG 5 INSPECT REAR SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. NS NS–194 NAVIGATION – NAVIGATION SYSTEM Standard resistance: Approximately 2.6 Ω NG REPLACE REAR SPEAKER OK 6 INSPECT FRONT STEREO COMPONENT SPEAKER (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. Standard resistance: 1.2 to 2.2 Ω NG REPLACE FRONT STEREO COMPONENT SPEAKER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–195 NAVIGATION – NAVIGATION SYSTEM Sound Signal Circuit between Radio and Navigation Assembly and Television Display Assembly DESCRIPTION The television display assembly sends an RSE sound signal to the radio and navigation assembly through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio and navigation assembly or speakers. WIRING DIAGRAM Television Display Assembly Radio Receiver 1 CSLD R11 CDR+ (Shielded) 27 R18 28 2 R11 R18 3 29 CDR- R11 4 CDL+ R11 5 CDL- R11 SG1 R+ R18 R30 R18 L+ 31 R18 L- E120034E05 NS NS–196 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY TELEVISION DISPLAY ASSEMBLY) (a) Disconnect the connectors from the television display assembly and radio and navigation assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: CDRCDR+ CDL+ CDL- CSLD Tester connection Condition Specified condition CDR+ - R+ Always Below 1 Ω R18 Always Below 1 Ω Always Below 1 Ω CDL- - L- Always Below 1 Ω CSLD - SG1 Always Below 1 Ω R- - Body ground Always 10 kΩ or higher L+ - Body ground Always 10 kΩ or higher R11 Television Display Assembly Wire Harness View: CDR- - RCDL+ - L+ L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher SG1 - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR LL+ SG1 R- R+ E121191E03 OK 2 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Reconnect the television display assembly connector and radio and navigation assembly connectors. (b) Check the waveform according to the conditions in the table below. Wire Harness View: R18 L- L+ R- R+ NS E120036E07 NS–197 NAVIGATION – NAVIGATION SYSTEM Standard resistance Tester connection Condition Specified condition R+ - Body ground Voice sound is being produced A waveform synchronized with sound is output R- - Body ground Voice sound is being produced A waveform synchronized with sound is output L+ - Body ground Voice sound is being produced A waveform synchronized with sound is output L- - Body ground Voice sound is being produced A waveform synchronized with sound is output NG REPLACE TELEVISION DISPLAY ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–198 NAVIGATION – NAVIGATION SYSTEM Sound Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier DESCRIPTION The radio and navigation assembly sends a sound signal to the stereo component amplifier through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Stereo Component Amplifier 6 SLD Radio and Navigation Assembly (Shielded) (Shielded) 10 S22 R12 SLD 2 19 L- S22 R12 L- L+ 3 S22 9 R12 L+ R- 4 S22 18 R12 R- 5 8 R+ S22 R12 R+ E120032E04 NS NS–199 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the connectors from the radio and navigation assembly and stereo component amplifier. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: SLD L+ R+ Tester connection Condition Specified condition L+ - L+ Always Below 1 Ω L- RR12 Stereo Component Amplifier Wire Harness View: Always Below 1 Ω Always Below 1 Ω R- - R- Always Below 1 Ω SLD - SLD Always Below 1 Ω SLD - Body ground Always 10 kΩ or higher L+ - Body ground Always 10 kΩ or higher L- - Body ground Always 10 kΩ or higher R+ - Body ground Always 10 kΩ or higher R- - Body ground Always 10 kΩ or higher NG S22 L- - LR+ - R+ REPAIR OR REPLACE HARNESS OR CONNECTOR R+ RL+ L- E121192E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–200 NAVIGATION – NAVIGATION SYSTEM Sound Signal Circuit between Radio and Navigation Assembly and Stereo Jack Adapter DESCRIPTION The stereo jack adapter sends an external device sound signal to the radio and navigation assembly through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier radio and navigation assembly or speakers. WIRING DIAGRAM Stereo Jack Adapter Radio and Navigation Assembly 4 AUXO S31 6 R27 ADPG 3 ASGN S31 5 R27 VA- 2 ARO S31 2 R27 VAR+ 3 1 ALO S31 R27 VAL+ (Shielded) (Shielded) E121224E03 NS NS–201 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO JACK ADAPTER) (a) Disconnect the connectors from the stereo jack adapter and radio and navigation assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: R27 VAR+ VAL+ Stereo Jack Adapter Connector Front View: ADPG VA- Tester connection Condition Specified condition AUXO - ADPG Always Below 1 Ω ASGN - VA- Always Below 1 Ω ARO - VAR+ Always Below 1 Ω ALO - VAL+ Always Below 1 Ω AUXO - Body ground Always 10 kΩ or higher ASGN - Body ground Always 10 kΩ or higher ARO - Body ground Always 10 kΩ or higher ALO - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR S31 ALO ARO ASGN AUXO E124115E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–202 NAVIGATION – NAVIGATION SYSTEM Mute Signal Circuit between Radio and Navigation Assembly and Television Display Assembly DESCRIPTION The radio and navigation assembly controls the volume according to the MUTE signal from the television display assembly. The MUTE signal is sent to reduce noise and a popping sound generated when switching the mode, etc. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the radio and navigation assembly is normal, no sound or only an extremely small sound can be produced. WIRING DIAGRAM Television Display Assembly Radio and Navigation Assembly 6 26 R11 MUTE LMUT R18 E110892E18 INSPECTION PROCEDURE 1 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: R18 LMUT E120036E08 NS NG Tester connection Condition Specified condition LMUT - Body ground Turn ignition switch to ACC, RSE system is playing → Changing mode Above 3.5 V → Below 1 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–203 NAVIGATION – NAVIGATION SYSTEM 2 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY TELEVISION DISPLAY ASSEMBLY) (a) Disconnect the radio and navigation assembly connector R11 and television display assembly connector R18. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: MUTE Tester connection Condition Specified condition MUTE - LMUT Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG R11 REPAIR OR REPLACE HARNESS OR CONNECTOR Television Display Assembly Wire Harness View: R18 LMUT E121191E04 OK 3 REPLACE TELEVISION DISPLAY ASSEMBLY (a) Replace the television display assembly and check if it operates normally. OK: The navigation system operates normally. OK NORMAL OPERATION NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–204 NAVIGATION – NAVIGATION SYSTEM Mute Signal Circuit between Radio and Navigation Assembly and Stereo Component Amplifier DESCRIPTION This circuit sends a signal to the stereo component amplifier to mute noise. Because of that, the noise produced by changing the sound source ceases. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier is normal, no sound, or only an extremely small sound, can be produced. WIRING DIAGRAM Stereo Component Amplifier Radio and Navigation Assembly 7 1 R12 MUTE MUTE S22 E110892E19 INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: S22 MUTE NS Condition Specified condition MUTE - Body ground Turn ignition switch to ACC, Audio system is playing → Changing Above 3.5 V → Below 1 V OK E120037E03 NG Tester connection PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–205 NAVIGATION – NAVIGATION SYSTEM 2 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the radio and navigation assembly connector R12 and television display assembly connector S22. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: MUTE R12 Tester connection Condition Specified condition MUTE - MUTE Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR Stereo Component Amplifier Wire Harness View: S22 MUTE E121192E04 OK 3 REPLACE STEREO COMPONENT AMPLIFIER (a) Replace the stereo component amplifier and check if it operates normally. OK: The navigation system operates normally. OK NORMAL OPERATION NG REPLACE RADIO AND NAVIGATION ASSEMBLY NS NS–49 NAVIGATION – NAVIGATION SYSTEM TERMINALS OF ECU 1. R12 RADIO AND NAVIGATION ASSEMBLY R10 R26 R9 R11 R27 E120079E02 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification Parking brake signal See "Vehicle Signal Check" (See page NS-22) - PKB (R9-1) - GND (R12-20) LG - BR SPD (R9-3) - GND (R12-20) R - BR Speed signal from combination meter See "Vehicle Signal Check" (See page NS-22) - REV (R9-5) - GND (R12-20) Y - BR Reverse signal See "Vehicle Signal Check" (See page NS-22) - SWG (R10-6) - Body ground W-R - Body ground Steering pad switch signal Always Steering pad switch signal No switch is pushed → SEEK+ switch pushed → SEEK- switch pushed → VOL+ switch pushed → VOL- switch pushed 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V Steering pad switch signal No switch is pushed → MODE switch pushed → ON HOOK switch pushed → OFF HOOK switch pushed → VOICE switch pushed 4 V or more → Approx. 0.5 V → Approx. 0.9 V → Approx. 2.0 V → Approx. 3.4 V SW1 (R10-7) - SWG (R10-6) SW2 (R10-8) - SWG (R10-6) V-W - W-R Y-B - W-R Below 1 V IVO+ (R10-11) - GND (R12-20) L - BR Voice guidance signal Voice guidance is provided A waveform synchronized with sounds is output IVO- (R10-12) - GND (R12-20) P - BR Voice guidance signal Voice guidance is provided A waveform synchronized with sounds is output SLD1 (R10-13) - Body ground Shielded - Body ground Voice sound signal shielded ground Always Below 1 V CSLD (R11-1) - Body ground (*1) Shielded - Body ground Shielded ground Always Below 1 V CDR+ (R11-2) - GND (R12-20) (*1) B - BR RSE system sound signal RSE system is playing A waveform synchronized with sounds is output CDR- (R11-3) - GND (R12-20) (*1) W - BR RSE system sound signal RSE system is playing A waveform synchronized with sounds is output CDL+ (R11-4) - GND (R12-20) (*1) R - BR RSE system sound signal RSE system is playing A waveform synchronized with sounds is output NS NS–50 Symbols (Terminal No.) Wiring Color Terminal Description CDL- (R11-5) - GND (R12-20) (*1) G - BR RSE system sound signal RSE system is playing MUTE (R11-6) - GND (R12-20) (*1) V - BR Mute signal RSE system is playing→ Source is changed with remote controller (signal from RSE system) TXM+ (R11-9) - GND (R12-20) (*1) R - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TXM- (R11-10) - GND (R12-20) (*1) G -BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V B (R12-1) - GND (R12-20) L-Y - BR Condition Battery Always ILL+ (R12-2) - GND (R12-20) G - BR Illumination signal Turn ignition switch ON Light control switch OFF → TAIL or ON ATX+ (R12-5) - GND (R12-20) B - BR AVC-LAN communication signal Turn ignition switch to ACC MUTE (R12-7) - GND (R12-20) W-R - BR Mute signal Audio system is playing→ Changing Specification A waveform synchronized with sounds is output Above 3.5 V → Below 1 V 10 to 14 V Below 1V → 10 to 14 V 2 to 3 V Above 3.5 V → Below 1 V R+ (R12-8) - GND (R12-20) B - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L+ (R12-9) - GND (R12-20) R - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output SLD (R12-10) - Body ground Shielded - Body ground Shielded ground Always ACC (R12-11) - GND (R12-20) GR - BR Accessory (ON) Turn ignition switch OFF→ ACC or ON Below 1 V → 10 to 14 V ILL- (R12-12) - GND (R12-20) W-G - BR Illumination signal Turn ignition switch ON Light control switch OFF → TAIL or ON Below 1 V →10 to 14 V ANT (R12-13) - GND (R12-20) B - BR Power source of antenna Radio switch ON and AM or FM 10 to 14 V ATX- (R12-15) - GND (R12-20) W - BR AVC-LAN communication signal Turn ignition switch to ACC R- (R12-18) - GND (R12-20) W - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output L- (R12-19) - GND (R12-20) G - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output GND (R12-20) - Body ground BR - Body ground Ground Always L - BR Microphone voice signal See "Microphone Check" (See page NS-27) - P - Body ground Microphone voice signal See "Microphone Check" (See page NS-27) - MACC (R26-17) - GND (R12-20) W - BR Microphone AMP power supply Turn ignition switch OFF → ON Below 1 V → 5 V TSW- (R26-12) - GND (R12 -20) B - BR Telephone relation switch signal Always Below 1 V SGND- (R26-18) - GND (R12-20) B - BR Ground Always Below 1 V CA+ (R26-24) - GND (R12-20) R - BR Television camera power supply Turn ignition switch ON, shift lever in R position CGND (R26-21) - Body ground W - Body ground Ground Always V+ (R26-22) - CGND (R12-21) B-W Television camera image signal Turn ignition switch ON, shift lever in R position V- (R26-23) - CGND (R12-21) Shielded - W Shielded ground Always MIC+ (R26-19) - GND (R12-20) MIC- (R26-20) - Body ground NS NAVIGATION – NAVIGATION SYSTEM Below 1 V 2 to 3 V Below 1 V Approx. 6 V Below 1 V Pulse generation (Refer to waveform 2) Below 1 V NS–51 NAVIGATION – NAVIGATION SYSTEM Symbols (Terminal No.) Wiring Color VV+ (R27-1) - GND (R12-20) (*1) VV- (R27-4) - Body ground (*1) P - BR L - Body ground Terminal Description Condition Display signal DVD is played on radio and navigation assembly Ground Always Specification A waveform synchronized with display signals is output. (Refer to waveform 1) Below 1 V VAR+ (R27-2) - GND (R12-20) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output VAL+ (R27-3) - GND (R12-20) R - BR Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sound is output Shielded ground Always Below 1 V External device connection detection signal External device is connection Below 1 V VA- (R27-5) - Body ground Shielded - Body ground ADPG (R27 - 6) - GND (R12-20) L - BR *1: with Rear Seat Entertainment System (a) Reference: waveform 1 HINT: • Terminal: VV+ - VV• Gauge set: 200 mV/DIV, 10 µs/DIV • Condition: DVD is played on radio and navigation assembly GND E120080E01 GND 2. (b) Reference: waveform 2 HINT: • Terminal: V+ - CGND • Gauge set: 0.2 V/DIV, 0.2µs/DIV • Condition: Ignition switch: ON, shift lever: R position STEREO COMPONENT AMPLIFIER E057967E08 S23 S22 E120081E04 Symbols (Terminal No.) MUTE (S22-1) - GND2 (S23-15) Wiring Color W-R - BR Terminal Description Mute signal from radio receiver Condition Specified Condition Audio system is playing → Changing Above 3.5 V → Below 1 V NS NS–52 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition L- (S22-2) - GND2 (S23-15) G - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output L+ (S22-3) - GND2 (S23-15) R - BR Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output R- (S22-4) - GND2 (S23-15) W - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output R+ (S22-5) - GND2 (S23-15) B - BR Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output Shielded ground Always SLD (S22-6) - Body ground Shielded - Body ground Below 1 V TX- (S22-7) - GND2 (S23-15) W - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX+ (S22-8) - GND2 (S23-15) B - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V SPD (S22-11) - GND2 (S23-15) V-R - BR Speed signal from combination meter Turn ignition switch to ON. Drive wheels are turned slowly ACC (S22-12) - GND2 (S23-15) GR - BR Accessory (ON) Turn ignition switch OFF → ACC INT- (S22-22) - GND2 (S23-15) P - BR Voice guidance signal Voice guidance is provided A waveform synchronized with sounds is output INT+ (S22-23) - GND2 (S23-15) L - BR Voice guidance signal Voice guidance is provided A waveform synchronized with sounds is output Battery Always +B (S23-1) - GND2 (S23-15) W-L - BR Pulse generation Below 1 V → 10 to 14 V 10 to 14 V CTR+ (S23-3) - GND2 (S23-15) G - BR Sound signal (Front Center) Audio system is playing A waveform synchronized with sounds is output RL+ (S23-4) - GND2 (S23-15) B - BR Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output RR+ (S23-5) - GND2 (S23-15) R - BR Sound signal (Rear Right) Audio system is playing A waveform synchronized with sounds is output FL+ (S23-6) - GND2 (S23-15) P - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output FR+ (S23-7) - GND2 (S23-15) LG - BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output WFL+ (S23-8) - GND2 (S23-15) BR - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output WFR+ (S23-9) - GND2 (S23-15) L-B - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output +B2 (S23-10) - GND2 (S23-15) W-L - BR Battery Always CTR- (S23-12) - GND2 (S23-15) NS NAVIGATION – NAVIGATION SYSTEM RL- (S23-13) - GND2 (S23-15) G-B - BR Y - BR 10 to 14 V Sound signal (Front Center) Audio system is playing A waveform synchronized with sounds is output Sound signal (Rear Left) Audio system is playing A waveform synchronized with sounds is output NS–53 NAVIGATION – NAVIGATION SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition RR- (S23-14) - GND2 (S23-15) W - BR Sound signal (Rear Right) Audio system is playing GND2 (S23-15) - Body ground BR - Body Ground Ground Always Below 1 V GND (S23-16) - Body ground BR - Body ground Ground Always Below 1 V FL- (S23-17) - GND2 (S23-15) V - BR Sound signal (Front Left) Audio system is playing A waveform synchronized with sounds is output FR- (S23-18) - GND2 (S23-15) L- BR Sound signal (Front Right) Audio system is playing A waveform synchronized with sounds is output A waveform synchronized with sounds is output WFL- (S23-19) - GND2 (S23-15) G-W- BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output WFR- (S23-20) - GND2 (S23-15) L-R - BR Sound signal (Woofer Box) Audio system is playing A waveform synchronized with sounds is output 3. TELEVISION DISPLAY ASSEMBLY (See page AV-155) NS NS–206 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the navigation system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the navigation system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 TXM+ ATX+ ATX- Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK 2 CHECK HARNESS AND CONNECTOR HINT: For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Check for an open or short in all AVC-LAN circuits. NS NS–207 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–208 NAVIGATION – NAVIGATION SYSTEM Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Leveliser) built into the stereo component amplifier. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio sound even when vehicle noise increases (as vehicle noise increases, the volume is turned up etc.). HINT: • A voltage of 12 V or 5 V is output from each ECU and then input to the combination meter. The signal is changed to a pulse signal at the transistor in the combination meter. Each ECU controls the respective system based on the pulse signal. • If a short occurs in an ECU, all systems in the diagram below will not operate normally. WIRING DIAGRAM Stereo Component Amplifier 11 S22 SPD From A/C Control Assembly From Moon Roof Control ECU From ECM From 4WD Control ECU From Tire Pressure Monitor ECU 5 C9 From Main Body ECU Combination Meter From Speed Sensor E120038E04 NS NAVIGATION – NAVIGATION SYSTEM NS–209 INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG CHECK COMBINATION METER OK 2 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connector S22. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the ignition switch to the ON position. Stereo Component Amplifier Wire Harness View: S22 SPD E120039E02 (4) Measure the voltage between terminal SPD of the stereo component amplifier and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. NG 4.5 to 14 V Go to step 3 Below 2 V 0 Turn the wheel E110855E01 NS NS–210 NAVIGATION – NAVIGATION SYSTEM OK REPLACE WOOFER BOX SPEAKER ASSEMBLY (BUILT- IN STEREO COMPONENT AMPLIFIER) 3 CHECK HARNESS AND CONNECTOR (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the stereo component amplifier connector S22 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: S22 Tester Connection Condition Specified Condition SPD - C9-5 Ignition switch OFF Below 1 Ω NG SPD Combination Meter (Left Side of Vehicle) Connector Front View: C9-5 E120040E01 OK NS REPAIR OR REPLACE HARNESS OR CONNECTOR NS–211 NAVIGATION – NAVIGATION SYSTEM 4 CHECK HARNESS AND CONNECTOR (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the stereo component amplifier connector S22 and combination meter connector C9. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Stereo Component Amplifier Wire Harness View: S22 SPD Combination Meter (Left Side of Vehicle) Connector Front View: Tester Connection Condition Specified Condition SPD - Body ground Ignition switch OFF 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OR CHECK EACH ECU C9-5 E120040E01 OK REPLACE COMBINATION METER NS NS–212 NAVIGATION – NAVIGATION SYSTEM Reverse Signal Circuit DESCRIPTION The radio and navigation assembly receives a reverse signal from the park/neutral position switch and information about the GPS antenna, and then adjusts vehicle position. WIRING DIAGRAM Radio and Navigation Assembly P1 Park/Neutral Position Switch 5 From IG1 Fuse 2 R9 1 REV E120120E03 INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R9. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: REV Tester connection Condition Specified condition REV - Body ground Ignition switch is ON. Shift lever is moved to R position. 10 to 14 V REV - Body ground Ignition switch is ON. Shift lever is moved to any position except R. Below 1 V R9 OK E113510E04 NG NS REPLACE RADIO AND NAVIGATION ASSEMBLY NS–213 NAVIGATION – NAVIGATION SYSTEM 2 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION - PARK / NEUTRAL POSITION SWITCH) (a) Disconnect the radio and navigation assembly connector R9 and park/neutral position switch connector P1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: REV Tester connection Condition Specified condition REV - P1-1 Always Below 1 Ω REV - Body ground Always 10 kΩ or higher NG R9 REPAIR OR REPLACE HARNESS OR CONNECTOR Park/Neutral Position Switch Connector Front View: P1 E120121E02 OK 3 INSPECT PARK / NEUTRAL POSITION SWITCH Park/Neutral Position Switch: P1 (a) Disconnect the park/neutral position switch connector P1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition P1-1 - P1-2 Shift lever is moved to R Below 1 Ω P1-1 - P1-2 Shift lever is moved to any position except R. 10 kΩ or higher E120122E01 NG REPLACE PARK / NEUTRAL POSITION SWITCH NS NS–214 NAVIGATION – NAVIGATION SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR NS NS–215 NAVIGATION – NAVIGATION SYSTEM Navigation Voice Circuit DESCRIPTION This circuit is used when the voice guidance in the navigation system is on. WIRING DIAGRAM Stereo Component Amplifier Radio and Navigation Assembly 22 S22 INT- 12 R10 IVO- 23 INT+ S22 11 R10 IVO+ (Shielded) (Shielded) 13 R10 SLD1 E121187E01 NS NS–216 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the radio and navigation assembly connector R10 and stereo component amplifier connector S22. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: IVO- IVO+ Tester connection Condition Specified condition IVO+ - INT+ Always Below 1 Ω IVO- - INT- Always Below 1 Ω IVO+ - Body ground Always 10 kΩ or higher IVO- - Body ground Always 10 kΩ or higher R10 NG REPAIR OR REPLACE HARNESS OR CONNECTOR Stereo Component Amplifier Wire Harness View: S22 INT+ INT- E121188E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–217 NAVIGATION – NAVIGATION SYSTEM Display Signal Circuit between Television Display Assembly and Radio and Navigation Assembly DESCRIPTION This circuit sends a DVD image signal from the television display assembly to the radio and navigation assembly. WIRING DIAGRAM Television Display Assembly NTS1 Radio and Navigation Assembly 11 R18 1 R27 VV+ 4 R27 VV- 10 SG3 R18 9 SGN1 R18 (Shielded) (Shielded) (Shielded) E121197E03 NS NS–218 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY TELEVISION DISPLAY ASSEMBLY) Radio and Navigation Assembly Wire Harness View: R27 VV+ VVTelevision Display Assembly Wire Harness View: (a) Disconnect the radio and navigation assembly connector R27 and television display assembly connector R18. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition VV+ - NTS1 Always Below 1 Ω VV- - SG3 Always Below 1 Ω VV+ - Body ground Always 10 kΩ or higher VV- - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR R18 SG3 NTS1 E121198E02 OK 2 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Reconnect the television display assembly connector R18. (b) Measure the waveform according to the table below. OK Radio and Navigation Assembly Wire Harness View: Tester connection Condition Specified condition DVD display is ON A waveform synchronized with display signals is output R27 VV+ - Body ground NS HINT: The waveform pattern may differ from that shown in the illustration below due to differences in oscilloscope setting. A normal television display assembly operating condition can be determined if any waveform is output. VV+ E113508E02 NAVIGATION – NAVIGATION SYSTEM NS–219 (c) Oscilloscope waveform (1) Terminal: VV+ - Body ground Setting: 200 mV/DIV., 10 µs/DIV. Condition: DVD display is ON. NG GND REPLACE TELEVISION DISPLAY ASSEMBLY E111833E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–220 NAVIGATION – NAVIGATION SYSTEM Microphone Circuit between Microphone and Radio and Navigation Assembly DESCRIPTION This circuit sends a microphone signal from the microphone to the radio and navigation assembly. It also supplies power from the radio and navigation assembly to the microphone. WIRING DIAGRAM Microphone Radio and Navigation Assembly 5 ACC T18 17 R26 MACC 1 MIC- T18 20 R26 MIC- 3 MIC+ T18 19 R26 MIC+ (Shielded) (Shielded) 12 R26 TSW18 R26 SGND E121194E02 NS NS–221 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: Tester connection Condition Specified condition MACC - Body ground Ignition SW ACC 4 to 6 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY R26 MACC E121195E02 OK 2 CHECK HARNESS AND CONNECTOR (a) Disconnect the radio and navigation assembly connector R26. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: Condition Specified condition SGND - TSW- Always Below 1 Ω NG R26 SGND Tester connection REPAIR OR REPLACE HARNESS OR CONNECTOR TSWE113512E02 OK NS NS–222 3 NAVIGATION – NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR (MICROPHONE - RADIO AND NAVIGATION ASSEMBLY) (a) Disconnect the microphone connector T18 and radio and navigation assembly connector R26. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Microphone Wire Harness View: Tester connection Condition Specified condition ACC - MACC Always Below 1 Ω MIC+ - MIC+ Always Below 1 Ω MIC- - MIC- Always Below 1 Ω MACC - Body ground Always 10 kΩ or higher MIC+ - Body ground Always 10 kΩ or higher MIC- - Body ground Always 10 kΩ or higher T18 ACC MIC- MIC+ Radio and Navigation Assembly Wire Harness View: NG REPAIR OR REPLACE HARNESS OR CONNECTOR R26 MACC MIC- MIC+ E121196E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–223 Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS30). Example: DTC Component shown by sub-code E121199E05 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Radio and navigation assembly (140) Radio and navigation assembly power source circuit (See page NS-229) Television display assembly (1B0) Television display assembly power source circuit (See page NS-231) NS NS–224 NAVIGATION – NAVIGATION SYSTEM NEXT 3 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 TXM+ ATX+ ATX- Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK 4 CHECK HARNESS AND CONNECTOR (STEREO COMPONENT AMPLIFIER COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. (1) Disconnect all connectors between the stereo component amplifier and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. NS NS–225 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE WOOFER BOX SPEAKER ASSEMBLY (BUILT-IN STEREO COMPONENT AMPLIFIER) OK END NS NS–226 NAVIGATION – NAVIGATION SYSTEM Radio and Navigation Assembly Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS30). Example: DTC Component shown by sub-code E121199E05 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: NS Component Proceed to Television display assembly (1B0) Television display assembly power source circuit (See page NS-231) Stereo component amplifier (440) Stereo component amplifier power source circuit (See page NS-227) NS–227 NAVIGATION – NAVIGATION SYSTEM NEXT 3 CHECK RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 Tester Connection Condition Specified Condition ATX+ (R12-5) ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) TXM- (R11-10) Always 60 to 80 Ω NG TXM+ ATX+ ATX- REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK 4 CHECK HARNESS AND CONNECTOR HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code. (1) Disconnect all connectors between the radio and navigation assembly and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code. NS NS–228 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END NS REPLACE RADIO AND NAVIGATION ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–229 Television Display Assembly Communication Error INSPECTION PROCEDURE 1 IDENTIFY THE COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (See page NS30). Example: DTC Component shown by sub-code E121199E05 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component Table: Component Proceed to Radio and navigation assembly (140) Radio and navigation assembly power source circuit (See page NS-229) Stereo component amplifier (440) Stereo component amplifier power source circuit (See page NS-227) NS NS–230 NAVIGATION – NAVIGATION SYSTEM NEXT 3 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: R12 R11 Tester connection Condition Specified condition ATX+ (R12-5) - ATX- (R12-15) Always 60 to 80 Ω TXM+ (R11-9) - TXM- (R11-10) Always 60 to 80 Ω NG TXM+ ATX+ ATX- REPLACE RADIO AND NAVIGATION ASSEMBLY TXME120086E02 OK 4 CHECK HARNESS AND CONNECTOR HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (See page NS-45). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the television display assembly and the component shown by the sub-code. (1) Disconnect all connectors between the television display assembly and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the television display assembly and the component shown by the sub-code. NS NS–231 NAVIGATION – NAVIGATION SYSTEM AVC-LAN WARNING DIAGRAM: Stereo Component Amplifier (*2) 8 TX+ S22 7 TX- S22 Radio and Navigation Assembly (*1) 5 9 R12 ATX+ TXM+ R11 14 R18 TX+ 10 R11 13 R18 TX- 15 R12 ATX- Television Display Assembly (*2) TXM- *1: Master Unit *2: Slave Unit E120087E02 OK: There is no open or short circuit. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE TELEVISION DISPLAY ASSEMBLY OK END NS NS–232 NAVIGATION – NAVIGATION SYSTEM Stereo Component Amplifier Power Source Circuit DESCRIPTION This circuit provides power to the stereo component amplifier. WIRING DIAGRAM Stereo Component Amplifier RADIO No. 2 From Battery 1 S23 +B 10 S23 +B2 ACC CUT Relay From ACC Fuse 12 S22 ACC 15 S23 GND2 16 S23 GND E120047E02 NS NS–233 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the stereo component amplifier connectors. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: S23 S22 Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω GND2 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage +B GND GND2 +B2 Tester connection Condition Specified condition +B2 - GND Always 10 to 14 V +B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V ACC E120048E05 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–54 NAVIGATION – NAVIGATION SYSTEM DTC CHECK / CLEAR HINT: • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. • If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication components and repair or replace problem parts (See page NS-201). • After the ignition switch is turned ON, check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. 1. START DIAGNOSTIC MODE (a) There are 2 methods to start diagnostic mode. Start the mode by using one of them. (b) Method 1 (1) Start the engine. (2) While pressing and holding the "INFO" switch, operate the light control switch: OFF → Turn ON → Turn OFF → Turn ON → Turn OFF → Turn ON → Turn OFF. (3) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. “INFO” Switch E120082E01 (c) 2. E109432 NS Method 2 (1) Start the engine. (2) Switch to the "Display Check" screen. (3) From the display quality adjustment screen, touch the corners of the screen in the following order: upper left → lower left → upper left → lower left → upper left → lower left. (4) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. FINISH DIAGNOSTIC MODE (a) There are 2 methods to end diagnostic mode. Use one of them. (1) Turn the ignition switch off. (2) Press and hold the "DISPLAY" switch for 3 seconds. NAVIGATION – NAVIGATION SYSTEM 3. NS–55 DIAGNOSIS MENU (a) The "Diagnosis MENU" screen will be displayed by pressing the menu switch on the "System Check Mode" screen. E120083E01 NS NS–56 NAVIGATION – NAVIGATION SYSTEM 4. Diagnostic Code Logical Address Diagnostic Code Logical Address E111721E02 NS CHECK DTC (a) Read the system check result. (1) If the check result is "EXCH", "CHEK" or "Old", touch the displayed check result to view the results on the "Unit Check Mode" screen and record them. HINT: • If all check results are "OK", go to communication DTC check. • If a device name is not known, its physical address is displayed. • When proceeding to view the results of another device, press the service switch to return to the "System Check Mode" screen. Repeat this step. NAVIGATION – NAVIGATION SYSTEM NS–57 (b) Read the communication diagnostic check result. (1) Return to the "System Check Mode" screen, and press the "LAN Mon" switch to enter the "LAN Monitor" screen. I038208E05 NS NS–58 NAVIGATION – NAVIGATION SYSTEM (2) If the check result is "CHEK" or "Old", touch the displayed check result to view the results on the individual communication diagnostic screen and record them. HINT: • If all check results are "No Err", the system judges that no DTC exists. • The sub-code (relevant device) will be indicated by its physical address. • When proceeding to view the results of another device, press the "Service" switch to return to the original "LAN Monitor" screen. Repeat this step. Sub-code Logical Address Diagnosis Code E120084E01 NS NAVIGATION – NAVIGATION SYSTEM 5. NS–59 DTC CLEAR/RECHECK (a) Clear DTC (1) Press the "Code CLR" switch for 3 seconds. (2) The check results are cleared. I038211E02 (b) Recheck (1) Press the "Recheck" switch. I038212E01 (2) Confirm that all diagnostic codes are "OK" when the check results are displayed. If a code other than "OK" is displayed, troubleshoot again. I038213E01 (3) Press the "LAN Mon" switch to change to the "LAN Monitor" screen. I038213E02 (4) Confirm that all diagnostic codes are "No Err". If a code other than "No Err" is displayed, troubleshoot again. NS I038214E01 NS–234 NAVIGATION – NAVIGATION SYSTEM Radio and Navigation Assembly Power Source Circuit DESCRIPTION This is the power source circuit to operate the radio and navigation assembly. WIRING DIAGRAM Radio and Navigation Assembly RADIO No. 1 Short Pin ACC CUT Relay From ACC Fuse 1 R12 B 11 R12 ACC 20 R12 GND E121223E05 NS NS–235 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R12. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Wire Harness View: B ACC Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage GND R12 Tester connection Condition Specified condition B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V E113513E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–236 NAVIGATION – NAVIGATION SYSTEM Television Display Power Source Circuit DESCRIPTION This is the power source circuit to operate the television display assembly. NS NS–237 NAVIGATION – NAVIGATION SYSTEM WIRING DIAGRAM Television Display Assembly Short Pin RADIO No. 1 I18 Ignition SW ACC AM1 ALT ACC CUT Relay 16 R18 +B2 15 R18 ACC4 12 R18 GND6 Battery E119746E01 NS NS–238 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT TELEVISION DISPLAY ASSEMBLY (a) Disconnect the connector from the television display assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Television Display Assembly Wire Harness View: R18 +B2 ACC4 Tester connection Condition Specified condition GND6 - Body ground Always Below 1 Ω (c) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition +B2 - GND Always 10 to 14 V ACC4 - GND Ignition SW ACC 10 to 14 V GND6 E113507E04 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–236 NAVIGATION – NAVIGATION RECEIVER INSTALLATION 1. INSTALL RADIO NO. 2 BRACKET 2. INSTALL RADIO NO. 1 BRACKET 3. INSTALL RADIO AND NAVIGATION ASSEMBLY (w/ Bracket) 4. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER 5. INSTALL AIR CONDITIONING CONTROL ASSEMBLY 6. INSTALL CONSOLE PANEL SUB-ASSEMBLY UPPER 7. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 8. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 9. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER 10. INSTALL INSTRUMENT PANEL FINISH PLATE NS NAVIGATION – NAVIGATION ANTENNA NS–239 REMOVAL 1. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assembly (See page IP-6). 2. REMOVE NAVIGATION ANTENNA (a) Remove the 3 clamps. (b) Remove the 2 screws and navigation antenna. I033320 NS NS–240 NAVIGATION – NAVIGATION ANTENNA INSTALLATION NS 1. INSTALL NAVIGATION ANTENNA 2. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY HINT: Refer to the installation procedures of the instrument panel safety pad sub-assembly (See page IP-12). NS–60 NAVIGATION – NAVIGATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART COMMUNICATION DIAGNOSIS: DTC No. 01-21 NS Detection Item ROM Error Trouble Area Radio and navigation assembly See page NS-59 01-22 RAM Error Radio and navigation assembly NS-59 01-D5 Absence of Registration Unit 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 01-D6 No Master 1. Radio and navigation assembly power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 4. Component which has stored this code 5. Radio and navigation assembly NS-62 01-D7 Connection Check Error 1. Radio and navigation assembly power source circuit 2. Power source circuit of the component which has stored this code 3. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 4. Component which has stored this code 5. Radio and navigation assembly NS-62 01-D8 No Response for Connection Check 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 01-D9 Last Mode Error 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 01-DA No Response Against ON / OFF Command 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 01-DB Mode Status Error 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 01-DC Transmission Error If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code NS-66 01-DD Master Reset 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. Radio and navigation assembly 4. Component which has stored this code NS-69 01-DE Slave Reset 1. Power source circuit of the component shown by the sub-code 2. AVC-LAN circuit between the radio and navigation assembly and the component shown by the sub-code 3. Component shown by the sub-code NS-60 NAVIGATION – NAVIGATION SYSTEM DTC No. Detection Item NS–61 Trouble Area See page 01-DF Master Error 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. Radio and navigation assembly 4. Component which has stored this code NS-73 01-E0 Registration Complete Indication Error - NS-77 01-E1 Voice Processing Device ON Error 1. Radio and navigation assembly power source circuit 2. AVC-LAN circuit between the radio and navigation assembly and the component which has stored this code 3. Radio and navigation assembly 4. Component which has stored this code NS-69 01-E2 ON / OFF Indication Parameter Error Radio and navigation assembly NS-78 01-E3 Registration Demand Transmission - NS-77 01-E4 Multiple Frame Incomplete - NS-77 SW: DTC No. Detection Item Trouble Area See page 21-10 Panel Switch Error Radio and navigation assembly NS-79 21-11 Touch Switch Error Radio and navigation assembly NS-79 SW WITH NAME: DTC No. Detection Item Trouble Area See page 23-10 Panel Switch Error Radio and navigation assembly NS-79 23-11 Touch Switch Error Radio and navigation assembly NS-79 SW CONVERTING: DTC No. Detection Item Trouble Area See page 24-10 Panel Switch Error Radio and navigation assembly NS-79 24-11 Touch Switch Error Radio and navigation assembly NS-79 COMMAND SW: DTC No. Detection Item Trouble Area See page 25-10 Panel Switch Error Radio and navigation assembly NS-79 25-11 Touch Switch Error Radio and navigation assembly NS-79 FRONT MONITOR: DTC No. 34-10 Detection Item Trouble Area See page Error in Picture Circuit Radio and navigation assembly NS-80 34-11 No Current in Back-light Error Radio and navigation assembly NS-80 34-12 Excess Current in Back-light Error Radio and navigation assembly NS-80 DVD PLAYER: DTC No. Detection Item Trouble Area See page 44-10 DVD Player Mechanical Error Television display assembly NS-81 44-11 DVD Insertion and Eject Error Television display assembly NS-81 44-12 DVD Reading Abnormal Television display assembly NS-81 44-41 Wrong Disc 1. DVD 2. Television display assembly NS-82 44-42 Disc cannot be Read 1. DVD 2. Television display assembly NS-82 44-43 DVD-ROM Abnormal 1. DVD 2. Television display assembly NS-84 44-44 DVD Error Television display assembly NS-85 44-45 Eject Error Television display assembly NS-86 NS NS–62 NAVIGATION – NAVIGATION SYSTEM DTC No. 44-46 Detection Item Scratched / Reversed Disc Trouble Area See page Television display assembly NS-87 44-47 High Temperature Television display assembly NS-89 44-48 Excess Current Television display assembly NS-85 44-50 Tray Insertion / Ejection Error Television display assembly NS-85 44-51 Elevator Error Television display assembly NS-86 44-52 Clamp Error Television display assembly NS-86 44-78 DSP Error - NS-90 44-7D Disc cannot be Played 1. DVD 2. Television display assembly NS-91 44-7E No Playable Files 1. DVD 2. Television display assembly NS-91 44-7F Copyright Protection Error 1. DVD 2. Television display assembly NS-91 TELEPHONE: DTC No. 57-47 Detection Item Bluetooth Module Initialization Failed Trouble Area Radio and navigation assembly See page NS-92 NAVI: DTC No. Detection Item Trouble Area See page 58-10 Gyro Error 1. Gyro sensor 2. Radio and navigation assembly NS-93 58-11 GPS Receiver Error Radio and navigation assembly NS-95 58-40 GPS Antenna Error 1. Wier harness 2. GPS antenna 3. Radio and navigation assembly NS-96 58-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-96 58-42 Map Disc Read Error 1. Map Disc 2. Radio and navigation assembly NS-97 58-43 SPD Signal Error 1. Speed signal circuit 2. Radio and navigation assembly NS-99 58-44 Player Error Radio and navigation assembly NS-100 58-45 High Temperature Radio and navigation assembly NS-101 IN-DASH CD CHANGER: DTC No. NS Detection Item Trouble Area See page 63-10 CD Changer Mechanical Error Radio and navigation assembly NS-106 63-11 CD Insertion and Eject Error Radio and navigation assembly NS-106 63-12 CD Reading Abnormal Radio and navigation assembly NS-106 63-41 Wrong Disc 1. CD 2. Radio and navigation assembly NS-107 63-42 Disc cannot be Read 1. CD 2. Radio and navigation assembly NS-107 63-43 CD-ROM Abnormal 1. CD 2. Radio and navigation assembly NS-109 63-44 CD Abnormal Radio and navigation assembly NS-110 63-45 Eject Error Radio and navigation assembly NS-111 63-46 Scratched / Reversed Disc 1. CD 2. Radio and navigation assembly NS-112 63-47 High Temperature Radio and navigation assembly NS-114 63-48 Excess Current Radio and navigation assembly NS-110 63-50 Tray Insertion / Ejection Error Radio and navigation assembly NS-110 63-51 Elevator Error Radio and navigation assembly NS-111 NAVIGATION – NAVIGATION SYSTEM DTC No. 63-52 Detection Item Clamp Error Trouble Area Radio and navigation assembly NS–63 See page NS-111 63-78 DSP Error - NS-115 63-7D Disc cannot be Played 1. CD 2. Radio and navigation assembly NS-116 63-7E No Playable Files 1. CD 2. Radio and navigation assembly NS-116 63-7F Copyright Protection Error 1. CD 2. Radio and navigation assembly NS-116 GPS: DTC No. Detection Item Trouble Area See page 80-10 Gyro Error 1. Gyro sensor 2. Radio and navigation assembly NS-93 80-11 GPS Receiver Error Radio and navigation assembly NS-95 80-40 GPS Antenna Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-96 80-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Radio and navigation assembly NS-96 80-42 Map Disc Read Error 1. Map disc 2. Radio and navigation assembly NS-97 80-43 SPD Signal Error 1. Speed signal circuit 2. Radio and navigation assembly NS-99 80-44 Player Error Radio and navigation assembly NS-100 80-45 High Temperature Radio and navigation assembly NS-101 CAMERA UNIT: DTC No. 5C-40 Detection Item Camera Picture Error Trouble Area 1. Wire harness 2. Television camera assembly 3. Radio and navigation assembly See page NS-102 NS NS–64 NAVIGATION – NAVIGATION SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition 01-21 A malfunction exists in ROM. 01-22 A malfunction exists in RAM. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE RADIO AND NAVIGATION ASSEMBLY Trouble Area Radio and navigation assembly NS–65 NAVIGATION – NAVIGATION SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset DESCRIPTION DTC No. DTC Detection Condition • Trouble Area A component shown by the sub-code is (was) disconnected from the system when turning the ignition switch to the ON or ACC position. The communication condition with the device that the code shows cannot be obtained when the engine starts. 01-D5 *1, *4 • 01-D8 *2, *4 A component shown by the sub-code is (was) disconnected from the system after engine start. 01-D9 *1, *4 The device that had functioned before the engine stopped is (was) disconnected from the system when the ignition switch to the ON or ACC position. • • • • 01-DA *4 No response is identified when changing mode. Detected when sound and image do not change by switch operation. 01-DB *1, *4 A dual alarm is detected. 01-DE *3, *4 A slave device has been disconnected after engine start. • Power source circuit of the component shown by the sub-code AVC-LAN circuit between the radio and navigation assembly and the component shown by the subcode Component shown by the sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or engine start voltage. • *2: If the power connector is disconnected after the engine starts, this code is stored after 180 seconds. • *3: This code may be stored if the engine is started and then the ignition switch is turned to the START position again. • *4: If it is reported that the device does not exist during verification, check the power source circuit and AVC-LAN circuit for the device. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The radio and navigation assembly is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. NS NS–66 1 NAVIGATION – NAVIGATION SYSTEM CHECK "RADIO AND NAVIGATION ASSEMBLY COMMUNICATION ERROR" IN FLOW CHART Refer to the radio and navigation assembly communication error (See page NS-221). NEXT END NS PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–3 SYSTEM DESCRIPTION 1. 2. Item GENERAL (a) To assist the driver with parking the vehicle by displaying an image of the area behind the vehicle, this system has a television camera mounted on the luggage compartment door. The system displays the image on the radio and navigation assembly. (b) This system consists of the following components: (1) Radio and navigation assembly (2) Television camera assembly (c) This system is equipped with a self-diagnosis system, which is operated on a dedicated window that appears on the display panel, just as in the navigation system. FUNCTION OF COMPONENTS (a) The radio and navigation assembly controls the system by using information from the following components: Function • Television Camera Assembly • • • Radio and Navigation Assembly • Mounted on the luggage compartment door to transmit the rear view of the vehicle to the radio and navigation assembly. A color video camera that uses a CCD (Charge Coupled Device) and a wide-angle lens. Transmits video signals, which contain an image of the area behind the vehicle taken with the television camera assembly. Radio and navigation assembly effects control of the system by receiving the shift position signal from park/neutral position switch. Displays the rear view monitor image on the display panel. Transmits a reverse shift position signal to the radio and navigation assembly. Park/Neutral Position Switch 3. 4. OPERATION EXPLANATION (a) The radio and navigation assembly receives the R position signal from the park / neutral position switch when the shift lever is moved to the R position. After receiving the R position signal, the radio and navigation assembly switches from the navigation system to the rear view monitor system. NOTES FOR REAR VIEW MONITOR (a) Notes for the rear view monitor. (1) The rear view monitor may not function properly if subjected to a severe blow by any hard object. (2) Do not "scrub" the cover part of the camera (resin made). Scrubbing it may scratch the cover and affect the image. Prevent organic solvents, waxes, bond removing solvents, or glass coating from adhering to the cover. Clean it off immediately, and wash with water. (3) Exposing the camera to a sudden temperature change may affect proper functioning of the camera. (4) A clear image may not appear if the camera is dirty with snow, mud, etc. In that case, wash it with water and wipe off the lens. Use a detergent to remove dirt if necessary. PM PM–4 PM PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM (b) Images are difficult to discern even in normal conditions if: (1) Camera screen is frosted over (the image immediately after turning the ignition switch to the on position may be blurred or darker than normal). (2) A strong beam of light, such as a sunbeam or headlight, hits the camera. (3) It is too dark around the camera (at night, etc.). (4) The ambient temperature around the camera is either too high or too low. HINT: When a strong light, such as a sunbeam reflected off the vehicle's body, hits the camera, the image may be blurred. This is called the "SMEAR" phenomenon, peculiar to the CCD camera. PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–5 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP PM NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CHECK AND CLEAR DTCs (a) Refer to the diagnostic check/clear (See page NS-49). NEXT 4 PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR (Go to step 5) SYMPTOM OCCURS (Go to step 6) 5 SYMPTOM SIMULATION NEXT 6 CHECK DTC DTC IS OUTPUT (Go to step 10) DTC IS NOT OUTPUT (Go to step 7) 7 CHECK IF THE SAME SYMPTOM APPEARS IN THE NAVIGATION SYSTEM (a) Refer to the navigation system (See page NS-41). THE SYMPTOM APPEARS (FOLLOW THE NAVIGATION SYMPTOM CHART TO PERFORM TROUBLESHOOTING) THE SYMPTOM DOES NOT APPEAR (Go to step 8) PM–6 8 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table (See page PM-5). THE CORRESPONDING SYMPTOM EXISTS (Go to step 10) PM THE CORRESPONDING SYMPTOM DOES NOT EXIST (Go to step 9) 9 BASED ON THE MALFUNCTION SYMPTOM, PERFORM TROUBLESHOOTING BELOW (a) Terminals of ECU (See page PM-6). NEXT 10 ADJUST, REPAIR OR REPLACE NEXT 11 NEXT END CONFIRMATION TEST PM–7 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PROBLEM SYMPTOMS TABLE • Before inspecting the suspected areas listed in the table below, check the fuse and relay. • Before inspecting the suspected areas listed in the table below, check the DTCs. • Methods used to verify the cause of the problem are listed in order of probability in the suspected area column. REAR VIEW MONITOR SYSTEM Symptom When shift lever is in R position, rear view monitor image is not displayed (Screen is not black). When shift lever is in R position, rear view monitor image is not displayed (Screen is black). When shift lever is not in R position, rear view monitor image is displayed. Problem with the rear view monitor image (color, disorder of picture). Suspected area See page 1. Reverse signal circuit PM-7 2. Proceed to "Display Signal Circuit between Radio and Navigation Assembly and Television Camera Assembly" PM-10 3. Radio and navigation assembly NS-235 1. Radio and navigation assembly power source circuit NS-229 2. Proceed to "Display Signal Circuit between Radio and Navigation Assembly and Television Camera Assembly" PM-10 3. Radio and navigation assembly NS-235 1. Reverse signal circuit PM-7 2. Radio and navigation assembly NS-235 1. Proceed to "Display Signal Circuit between Radio and Navigation Assembly and Television Camera Assembly" PM-10 2. Radio and navigation assembly NS-235 PM PM–8 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM TERMINALS OF ECU 1. TELEVISION CAMERA ASSEMBLY (a) Disconnect the T11 camera connector. T11 PM E130378E01 (b) Measure the voltage and resistance of each terminal of the wire harness side connector. Wiring Color Terminal Description CGND (T11-2) - Body ground W - Body ground Ground CB+ (T11-1) - CGND (T11-2) R-W Power source Symbols (Terminal No.) Condition Specified value Below 1 Ω Always Ignition switch ON, shift lever R position Approx. 6 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T11 camera connector. (d) Measure the voltage and frequency of each terminal of the connector. Symbols (Terminal No.) CV+ (T11-4) - CV- (T11-3) Wiring Color Terminal Description B - Shielded Display signal Condition Specified value Ignition switch ON, shift lever R position See waveform 1 If the result is not as specified, the camera may have a malfunction. (e) Reference: Oscilloscope waveform (1) Waveform 1 Item GND 2. E119731E01 Content Measure terminal CV+ - CV- Measure set 0.2 V/DIV., 0.2 µS/DIV. Condition Ignition switch: ON, Shift lever: R position RADIO AND NAVIGATION ASSEMBLY (See page NS45) PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–1 REAR VIEW MONITOR SYSTEM BODY ASSIST PARK ELECTRICAL / MONITORING PARTS LOCATION PM ENGINE ROOM R/B: DRIVER SIDE J/B: ACC FUSE RADIO NO. 1 FUSE RADIO AND NAVIGATION ASSEMBLY BACK MONITOR CAMERA WIRE PARK/NEUTRAL POSITION SWITCH TELEVISION CAMERA ASSEMBLY E116255E01 PM–2 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM SYSTEM DIAGRAM From Battery PM Reverse Signal Radio and Navigation Assembly Park/Neutral Position Switch Television Camera Assembly Visual Signal E121276E01 PM–9 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Reverse Signal Circuit DESCRIPTION The radio and navigation assembly receives a reverse signal from the park/neutral position switch. PM WIRING DIAGRAM Radio and Navigation Assembly P1 Park/Neutral Position Switch 5 From GAUGE1 Fuse 2 R9 1 REV E120120E04 INSPECTION PROCEDURE 1 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Disconnect the radio and navigation assembly connector R9. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Wire Harness View: REV Tester connection Condition Specified condition REV - Body ground Ignition switch is ON. Shift lever is moved to R position. 10 to 14 V REV - Body ground Ignition switch is ON. Shift lever is moved to any position except R. Below 1 V R9 OK E113510E10 NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PM–10 2 PM PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY - PARK/ NEUTRAL POSITION SWITCH) (a) Disconnect the radio and navigation assembly connector R9 and park/neutral position switch connector P1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Radio and Navigation Assembly Wire Harness View: REV Tester connection Condition Specified condition REV - P1-1 Always Below 1 Ω REV - Body ground Always 10 kΩ or higher OK R9 REPAIR OR REPLACE HARNESS OR CONNECTOR Park/Neutral Position Switch Connector Front View: P1 E132185E01 OK 3 INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Park/Neutral Position Switch: P1 (a) Disconnect the park/neutral position switch connector P1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition P1-1 - P1-2 Shift lever is moved to R position. Below 1 Ω P1-1 - P1-2 Shift lever is moved to any position except R. 10 kΩ or higher E120122E01 NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–11 OK REPAIR OR REPLACE HARNESS OR CONNECTOR PM PM–14 PARK ASSIST / MONITORING – TELEVISION CAMERA TELEVISION CAMERA BODY ASSIST PARK ELECTRICAL / MONITORING COMPONENTS BACK DOOR SERVICE HOLE COVER LH PM BACK DOOR TRIM BOARD Non-reusable part B134215E02 PARK ASSIST / MONITORING – TELEVISION CAMERA PM–15 PM TELEVISION CAMERA ASSEMBLY E115641E01 PM–12 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Display Signal Circuit between Radio and Navigation Assembly and Television Camera Assembly DESCRIPTION PM This is the display signal circuit of the television camera assembly. WIRING DIAGRAM T11 Television Camera Assembly Radio and Navigation Assembly 22 R26 V+ CV+ 4 CGND 21 R26 CGND 2 24 R26 CA+ CB+ 1 CV- 3 (*1) (*1) (*1) (*1) 23 R26 V- *1: Shielded E120090E01 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (RADIO AND NAVIGATION ASSEMBLY TELEVISION CAMERA ASSEMBLY) (a) Disconnect the R26 connector from the radio and navigation assembly. (b) Disconnect the T11 connector from the television camera assembly. PM–13 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Radio and Navigation Assembly: Television Camera Assembly: T11 CGND R26 CV+ PM CB+ CV- CGND CA+ V- V+ E130380E01 (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection (Terminal No.) Condition Specified condition CB+ (T11-1) - CA+ (R26-24) Always Below 1 Ω CGND (T11-2) - CGND (R26-21) Always Below 1 Ω CV+ (T11-4) - V+ (R26-22) Always Below 1 Ω CV- (T11-3) - V- (R26-23) Always Below 1 Ω CB+ (T11-1) - Body ground Always 10 kΩ or higher CGND (T11-2) - Body ground Always 10 kΩ or higher CV+ (T11-4) - Body ground Always 10 kΩ or higher CV- (T11-3) - Body ground Always 10 kΩ or higher NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT RADIO AND NAVIGATION ASSEMBLY (a) Reconnect the radio and navigation assembly R26 connector. PM–14 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Television Camera Assembly Connector Front View: Radio and Navigation Assembly: PM T11 CB+ CGND R26 E130381E01 (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified condition CB+ (T11-1) - CGND (T11-2) Ignition switch ON Shift lever R position Approx. 6 V NG REPLACE RADIO AND NAVIGATION ASSEMBLY OK 3 INSPECT TELEVISION CAMERA ASSEMBLY (a) Reconnect the radio and navigation assembly R26 connector and the television camera assembly T11 connector. PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Radio and Navigation Assembly: PM–15 Television Camera Assembly: PM T11 CV+ CV- R26 E130382E02 (b) Check the waveform of the television camera assembly using an oscilloscope. (1) Measurement terminal: CV+ - CVMeasurement setting: 0.2 V/DIV, 0.2 µs/DIV Condition: Ignition switch ON, Shift lever in R range OK: Pulses as shown in the illustration. GND NG E119731E02 REPLACE TELEVISION CAMERA ASSEMBLY OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PM–16 PARK ASSIST / MONITORING – TELEVISION CAMERA REMOVAL 1. REMOVE BACK DOOR TRIM BOARD 2. REMOVE BACK DOOR SERVICE HOLE COVER LH 3. REMOVE TELEVISION CAMERA ASSEMBLY (a) Disconnect the connector and remove the connector clamp. (b) Remove the 2 screws and the television camera assembly. PM I033315 INSTALLATION I033315 1. INSTALL TELEVISION CAMERA ASSEMBLY (a) Install the television camera assembly and the 2 screws. (b) Install the connector clamp and reconnect the connector. 2. INSTALL BACK DOOR SERVICE HOLE COVER LH 3. INSTALL BACK DOOR TRIM BOARD HORN – HORN SYSTEM HO–1 HORN SYSTEM BODY ELECTRICAL HORN PARTS LOCATION STEERING WHEEL PAD (HORN BUTTON SWITCH) HO HIGH PITCHED HORN LOW PITCHED HORN HORN RELAY INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY C131376E01 HO–2 HORN – HORN SYSTEM PROBLEM SYMPTOMS TABLE HORN SYSTEM Symptom horn does not sound. HO Suspected area See page 1. Horn button switch - 2. High pitched horn HO-7 3. Low pitched horn HO-5 4. HORN relay HO-3 5. Wire harness - HO–3 HORN – HORN RELAY HORN RELAY INSPECTION 1. B016200E24 INSPECT HORN RELAY ASSEMBLY (a) Remove the horn relay from the instrument panel junction block assembly. (b) Inspect the horn relay continuity. Standard resistance Tester Connection Condition 1-2 Always 3-5 Apply B+ between terminals 1 and 2 Specified Condition Below 1 Ω If the result is not as specified, replace the relay assembly. HO HO–4 HORN – LOW PITCHED HORN LOW PITCHED HORN BODY ELECTRICAL HORN COMPONENTS HO 20 (199, 15) LOW PITCHED HORN ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120216E02 HORN – LOW PITCHED HORN HO–5 REMOVAL 1. REMOVE LOW PITCHED HORN ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and horn assembly. INSPECTION 1. INSPECT LOW PITCHED HORN ASSEMBLY (a) Connect the positive (+) lead from the battery to the terminal and the negative (-) lead to the horn body, and check that the horn blows. If the result is not as specified, replace the horn assembly. B064930 INSTALLATION 1. B062198 INSTALL LOW PITCHED HORN ASSEMBLY (a) Place the stay onto the baffle part in the radiator support upper, and then install the horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 15 ft.*lbf) (b) Connect the connector. HO HO–6 HORN – HIGH PITCHED HORN HIGH PITCHED HORN BODY ELECTRICAL HORN COMPONENTS HO 20 (199, 15) HIGH PITCHED HORN ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120216E03 HORN – HIGH PITCHED HORN HO–7 REMOVAL 1. REMOVE HIGH PITCHED HORN ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and horn assembly. INSPECTION 1. INSPECT HIGH PITCHED HORN ASSEMBLY (a) Connect the positive (+) lead from the battery to the terminal and the negative (-) lead to the horn body, and check that the horn blows. If the result is not as specified, replace the horn assembly. B064929 INSTALLATION 1. B065154 INSTALL HIGH PITCHED HORN ASSEMBLY (a) Place the stay onto the baffle part in the radiator support upper, and then install the horn assembly with the bolt. Torque: 20 N*m (199 kgf*cm, 15 ft.*lbf) (b) Connect the connector. HO GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–1 GARAGE DOOR OPENER SYSTEM REGISTRATION 1. These Switches LED B056159E01 REGISTRATION TRANSMITTER CODE HINT: The garage door opener is built into the dome light assembly No. 1. If replacing the dome light assembly No. 1, codes for any systems previously registered in the garage door opener must be re-registered. (a) Re-register systems in the garage door opener registration mode. NOTICE: • When registering a code in a garage door opener system, a garage door or other device may operate. In order to prevent injury or damage, make sure that people and objects are out of the way of the garage door or other device. • Before transmitter code registration, confirm that all the electrical systems (headlight, blower motor, rear defogger, etc.) are turned off and no key is in the vehicle. • The garage door opener cannot be used with systems that: 1) were manufactured before April 1, 1982; or 2) do not meet Federal Standards (for example, garage doors without a jam protection function). HINT: • 3 transmitter codes can be registered with the garage door opener, one transmitter code for each of the 3 garage door opener switches. • Disconnecting the battery will not erase the transmitter codes registered with the garage door opener. • An attempt to overwrite a previously registered transmitter code with a new system's transmitter code may fail. In these situations, the previously registered transmitter code will not be erased. (1) Select a garage door opener switch for transmitter code registration. (2) Press and hold the selected switch for 20 seconds. The garage door opener will enter registration mode. HINT: Before entering registration mode, the LED is ON. After entering registration mode, the LED flashes at a cycle of 1 Hz. For a" rolling code" type system, after entering registration mode, the LED flashes at a cycle of 8.8 Hz for 1.6 seconds, and then the LED flashes at a cycle of 1 Hz. GD GD–2 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM Press Original Transmitter GD B056160E01 (3) After the garage door opener has entered registration mode, bring the original transmitter of the system to be registered within 1 inch of the garage door opener switches. Then press the original transmitter switch. (4) If the transmitter code registration was successful, the LED of the garage door opener flashes at a cycle of 5.6 Hz. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch. HINT: • If the code registration has failed, the battery of the original transmitter may be weak or the system may not meet the garage door opener. In this case, press the original transmitter repeatedly. Some transmitters may need 1 to 2 seconds to stop transmitting signals. • If the transmitter code registration has not been completed in 90 seconds after the garage door opener has entered registration mode, the garage door opener will enter low power mode (See procedure "A"). (5) Timing chart of registration mode: Timing chart of registration mode : Garage Door Opener Switch PRESSED RELEASED ENTER Registration Mode LED Operation 20 sec. EXIT ON OFF LED flashes at a cycle of 1 Hz ON Original Transmitter LED flashes at a cycle of 5.6 Hz OFF I003487E11 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–3 (b) Erase transmitter codes in the garage door opener clear mode. HINT: • All 3 registered transmitter codes will be erased at the same time (maximum 3 codes). • If the switches are released within 10 seconds after the transmitter codes have been erased, the garage door opener will enter registration mode. • If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to the switches of the garage door opener. Using these default codes, operation of the garage door opener can be checked using a Home Link tester. (1) Press and hold the 2 switches of the garage door opener for 20 seconds. The LED will begin to flash at a cycle of 5.6 Hz. Releasing the switches will end clear mode. (2) Timing chart of clear mode: These Switches LED B056159E01 Timing chart of clear mode : Garage Door Opener Switches (at both ends) PRESSED Enter clear mode to erase all 3 codes RELEASED Load Default Code ON 20 sec. Clear Mode / Default Mode 10 sec. OFF LED Operation ON OFF LED flashes at a cycle of 5.6 Hz A053171E09 (c) Low power mode (Procedure "A"): (1) If the garage door opener switch is held for 100 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off. GD GD–4 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM These Switches INSPECTION 1. INSPECT GARAGE DOOR OPENER (a) Press the switch and check that each red LED turns on. If one or more of the switches does not turn on the LED, confirm normal operation of the fuse and wire harness, then replace the garage door opener system unit. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING HINT: Use the home link tester made by KENT MORE for this test. Because it is necessary to register the code of the hand-held transmitter, the customer's code should be erased. When the inspection is complete, register the customer's again. LED GD B056159E01 (a) Check if the tester transmitter code was successfully registered. HINT: If the code cannot be registered, replace the garage door opener system unit. Press Original Transmitter B056160E01 (b) Press the garage door opener switch that was registered to the tester transmitter. Check if the "Home Link" tester's green LED illuminates. HINT: If the green LED does not illuminate, replace the garage door opener. Garage Door Opener Press Home Link Tester B062199E02 WS–4 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedures on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP NEXT WS 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 DTC CHECK (a) Check for DTCs and make a note of the code that is output. (b) Delete the DTC. HINT: See page WS-12 (c) Check if the DTC will be output once again when the problem symptom is simulated based on the noted code. (1) With an output of the code, proceed to A. (2) Without an output of the code, proceed to B. A GO TO STEP 5 B 4 PROBLEM SYMPTOMS TABLE HINT: See page WS-7 NEXT 5 PERFORM TROUBLESHOOTING (a) Operation check. HINT: See page WS-5 (b) Circuit inspection. NEXT WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 6 WS–5 ADJUST, REPAIR OR REPLACE NEXT 7 RESET POWER WINDOW REGULATOR MOTOR (a) If any of the power window switch illuminations is blinking after repair, reset the power window. (1) Turn the ignition switch ON. (2) Open the driver side door glass. (3) Fully pull up the AUTO switch of the power window master switch until the door glass is fully closed. (4) Check that the AUTO UP/DOWN function operates normally. NEXT END OPERATION CHECK 1. B066761 2. CHECK WINDOW LOCK SWITCH (a) Check that the operation of the door glasses except the driver side door glass and the back door glass and the roof glass is disabled when the window lock switch of the power window master switch is pressed. (b) Check that the door glasses, the back door glass and the roof glass can be operated when the window lock switch is pressed again. CHECK MANUAL UP/DOWN FUNCTION (FOR EXCEPT BACK DOOR) (a) Check that the door glass can be operated using the master switch as follows. Standard Condition Master Switch Ignition switch ON AUTO Switch Operation Power Window Pull halfway up UP (Closed) Push halfway down DOWN (Open) (b) Check that each door glass can be operated using each power window switch as follows. Standard Condition Master Switch Passenger side • • Ignition switch ON Window lock switch OFF Rear LH Rear RH Switch Operation Power Window Pull up UP (Closed) Push down DOWN (Open) Pull up UP (Closed) Push down DOWN (Open) Pull up UP (Closed) Push down DOWN (Open) WS WS–6 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 3. CHECK MANUAL UP/DOWN FUNCTION (FOR BACK DOOR) (a) Check that the back door glass can be operated using the back power window switch as follows. Standard Condition •Ignition switch ON •Window lock switch OFF •Rear wiper is retracted Master Switch Manual 4. WS Switch Operation Power Window Press on up side within 0.3 sec. UP (Closed) Press on down side within 0.3 sec. DOWN (Open) CHECK AUTO UP/DOWN FUNCTION (FOR EXCEPT BACK DOOR) (a) Check that the driver side power window can be operated using the AUTO (driver side) switch of the power window master switch as follows: Standard Condition Master Switch Ignition switch ON AUTO 5. Switch Operation Power Window Pull halfway up AUTO UP (Fully closed) Push halfway down AUTO DOWN (Fully open) CHECK MANUAL UP/DOWN FUNCTION (FOR BACK DOOR) (a) Check that the back door glass can be operated using the back power window switch as follows. Standard Condition •Ignition switch ON •Window lock switch OFF •Rear wiper is retracted Master Switch Manual 6. Switch Operation Power Window Press on up side within 0.3 sec. UP (fully closed) Press on down side within 0.3 sec. DOWN (Fully open) CHECK REMOTE MANUAL UP/DOWN FUNCTION (a) Check that the door glasses other than the driver side door glass can be operated using the master switch as follows. Standard Condition Master Switch Passenger side • • Ignition switch ON Window lock switch OFF Rear LH Rear RH 7. Switch Operation Power Window Pull up UP (Closed) Push down DOWN (Open) Pull up UP (Closed) Push down DOWN (Open) Pull up UP (Closed) Push down DOWN (Open) CHECK MANUAL UP/DOWN FUNCTION VIA BACK DOOR LOCK KEY CYLINDER (FOR BACK DOOR) (a) Check that the back door glass can be operated using the back power window switch as follows. Standard Condition Rear wiper is retracted Master Switch Manual Switch Operation Power Window Turn right (LOCK) for more than 0.75 sec. UP (Closed) Turn left (UNLOCK) for more than 0.75 sec. DOWN (Open) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 8. WS–7 CHECK POWER WINDOW OPERATION FUNCTION AFTER IGNITION SWITCH IS TURNED OFF (a) When both of the following conditions are fulfilled, check that the door glasses, the back door glass and the roof glass can be operated even after the ignition switch is turned OFF: • Within 45 seconds after the ignition switch is turned OFF. • The driver side door is closed. 9. Hammer B051853E01 CHECK JAM PROTECTION FUNCTION (DRIVER SIDE) HINT: The jam protection function prevents any part of your body from getting caught by accident between the door frame and the door glass during power window operation. (a) Check that the door glass goes down by approximately 50 mm (2.0 in.) right when something gets caught between the door frame and door glass during power window operation. However, when the opening amount between the vehicle body and the door glass is less than 200 mm (7.9 in.), the door glass keeps going down until the opening amount reaches 200 mm (7.9 in.) and stops there. • AUTO UP • AUTO UP operation after the ignition switch OFF • MANUAL UP operation after the ignition switch OFF 10. CHECK POWER WINDOW FAIL-SAFE FUNCTION (a) If the pulse sensor of the power window motor malfunctions, the power window functions will be restricted: • The AUTO UP/DOWN and the remote UP/ DOWN functions are disabled. • The manual UP/DOWN function can be performed via each power window switch. WS WS–8 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM PROBLEM SYMPTOMS TABLE POWER WINDOW CONTROL SYSTEM (FOR EXCEPT BACK DOOR) Symptom AUTO UP/DOWN function does not operate Remote UP/DOWN function does not operate Manual UP/DOWN function does not operate on driver side WS Manual UP/DOWN function does not operate on passenger side Manual UP/DOWN function does not operate on rear LH Manual UP/DOWN function does not operate on rear RH Power window do not operate at all Door glass does down during AUTO UP operation Suspected area See page 1. Power window regulator motor assembly LH (Driver side) WS-17 2. Wire harness WS-17 3. Power window regulator master switch assembly WS-17 1. Power window regulator motor assembly LH (Driver side) WS-20 2. Wire harness WS-20 3. Power window regulator master switch assembly WS-20 1. Power window regulator master switch assembly - 2. Power window regulator motor assembly LH (Driver side) - 3. Wire harness - 1. Power window regulator switch assembly (Passenger side) WS-26 2. Power window regulator motor assembly RH (Passenger side) WS-26 3. Wire harness WS-26 1. Power window regulator switch assembly rear (Rear LH) WS-29 2. Power window regulator motor assembly RH (Rear LH) WS-29 3. Wire harness WS-29 1. Power window regulator switch assembly rear (Rear RH) WS-32 2. Power window regulator motor assembly RH (Rear RH) WS-32 3. Wire harness WS-32 1. POWER fuse WS-35 2. Power window relay WS-35 3. Power window regulator master switch assembly WS-35 4. Wire harness WS-35 5. Instrument panel J/B assembly WS-35 1. Front door glass run LH - 2. Front door window glass LH - 3. Front door window regulator sub-assembly LH - POWER WINDOW CONTROL SYSTEM (FOR BACK DOOR) Symptom AUTO UP/DOWN function does not operate Door glass down during AUTO/UP operation Manual UP/DOWN function does not operate Manual UP/DOWN function via back door lock key cylinder does not operate Suspected area See page 1. Power window regulator motor assembly LH (Back door) WS-15 2. Wire harness WS-15 1. Back door glass run WS-38 2. Back door power window regulator motor assembly LH (Back door) WS-38 3. Back door glass WS-38 1. Rear wiper motor assembly WS-23 2. Power window regulator motor assembly LH (Back door) WS-23 3. Wire harness WS-23 4. Multiplex network door ECU (Back door ECU) WS-23 1. Back door lock key cylinder assembly WS-39 2. Wire harness WS-39 3. Multiplex network door ECU (Back door ECU) WS-39 WS–9 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM TERMINALS OF ECU 1. CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (BODY ECU) B4 B5 B6 B6 B5 WS B4 B062914E02 (a) Check the voltage or resistance between the terminals of the connectors. Standard Symbols (Terminal No.) Wiring Color Condition • • BUP (B5-10) ←→ COM (B5-19) Y-R ←→ B-Y Ignition switch ON Back door power window switch UP Back door power window switch OFF • • BDN (B5-8) ←→ COM (B5-19) W/L1 (B6-24) ←→ W/L2 (B6-22) B-L ←→ B-Y L-Y ←→ L-R Ignition switch ON Back door power window switch DOWN Specified Condition Less than 1.5 V More than 5 kΩ Less than 1.5 V Back door power window switch OFF More than 5 kΩ Window lock switch ON Less than 1.0 V Window lock switch OFF More than 1 kΩ If the result is not as specified, the instrument panel J/B assembly (body ECU) malfunctions. WS–10 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2. B9 CHECK MULTIPLEX NETWORK DOOR ECU (BACK DOOR ECU) B8 WS B134204E02 (a) Check the voltage or continuity between the terminals of the connectors. Standard Symbols (Terminal No.) Wiring Color Condition Specified Condition BDR (B8-4) ←→ Body ground L ←→ - Constant 10 to 14 V BECU (B8-5) ←→ Body ground L-R ←→ - SIG (B8-6) ←→ Body ground B ←→ - SGND (B9-18) ←→ GND (B8-3) G-R ←→ W-B GND (B8-3) ←→ Body ground Constant 10 to 14 V Ignition switch OFF Less than 1 V Ignition switch ON 10 to 14 V Constant Continuity W-B ←→ - Constant Continuity BDUP (B9-13) ←→ BDDN (B925) Y-B ←→ R-B Back door power window in close operation 10 to 14 V BDDN (B9-25) ←→ BDUP (B913) R-B ←→ Y-B Back door power window in open operation 10 to 14 V IC+ (B9-11) ←→ IC- (B9-23) Y-G ←→ L-W Constant 6 to 14 V IC1 (B9-16) ←→ IC- (B9-23) B-O ←→ L-W Back door power window in operation Pulse generates IC2 (B9-17) ←→ IC- (B9-23) W-R ←→ L-W Back door power window in operation Pulse generates UP (B9-5) ←→ E (B9-19) V-Y ←→ LG-B Back door lock key cylinder turned right using key Continuity DOWN (B9-4) ←→ E (B9-19) GR-R ←→ LG-B Back door lock key cylinder turned left using key Continuity E (B9-19) ←→ SGND (B9-18) LG-B ←→ G-R Constant Continuity P (B9-12) ←→ SGND (B9-18) P-B ←→ G-R Rear wiper in retract position Less than 1 V If the result is not as specified, the multiplex network door ECU back (back door ECU) malfunctions. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–11 DATA LIST / ACTIVE TEST 1. 2. USING INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Monitor the ECU data by following the prompts on the tester screen. HINT: The intelligent tester has a "Snapshot" function which records the monitored data. Refer to the intelligent tester operator's manual for further details. DATA LIST HINT: Using the DATA LIST displayed on the intelligent tester, the value of the switch, sensor, actuator, etc. can be read without part removal. Reading the DATA LIST as the first step of troubleshooting is one way to shorten the labor time. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Read the DATA LIST according to the display on the tester. BACK DOOR ECU: Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note WIPER RTRCT SW Rear wiper retract switch/ON or OFF ON: Rear wiper retract switch is in ON position OFF: Rear wiper retract switch is in OFF position - KEY SW (UNLK) Rear door lock key switch at UNLOCK position/ON or OFF ON: Rear door lock key switch at UNLOCK is in ON position OFF: Rear door lock key switch at UNLOCK is in OFF position - KEY SW (LOCK) Rear door lock key switch at LOCK position/ON or OFF ON: Rear door lock key switch at LOCK is in ON position OFF: Rear door lock key switch at LOCK is in OFF position - P/W POSITION Back door glass position/CLOSE or OPEN CLOSE: Back door glass is in CLOSE position OPEN: Back door glass is in OPEN position - Door glass position (Fully closed 1/4 open) signal/OK or CAUTION OK: Power window is going UP by manual operation CAUTION: CAUTION may be displayed when resistance is applied in each position. In this case, there must be a foreign object stuck in that position - Door glass position (1/4 open - 2/ 4 open) signal/OK or CAUTION OK: Power window is going UP by manual operation CAUTION: CAUTION may be displayed when resistance is applied in each position. In this case, there must be a foreign object stuck in that position - GLASS POS-1/4 GLASS POS-2/4 WS WS–12 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Measurement Item/ Display (Range) Item Door glass position (2/4 open - 3/ 4 open) signal/OK or CAUTION GLASS POS-3/4 Normal Condition OK: Power window is going UP by manual operation CAUTION: CAUTION may be displayed when resistance is applied in each position. In this case, there must be a foreign object stuck in that position Diagnostic Note - BODY: Measurement Item/ Display (Range) Item WS Normal Condition Diagnostic Note IG SW Engine switch signal/ ON or OFF ON: Power source mode is on (IG) OFF: Power source mode is off or on (ACC) D DOR CTY SW Driver side door courtesy switch signal/ or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CYT SW Front passenger side door courtesy switch signal/ ON or OFF ON: Front passenger side door is open OFF: Front passenger side door is closed - 3. - ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows you to operate the relay, VSV, actuator, etc. without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one way to shorten the labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the engine switch on (IG). (c) Perform the ACTIVE TEST according to the display on the tester. BACK DOOR ECU Item Test Detail Diagnostic Note P/W UP/DOWN Operates back door power window UP/ DOWN - WS–36 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Power Windows do not Operate at All DESCRIPTION If all the door glasses do not operate or if the operation function after the ignition switch is turned OFF does not operate, no power may be supplied to the power window master switch or the power window master switch itself may malfunction. WIRING DIAGRAM D17 Power Window Regulator Master Switch Assembly WS Instrument Panel J/B Assembly 11 From Ignition Switch B 7 Power Window Relay POWER From Battery 1 2 5 3 6 B 1 From Courtesy Switch R B2 BW B 2 Body ECU From Ignition Switch To Power Window Motor *1 To Power Window Motor *2 1 E *1: Driver Side Power Window *2: Power Window Ezcept Driver Side B140740E02 WS–37 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (POWER) (a) Remove the fuse from the instrument panel J/B assembly. (b) Check the continuity. Standard: Continuity NG REPLACE FUSE OK 2 WS INSPECT INSTRUMENT PANEL J/B ASSEMBLY (a) Remove the power window relay. (b) Turn the ignition switch ON. (c) Check the voltage between the J/B terminals 1 and 2. Standard: 10 to 14 V Power Window Relay NG REPLACE INSTRUMENT PANEL J/B ASSEMBLY B063172E01 OK 3 INSPECT POWER WINDOW RELAY (POWER) 1 5 3 1 2 2 5 (a) Remove the relay from the backside of the instrument panel J/B assembly. (b) Check the continuity. (c) Check the voltage between the J/B terminals 1 and 2. Standard Terminal No. Condition Specified Condition 1-2 Constant Continuity 3-5 Apply battery voltage to terminal 1 and 2 Continuity 3 B060778E82 WS–38 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM NG REPLACE POWER WINDOW RELAY OK 4 CHECK WIRE HARNESS (TERMINAL B2, BW OR E) (a) Disconnect the D17 switch connector. (b) Check the voltage or continuity between each terminal of the wire harness side connector and the body ground. Standard Wire Harness Side D17 Power Window Regulator Master Switch Assembly WS B062895E13 Symbols (Terminal No.) Condition Specified Condition B2 (D17-11) - Body ground Ignition ON 10 to 14 V BW (D17-7) - Body ground Constant 10 to 14 V E (D17-1) - Body ground Constant Continuity NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 CHECK WIRE HARNESS (TERMINAL B) (a) Turn the ignition switch ON. (b) Check the voltage between terminal 6 of the wire harness side connector and the body ground. Standard Wire Harness Side D17 Power Window Regulator Master Switch Assembly Terminal No. Condition Specified Condition B (D17-6) - Body ground Ignition switch ON 10 to 14 V OK B062895E13 REPLACE POWER WINDOW MASTER SWITCH ASSEMBLY NG REPAIR OR REPLACE HARNESS AND CONNECTOR (POWER WINDOW RELAY - MASTER SWITCH) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–39 Back Door Glass goes Down During Auto Up Operation DESCRIPTION If the door glass or the power window regulator does not smoothly operate, the jam protection function may operate abnormally, resulting in this symptom. INSPECTION PROCEDURE 1 RESET POWER WINDOW REGULATOR MOTOR (a) Turn the ignition switch ON. (b) Open the back door glass. (c) Press the back door power window switch until the door glass is fully closed, and continue to hold the switch 1 second more even after the door glass is fully closed. (d) Check that the AUTO UP/DOWN function operates normally. OK END NG 2 CHECK POWER WINDOW REGULATOR W/MOTOR (a) Remove the back door glass. (b) Operate the power window regulator via the back door power window switch while the back door glass is not installed. (c) Check that the power window regulator operates smoothly. OK REPLACE BACK DOOR GLASS RUN NG REPLACE BACK DOOR POWER WINDOW REGULATOR MOTOR WS WS–40 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function Via Back Door Lock Key Cylinder does not Operate DESCRIPTION If the manual UP/DOWN function via the back door lock key cylinder does not operate, the back door lock key cylinder or the wire harness may be abnormal. WIRING DIAGRAM T10 Tail Gate Control Switch Assembly (Back Door Lock Key Cylinder) B9 Multiplex Network Door ECU Back (Back Door ECU) WS UP 1 5 V-Y 2 4 DOWN GR-R 3 19 LG-B E UP DOWN E To Back Door Power Window Motor B062910E01 INSPECTION PROCEDURE 1 CHECK BACK DOOR WINDOW OPERATION (a) Check that the back door power window operates via the back door power window switch. NG OTHER PROBLEM OK 2 INSPECT TAIL GATE CONTROL SWITCH ASSEMBLY (BACK DOOR LOCK KEY CYLINDER) (a) Disconnect the switch connector. (b) Insert the key into the key cylinder. (c) Check the continuity between the terminals of the switch connector when turning the key. Standard Terminal No. Operation Specified Condition 1-3 Turn key to right Continuity 1-2 No operation No continuity 2-3 Turn key to left Continuity B062911E01 NG REPLACE TAIL GATE CONTROL SWITCH ASSEMBLY WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–41 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (BACK DOOR ECU - SWITCH) WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–1 POWER WINDOW CONTROL SYSTEM WINDSHIELD / WINDOWGLASS BODY PARTS LOCATION FOR EXCEPT BACK POWER WINDOW: POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (PASSENGER SIDE) POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS POWER WINDOW REGULATOR SWITCH ASSEMBLY (PASSENGER SIDE) INSTRUMENT PANEL J/B ASSEMBLY (BODY ECU) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (DRIVER SIDE) POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR (REAR LH) POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (REAR RH) POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR (REAR RH) POWER WINDOW REGULATOR SUB- ASSEMBLY LH (DRIVER SIDE) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (REAR LH) B120211E02 WS–2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSTRUMENT PANEL J/B ASSEMBLY: (BODY ECU) WS VEHICLE REAR SIDE POWER FUSE VEHICLE FRONT SIDE POWER WINDOW RELAY B120212E02 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM FOR BACK POWER WINDOW: WS–3 TAIL GATE CONTROL SWITCH ASSEMBLY (BACK DOOR LOCK KEY CYLINDER) REAR WIPER MOTOR ASSEMBLY INSTRUMENT PANEL J/B ASSEMBLY (BODY ECU) BACK DOOR POWER WINDOW REGULATOR SWITCH ASSEMBLY WS POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (WINDOW LOCK SWITCH) MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) POWER WINDOW REGULATOR SUB-ASSEMBLY (BACK DOOR) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (BACK DOOR) B120210E02 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–43 REMOVAL 1. Windshield Glass Moulding Cut Cut Vehicle Body B111429E01 REMOVE ROOF HEADLINING ASSEMBLY (a) Remove the front door weatherstrip LH. (b) Remove the front door weatherstrip RH. (c) Remove the 2 assist grips. (d) Remove the front pillar garnish LH. (e) Remove the front pillar garnish RH. (f) Remove the LH Visor assembly. (g) Remove the RH Visor assembly. (h) Remove the LH visor. (i) Remove the RH visor. (j) Remove the 2 visor holders. (k) Remove the roof console box assembly. (l) Remove the roof headlining assembly. 2. REMOVE INNER REAR VIEW MIRROR ASSEMBLY HINT: See page MI-7 3. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (a) Remove the 2 front wiper arm head caps. (b) Remove the FR wiper arm LH. (c) Remove the FR wiper arm RH. (d) Remove the front fender to cowl side seal LH. (e) Remove the front fender to cowl side seal RH. (f) Remove the cowl top ventilator louver. 4. REMOVE WINDSHIELD MOULDING OUTSIDE LH (See page WS-54) 5. REMOVE WINDSHIELD MOULDING OUTSIDE RH 6. REMOVE WINDSHIELD MOULDING OUTER UPPER (a) Using a knife, cut off the moulding, as shown in the illustration. NOTICE: Do not damage the vehicle body with the knife. (b) Remove the remaining moulding. HINT: When removing, make a partial a cut, then pull and remove it by hand. (c) w/ Deicer: Disconnect the connector, as shown in the illustration. WS WS–44 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS 7. REMOVE WINDSHIELD GLASS (a) Pass a piano wire between the vehicle body and glass from the interior. Stopper Piano Wire B062805E04 (b) Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE: • When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. • To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad. (c) Cut off the adhesive by pulling piano wire around the glass. (d) Disengage the stoppers. (e) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. Protective Tape WS Plastic Sheet B106959E01 8. B106929 CLEAN WINDSHIELD GLASS (a) Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gasoline. NOTICE: Do not touch the glass surface after cleaning it. WS–45 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS INSTALLATION Backside: 1. Ceramic Line A B C C Stopper INSTALL WINDSHIELD GLASS NO. 2 STOPPER (a) Coat the installation part of the stoppers with Primer G. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. • Do not apply too much Primer . (b) Install 2 new stoppers onto the glass, as shown in the illustration. Dimension B106960E01 A 40.0 mm (1.575 in.) B 7.7 mm (0.303 in.) INSTALL WINDSHIELD GLASS NO. 1 STOPPER (a) Install 2 new stoppers to the vehicle body, as shown in the illustration. 3. INSTALL WINDOW GLASS ADHESIVE DAM (a) Coat the installation part of the windshield glass adhesive dam with Primer G. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not apply too much Primer. (b) Install a new dam, applying double-sided tape all the way around the glass except where the stoppers are installed, as shown in the illustration. Vehicle Body B106961E01 A Measurement 2. Stopper Backside: Area A A A A B Ceramic Line B b Dam C C A-A B-B Ceramic Line Stopper b Dam C-C a c Ceramic End B067566E01 WS WS–46 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Dimension Area Adhesive Body B106934E01 Mark B111406E01 a 905 mm (0.375 in.) c 31.4 mm (1.236 in.) 4. INSTALL WINDSHIELD MOULDING OUTER UPPER (a) Using the brush or sponge, coat the edge of the glass and the contact surface with Primer G. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not coat the adhesive with Primer G. • Do not keep any of the opened Primer G for later use. (b) Install the moulding. 5. INSTALL WINDSHIELD GLASS (a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. HINT: Leave as much of the adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS Adhesive Measurement (b) Position the glass. (1) Using a suction cup, place the glass in the correct position. (2) Check that the whole contact surface of the glass rim is perfectly even. (3) Place reference marks between the glass and vehicle body. NOTICE: Check that the stoppers are attached to the vehicle body correctly. HINT: When reusing the glass, check and correct the reference mark positions. (4) Remove the glass. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS CORRECT Primer M Primer M WS–47 (c) Using a brush, coat the exposed part of the vehicle body with Primer M. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not coat the adhesive with Primer M. • Do not keep any of the opened Primer M for later use. Adhesive WRONG WS Primer M B067819E03 Backside: a b a b c c Primer G a-a b-b c-c Primer G Primer G B067567E01 (d) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. WS–48 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Backside: A B B A C (e) Apply adhesive (Adhesive: Part No.08850-00801 or equivalent). (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Tackfree time Temperature C a A-A 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours b WS B-B C-C a b c Usage Timeframe (2) Load the sealer gun with the cartridge. (3) Coat the glass with adhesive, as shown in the illustration. Dimension c Ceramic End dB067568E02 (f) Mark B111406E01 Area Measurement a 12.0 mm (0.472 in.) b 8.0 mm (0.315 in.) c 3.0 mm (0.118 in.) d 24.9 mm (0.980 in.) Install the glass. (1) Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Check that the stoppers are attached to the vehicle body correctly. • Check that clearance between the vehicle body and glass. (2) Lightly press the front surface of the glass to ensure a close fit. (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive on the glass rim. Adhesive B073131E02 WS–49 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time Windshield Dam Adhesive Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours N008495E03 6. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. WS WS–51 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM PROBLEM SYMPTOMS TABLE WINDOW DEFOGGER SYSTEM Symptom Rear window defogger does not does not operate (Indicator light ON) Rear window defogger does not operate (Indicator light OFF) Suspected area See page 1. DEFOG fuse - 2. DEF relay WS-54 3. Rear window defogger wire WS-51 4. Wire harness - 5. Instrument panel junction block assembly - 1. DEFOG fuse - 2. DEF relay WS-54 3. Air conditioning control assembly WS-53 4. Rear window defogger WS-51 5. Wire harness - 6. Instrument panel junction block assembly - WS WS–52 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM ON-VEHICLE INSPECTION Defogger Wire Tester Probe WS 1. CHECK REAR WINDOW DEFOGGER SYSTEM (a) When the engine switch is turned on (IG) and the defogger switch is pressed, check that the rear window defogger operates. HINT: After 15 minutes, check that the defogger automatically turns OFF. 2. INSPECT BACK WINDOW (DEFOGGER WIRE) NOTICE: • When cleaning the glass, wipe the glass along the wire using a soft and dry cloth. Take care not to damage the wires. • Do not use detergents or glass cleaners that have abrasive ingredients. Tin Foil B106755E01 • When measuring voltage, wrap a piece of tin foil around the tip of the negative rester probe and press the foil against the wire with your finger, as shown in the illustration. (a) Turn the engine switch on (IG). (b) Turn the defogger switch ON. At Center B106756E01 0V Foil Strip Ground Side (-) Less than 10 V Battery Side (+) Broken Wire B106757E01 (c) Check the voltage at the center of each defogger wire, as shown in the illustration. Standard voltage Voltage Criteria Approx. 5 V Wire is not broken Approx. 10 or 0 V Wire is broken HINT: If there is approximately 10 V, the wire may be faulty between the center of the wire and the wire and on the battery side. If there is no voltage, the wire may be faulty between the center of the wire and the wire end on the ground side. (d) Place the voltmeter's positive (+) lead against the defogger wire on the battery side. (e) Place the voltmeter's negative (-) lead with the foil strip against the wire on the ground side. (f) Slide the positive (+) lead from the battery side to the ground side. WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–53 (g) The point where the voltage drops from approximately 10 V to 0 V is the place where the defogger wire is broken. HINT: If the defogger wire is not broken, the voltmeter should indicate 0 V at the positive (+) end of the defogger wire but gradually increases to approximately 12 V as the meter probe moves to the other end. REPAIR 1. Masking Tape IF NECESSARY, REPAIR THE DEFOGGER WIRE (a) Clean the broken wire tips with a grease, wax and silicone remover. (b) Place the masking tape along both sides of the wire. Broken Wire Repair Point B106758E03 (c) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). (d) Using a fine tip brush, apply a small amount of the agent to the wire. (e) After a few minutes, remove the masking tape. NOTICE: Do not repair the defogger wire again for at least 24 hours. B106759 WS WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–57 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • bolt without a torque specification is shown in the standard bolt chart. 1. REMOVE REAR SEAT CUSHION ASSEMBLY LH 2. REMOVE REAR SEATBACK ASSEMBLY LH 3. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER LH (a) Remove the deck board. (b) Remove the deck board assembly. (c) Remove the rear floor mat support plate. (d) Remove the back door weatherstrip. (e) Remove the rear door scuff plate LH. (f) Remove the rear door opening trim weatherstrip LH. (g) Remove the luggage hold belt striker assembly. (h) Remove deck trim cover rear. (i) Remove the deck floor box LH (j) Remove deck trim side panel assembly LH. (k) Remove the quarter trim cover RH. (l) Remove the tonneau cover hook B. (m) Remove the roof side garnish assembly inner LH. 4. Piano Wire Stopper Cushion Clip Clip Clip B140741E01 REMOVE QUARTER WINDOW ASSEMBLY LH (a) Disconnect the connectors. (b) Pass a piano wire through between the body and glass from the interior. WS WS–58 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS (c) Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface to prevent the surface from being scratched. NOTICE: • When separating the glass, take care not to damage the paint and the interior and exterior ornaments. • To prevent scratching the safety pad when removing the glass, place a plastic sheet between the piano wire and safety pad. (d) Cut off the adhesive by pulling the piano wire around the glass. (e) Remove the glass. NOTICE: Leave as much adhesive on the body as possible when removing the glass. Protective Tape WS B140742E01 5. CLEAN QUARTER WINDOW ASSEMBLY LH (a) Clean the outer circumference of the glass with white gasoline. NOTICE: • Do not touch the glass surface after cleaning it. • Be careful not to damage the glass. WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–59 INSTALLATION Adhesive Adhesive Body B106934E01 1. INSTALL STOPPER CUSHION (a) Clean the installation area. (b) Install 4 new spacers onto the glass. 2. INSTALL QUARTER WINDOW ASSEMBLY LH (a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. HINT: Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. (b) Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not coat the adhesive with Primer M. • Do not keep any of the opened Primer M for later use. Primer M Primer M Adhesive B111407E01 WS WS–60 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS (c) Using brush or sponge, coat the edge of the glass and the contact surface with Primer G. a a b b c d-d A B WS b-b c-c A 20.0 mm (0.787 in.) B 26.0 mm (1.024 in.) C 5.0 mm (0.197 in.) d d c a-a A A HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Do not keep any of the opened Primer G for later use. : Primer G B063580E01 Backside a a b d b d c c a-a B d-d A D E B Temperature Usage Timeframe 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Coat the glass with adhesive, as shown in the illustration. Specification b-b A (d) Apply adhesive (Adhesive: Part No. 08850-00801 or equivalent). (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe c-c Area Measurement A 12.0 mm (0.472 in.) B 8.0 mm (0.315 in.) C 13.0 mm (0.512 in.) D 13.0 mm (0.512 in.) E 8.0 mm (0.315 in.) (e) Install the quarter window to the vehicle body. (1) Hold the quarter window in place securely with protective tape or equivalent until the adhesive hardens. NOTICE: • Allow the primer coating to dry for 3 minutes or more. : Adhesive B062849E01 WS–61 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS • Check that the spacers are attached to the vehicle body correctly. • Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface for close contact. (3) Using a scraper, remove any excess or protruding adhesive. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Adhesive WS B073131E02 Minimum time Windshield Dam Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours 3. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. 4. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER LH 5. INSTALL REAR NO.2 SEAT BELT ASSEMBLY OUTER LH (w/ Rear No. 2 Seat) Adhesive N008495E03 WS–13 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART BACK DOOR POWER WINDOW CONTROL SYSTEM (FOR BACK DOOR WINDOW) DTC No. Detection Item Suspected Part B1241 Body ECU Switch Circuit Diagnosis 1. Back door power window regulator switch assembly 2. Defogger switch relay 3. Rear wiper switch relay 4. Wire harness B2221 Jam Protection Pulse Sensor Circuit on Back Door 1. Power window regulator motor assembly LH (Back door) 2. Wire harness See page WS-13 WS-15 WS WS–14 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC B1241 Body ECU Switch Circuit Diagnosis DESCRIPTION DTC B1241 is output when the back door power window switch, the defogger switch and the rear power window switch are on. When these switches are off, this DTC is not output. Using this DTC, you can check whether these switches are normal or not. DTC No. DTC Detection Condition Suspected Part • B1241 WS Back door power window switch, defogger switch and rear wiper switch are operating • • • Back door power window regulator switch assembly Defogger switch assembly Rear wiper switch assembly Wire harness WIRING DIAGRAM B1 Back Door Power Window Regulator Switch Assembly B5 Multiplex Network Door ECU Back DOWN 6 B-L 8 UP 3 Y-R 10 E 1 B-Y 19 BDN BUP COM B062903E02 INSPECTION PROCEDURE 1 CHECK BACK DOOR POWER WINDOW OPERATION (a) Check that the back door power window operates via the back door power window switch. OK NG INSPECT DEFOGGER SWITCH OR REAR WIPER SWITCH WS–15 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2 INSPECT BACK DOOR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Remove the power window switch. (b) Check the continuity between the terminals of the switch connector when the switch is operated. Standard Terminal No. Switch Specified Condition 3 ←→ 1 Down Continuity 6 ←→ 3 ←→ 1 OFF No continuity 6 ←→ 1 Up Continuity B062904 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SWITCH - BODY ECU) NG REPLACE BACK DOOR POWER WINDOW REGULATOR SWITCH ASSEMBLY WS WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–41 WINDSHIELD GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS ROOF HEADLINING ASSEMBLY WS RH VISOR ASSEMBLY ROOF CONSOLE BOX ASSEMBLY LH VISOR ASSEMBLY VISOR HOLDER RH VISOR VISOR HOLDER INNER REAR VIEW MIRROR ASSEMBLY LH VISOR WITH ELECTRO CHROMIC MIRROR: MIRROR COVER INNER REAR VIEW MIRROR ASSEMBLY B120220E02 WS–42 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS FRONT PILLAR GARNISH RH FRONT DOOR WEATHERSTRIP RH WINDSHIELD MOULDING OUTSIDE RH WINDSHIELD MOULDING OUTER UPPER CLIP WINDOW GLASS ADHESIVE DAM WINDSHIELD GLASS NO. 1 STOPPER WINDSHIELD GLASS NO. 2 STOPPER WS WINDSHIELD MOULDING OUTSIDE LH ASSIST GRIP ASSIST GRIP FRONT DOOR WEATHERSTRIP LH WINDSHIELD GLASS CLIP FRONT PILLAR GARNISH LH FR WIPER ARM HEAD CAP FR WIPER ARM RH FR WIPER ARM LH FRONT WIPER ARM HEAD CAP 20 (204, 15) FRONT FENDER TO COWL SIDE SEAL RH FRONT FENDER TO COWL SIDE SEAL LH COWL TOP VENTILATOR LOUVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120221E02 WS–16 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DTC B2221 Jam Protection Pulse Sensor Circuit on Back Door DESCRIPTION The back door ECU monitors the condition of the power window motor and detects the position of the door glass by using pulse signals output from the 2 pulse sensors in the power window motor. DTC No. B2221 DTC Detection Condition • • • • • WS PLS pulse sensor circuit malfunction PLS2 pulse sensor circuit malfunction Pulse direction is opposite to motor rotating direction (Short circuit between PLS and PLS2) PLS and PLS2 pulse sensors circuit malfunction Fully closed position is misaligned Suspected Part • • Power window regulator motor assembly LH (Back door) Wire harness FAIL-SAFE If the pulse sensor in the back door power window motor malfunctions (DTC B2221 is output), the power window functions will be restricted: • The AUTO UP/ DOWN function is disabled. • The MANUAL DOWN function via the transmitter is disabled. • The MANUAL UP/DOWN function via the back door power window switch can be performed (the ignition switch ON). • The MANUAL UP/DOWN function via the back door lock key cylinder can be performed (the ignition switch ON). WIRING DIAGRAM B11 Power Window Regulator Motor Assembly LH (Back Door) B9 Multiplex Network Door ECU Back SSRB 1 Y-G 11 PLS 2 W-R 17 PLS2 6 B-O 16 3 L-W 23 PLS PLS2 E IC+ IC2 IC1 IC- B062902E07 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–17 INSPECTION PROCEDURE 1 RESET POWER WINDOW REGULATOR MOTOR ASSEMBLY (a) Turn the ignition switch ON. (b) Open the back door glass. (c) Press the back door power window switch until the door glass is fully closed, and continue to hold the switch 1 second more even after the door glass is fully closed. (d) Check that the AUTO UP/DOWN function operates normally. OK END WS NG 2 CHECK WIRE HARNESS (BACK DOOR ECU - WINDOW MOTOR) (BACK DOOR ECU BODY GROUND) Wire Harness Side: B9 Multiplex Network Door ECU Back (Back Door ECU) (a) Disconnect the B9 ECU connector. (b) Disconnect the B11 motor connector. (c) Check the continuity between the wire harness side connectors. Standard Terminal No. Specified Condition B9-23 ←→ B11-3 Continuity B9-17 ←→ B11-2 Continuity B9-16 ←→ B11-6 Continuity B9-11 ←→ B11-1 Continuity (d) Check the continuity between the B9 ECU connector and the body ground. Standard B11 Power Window Regulator Motor Assembly LH (Back Door) B062905E01 OK Terminal No. Specified Condition B9-11 ←→ Body ground No continuity B9-16 ←→ Body ground No continuity B9-17 ←→ Body ground No continuity REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY NG REPAIR OR REPLACE HARNESS AND CONNECTOR WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–49 WINDOW DEFOGGER SYSTEM WINDSHIELD / WINDOWGLASS BODY PARTS LOCATION WS ENGINE ROOM R/B NO. 2: DEFOGGER FUSE (MARKING: DEFOG) DEFOGGER RELAY (MARKING: DEF) MIRRO HEATER FUSE (MARKING: MIR HEATER) B120223E02 WS–50 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM AIR CONDITIONING CONTROL ASSEMBLY: DEFOGGER SWITCH WS WITH OUTER MIRROR HEATER: OUTER REAR VIEW MIRROR ASSEMBLY RH INSTRUMENT PANEL J/B REAR WINDOW DEFOGGER WIRE - BODY ECU WITH OUTER MIRROR HEATER: OUTER REAR VIEW MIRROR ASSEMBLY LH B134259E02 WS–18 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Auto Up / Down Function does not Operate DESCRIPTION WS If the AUTO UP/DOWN function does not operate, any of the following troubles may be the cause: • When the PWR fuse or the power window relay (Marking: PWR) is replaced with new ones, or when the battery terminal and the connector of the power window master switch are disconnected, the power window memory of the fully closed position which is recorded in the power window master switch is erased. • The pulse sensors in the driver side power window motor have a malfunction. • There is an open or short circuit in the wiring between the power window master switch and the driver side power window motor. • The power window master switch has a malfunction. WIRING DIAGRAM P12 Power Window Regulator Motor Assembly LH (Driver Side) PLS PLS2 D17 Power Window Regulator Master Switch Assembly SSRB 4 W-L 3 PLS 5 W-R 14 PLS2 3 W-G 17 E BR-B 2 6 VCC PLS PLS2 GND B062902E14 INSPECTION PROCEDURE 1 CHECK MANUAL UP/DOWN FUNCTION (DRIVER SIDE) (a) Check that the door glass can be operated manually. NG OK OTHER PROBLEM WS–19 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2 CHECK ILLUMINATION OF POWER WINDOW MASTER SWITCH (a) Turn the ignition switch ON. (b) Operate the AUTO (drive side) switch of the master switch. (c) Check the blinking pattern of the AUTO light as shown in the illustration. (1) If pattern (1) is displayed, proceed to A. (2) If pattern (2) or (3) is displayed, proceed to B. (3) If the normal pattern is displayed, proceed to C. WS B067295 Blinking Pattern of AUTO Light: (1): Fully closed position is misaligned (3): Both (1) and (2) (2): Pulse sensor circuit malfunction Normal ON OFF (AUTO Light) 1.5 2.0 (sec.) 0.5 1.0 (sec.) 1.0 1.5 2.0 (sec.) 0.5 B128873E01 B C Go to step 4 REPLACE POWER WINDOW MASTER SWITCH A 3 RESET POWER WINDOW REGULATOR MOTOR (a) Turn the ignition switch ON. (b) Open the door glass. (c) Fully pull up the AUTO switch of the power window master switch until the door glass is fully closed. (d) Check that the AUTO UP/DOWN function operates normally. OK NG END WS–20 4 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (MASTER SWITCH - MOTOR) (a) Disconnect the D17 master switch connector. (b) Disconnect the P12 motor connector (driver side). (c) Check the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: D17 Power Window Regulator Master Switch Assembly Terminal No. Specified Condition D17-4 - P12-5 D17-17 - P12-3 D17-3 - P12-4 WS Continuity D17-2 - P12-6 D17-2 - P12-3 P12 Power Window Regulator Motor Assembly LH (Driver Side) D17-2 - P12-4 No continuity D17-2 - P12-5 NG REPAIR OR REPLACE HARNESS OR CONNECTOR B062894E02 OK REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (DRIVER SIDE) WS–53 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SWITCH WINDOW DEFOGGER SWITCH INSPECTION 1. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (DEFOGGER SWITCH) (a) Inspect operation of the defogger switch indicator. Standard Measurement Condition B063893E01 Battery positive (+) - IG+ (2) Battery negative (-) - DIND (11) Specified Condition Indicator light comes up If the result is not as specified, replace the air conditioning control assembly. (b) Inspect the defogger switch continuity. Standard resistance Terminal No. Switch Condition Specified Condition 4-7 ON Continuity 4-7 OFF No continuity If the result is not as specified, replace the air conditioning control assembly. Switch ON B063894E01 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–21 Remote Up / Down Function does not Operate DESCRIPTION If the REMOTE UP/DOWN function does not operate, any of the following troubles may be the cause: • When the POWER fuse and the POWER relay are replaced with new ones, or when the battery terminal and the connectors of the power window master switch are disconnected, the power window memory of the fully closed position which is recorded in the power window master switch is erased. • The pulse sensors in the driver side power window motor have a malfunction. • There is an open or short circuit in the wiring between the power window master switch and the applicable power window switch. • The power window master switch has a malfunction. WS WIRING DIAGRAM P11 Power Window Regulator Switch Assembly Rear (Rear RH) SD SU 2 G 5 G-B D17 Power Window Regulator Master Switch Assembly 6 BB1 G 10 IA2 7 BB1 G-B 11 IA2 R-L 16 B 18 RRD RRU P10 Power Window Regulator Switch Assembly Rear (Rear LH) SD SU 2 G-R 6 BA1 G-R 6 IA2 G 10 5 G-W 11 BA1 G-W 9 IA2 L 12 RLD RLU P9 Power Window Regulator Switch Assembly (Passenger Side) J/C SD SU 2 R 5 R-B 5 IP2 L-R A J22 A L-R J22 12 IA2 R 9 IP2 L-Y B J22 B J22 7 IA2 R-B 13 L-Y 15 PD PU B067292E02 WS–22 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK AUTO DOWN FUNCTION (a) Check that the AUTO UP/DOWN function operates normally. NG OTHER PROBLEM OK WS 2 CHECK POWER WINDOW LOCK SWITCH (a) Push the window lock switch OFF (normal) and check that the remote UP/DOWN function operates. OK END B066761 NG 3 CHECK MANUAL UP/DOWN FUNCTION (a) Inspect the switch with which the remote function cannot be operated. NG OTHER PROBLEM OK 4 INSPECT POWER WINDOW MASTER SWITCH HINT: Inspect the switch with the nonoperational remote function. (a) Remove the master switch. (b) Check the continuity between the terminals of the master switch connector when the switch is operated. Standard resistance: Passenger side switch B060766 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Window Lock Switch Power Window Switch Terminal No. UP 1 - 15, 6 - 13 OFF (Normal) OFF 1 - 13 - 15 DOWN 1 - 13, 6 - 15 UP 6 - 13 OFF 13 - 15 DOWN 6 - 15 ON (Lock) WS–23 Specified Condition Continuity Rear RH switch Window Lock Switch Power Window Switch Terminal No. UP 1 - 16, 6 - 18 OFF (Normal) OFF 1 - 6 - 18 DOWN 1 - 18, 6 - 16 UP 6 - 18 OFF 16 - 18 DOWN 6 - 16 ON (Lock) Specified Condition Continuity Rear LH switch Window Lock Switch OFF (Normal) ON (Lock) Power Window Switch Terminal No. UP 1 - 10, 6 - 12 OFF 1 - 10 - 12 DOWN 1 - 12, 6 - 10 UP 6 - 12 OFF 10 - 12 DOWN 6 - 10 NG Specified Condition Continuity REPLACE POWER WINDOW MASTER SWITCH OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MASTER SWITCH - EACH REGULATOR SWITCH) WS WS–54 WINDSHIELD / WINDOWGLASS – DEFOGGER RELAY DEFOGGER RELAY ON-VEHICLE INSPECTION 1. INSPECT DEFOGGER RELAY (Marking: DEFOG) (a) Measure the resistance of the DEFOG relay. Standard Tester Condition Continuity 3-5 No continuity (when battery voltage is not applied between terminals) 3 -5 Continuity (when battery voltage is applied to terminals 1 and 2) B057491E07 WS Specified Condition 1-2 If the result is not as specified, replace the relay. WS–24 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Back Door Only DESCRIPTION If the back door power window does not operate, the retract switch in the rear wiper motor, the back door power window motor or the wire harness may be abnormal. WIRING DIAGRAM B11 Back Door Power Window Regulator Motor Assembly Multiplex Network Door ECU Back 25 B9 BDDN 5 WS R-B Body ECU Back Power Window Switch 13 B9 BDUP 4 Y-B Multiplex Communication R23 Rear Wiper Motor Assembly Retract SW 1 P-B 2 G-R 12 B9 P 18 B9 SGND B062906E01 INSPECTION PROCEDURE 1 CHECK REAR WIPER OPERATION (a) Turn the ignition switch ON. (b) Operate the rear wiper and turn the rear wiper switch OFF. (c) Check that the rear wiper stops at the retract position when the rear wiper switch is turned OFF. NG REPAIR OR REPLACE BACK DOOR POWER WINDOW REGULATOR MOTOR ASSEMBLY B062907E01 OK 2 INSPECT BACK DOOR POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Using the hand?held tester, read the DTC when the back power window switch is operated. (1) When DTC B1287 is output, proceed to A. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–25 (2) When no DTC is output, proceed to B. (3) When DTC B1241 is output, proceed to C. A INSPECT MULTIPLEX COMMUNICATION SYSTEM B INSPECT BACK DOOR POWER WINDOW REGULATOR SWITCH ASSEMBLY C 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) Check the condition of the retract switch using the data list. Standard: Data list for back door ECU Measurement Item Label Perameter Wiper retract switch WIPER RTRCT SW ON NG Go to step 6 OK 4 WIRE HARNESS (BACK DOOR ECU - POWER WINDOW MOTOR) (BACK DOOR ECU GROUND) Wire Harness Side: B9 Multiplex Network Door ECU Back (Back Door ECU) (a) Disconnect the B9 ECU connector. (b) Disconnect the B11 motor connector. (c) Check the continuity between the wire harness side connectors. Standard Terminal No. Specified Condition B9-25 - B11-5 Continuity B9-13 - B11-4 Continuity (d) Check the continuity between the B9 ECU connector and the body ground. Standard B11 Power Window Regulator Motor Assembly LH (Back Door) NG B062905E02 OK Terminal No. Specified Condition B9-13 - Body ground No continuity B9-25 - Body ground No continuity REPAIR OR REPLACE HARNESS AND CONNECTOR WS WS–26 5 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECT BACK DOOR POWER WINDOW REGULATOR MOTOR ASSEMBLY Counterclockwise (a) Remove the motor. (b) Apply battery voltage between the connector terminals and check that the motor gear rotates smoothly. NOTICE: Do not apply battery voltage to any terminals except terminals 4 and 5. Standard Terminal No. Clockwise WS B062908E01 Specified Condition Battery positive voltage → 5 Battery negative voltage → 4 Counterclockwise Battery positive voltage → 4 Battery negative voltage → 5 Clockwise NG REPLACE BACK DOOR POWER WINDOW REGULATOR MOTOR ASSEMBLY OK CHECK AND REPLACE MULTIPLEX NETWORK DOOR ECU BACK 6 CHECK WIRE HARNESS (BACK DOOR ECU - POWER WINDOW MOTOR) (BACK DOOR ECU - GROUND) (a) Disconnect the B9 ECU connector. (b) Disconnect the B23 motor connector. (c) Check the continuity between the wire harness side connectors. Standard Wire Harness Side: B9 Multiplex Network Door ECU Back (Back Door ECU) Terminal No. Specified Condition B9-12 - R23-1 Continuity B9-18 - R23-2 Continuity (d) Check the continuity between the B9 ECU connector and the body ground. Standard R23 Rear Wiper Motor Assembly NG Terminal No. Specified Condition B9-12 - Body ground No continuity B9-18 - Body ground No continuity REPAIR OR REPLACE HARNESS AND CONNECTOR B062909E02 OK REPLACE BACK DOOR POWER WINDOW REGULATOR MOTOR ASSEMBLY WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–55 QUARTER WINDOW GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS WS BACK DOOR WEATHERSTRIP REAR FLOOR MAT SUPPORT PLATE COVER COVER DECK BOARD ASSEMBLY DECK BOARD LUGGAGE HOLD BELT STRIKER ASSEMBLY DECK TRIM COVER NO. 1 B120222E02 WS–56 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS ROOF SIDE GARNISH ASSEMBLY INNER LH COVER WS DECK TRIM COVER REAR LUGGAGE HOLD BELT STRIKER ASSEMBLY 42 (428, 31) DECK FLOOR BOX LH QUARTER TRIM COVER LH TONNEAU COVER HOOK B STOPPER CUSHION DECK TRIM SIDE PANEL ASSEMBLY LH QUARTER WINDOW ASSEMBLY RR LH REAR DOOR SCUFF PLATE LH REAR DOOR OPENING TRIM WEATHERSTRIP N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B134258E02 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–27 Manual Up / Down Function does not Operate on Passenger Side Only DESCRIPTION If the manual UP/DOWN function does not operate, the power window motor, the power window switch or the wire harness is abnormal. WIRING DIAGRAM P13 Power Window Regulator Motor Assembly RH (Passenger Side) P9 Power Window Regulator Switch Assembly (Passenger Side) WS 2 L-B 1 D 1 L 3 U 4 B 2 SD 5 SU B From Power Window Relay To Power Window Master Switch (Ground) To Power Window Master Switch (Ground) B062900E06 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER SOURCE) Wire Harness Side P9 Power Window Regulator Switch Assembly (Passenger Side) (a) Disconnect the P9 switch connector. (b) Turn the ignition switch ON. (c) Check the voltage between terminal 4 of the wire harness side connector of the switch and the body ground. Standard voltage: 10 to 14 V NG B062901E07 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SWITCH - RELAY) WS–28 2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (PASSENGER SIDE) (a) Remove the power window switch. (b) Check the continuity between the terminals of the switch connector when the switch is operated. Standard resistance WS Terminal No. Switch 1 - 2, 3 - 4 UP 1 - 2, 3 - 5 OFF 1 - 4, 3 - 5 DOWN Specified Condition Continuity B063163E12 NG REPLACE POWER WINDOW REGULATOR SWITCH ASSEMBLY OK 3 CHECK WIRE HARNESS (SWITCH - MOTOR) (SWITCH - BODY GROUND) (a) Disconnect the P13 motor connector. (b) Check the continuity between the wire harness side connectors. Standard resistance Wire Harness Side: P9 Power Window Regulator Switch Assembly (Passenger Side) Terminal No. P9-1 - P13-1 P9-3 - P13-2 Specified Condition Continuity (c) Check the continuity between the P9 switch connector and the body ground. Standard resistance Terminal No. P13 Power Window Regulator Motor Assembly RH (Passenger Side) P9-1 - Body ground P9-3 - Body ground NG B063164E06 OK Specified Condition No continuity REPAIR OR REPLACE HARNESS OR CONNECTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 4 WS–29 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH Motor Gear (a) Remove the motor. (b) Apply battery voltage to connector terminals 1 and 2. (c) Check that the motor rotates smoothly. Standard Clockwise Couterclockwise Terminal No. Specified Condition Battery positive (+) → 1 Battery negative (-) → 2 Motor gear rotates clockwise Battery positive (+) → 2 Battery negative (-) → 1 Motor gear rotates counterclockwise B127536E02 NG REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY RH OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MASTER SWITCH - SWITCH) WS WS–30 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Rear LH Only DESCRIPTION If the manual UP/DOWN function does not operate, the power window motor, the power window switch or the wire harness is abnormal. WIRING DIAGRAM P14 Power Window Regulator Motor Assembly LH (Rear LH) P10 Power Window Regulator Switch Assembly Rear (Rear LH) WS 2 L-B 1 D 1 L 3 U 4 B 2 SD 5 SU W From Power Window Relay To Power Window Master Switch (Ground) To Power Window Master Switch (Ground) B062900E05 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER SOURCE) Wire Harness Side P10 Power Window Regulator Switch Assembly Rear (Rear LH) (a) Disconnect the P38 regulator switch connector. (b) Turn the ignition switch ON. (c) Check the voltage between the terminal 4 of the wire harness side connector and the body ground. Standard voltage: 10 to 14 V NG B062901E08 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SWITCH - RELAY) WS–31 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2 INSPECT POWER WINDOW REGULATOR SWITCH (REAR LH) (a) Remove the regulator switch. (b) Check the resistance between the switch terminals when the switch is operated, as shown in the table below. Standard resistance Terminal No. Regulator Switch 1 - 2, 3 - 4 UP 1 - 2, 3 - 5 OFF 1 - 4, 3- 5 DOWN Specified Condition Continuity B063163E12 NG REPLACE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR (REAR LH) OK 3 CHECK WIRE HARNESS (SWITCH - MOTOR) (SWITCH - BODY GROUND) (a) Disconnect the P14 motor connector. (b) Check the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: P10 Power Window Regulator Switch Assembly Rear (Rear LH) Terminal No. P10-3 - P14-1 P10-1 - P14-2 Specified Condition Continuity (c) Check the resistance between the P10 regulator switch connector and body ground. Standard resistance Terminal No. P14 Power Window Regulator Motor Assembly LH (Rear LH) P10-1 - Body ground P10-3 - Body ground NG B063164E07 OK Specified Condition No continuity REPAIR OR REPLACE HARNESS OR CONNECTOR WS WS–32 4 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (REAR LH) (a) Remove the motor. (b) Apply battery voltage to connector terminals 1 and 2. (c) Check that the motor smoothly rotates. Standard Motor Gear Counterclockwise Clockwise WS Terminal No. Specified Condition Battery positive (+) → 2 Battery negative (-) → 1 Motor gear rotates clockwise Battery positive (+) → 1 Battery negative (-) → 2 Motor gear rotates counterclockwise B127535E01 NG REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (REAR LH) OK REPAIR OR REPLACE HARNESS OR CONNECTOR (MASTER SWITCH - SWITCH) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–33 Manual Up / Down Function does not Operate on Rear RH Only DESCRIPTION If the manual UP/DOWN function does not operate, the power window motor, the regulator switch or the wire harness may be malfunctioning. WIRING DIAGRAM P15 Power Window Regulator Motor Assembly RH (Rear RH) P11 Power Window Regulator Switch Assembly Rear (Rear RH) WS 2 L-B 1 D 1 L 3 U 4 B 2 SD 5 SU W From Power Window Relay To Power Window Master Switch (Ground) To Power Window Master Switch (Ground) B062900E07 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER SOURCE) Wire Harness Side P11 Power Window Regulator Switch Assembly Rear (Rear RH) (a) Disconnect the P11 regulator switch connector. (b) Turn the ignition switch ON. (c) Check the voltage between the terminal 4 of the wire harness side connector and the body ground. Standard voltage: 10 to 14 V NG B062901E09 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (SWITCH - RELAY) WS–34 2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR SWITCH (REAR RH) (a) Remove the regulator switch. (b) Check the resistance between the switch terminals when the switch is operated, as shown in the table below. Standard resistance WS Terminal No. Regulator Switch 1 - 2, 3 - 4 UP 1 - 2, 4 - 5 OFF 1 - 4, 3- 5 DOWN Specified Condition Continuity B063163E12 NG REPLACE POWER WINDOW REGULATOR SWITCH (REAR RH) OK 3 CHECK WIRE HARNESS (SWITCH - MOTOR) (SWITCH - BODY GROUND) (a) Disconnect the P15 motor connector. (b) Check the resistance between the wire harness side connectors. Standard resistance Wire Harness Side: P11 Power Window Regulator Switch Assembly Rear (Rear RH) Terminal No. P11-3 - P15-1 P11-1 - P15-2 Specified Condition Continuity (c) Check the resistance between the P9 regulator switch connector and body ground. Standard resistance Terminal No. P15 Power Window Regulator Motor Assembly RH (Rear RH) P11-1) - Body ground P11-3) - Body ground NG B063164E08 OK Specified Condition No continuity REPAIR OR REPLACE HARNESS OR CONNECTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 4 WS–35 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (REAR RH) Motor Gear (a) Remove the motor. (b) Apply battery voltage to connector terminals 1 and 2. (c) Check that the motor smoothly rotates. Standard Clockwise Couterclockwise Terminal No. Specified Condition Battery positive (+) → 1 Battery negative (-) → 2 Motor gear rotates counterclockwise Battery positive (+) → 2 Battery negative (-) → 1 Motor gear rotates clockwise B127536E02 NG REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (REAR RH) OK REPAIR OR REPLACE HARNESS AND CONNECTOR (MASTER SWITCH - SWITCH) WS MI–7 MIRROR – INNER REAR VIEW MIRROR PROBLEM SYMPTOMS TABLE AUTOMATIC GLARE-RESISTANT EC MIRROR Symptom Suspected area 1. Fuse Auto glare-resistant EC mirror does not operate See page - 2. Inner rear view mirror MI-8 3. Wire harness - REMOVAL 1. (a) Cover REMOVE INNER REAR VIEW MIRROR (w/o Electronic Mirror) (a) Pushing portions (a) as indicated in the illustration, remove the cover. (b) Pushing the claw in the direction (b), slide the mirror assembly in the direction (c) to remove it. (a) Claw (b) (c) B064964E08 2. Slide B064963E01 REMOVE INNER REAR VIEW MIRROR (w/ Electronic Mirror) (a) Disconnect the mirror cover. (b) Disconnect the connector. (c) Remove the mirror assembly as shown in the illustration. MI MI–8 MIRROR – INNER REAR VIEW MIRROR INSPECTION 1. 1 2 MI Black Colored Tape Forward Sensor B057086E01 INSPECT INNER REAR VIEW MIRROR ASSEMBLY (a) Inspect operation of the electrochromic inner mirror. (1) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. (2) Attach black colored tape to the forward sensor to prevent it from sensing. (3) Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. Standard: Mirror surface changes from bright to dark If the result is not as specified, replace the mirror assembly. MIRROR – INNER REAR VIEW MIRROR MI–9 INSTALLATION 1. INSTALL INNER REAR VIEW MIRROR (w/ Electronic Mirror) 2. INSTALL INNER REAR VIEW MIRROR (w/o Electronic Mirror) MI MI–11 MIRROR – OUTER REAR VIEW MIRROR REMOVAL 1. REMOVE FRONT DOOR SERVICE HOLE COVER LH (a) Remove the front door lower frame bracket garnish LH. (b) Remove the front door inside handle bezel LH. (c) Remove the front armrest assembly LH. (d) Remove the front door trim board LH. (e) Remove the front door service cover LH. 2. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the connector. (b) Remove the 3 nuts and mirror. MI B062419E01 INSPECTION 1. (A) (C) (D) (B) B062851E01 INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the mirror connector. (b) Apply battery voltage and check operation of the mirror face, as shown in the table and illustration. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 3 (MV) Battery negative (-) → Terminal 1 (M+) Turns upward (A) Battery positive (+) → Terminal 1 (M+) Battery negative (-) → Terminal 3 (MV) Turns downward (B) Battery positive (+) → Terminal 1 (M+) Battery negative (-) → Terminal 2 (MH) Turns right (C) Battery positive (+) → Terminal 2 (MH) Battery negative (-) → Terminal 1 (M+) Turns left (D) If the result is not as specified, replace the mirror assembly. MI–12 MIRROR – OUTER REAR VIEW MIRROR 2. (A) (C) (B) (D) MI B062850E01 INSPECT OUTER REAR VIEW MIRROR ASSEMBLY RH (a) Inspect outer mirror motor operation. (b) Apply battery voltage and check operation of the mirror face, as shown in the table and illustration. Standard Measurement Condition Specified Condition Battery positive (+) → Terminal 3 (MV) Battery negative (-) → Terminal 1 (M+) Turns upward (A) Battery positive (+) → Terminal 1 (M+) Battery negative (-) → Terminal 3 (MV) Turns downward (B) Battery positive (+) → Terminal 1 (M+) Battery negative (-) → Terminal 2 (MH) Turns right (C) Battery positive (+) → Terminal 2 (MH) Battery negative (-) → Terminal 1 (M+) Turns left (D) If the result is not as specified, replace the mirror assembly. INSTALLATION 1. B062419E02 INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Install the mirror with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect the connector. MIRROR – POWER MIRROR CONTROL SYSTEM MI–1 POWER MIRROR CONTROL SYSTEM MIRROR BODY PARTS LOCATION OUTER MIRROR SWITCH MI OUTER REAR VIEW MIRROR OUTER REAR VIEW MIRROR B142022E01 MI–2 MIRROR – POWER MIRROR CONTROL SYSTEM PROBLEM SYMPTOMS TABLE POWER MIRROR CONTROL SYSTEM Symptom Mirror does not operate Suspected area MI-13 2. Outer rear view mirror assembly MI-11 3. Wire harness Mirror operate abnormally - 1. Outer mirror switch assembly MI-13 2. Outer rear view mirror assembly MI-11 3. Wire harness MI See page 1. Outer mirror switch assembly - MI–3 MIRROR – INNER REAR VIEW MIRROR INNER REAR VIEW MIRROR MIRROR BODY COMPONENTS ROOF HEADLINING ASSEMBLY MI RH VISOR ASSEMBLY ROOF CONSOLE BOX ASSEMBLY LH VISOR ASSEMBLY VISOR HOLDER RH VISOR VISOR HOLDER LH VISOR INNER REAR VIEW MIRROR W/ ELECTRO CHROMIC MIRROR: MIRROR COVER INNER REAR VIEW MIRROR B120220E04 MI–4 MIRROR – INNER REAR VIEW MIRROR CALIBRATION 1. 2. MI 3. 4. SELECT COMPASS DISPLAY MODE (a) The COMP switch allows you to select the Display or Non-display mode of the compass. SET ZONE (a) Deviation between the "magnetic north" and "actual north" differs depending on the location. Therefore, adjustment of the magnetism is required. Since the magnetic condition differs depending on the area where the vehicle is used, it is necessary for each user to set the zone (Refer to Compass Zone Map). The zone setting can be changed using the COMP switch of the inner mirror. PERFORM CALIBRATION (a) Because each vehicle has its own magnetic field, calibration should be performed for each vehicle. This compass function is used when storing the record of the vehicle's magnetic field. WHEN COMPASS IS MAGNETIZED (a) A compass could be magnetized during shipping by vessels or freight cars. Therefore, make sure to perform calibration and ensure that calibration is performed properly before delivery. If it cannot be done (cannot be completed in spite of driving around several times), it may be caused by magnetization. Demagnetize the vehicle using a demagnetizer and perform calibration again. MI–5 MIRROR – INNER REAR VIEW MIRROR 5. COMP Switch SET COMPASS On Duration Normal Ignition Switch ON Pressed Compass Non-display Mode Pressed for 3 sec. Zone Setting Mode (Step 6) Pressed for 6 sec. MI COMP Switch ON Zone area +1 Calibration (Step 7) Leaving it untouched for a while Normal Mode B111243E01 6. 7. ZONE SETTING MODE (a) Pressing the COMP switch for 3 seconds in the normal mode will activate the zone setting mode. A number (1 to 15) is displayed on the compass display. NOTICE: In the initial state, "8" is displayed. (b) The displayed number increases by 1 every time the COMP switch is pressed. Referring to the map, check the number for the area where the vehicle will be used and set the zone number. (c) Leave it untouched for several seconds after setting and check that the compass display shows an azimuthal direction (N, NE, E, SE, S, SW, W or NW) or "C". CALIBRATION SETTING MODE (a) Pressing the COMP switch for 6 seconds in the normal mode will activate the calibration setting mode. MI–6 MIRROR – INNER REAR VIEW MIRROR (b) Drive the vehicle at a slow speed of 8 km/h (5 mph) or less in the circular direction. (c) Driving around the circle 1 to 3 times will display the azimuthal direction on the display, completing the calibration. NOTICE: After the calibration is completed, it is not necessary to perform the above procedures unless the magnetic field strength is drastically changed. If this happens, the azimuthal display will be changed to "C". Zone Setting Map: MI B057087E01 MIRROR – OUTER REAR VIEW MIRROR MI–9 OUTER REAR VIEW MIRROR MIRROR BODY COMPONENTS FRONT DOOR SERVICE HOLE COVER LH MI FRONT ARMREST ASSEMBLY LH FRONT DOOR INSIDE HANDLE BEZEL LH N*m (kgf*cm, ft.*lbf) : Specified torque FRONT DOOR TRIM BOARD LH Non-reusable part B120197E04 MI–10 MIRROR – OUTER REAR VIEW MIRROR MI OUTER REAR VIEW MIRROR ASSEMBLY LH OUTER REAR VIEW MIRROR ASSEMBLY RH B134259E04 MI–13 MIRROR – OUTER MIRROR SWITCH OUTER MIRROR SWITCH LEFT RIGHT INSPECTION Left/Right Adjustment Switch 1. Mirror Switch UP LEFT OFF INSPECT OUTER MIRROR SWITCH ASSEMBLY (a) Inspect the outer mirror switch. (1) Measure the resistance according to the value(s) in the table below when the switch is operated. Resistance: Select "L" on the left/right adjustment switch Tester Connection RIGHT 4-8 No Pin No Pin 4-7 MI DOWN 6-8 Below 1 Ω 5-8 LEFT 6-7 B059702E10 Specified Condition UP 6-7 DOWN Switch Position 5-7 RIGHT 6-8 Select "R" on the left/right adjustment switch Tester Connection 3-8 6-7 3-7 6-8 2-8 6-7 2-7 6-8 Switch Position Specified Condition UP DOWN Below 1 Ω LEFT RIGHT IP–6 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD REMOVAL 1. BOLT, SCREW AND NUT TABLE HINT: The bolts, screws and nuts, which are necessary for installation and removal of the instrument panel are shown in the illustration below and the text with alphabets. mm (in.) (L = Length) Code Shape Code φ=8 (0.31) L = 24 (0.94) Shape Code φ=6 (0.24) L = 18 (0.71) φ=5 (0.20) L = 14 (0.55) φ=5 (0.20) L = 18.5 (0.73) φ=5 (0.20) L = 18 (0.71) φ=6 (0.24) IP Shape φ=6 (0.24) L = 20 (0.79) φ=5 (0.20) L = 14 (0.55) B065712E01 B062737 2. DISCONNECT BATTERY NEGATIVE TERMINAL HINT: RS-1 3. REMOVE INSTRUMENT PANEL FINISH PLATE (a) Remove the instrument panel finish plate. INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 4 Clips IP–7 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Remove the 2 bolts . (b) Disconnect the hood lock control cable assembly and fuel lid lock control cable sub-assembly. (c) Disengage the 4 clips. (d) Disconnect the connectors and remove the lower instrument panel finish panel sub-assembly. 5. REMOVE CONSOLE UPPER REAR PANEL SUBASSEMBLY (a) Disengage the 5 clips and 2 claws, and remove the console upper rear panel, and then disconnect the connectors. B062738E01 IP 2 Claws 5 Clips 2 Claws 6 Clips Clip B062740E01 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (a) Disengage the 6 clips and 2 claws, and then remove the upper console panel sub-assembly. NOTICE: Be careful not to snap the claws during the operation. 7. REMOVE NO. 1 CONSOLE UPPER PANEL GARNISH (a) Disengage the clip. (b) Pull the No. 1 console upper panel garnish rearward to be removed. 8. REMOVE NO. 2 CONSOLE UPPER PANEL GARNISH 9. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (a) Remove the screw. B062741E01 B062742E01 B062744 IP–8 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD (b) Disengage the 4 clips and remove the air conditioner, and then disconnect the connectors. 4 Clips B062757E01 10. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (a) Remove the 3 bolts . (b) Disengage the 8 clips and remove the center instrument cluster finish panel sub-assembly. IP 11. REMOVE RADIO RECEIVER ASSEMBLY (w/ Bracket) (See page AV-167) 12. REMOVE NO. 2 LOWER STEERING WHEEL COVER 8 Clips B062745E01 13. REMOVE NO. 3 LOWER STEERING WHEEL COVER 14. REMOVE STEERING PAD (See page RS-388) 15. REMOVE STEERING WHEEL ASSEMBLY (See page SR-9) 16. REMOVE UPR STEERING COLUMN COVER 17. REMOVE TURN SIGNAL SWITCH ASSEMBLY (w/ Bracket) (See page SR-10) 18. REMOVE INSTRUMENT PANEL LOWER LH (a) Remove the 2 bolts . (b) Disengage the 2 claws and remove the instrument panel lower LH. 2 Claws B062739E01 19. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (a) Disengage the 7 clips. (b) Disconnect the connectors and remove the instrument cluster finish panel sub-assembly. 20. REMOVE COMBINATION METER ASSEMBLY (See page ME-60) 7 Clips B062746E01 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 21. REMOVE REAR CONSOLE BOX ASSEMBLY (a) Disconnect the connectors. (b) Remove the 6 bolts and rear console box assembly. IP–9 22. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-9) B078371E01 23. REMOVE COWL SIDE TRIM BOARD RH (a) Remove the clip. (b) Disengage the 2 claws and remove the cowl side trim board RH. IP 2 Claws B062748E01 24. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) Remove the screw . (b) Disengage the 3 clips and remove the No. 2 instrument panel under cover sub-assembly. 3 Clips B062749E01 25. REMOVE GLOVE COMPARTMENT DOOR SUBASSEMBLY (a) Remove the screw and glove compartment door. (b) Deform the upper part of the glove compartment door to release the stoppers. (c) Pull the glove compartment door upward to remove it. 2 Claws 2 Clips B062750E01 26. DISCONNECT PASSENGER AIRBAG CONNECTOR (See page RS-403) 27. REMOVE NO. 2 LOWER INSTRUMENT PANEL FINISH PANEL (a) Remove the 4 screws . (b) Disengage the 2 claws and remove the instrument panel finish panel. 2 Claws B062751E01 IP–10 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 28. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Remove the screw . (b) Disengage the 2 clips and 2 claws, and then remove the No. 2 instrument panel register assembly. 29. REMOVE ASSIST GRIP SUB-ASSEMBLY 2 Claws 2 Clips B062752E01 Clip B IP Clip A Claw Claw B063600E04 30. REMOVE FRONT PILLAR GARNISH LH (a) Using a screwdriver, remove the 2 assist grip plugs. HINT: Tape the screwdriver tip before use. (b) Remove the 2 bolts. (c) Using a screwdriver, disengage the claw. Remove the clip labeled A, clip labeled B and pillar garnish. 31. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure described for the LH side. IP–11 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 32. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY (a) Remove the 9 bolts and nut . IP B120219E01 (b) Disconnect the connectors. (c) Remove the instrument panel safety pad subassembly. 33. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a moulding remover, disengage the 4 clips and remove the No. 1 instrument panel speaker panel sub-assembly. 34. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY (a) Remove the 2 screws and the front stereo component speaker assembly. IP–12 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 35. REMOVE NO. 1 INSTRUMENT PANEL PIN (a) Remove the screw and the No. 1 instrument panel pin. 36. REMOVE DEFROSTER NOZZLE ASSEMBLY (a) Remove the 2 screws and the defroster nozzle assembly. 37. REMOVE NO. 2 HEATER TO REGISTER DUCT (a) Remove the 5 screws and the No. 2 heater to register duct. 38. REMOVE NO. 1 METER HOOD RETAINER (a) Remove the screw and the No. 1 meter hood retainer. IP 39. REMOVE CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY (a) Remove the screw and the center instrument panel bracket sub-assembly. 40. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (a) Disconnect the connector. (b) Remove the automatic light control sensor. 41. REMOVE COOLER (SOLAR SENSOR) THERMISTOR (a) Disconnect the connector. (b) Remove the cooler (solar sensor) thermistor. 42. REMOVE NO. 2 INSTRUMENT PANEL WIRE 43. REMOVE ANTENNA CORD SUB-ASSEMBLY (See page AV-181) 44. REMOVE NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) (See page NS-239) 45. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Remove the 3 screws and the instrument cluster finish panel garnish. 46. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS-403) 47. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–13 INSTALLATION 1. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY 2. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY 3. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH 4. INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) 5. INSTALL ANTENNA CORD SUB-ASSEMBLY 6. INSTALL NO. 2 INSTRUMENT PANEL WIRE 7. INSTALL COOLER (SOLAR SENSOR) THERMISTOR 8. INSTALL AUTOMATIC LIGHT CONTROL SENSOR 9. INSTALL CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY 10. INSTALL NO. 1 METER HOOD RETAINER 11. INSTALL NO. 2 HEATER TO REGISTER DUCT 12. INSTALL DEFROSTER NOZZLE ASSEMBLY 13. INSTALL NO. 1 INSTRUMENT PANEL PIN 14. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY 15. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY 16. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY (a) Using a torque wrench, install the bolt . Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) IP IP–14 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP B120219E02 17. INSTALL FRONT PILLAR GARNISH RH 18. INSTALL FRONT PILLAR GARNISH LH 19. INSTALL ASSIST GRIP SUB-ASSEMBLY 20. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY 21. INSTALL NO. 2 LOWER INSTRUMENT PANEL FINISH PANEL 22. CONNECT PASSENGER AIRBAG CONNECTOR 23. INSTALL GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 24. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–15 25. INSTALL COWL SIDE TRIM BOARD RH 26. INSTALL FRONT DOOR SCUFF PLATE RH 27. INSTALL REAR CONSOLE BOX ASSEMBLY 28. INSTALL COMBINATION METER ASSEMBLY 29. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 30. INSTALL INSTRUMENT PANEL LOWER LH 31. INSTALL TURN SIGNAL SWITCH ASSEMBLY (w/ Bracket) 32. INSTALL UPPER STEERING COLUMN COVER 33. INSTALL STEERING WHEEL ASSEMBLY 34. INSTALL STEERING PAD 35. INSTALL NO. 3 LOWER STEERING WHEEL COVER 36. INSTALL NO. 2 LOWER STEERING WHEEL COVER 37. INSTALL RADIO RECEIVER ASSEMBLY (w/ Bracket) 38. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 39. INSTALL AIR CONDITIONING CONTROL ASSEMBLY 40. INSTALL NO. 2 CONSOLE UPPER PANEL GARNISH 41. INSTALL NO. 1 CONSOLE UPPER PANEL GARNISH 42. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY 43. INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY 44. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 45. INSTALL INSTRUMENT PANEL FINISH PLATE 46. CONNECT BATTERY NEGATIVE TERMINAL IP INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–1 INSTRUMENT PANEL SAFETY PAD PRECAUTION 1. PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) Some operations in this section may affect the SRS airbag. Prior to performing the corresponding operations, read the SRS airbag NOTICE (See page RS-1). IP IP–2 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD COMPONENTS RADIO RECEIVER ASSEMBLY WITH BRACKET IP INSTRUMENT CLUSTER FINISH PANEL GARNISH CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY INSTRUMENT PANEL LOWER LH B120190E04 IP–3 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD NO. 1 CONSOLE UPPER PANEL GARNISH NO. 2 CONSOLE UPPER PANEL GARNISH INSTRUMENT PANEL FINISH PLATE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY UPPER CONSOLE PANEL SUB-ASSEMBLY TURN SIGNAL SWITCH ASSEMBLY WITH BRACKET UPPER STEERING COLUMN COVER REAR CONSOLE BOX ASSEMBLY STEERING WHEEL ASSEMBLY NO. 3 LOWER STEERING WHEEL COVER NO. 2 LOWER STEERING WHEEL COVER STEERING PAD B120191E06 IP IP–4 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP SUB-ASSEMBLY FRONT PILLAR GARNISH RH 20 (204, 15) INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY FRONT PILLAR GARNISH LH IP C A A C C C C B H G C NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY COWL SIDE TRIM BOARD RH NO. 2 LOWER INSTRUMENT PANEL FINISH PANEL E E E E FRONT DOOR SCUFF PLATE RH GLOVE COMPARTMENT DOOR SUB-ASSEMBLY F GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY E NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120192E03 IP–5 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD NO. 2 HEATER TO REGISTER DUCT FRONT PASSENGER AIRBAG ASSEMBLY DEFROSTER NOZZLE ASSEMBLY WITH AUDIO PREMIUM VERSION: NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY IP ANTENNA CORD SUB-ASSEMBLY WITH LIGHT CONTROL SYSTEM: COOLER (SOLAR SENSOR) THERMISTOR AUTOMATIC LIGHT CONTROL SENSOR NO. 1 INSTRUMENT PANEL PIN NO. 1 INSTRUMENT PANEL PIN WITH NAVIGATION SYSTEM: CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY NAVIGATION ANTENNA ASSEMBLY NO. 1 METER HOOD RETAINER B120193E03 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) SE–9 REMOVAL CAUTION: • Always wear gloves because the sharp edges of the seatback frame and seat adjuster may cause injury. • Work must be started 90 seconds after the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source. If work is started within 90 seconds after disconnecting the negative (-) terminal cable of the battery, the SRS may deploy.) HINT: • Installation is in the reverse order of removal. However, only installation procedures requiring additional information are included. • Use the same procedures for the RH side and LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-1). • COMPONENTS: See page SE-6 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH (a) Using a screwdriver, pry out the seat track bracket cover outer front LH. HINT: Tape the screwdriver tip before use. 3. REMOVE SEAT TRACK BRACKET COVER INNER FRONT LH HINT: Removal procedure of the seat track bracket cover inner front LH is the same as for the seat track bracket cover outer front LH. 4. REMOVE SEAT TRACK OUTER COVER LH HINT: Removal procedure of the seat track outer cover LH is the same as for the seat track bracket cover outer front LH. 5. REMOVE SEAT TRACK BRACKET COVER INNER LH HINT: Removal procedure of the seat track bracket cover inner LH is the same as for the seat track bracket cover outer front LH. 6. REMOVE FRONT SEAT ASSEMBLY LH (a) Disconnect the connectors under the front seat assembly LH. (b) Remove the 4 bolts and front seat assembly LH. NOTICE: Be careful not to damage the body. SE SE–10 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) DISASSEMBLY Claw 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE VERTICAL SEAT ADJUSTER KNOB LH (a) Using a cloth etc., remove the snap ring and vertical seat adjuster knob LH. 3. REMOVE VERTICAL SEAT ADJUSTER KNOB CAP (a) Using a scraper, disengage the 3 claws and remove the vertical seat adjuster knob cap. HINT: Tape the scraper tip before use. 4. REMOVE VERTICAL ADJUSTING HANDLE NO. 2 (a) Remove the 2 screws and vertical adjusting handle No. 2. 5. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH (a) Using a screwdriver, pry out the reclining adjuster release handle LH. HINT: Tape the screwdriver tip before use. 6. REMOVE FRONT SEAT CUSHION SHIELD LH (a) Remove the screw. (b) Driver seat only: (1) Using a screwdriver, disengage the 2 claws and clip, and remove the front seat cushion shield LH, and then disconnect the connector. HINT: Tape the screwdriver tip before use. (c) Passenger seat only: (1) Using a screwdriver, disengage the 2 claws and clip, and remove the front seat cushion shield LH. HINT: Tape the screwdriver tip before use. 7. REMOVE POWER SEAT SWITCH ASSEMBLY (a) Remove the 2 screws and power seat switch assembly. 8. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH B089215E01 SE B089216 Claw Clip B065148E01 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) 9. Claw Clip B065149E01 SE–11 REMOVE FRONT SEAT CUSHION SHIELD INNER LH (a) Remove the screw. (b) Using a screwdriver, disengage the claw and clip, and remove the front seat cushion shield inner LH. HINT: Tape the screwdriver tip before use. 10. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (a) Disengage the hook and remove the seat cushion cover together with the pad. 11. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Remove the hog rings and seat cushion cover. 12. REMOVE FRONT SEAT HEADREST SUPPORT (a) Remove the 2 front seat headrest supports. SE B060977 13. REMOVE SEPARATE TYPE SEATBACK COVER WITH PAD (a) with Side airbag: (1) Remove the hog rings, nut and seatback cover bracket. (b) Remove the hog rings and seatback cover together with the pad. B065179 14. REMOVE SEPARATE TYPE FRONT SEATBACK COVER (a) Remove the hog rings and front seatback cover. 15. REMOVE RECLINING ADJUSTER INSIDE COVER LH (a) Remove the screw and reclining adjuster inside cover LH (lower). (b) Remove the screw and reclining adjuster inside cover LH (upper). 16. REMOVE RECLINING ADJUSTER INSIDE COVER RH (a) Remove the screw and reclining adjuster inside cover RH (lower). (b) Remove the screw and reclining adjuster inside cover RH (upper). 17. REMOVE FRONT SEAT CUSHION SHIELD LOWER LH (a) Remove the front seat cushion shield lower LH. 18. REMOVE FRONT SEAT CUSHION SHIELD LOWER RH (a) Remove the front seat cushion shield lower RH. SE–12 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) 19. REMOVE VERTICAL ADJUSTER BUSH 20. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY LH (a) Disconnect the connector. (b) Remove the 2 screws and lumbar support adjuster assembly LH. 21. REMOVE SEAT POSITION AIR BAG SENSOR 22. REMOVE FRONT SEAT CUSHION PROTECTOR 23. REMOVE SEAT WIRE NO. 2 (a) Remove the wiring harness connectors. 24. REMOVE OCCUPANT DETECTION ECU HINT: See page RS-447 SE SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) SE–13 REASSEMBLY 1. INSTALL OCCUPANT DETECTION ECU HINT: See page RS-447 2. INSTALL SEAT WIRE NO. 2 3. INSTALL FRONT SEAT CUSHION PROTECTOR 4. INSTALL SEAT POSITION AIR BAG SENSOR HINT: See page RS-444 5. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY LH 6. INSTALL VERTICAL ADJUSTER BUSH 7. INSTALL FRONT SEAT CUSHION SHIELD LOWER RH 8. INSTALL FRONT SEAT CUSHION SHIELD LOWER LH 9. INSTALL RECLINING ADJUSTER INSIDE COVER RH 10. INSTALL RECLINING ADJUSTER INSIDE COVER LH 11. INSTALL SEPARATE TYPE FRONT SEATBACK COVER (a) Install the seatback pad. (b) Cover the top of the seatback pad with the front seatback cover. Hog Ring Pliers B050126E17 (c) Using hog ring pliers, install the front seatback cover to the seatback pad with new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to prevent wrinkles as much as possible. 12. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (a) Install the seatback cover together with the pad with new hog rings. (b) with Side airbag: (1) Install the front seatback cover bracket with the nut. Torque: 5.5 N*m (56 kgf*cm, 48 in.*lbf) B065179 SE SE–14 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) (c) with Side airbag: (1) Install the wire harness and clamp of the side airbag through the seat cushion cover end. (d) Using hog ring pliers, install new hog rings. NOTICE: Be careful not to damage the cover. Clamp 13. INSTALL FRONT SEAT HEADREST SUPPORT B065611E01 Hog Ring Pliers SE 14. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Install the front seat cushion pad to the seat cushion cover. (b) Using hog ring pliers, install the seat cushion cover to the seat cushion pad with new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to prevent wrinkles as much as possible. 15. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD B050126E17 16. INSTALL FRONT SEAT CUSHION SHIELD INNER LH 17. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH 18. INSTALL POWER SEAT SWITCH ASSEMBLY 19. INSTALL FRONT SEAT CUSHION SHIELD LH 20. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH 21. INSTALL VERTICAL ADJUSTING HANDLE NO. 2 22. INSTALL VERTICAL SEAT ADJUSTER KNOB CAP 23. INSTALL VERTICAL SEAT ADJUSTER KNOB LH 24. INSTALL FRONT SEAT HEADREST ASSEMBLY SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) SE–15 INSTALLATION 1. INSTALL FRONT SEAT ASSEMBLY LH (a) Place the front seat assembly LH in the cabin. NOTICE: Be careful not to damage the body. (b) Connect the connectors under the front seat assembly LH. (c) Install the front seat assembly LH with the 4 bolts. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 2. INSTALL SEAT TRACK BRACKET COVER INNER LH 3. INSTALL SEAT TRACK OUTER COVER LH 4. INSTALL SEAT TRACK BRACKET COVER INNER FRONT LH 5. INSTALL SEAT TRACK BRACKET COVER OUTER FRONT LH 6. CHECK SRS WARNING LIGHT 7. CHECK SEAT SLIDE ADJUSTER LOCKS (a) When sliding the front seat assembly LH, check that both sides of the adjuster lock simultaneously. SE SE–42 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) REMOVAL 1. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (a) Remove the headrest. (b) Tumble the seat. (c) Disengage the claws and remove the rear seat cushion hinge covers No. 2 LH and RH. (d) Set the rear seat to the floor. Claw B078863E01 (e) Disengage the claws and remove the rear seat cushion hinge covers No .3 LH and RH. (f) Tumble the seat. (g) Remove the 3 bolts, nut and seat. SE Claw B064886E01 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SE–43 DISASSEMBLY 1. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER LH (a) Using a screwdriver, remove the screw cover, screw and release handle LH. (b) Disengage the claws and remove the 2 screws and reclining cover LH. A Claw A B B B B063206E01 A A Claw B (c) Disengage the claws and remove the 2 screws and reclining cover RH. B C B C C B063202E01 (d) Disengage the seatback cover hem. B063210 B063212 (e) Insert a screwdriver between the seat cushion cover and seat cushion under cover. NOTICE: Tape the screwdriver tip before use. (f) Pry the seat cushion cover hem to disengage it. (g) Cut the hog rings and bring out the seat cushion cover together with the pad. (h) Remove the nut and disconnect the rear seat 3point type seat belt assembly LH. (i) Remove the seat cushion cover together with the pad. (j) Cut the hog rings and remove the seat cushion cover from the pad. SE SE–44 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) 2. REMOVE REAR SEAT ARMREST ASSEMBLY CENTER (a) Open the faster of the seatback cover. (b) Remove the screw and armrest cover. (c) Remove the 3 bolts, guide, armrest hinge and armrest. 3. REMOVE REAR SEATBACK ASSEMBLY LH (a) Disconnect the seat lock control cables from the seatback frame. (b) Remove the 3 bolts, washer, grommet and seatback stopper plate. (c) Disengage the claws and remove the 2 screws and 2 reclining covers. (d) Remove the 4 bolts and rear seatback LH. 4. SE Claw REMOVE REAR SEATBACK COVER LH (a) Remove the 2 tether anchor covers. (b) Remove the rear seat protector. B064887E01 (c) Push the claws and remove the 4 headrest supports. (d) Remove the rear seat shoulder belt hole cover. (e) Remove the seatback cover together with the pad. (f) Cut the rings and remove the seatback cover. 5. REMOVE NO. 1 SEAT 3 POINT TYPE BELT ASSEMBLY LH (a) Remove the 2 screws and reclining adjuster cover. (b) Using a screwdriver, remove the rear seat shoulder belt hole cover. (c) Remove the 2 nuts, 2 screws and seat belt. 6. REMOVE REAR SEAT HINGE SUB-ASSEMBLY LH (a) Using the screwdriver, remove the spring of the seat stay ball-joint. (b) Disconnect the ball-joint from the seat cushion frame. (c) Remove the hinge cover, E-ring, pin, hinge guide, spring and hinge together with the seat stay. 7. REMOVE REAR SEAT HINGE SUB-ASSEMBLY RH (a) Remove the hinge cover, E-ring, pin, hinge guide and hinge. 8. REMOVE REAR SEAT CUSHION UNDER COVER LH (a) Remove the 7 screws, cushion and cover. 9. REMOVE REAR SEAT INNER BELT ASSEMBLY (a) Remove the nut and rear seat belt inner. (b) Remove the nut and rear seat belt inner No. 2. B060977 B064869 10. REMOVE FOLD SEAT LOCK CONTROL CABLE ASSEMBLY SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SE–45 11. REMOVE REAR NO. 1 SEAT LOCK CABLE ASSEMBLY 12. REMOVE REAR SEAT RECLINING CONTROL WIRE SUB-ASSEMBLY SE SE–46 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) REASSEMBLY 1. INSTALL FOLD SEAT LOCK CONTROL CABLE SUBASSEMBLY 2. INSTALL REAR SEAT INNER BELT ASSEMBLY (a) Install the rear seat belt inner No. 2 with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (b) Install the rear seat belt inner with the nut. 3. INSTALL REAR SEAT CUSHION UNDER COVER LH (a) Install the cover with the 6 screws. (b) Install the cushion with the screw. 4. INSTALL REAR SEAT HINGE SUB-ASSEMBLY RH (a) Install the hinge guide to the hinge. (b) Install the hinge with the pin and new E-ring. (c) Install the hinge cover. 5. INSTALL REAR SEAT HINGE SUB-ASSEMBLY LH (a) Install the spring to the ball-joint of the seat stay. (b) Connect the ball-joint to the seat cushion frame securely. (c) Install the spring and hinge guide to the hinge. (d) Install the hinge with the pin and new E-ring. (e) Install the hinge cover. 6. INSTALL NO. 1 3 POINT TYPE BELT ASSEMBLY LH (a) Install the seat belt with the 2 nuts and 2 screws. (b) Install the rear seat shoulder belt hole cover. (c) Install the reclining adjuster cover with the 2 screws. 7. INSTALL REAR SEATBACK COVER LH (a) Install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover together with the pad to the seatback frame. (c) Install the 2 headrest supports. NOTICE: Be careful not to mistake the headrest support direction. (d) Connect the rear seat lock cable to the rear seat reclining cover. (e) Install the rear seat protector. (f) Install the 2 tether anchor covers. 8. INSTALL REAR SEATBACK FRAME SUB-ASSEMBLY LH (a) Install the rear seatback LH with the 4 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) SE SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SE–47 (b) Install the 2 reclining covers with the 2 screws. (c) Install the seatback stopper plate to the seat cushion frame with the 2 bolts. (d) Install the grommet, washer and bolt. (e) Connect the seat lock control cables to the seatback frame. 9. Claw B064887E01 INSTALL REAR SEAT ARMREST ASSEMBLY CENTER (a) Install the armrest. (b) Install the guide to the armrest hinge. (c) Install the armrest hinge with the 3 bolts. (d) Install the armrest cover with the screw. (e) Close the faster of the seatback cover. 10. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER LH (a) Install the seat cushion cover to the seat cushion pad with new hog rings. (b) Install the No .1 seat 3-point type belt through the seat cushion pad. (c) Install the No .1 seat 3-point type belt with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) (d) Install the seat cushion cover together with the pad to the seat cushion frame with new hog rings. (e) Securely engage the seat cushion cover hem to the seat cushion under cover. B063212 (f) B063210 Engage the seatback cover hem. SE SE–48 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) (g) Install the reclining cover RH with the 2 screws. A A Claw B B B C C C B063202E01 A B B Claw A B SE B063206E01 (h) Install the reclining cover LH with the 2 screws. (i) Install the release handle LH with the screw. (j) Install the screw cover. SE–1 SEAT – FRONT POWER SEAT CONTROL SYSTEM FRONT POWER SEAT CONTROL SYSTEM SEAT BODY PARTS LOCATION LUMBER SUPPORT MOTOR RECLINING MOTOR RECLINING MOTOR SE FRONT POWER SEAT SWITCH RH SLIDE MOTOR SLIDE MOTOR FRONT POWER SEAT SWITCH LH REAR VERTICAL MOTOR FRONT VERTICAL MOTOR POWER SEAT SWITCH ASSEMBLY (LUMBER SUPPORT) B120224E02 SE–2 SEAT – FRONT POWER SEAT CONTROL SYSTEM PROBLEM SYMPTOMS TABLE FRONT POWER SEAT CONTROL SYSTEM: Symptom Suspected area 1. Front power seat switch Power seat does not operate Only slide operation function does not operate - 3. Wire harness - 1. Front power seat switch SE-54 2. Slide motor SE-56 SE-54 2. Front vertical motor SE-56 Only reclining operation function does not operate SE-54 2. Lifter motor SE-56 - 1. Front power seat switch SE-54 2. Reclining motor SE-56 3. Wire harness Only lumbar support operation function does not operate (Driver seat only) - 1. Front power seat switch 3. Wire harness SE - 1. Front power seat switch 3. Wire harness Only Rear vertical operation function does not operate (Driver seat only) SE-54 2. PWR SEAT fuse 3. Wire harness Only front vertical operation function does not operate (Driver seat only) See page - 1. Power seat switch assembly (Lumbar support) SE-58 2. Lumbar support adjuster motor SE-59 3. Wire harness - ON-VEHICLE INSPECTION 1. CHECK POWER SEAT FUNCTION (a) Check the basic functions. (1) Operate the power seat switches and check the following seat functions: • Sliding • Reclining • Front vertical (Driver side seat only) • Lifter (Driver side seat only) • Lumbar support (Driver side seat only) 2. CHECK POWER SEAT MOTOR ASSEMBLY (SLIDING, FRONT VERTICAL, LIFTER AND RECLINING FUNCTION) (a) Inspect the PTC operation inside the power seat motor. NOTICE: The inspection should be performed with the seat installed in the vehicle. (1) Move the seat to any of the maximum position by operating the power seat switch, and keep the seat there for approximately 60 seconds. (2) Try to move the power seat beyond the maximum position using the power seat switch. Measure the time needed for shutting off the electrical current after the lumbar support stops moving. (motor operation sound will stop, inspection of current shut-off). Standard: 4 to 90 seconds Reclining Function Lumbar Support Function Front Vertical Function Lifter Function Sliding Function B076688E01 SEAT – FRONT POWER SEAT CONTROL SYSTEM SE–3 (3) Release the power seat switch, and wait for approximately 60 seconds. (4) Operate the power seat switch to move the seat to the opposite position and check that the motor operates. 3. CHECK LUMBAR SUPPORT ADJUSTER ASSEMBLY (a) Inspect the PTC operation inside the power seat motor. NOTICE: The inspection should be performed with the seat installed in the vehicle. (1) Move the lumbar support to either the foremost or rearmost position by operating the lumbar support switch, and keep it there for approximately 60 seconds. (2) Try to move the lumbar support beyond the maximum position using the switch. Measure the time needed for shutting off the electrical current after the lumbar support stops moving. (motor operation sound will stop, inspection of current shut-off). Standard: 4 to 90 seconds (3) Release the lumbar support switch, and wait for approximately 60 seconds. (4) Operate the lumbar support switch to move the lumbar support to the opposite position and check that the motor operates. SE SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SE–49 INSTALLATION 1. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (a) Install the seat with the 3 bolts and nut. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) (b) Set the rear seat to the floor. (c) Install the rear sat cushion hinge covers No. 2 LH and RH. (d) Tumble the seat. Claw B064886E01 (e) Install the rear seat cushion hinge covers No. 2 LH and RH. (f) Install the headrest. Claw B078863E01 SE SE–50 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) REMOVAL 1. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (a) Remove the headrest. (b) Tumble the seat. (c) Disengage the claws and remove the rear seat cushion hinge covers No. 2 LH and RH. (d) Set the rear seat to the floor. Claw B078863E01 (e) Disengage the claws and remove the rear seat cushion hinge covers No. 3 LH and RH. (f) Tumble the seat. (g) Remove the 3 bolts, nut and seat. SE Claw B064886E01 DISASSEMBLY A B Claw A B C B C C 1. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER RH (a) Disengage the claws and remove the 2 screws and reclining cover LH. (b) Using a screwdriver and remove the screw cover, screw and release handle RH. B063201E01 (c) Disengage the claws and remove the 2 screws and reclining cover RH. Claw A A B B B B063205E01 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) SE–51 (d) Disengage the seatback cover hem. (e) Remove the tether anchor cover. (f) Open the fastener of the seatback cover and remove the rear seat protector. B063209 (g) Push the claws and remove the 2 headrest supports. (h) Remove the seatback cover together with the pad. (i) Cut the hog rings and remove the seatback cover. SE B060977 2. REMOVE REAR SEATBACK COVER RH (a) Insert a screwdriver between the seat cushion cover and seat cushion under cover. NOTICE: Tape the screwdriver tip before use. (b) Pry the seat cushion cover hem to disengage it. (c) Cut the hog rings and remove the seat cushion cover together with the pad. (d) Cut the hog rings and remove the seat cushion cover. 3. REMOVE REAR SEAT HINGE SUB-ASSEMBLY LH (a) Remove the hinge cover, E-ring, pin, hinge guide and hinge. 4. REMOVE REAR SEAT HINGE SUB-ASSEMBLY RH (a) Using a screwdriver, remove the spring of the seat stay ball-joint. (b) Disconnect the ball-joint from the seat cushion frame. (c) Remove the hinge cover, E-ring, pin, hinge guide, spring and hinge together with the seat stay. 5. REMOVE REAR SEAT CUSHION UNDER COVER RH (a) Remove the 4 screws and cover. 6. REMOVE REAR SEAT INNER BELT ASSEMBLY (a) Remove the nut and belt. 7. REMOVE REAR NO. 1 SEAT LOCK CABLE ASSEMBLY 8. REMOVE FOLD SEAT LOCK CONTROL CABLE SUBASSEMBLY B063211 B064868 SE–52 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) REASSEMBLY 1. INSTALL REMOVE SEAT LOCK CONTROL CABLE SUB-ASSEMBLY 2. INSTALL REAR NO. 1 SEAT LOCK CABLE ASSEMBLY 3. INSTALL REAR SEAT INNER BELT ASSEMBLY (a) Remove the nut and belt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 4. INSTALL REAR SEAT CUSHION UNDER COVER LH (a) Remove the 4 screws and cover. 5. INSTALL REAR SEAT HINGE SUB-ASSEMBLY RH (a) Install the spring to the ball-joint of the seat stay. (b) Connect the ball-joint to the seat cushion frame securely. (c) Install the spring and hinge guide to the hinge. (d) Install the hinge with the pin and new E-ring. (e) Install the hinge cover. 6. INSTALL REAR SEAT HINGE SUB-ASSEMBLY LH (a) Install the hinge guide to the hinge. (b) Install the hinge with the pin and new E-ring. (c) Install the hinge cover. 7. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER RH (a) Install the seat cushion cover to the seat cushion pad with new hog rings. (b) Install the seat cushion cover together with the pad to the seat cushion frame with new hog rings. SE (c) Engage the seat cushion cover hem to the seat cushion under cover securely. 8. B063211 REMOVE REAR SEATBACK COVER RH (a) Install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover together with the pad to the seatback frame. (c) Install the 2 headrest supports. NOTICE: Be careful not to mistake the headrest support direction. (d) Install the rear seat protector and close the fastener of the seatback cover. (e) Install the tether anchor cover. SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) (f) SE–53 Engage the seatback cover hem. B063209 Claw (g) Install the reclining cover RH with the 2 screws. (h) Install the release handle RH with the screw. (i) Install the screw cover. A A B B B SE B063205E01 (j) A B C Claw A B C B C B063201E01 Install the reclining cover LH with the 2 screws. SE–54 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) INSTALLATION 1. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (a) Install the seat with the 3 bolts and nut. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) (b) Set the rear seat to the floor. (c) Install the rear seat cushion hinge covers No. 3 LH and RH. (d) Tumble the seat. Claw B064886E01 SE (e) Install the rear seat cushion hinge covers No. 2 LH and RH. (f) Install the headrest. Claw B078863E01 SE–18 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) REMOVAL SE CAUTION: • Always wear gloves because the sharp edges of the seatback frame and seat adjuster may cause injury. • Work must be started 90 seconds after the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source. If work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) HINT: • Installation is in the reverse order of removal. However, only installation procedures requiring additional information are included. • Use the same procedures for the RH side and LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page SS-2). • COMPONENTS: See page SE-15 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH (a) Using a screwdriver, remove the seat track bracket cover outer front LH. HINT: Tape the screwdriver tip before use. 3. REMOVE SEAT TRACK OUTER COVER RH HINT: Removal procedure of the seat track bracket cover inner front LH is the same as for the seat track bracket cover outer front LH. 4. REMOVE SEAT TRACK OUTER COVER LH HINT: Removal procedure of the seat track outer cover RH is the same as for the seat track bracket cover outer front LH. 5. REMOVE SEAT TRACK BRACKET COVER INNER LH HINT: Removal procedure of the seat track bracket cover inner LH is the same as for the seat track bracket cover outer front LH. 6. REMOVE FRONT SEAT ASSEMBLY LH (a) Disconnect the connectors under the front seat assembly LH. (b) Remove the 4 bolts and front seat assembly LH. NOTICE: Be careful not to damage the body. SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SE–19 DISASSEMBLY 1. REMOVE FRONT SEAT HEADREST ASSEMBLY 2. REMOVE RECLINING POWER SEAT SWITCH KNOB (a) Using a screwdriver, remove the reclining power seat switch knob. HINT: Tape the screwdriver tip before use. 3. REMOVE SLIDE & VERTICAL POWER SEAT SWITCH KNOB (a) Using a screwdriver, remove the slide & vertical power seat switch knob. HINT: Tape the screwdriver tip before use. 4. REMOVE FRONT SEAT CUSHION SHIELD INNER NO. 1 LH (a) Remove the 5 screws. (b) Driver seat only: (1) Using a screwdriver, disengage the 2 claws and remove the front seat cushion shield inner No. 1 LH with the front seat cushion shield LH, and then disconnect the connector. HINT: Tape the screwdriver tip before use. (c) Passenger seat only: (1) Using a screwdriver, disengage the 2 claws and remove the front seat cushion shield inner No. 1 LH with the front seat cushion shield LH. HINT: Tape the screwdriver tip before use. (d) Remove the screw and front seat cushion shield inner No. 1 LH. Claw B065797E01 Claw Clip 5. REMOVE POWER SEAT SWITCH ASSEMBLY (a) Remove the 2 screws and power seat switch assembly. 6. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH 7. REMOVE FRONT SEAT CUSHION SHIELD INNER LH (a) Remove the screw. (b) Using a screwdriver, disengage the 2 claws and clip, and remove the front seat cushion shield inner LH. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT POWER SEAT SWITCH LH (a) Disconnect the connectors. (b) Remove the 3 screws and front power seat switch LH. 9. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (a) Disengage the hook and remove the seat cushion cover together with the pad. B065449E01 SE SE–20 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) 10. REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Remove the hog rings and seat cushion cover. 11. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY LH 12. REMOVE FRONT SEATBACK BOARD SUBASSEMBLY (a) Remove the 2 screws and front seatback board. 13. REMOVE FRONT SEATBACK BOARD COVER SUBASSEMBLY 14. REMOVE FRONT SEAT HEADREST SUPPORT (a) Remove the 2 front seat headrest supports. SE B060977 15. REMOVE SEPARATE TYPE SEATBACK COVER WITH PAD (a) with Side airbag: (1) Remove the hog rings, nut and seatback cover bracket. (b) Remove the hog rings and seatback cover together with the pad. B065179 16. REMOVE SEPARATE TYPE FRONT SEATBACK COVER (a) Remove the hog rings and front seatback cover. 17. REMOVE FRONT SEATBACK HEATER ASSEMBLY LH 18. REMOVE RECLINING ADJUSTER INSIDE COVER LH (a) Remove the 2 screws and reclining adjuster inside cover LH (lower). (b) Remove the screw and reclining adjuster inside cover LH (upper). 19. REMOVE RECLINING ADJUSTER INSIDE COVER RH (a) Remove the 2 screws and reclining adjuster inside cover RH (lower). (b) Remove the screw and reclining adjuster inside cover RH (upper). 20. REMOVE VERTICAL ADJUSTER BRACKET COVER OUTER (a) Remove the screw and vertical adjuster bracket cover outer. SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SE–21 21. REMOVE VERTICAL ADJUSTER BRACKET COVER INNER (a) Remove the screw and vertical adjuster bracket cover inner. 22. REMOVE LUMBAR SUPPORT ADJUSTER ASSEMBLY LH (a) Remove the 2 screws and lumbar support adjuster assembly LH. 23. REMOVE SEAT POSITION AIR BAG SENSOR HINT: See page RS-443 24. REMOVE FRONT SEAT CUSHION PROTECTOR 25. REMOVE SEAT WIRE NO. 2 26. REMOVE OCCUPANT DETECTION ECU HINT: See page RS-447 SE SE–4 SEAT – SEAT HEATER SYSTEM SEAT HEATER SYSTEM SEAT BODY PARTS LOCATION FRONT SEATBACK HEATER ASSEMBLY RH FRONT SEATBACK HEATER ASSEMBLY LH SE FRONT SEAT CUSHION HEATER ASSEMBLY RH SEAT HEATER SWITCH RH SEAT HEATER SWITCH LH FRONT SEAT CUSHION HEATER ASSEMBLY LH B120225E01 SE–5 SEAT – SEAT HEATER SYSTEM PROBLEM SYMPTOMS TABLE SEAT HEATER SYSTEM: Symptom Suspected area 1. SEAT HEATER fuse Seat heaters do not operate (Seat is not warmed up) - 2. IG1 fuse - 3. IG relay - 4. Front seat cushion heater assembly LH SE-63 5. Front seat cushion heater assembly RH SE-63 6. Front seatback heater assembly LH SE-62 7. Front seatback heater assembly RH SE-62 8. Seat heater switch LH SE-60 9. Seat heater switch RH SE-60 10.Wire harness Temperature of seat heater cannot be adjusted See page - 1. Seat heater switch LH SE-60 2. Seat heater switch RH SE-60 3. Wire harness - SE SE–22 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) REASSEMBLY SE 1. INSTALL OCCUPANT DETECTION ECU HINT: See page RS-447 2. INSTALL SEAT WIRE NO. 2 3. INSTALL FRONT SEAT CUSHION PROTECTOR 4. INSTALL SEAT POSITION AIR BAG SENSOR HINT: See page RS-444 5. INSTALL LUMBAR SUPPORT ADJUSTER ASSEMBLY LH 6. INSTALL VERTICAL ADJUSTER BRACKET COVER INNER 7. INSTALL VERTICAL ADJUSTER BRACKET COVER OUTER 8. INSTALL RECLINING ADJUSTER INSIDE COVER RH 9. INSTALL RECLINING ADJUSTER INSIDE COVER LH 10. REMOVE FRONT SEATBACK HEATER ASSEMBLY LH 11. INSTALL SEPARATE TYPE FRONT SEATBACK COVER (a) Install the seatback pad. (b) Cover the top of the seatback pad with the front seatback cover. Hog Ring Pilers B050126E13 (c) Using hog ring pliers, install the front seatback cover completely with new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to prevent wrinkles as much as possible. 12. INSTALL SEPARATE TYPE FRONT SEATBACK COVER WITH PAD (a) Install the seatback cover together with the pad with new hog rings. (b) with Side airbag: (1) Install the front seatback cover bracket with the nut. Torque: 5.5 N*m (56 kgf*cm, 48 in.*lbf) B065179 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SE–23 (c) with Side airbag: (1) Install the wire harness and clamp of the side airbag through the seat cushion cover end. NOTICE: Be careful not to damage the cover. (d) Using hog ring pliers, install new hog rings. Clamp 13. INSTALL FRONT SEAT HEADREST SUPPORT B065611E01 14. REMOVE FRONT SEATBACK BOARD COVER SUBASSEMBLY 15. REMOVE FRONT SEATBACK BOARD SUBASSEMBLY 16. REMOVE FRONT SEAT CUSHION HEATER ASSEMBLY LH 17. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER 18. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER WITH PAD (a) Install the seat cushion pad to the seat cushion cover. Hog Ring Pilers (b) Using hog ring pliers, install the seat cushion cover to the seat cushion pad with new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, take care to prevent wrinkles as much as possible. 19. REMOVE FRONT POWER SEAT SWITCH LH 20. INSTALL FRONT SEAT CUSHION SHIELD INNER LH B050126E13 21. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH HINT: See page RS-28 22. INSTALL POWER SEAT SWITCH ASSEMBLY 23. INSTALL FRONT SEAT CUSHION SHIELD INNER NO.1 LH 24. INSTALL SLIDE & VERTICAL POWER SEAT SWITCH KNOB 25. INSTALL RECLINING POWER SEAT SWITCH KNOB 26. INSTALL FRONT SEAT HEADREST ASSEMBLY SE SE–6 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) SEAT BODY COMPONENTS SEAT TRACK BRACKET COVER INNER LH FRONT SEAT ASSEMBLY LH SE 37 (375, 27) 37 (375, 27) 37 (375, 27) SEAT TRACK OUTER COVER LH SEAT TRACK BRACKET COVER OUTER FRONT LH SEAT TRACK BRACKET COVER INNER FRONT LH N*m (kgf*cm, ft.*lbf) : Specified torque B120226E01 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) SE–7 SEAT CUSHION COVER HOG RING SEAT CUSHION PAD FRONT SEAT INNER BELT ASSEMBLY LH DRIVER SEAT ONLY: POWER SEAT SWITCH ASSEMBLY SE 42 (428, 31) RECLINING ADJUSTER RELEASE HANDLE LH FRONT SEAT CUSHION SHIELD INNER LH FRONT SEAT CUSHION SHIELD LH VERTICAL ADJUSTING HANDLE NO. 2 SNAP RING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part VERTICAL SEAT ADJUSTER VERTICAL SEAT ADJUSTER KNOB LH KNOB CAP B120227E02 SE–8 SEAT – FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side) FRONT SEAT HEADREST ASSEMBLY FRONT SEAT HEADREST SUPPORT FRONT SEAT HEADREST SUPPORT 5.5 (56, 48 in.*lbf) WITH SIDE AIRBAG: FRONT SEATBACK PAD HOG RING SE FRONT SEATBACK COVER DRIVER SEAT ONLY: LUMBAR SUPPORT ADJUSTER ASSEMBLY LH RECLINING ADJUSTER INSIDE COVER RH (LOWER) RECLINING ADJUSTER INSIDE COVER RH (UPPER) RECLINING ADJUSTER INSIDE COVER LH (LOWER) RECLINING ADJUSTER INSIDE COVER LH (UPPER) SEAT WIRE NO. 2 PASSENGER SEAT ONLY: FRONT SEAT CUSHION PROTECTOR FRONT SEAT CUSHION SHIELD LOWER RH FRONT SEAT CUSHION SHIELD LOWER LH OCCUPANT CLASSIFICATION ECU 8.0 (82, 71 in.*lbf) DRIVER SEAT ONLY: SEAT POSITION AIR BAG SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120228E02 SE–24 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) INSTALLATION SE 1. INSTALL FRONT SEAT ASSEMBLY LH (a) Place the front seat assembly LH in the cabin. NOTICE: Be careful not to damage the body. (b) Connect the connectors under the front seat assembly LH. (c) Install the front seat assembly LH with the 4 bolts. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 2. INSTALL SEAT TRACK BRACKET COVER INNER LH 3. INSTALL SEAT TRACK OUTER COVER LH 4. INSTALL SEAT TRACK BRACKET COVER INNER FRONT LH 5. INSTALL SEAT TRACK BRACKET COVER OUTER FRONT LH 6. CHECK SRS WARNING LIGHT HINT: See page RS-28 7. CHECK SEAT SLIDE ADJUSTER LOCKS SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SE–15 FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SEAT BODY COMPONENTS SEAT TRACK BRACKET COVER INNER LH FRONT SEAT ASSEMBLY LH SE 37 (375, 27) 37 (375, 27) 37 (375, 27) SEAT TRACK OUTER COVER LH SEAT TRACK BRACKET COVER OUTER FRONT LH SEAT TRACK BRACKET COVER INNER FRONT LH N*m (kgf*cm, ft.*lbf) : Specified torque B120229E01 SE–16 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) HOG RING SEAT CUSHION COVER SEAT CUSHION PAD WIRING HARNESS CONNECTOR FRONT SEAT INNER BELT ASSEMBLY LH SE DRIVER SEAT ONLY: 42 (428, 31) POWER SEAT SWITCH ASSEMBLY FRONT SEAT CUSHION SHIELD INNER NO. 1 LH FRONT SEAT CUSHION SHIELD INNER LH FRONT SEAT CUSHION SHIELD LH FRONT POWER SEAT SWITCH LH SLIDE & VERTICAL POWER SEAT SWITCH KNOB N*m (kgf*cm, ft.*lbf) : Specified torque RECLINING POWER SEAT SWITCH KNOB Non-reusable part B120230E02 SEAT – FRONT SEAT ASSEMBLY (for Power Seat Type LH Side) SEPARATE TYPE FRONT SEATBACK COVER WITH PAD FRONT SEAT HEADREST ASSEMBLY SE–17 FRONT SEATBACK BOARD COVER SUB-ASSEMBLY RH FRONT SEATBACK BOARD COVER SUB-ASSEMBLY FRONT SEAT HEADREST SUPPORT HOG RING DRIVER SEAT ONLY: 5.5 (56, 48 in.*lbf) WITH SIDE AIRBAG: SEPARATE TYPE FRONT SEATBACK COVER LUMBAR SUPPORT ADJUSTER ASSEMBLY LH RECLINING ADJUSTER INSIDE COVER RH (UPPER) RECLINING ADJUSTER INSIDE COVER LH (UPPER) RECLINING ADJUSTER INSIDE COVER RH (LOWER) FRONT SEAT CUSHION PROTECTOR RECLINING ADJUSTER INSIDE COVER LH (LOWER) SEAT WIRE NO. 2 PASSENGER SEAT ONLY: VERTICAL ADJUSTER BRACKET COVER OUTER VERTICAL ADJUSTER BRACKET COVER INNER OCCUPANT CLASSIFICATION ECU N*m (kgf*cm, ft.*lbf) : Specified torque 8.0 (82, 71 in.*lbf) DRIVER SEAT ONLY: Non-reusable part SEAT POSITION AIR BAG SENSOR B120231E02 SE SEAT – REAR NO. 1 SEAT ASSEMBLY SE–27 REMOVAL HINT: Installation is in the reverse order of removal. However, only installation procedures requiring additional information are included. 1. REMOVE REAR SEAT HEADREST ASSEMBLY LH AND RH 2. REMOVE REAR SEAT HEADREST ASSEMBLY CENTER 3. REMOVE REAR SEAT CUSHION ASSEMBLY LH (a) Remove the 2 hinge covers. (b) Remove the 2 bolts and seat cushion. 4. REMOVE REAR SEAT CUSHION ASSEMBLY RH (a) Remove the 2 hinge covers. (b) Remove the 2 bolts and seat cushion. 5. REMOVE REAR SEATBACK BOARD CARPET ASSEMBLY LH (a) Using a screwdriver, disengage the 6 clips and remove the carpet. HINT: Tape the screwdriver tip before use. 6. REMOVE REAR SEATBACK ASSEMBLY LH (a) Remove the 2 bolts and seatback. 7. REMOVE REAR SEATBACK BOARD CARPET ASSEMBLY RH (a) Using a screwdriver, disengage the 9 clips and remove the carpet. HINT: Tape the screwdriver tip before use. 8. REMOVE REAR SEATBACK ASSEMBLY RH (a) Remove the bolt and the floor anchor for the rear seat belt outer center. (b) Remove the 2 bolts and seatback. Clip B064775E01 Clip B064776E01 SE SE–28 SEAT – REAR NO. 1 SEAT ASSEMBLY DISASSEMBLY 1. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY LH (a) Remove the bolt and seatback hinge. 2. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY RH (a) Remove the bolt and seatback hinge. 3. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY CENTER (a) Remove the 2 bolts and seatback hinge. 4. REMOVE REAR SEAT LOCK STRIKER SUBASSEMBLY (a) Remove the 6 bolts and 2 lock strikers. 5. REMOVE REAR SEAT ARMREST ASSEMBLY CENTER (a) Remove the screw and armrest cover. (b) Remove the bolt and armrest. 6. REMOVE REAR SEATBACK LOCK COVER LH (a) Remove the screw and seatback lock cover. 7. REMOVE REAR SEATBACK LOCK COVER RH (a) Remove the screw and seatback lock cover. 8. REMOVE SEPARATE TYPE REAR SEATBACK LOCK COVER LH (a) Using a screwdriver, disengage the 2 claws and remove the stop button grommet. HINT: Tape the screwdriver tip before use. (b) Remove the 2 headrest supports. (c) Remove the hog rings and seatback cover together with the pad from the seatback frame. (d) Remove the hog rings and seatback cover from the seatback pad. 9. REMOVE SEPARATE TYPE REAR SEATBACK LOCK COVER RH (a) Using a screwdriver, disengage the 2 claws and remove the stop button grommet. HINT: Tape the screwdriver tip before use. SE B065129 B065130 SEAT – REAR NO. 1 SEAT ASSEMBLY SE–29 (b) Using a screwdriver, disengage the 4 claws and remove the shoulder belt cover. HINT: Tape the screwdriver tip before use. (c) Remove the 2 headrest supports. (d) Remove the hog rings and seatback cover together with the pad from the seatback frame. (e) Remove the hog rings and seatback cover from the seatback pad. Claw Claw B064861E01 10. REMOVE REAR SEATBACK LOCK ASSEMBLY LH (a) Remove the seatback lock release button. (b) Remove the 2 bolts and seatback lock. 11. REMOVE REAR SEATBACK LOCK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 12. REMOVE REAR SEAT BELT ASSEMBLY OUTER CENTER (a) Remove the nut and belt assembly. 13. REMOVE REAR NO. 1 SEAT HINGE SUB-ASSEMBLY LH (a) Remove the 2 bolts and 2 hinge sub-assembly. 14. REMOVE REAR NO. 1 SEAT HINGE SUB-ASSEMBLY RH (a) Remove the 2 bolts and 2 hinge sub-assembly. 15. REMOVE REAR SEAT CUSHION UNDER COVER LH (a) Disengage the cushion cover hook. (b) Remove the cushion cover together with the pad. (c) Remove the 4 clips and cushion under cover. 16. REMOVE REAR SEAT CUSHION UNDER COVER RH HINT: Use the same procedures described for the LH side. 17. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER LH (a) Remove the hog rings and cushion cover from the cushion pad. 18. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER RH (a) Remove the hog rings and cushion cover from the cushion pad. Hog Ring Pliers REASSEMBLY 1. B050126E17 INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER LH (a) Install the seat cushion cover to the seat cushion pad with new hog rings. (b) Install the seat cushion cover with the pad to the seat cushion frame with new hog rings. HINT: When installing hog rings, take care to prevent wrinkles as much as possible. SE SE–30 SEAT – REAR NO. 1 SEAT ASSEMBLY Hog Ring Pliers SE B050126E17 2. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER RH HINT: Use the same procedures described for the LH side. 3. INSTALL REAR SEAT CUSHION UNDER COVER LH (a) Install the under cover with the 5 clips. 4. INSTALL REAR SEAT CUSHION UNDER COVER RH (a) Install the under cover with the 7 clips. 5. INSTALL SEPARATE TYPE REAR SEATBACK COVER LH (a) Install the seatback cover to the seatback pad RH with new hog rings. (b) Install the seatback cover with the pad to the seatback frame with new hog rings. HINT: When installing hog rings, take care to prevent wrinkles as much as possible. 6. INSTALL SEPARATE TYPE REAR SEATBACK COVER RH HINT: Use the same procedures described for the LH side. 7. INSTALL REAR NO. 1 SEAT HINGE SUB-ASSEMBLY LH (a) Install the 2 hinge with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 8. INSTALL REAR NO. 1 SEAT HINGE SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side. 9. INSTALL REAR SEAT BELT OUTER CENTER (a) Install the belt with the nut. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 10. INSTALL REAR SEAT ARMREST ASSEMBLY CENTER (a) Install the armrest with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Install the armrest cover with the screw. 11. INSTALL REAR SEAT LOCK STRIKER SUBASSEMBLY (a) Install the 2 strikers with the 6 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 12. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY CENTER (a) Install the hinge with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 13. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY LH (a) Install the hinge with the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) SEAT – REAR NO. 1 SEAT ASSEMBLY SE–31 14. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side. SE SE–24 SEAT – REAR NO. 1 SEAT ASSEMBLY REAR NO. 1 SEAT ASSEMBLY SEAT BODY COMPONENTS REAR SEAT HEADREST ASSEMBLY CENTER REAR SEAT LOCK STRIKER SUB-ASSEMBLY REAR SEATBACK LOCK COVER RH REAR SEAT HEADREST ASSEMBLY RH REAR SEATBACK LOCK ASSEMBLY RH REAR SEATBACK STOP BUTTON GROMMET REAR SEATBACK LOCK RELEASE BUTTON REAR SEAT BELT ASSEMBLY OUTER CENTER SE REAR SEAT SHOULDER BELT COVER 18 (184, 13) 18 (184, 13) 42 (428, 31) REAR SEAT HEADREST SUPPORT 37 (377, 27) REAR SEATBACK HINGE SUB-ASSEMBLY RH HOG RING REAR SEATBACK BOARD CARPET ASSEMBLY RH SEPARATE TYPE REAR SEATBACK COVER RH REAR SEATBACK PAD RH REAR SEATBACK FRAME SUB-ASSEMBLY RH REAR SEATBACK TOP TETHER COVER INNER REAR SEATBACK TOP TETHER COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120293E01 SEAT – REAR NO. 1 SEAT ASSEMBLY SE–25 REAR SEATBACK BOARD CARPET ASSEMBLY LH REAR SEAT HEADREST ASSEMLBY LH REAR SEAT HEADREST SUPPORT REAR SEATBACK TOP TERHER COVER REAR SEATBACK TOP TETHER COVER INNER REAR SEATBACK FRAME SUB-ASSEMBLY LH REAR SEATBACK PAD LH SE SEPARATE TYPE REAR SEATBACK COVER LH REAR SEAT ARMREST ASSEMBLY CENTER REAR SEATBACK LOCK RELEASE BUTTON 18 (184, 13) 8.0 (82, 71 in.*lbf) HOG RING 37 (377, 27) REAR SEAT CENTER ARMREST SUPPORT RH HOG RING 18 (184, 27) REAR SEAT ARMREST COVER REAR SEAT LOCK STRIKER SUB-ASSEMBLY REAR SEATBACK HINGE SUB-ASSEMBLY LH REAR SEATBACK STOP BUTTON GROMMET REAR SEATBACK LOCK ASSEMBLY LH REAR SEATBACK LOCK COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120294E01 SE–26 SEAT – REAR NO. 1 SEAT ASSEMBLY REAR SEAT CUSHION UNDER COVER RH REAR SEAT CUSHION FRAME SUB-ASSEMBLY RH REAR SEAT CUSHION PAD RH SEPARATE TYPE REAR SEAT CUSHION COVER RH REAR SEAT CUSHION UNDER COVER LH REAR SEAT CUSHION FRAME SUB-ASSEMBLY LH REAR SEAT CUSHION PAD LH SEPARATE TYPE REAR SEAT CUSHION COVER LH SE REAR NO. 1 SEAT HINGE SUB-ASSEMBLY RH HOG RING x7 37 (377, 27) 18 (184, 13) 18 (184, 13) x5 37 (377, 27) 37 (377, 27) REAR SEAT CUSHION HINGE COVER REAR SEAT CUSHION HINGE COVER 18 (184, 13) REAR NO. 1 SEAT HINGE SUB-ASSEMBLY LH REAR SEATBACK HINGE SUB-ASSEMBLY CENTER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B134256E02 SE–32 SEAT – REAR NO. 1 SEAT ASSEMBLY INSTALLATION SE 1. INSTALL REAR SEATBACK ASSEMBLY LH (a) Install the seatback with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 2. INSTALL REAR SEATBACK ASSEMBLY RH (a) Install the seatback with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) (b) Install the floor anchor with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 3. INSTALL REAR SEAT CUSHION ASSEMBLY LH (a) Install the cushion with the 2 bolts. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) (b) Install the 2 hinge covers. 4. INSTALL REAR SEAT CUSHION ASSEMBLY RH HINT: Use the same procedures described for the LH side. SE–32 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) SEAT BODY COMPONENTS LH: HEADREST REAR NO. 2 SEAT LH SEAT NO. 2 BACK PAD LH SE SEAT NO. 2 LEG COVER SEAT NO. 2 BACK COVER SUB-ASSEMBLY LH SEAT NO. 3 LEG COVER SEAT NO. 2 LEG COVER HOG RING NO. 2 SEAT CUSHION COVER SUB-ASSEMBLY LH HOG RING SEAT NO. 2 CUSHION PAD LH Non-reusable part B120237E01 SE–33 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) LH: REAR SEAT FRAME HEADREST SUPPORT REAR SEATBACK PROTECTOR REAR SEAT RECLINING COVER NO. 2 RH 18 (185, 13) REAR SEAT RECLINING COVER NO. 2 LH 18 (185, 13) NO. 1 SEAT CUSHION CARPET SCREW COVER RELEASE HANDLE NO. 1 SEAT CUSHION FRAME SUB-ASSEMBLY 42 (430, 31) REAR SEAT BELT INNER STOPPER BAND SEAT CUSHION UNDER COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120238E02 SE SE–34 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) RH: HEADREST REAR NO. 2 SEAT RH SEAT NO. 2 LEG COVER SEAT NO. 3 LEG COVER SE SEAT NO. 2 LEG COVER NO. 2 SEATBACK COVER SUB-ASSEMBLY RH SEAT NO. 2 BACK PAD RH HOG RING NO. 2 SEAT CUSHION COVER SUB-ASSEMBLY RH HOG RING SEAT NO. 2 SUCHION PAD RH Non-reusable part B120239E01 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) SE–35 RH: HEADREST SUPPORT REAR SEAT FRAME REAR SEATBACK PROTECTOR SCREW COVER RELEASE HANDLE SE REAR SEAT RECLINING COVER NO. 2 RH 18 (185, 13) REAR SEAT RECLINING COVER NO. 2 LH NO. 1 SEAT CUSHION CARPET 18 (185, 13) STOPPER BAND 42 (430, 31) REAR SEAT BELT INNER NO. 1 SEAT CUSHION FRAME SUB-ASSEMBLY SEAT CUSHION UNDER COVER N*m (kgf*cm, ft.*lbf) : Specified torque B120240E02 SE–36 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) REMOVAL 1. Claw REMOVE REAR NO. 2 SEAT ASSEMBLY LH (a) Disengage the claws and remove the seat leg cover. B064892E01 (b) Release the rear seat lock and remove the seat. (c) Remove the headrests. SE B064896 DISASSEMBLY Claw 1. REMOVE NO. 2 SEATBACK COVER SUB-ASSEMBLY LH (a) Disengage the claws and remove the 2 screws and reclining cover LH. B078862E01 (b) Remove the screw cover, screw and release handle. B064894 (c) Disengage the claws and remove the 2 screws and reclining cover RH. (d) Open the fastener of the seatback cover and remove the seatback protector. (e) Remove the screw and the cushion. Claw B064895E01 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) SE–37 (f) Remove the headrest supports. (g) Remove the seatback cover together with the pad. (h) Cut the hog rings and remove the seatback cover. 2. REMOVE NO. 2 SEATBACK COVER SUB-ASSEMBLY RH 3. REMOVE NO. 2 SEAT CUSHION COVER SUBASSEMBLY LH (a) Insert a screwdriver between the seat cushion cover and seat cushion under cover. NOTICE: Tape the screwdriver tip before use. (b) Pry the seat cushion cover hem to disengage it. (c) Cut the hog rings and remove the seat cushion cover. 4. REMOVE NO. 2 SEAT CUSHION COVER SUBASSEMBLY RH 5. REMOVE NO. 1 SEAT CUSHION FRAME SUBASSEMBLY LH (a) Remove the 4 screws and seat cushion under cover. (b) Remove the nut and stopper band. (c) Remove the 2 bolts, 2 springs and seat leg. B060977 SE SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SE–39 REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) SEAT BODY COMPONENTS HEADREST REAR NO. 1 SEAT ASSEMBLY LH REAR SEAT CUSHION HINGE COVER NO. 3 RH REAR SEAT CUSHION HINGE COVER NO. 2 RH 37 (375, 27) REAR SEAT CUSHION HINGE COVER NO. 2 LH 37 (375, 27) REAR SEAT CUSHION HINGE COVER NO. 3 LH N*m (kgf*cm, ft.*lbf) : Specified torque B120232E01 SE SE–40 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) REAR SEAT BELT SHOULDER COVER REAR SEAT 3-POINT TYPE BELT ASSEMBLY LH HEADREST SUPPORT REAR SEATBACK FRAME 42 (430, 31) SE REAR SEAT RECLINING COVER NO. 1 TETHER ANCHOR COVER REAR SEAT SHOULDER BELT HOLE COVER LH REAR SEAT RECLINING COVER INNER LH ARMREST COVER REAR SEAT PROTECTOR REAR SEATBACK PAD REAR SEATBACK COVER REAR SEAT ARMREST ASSEMBLY CENTER ARMREST HINGE B120233E01 SE–41 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) REAR SEAT RECLINING COVER INNER LH REAR SEAT CUSHION COVER REAR SEAT RECLINING COVER INNER RH SEATBACK STOPPER PLATE REAR SEAT RECLINING COVER INNER LH REAR SEAT RECLINING COVER INNER RH FOLD SEAT LOCK CONTROL CABLE SUB-ASSEMBLY REAR NO. 1 SEAT LOCK CABLE ASSEMBLY REAR SEAT RECLINING CONTROL WIRE SUB-ASSEMBLY RECLINING COVER RH HOG RING SE 42 (430, 31) REAR SEAT BELT INNER REAR SEAT CUSHION PAD REAR SEAT CUSHION FRAME RELEASE HANDLE LH REAR SEAT BELT INNER NO. 2 HINGE COVER PIN SPRING PROTECTOR E-RING REAR SEAT HINGE SUB-ASSEMBLY RH SPRING SEAT STAY SCREW COVER GUIDE PIN E-RING REAR SEAT HINGE SUB-ASSEMBLY LH PIN REAR SEAT CUSHION UNDER COVER PROTECTOR N*m (kgf*cm, ft.*lbf) : Specified torque RECLINING COVER LH Non-reusable part B120234E01 SE–38 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) REASSEMBLY 1. INSTALL NO. 1 SEAT CUSHION FRAME SUBASSEMBLY LH (a) Install the spring between the seat frame and seat leg. (b) Install the seat leg with the 2 bolts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) (c) Install the stopper band with the nut. (d) Install the seat cushion under cover with the 4 screws. 2. REMOVE REAR SEAT INNER BELT ASSEMBLY (a) Install the seat belt inner with the nut. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 3. INSTALL NO. 2 SEAT CUSHION COVER SUBASSEMBLY LH (a) Using hog ring pliers, install the the seat cushion cover with new hog rings. (b) Place the seat cushion cover together with the pad on the seat frame. (c) Engage the seat cushion cover hem to the seat cushion under cover securely. 4. INSTALL NO. 2 SEATBACK COVER SUB-ASSEMBLY LH (a) Using hog ring pliers, install the seatback cover with new hog rings. (b) Install the seatback cover together with the pad to the seat frame. (c) Install the headrest supports. (d) Install the seatback protector. (e) Close the fastener of the seatback cover. (f) Install the cushion with the screw. SE (g) Install the reclining cover RH with the 2 screws. Claw B064895E01 (h) Install the release handle with the screw. (i) Install the screw cover. B064894 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) (j) SE–39 Install the reclining cover LH with the 2 screws. Claw B078862E01 SE SE–48 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) SEAT BODY COMPONENTS REAR NO. 1 SEAT ASSEMBLY RH HEADREST REAR SEAT CUSHION HENGE COVER NO. 3 RH REAR SEAT CUSHION HINGE COVER NO. 2 RH 37 (375, 27) REAR SEAT CUSHION HENGE COVER NO. 3 LH SE 37 (375, 27) REAR SEAT CUSHION HINGE COVER NO. 2 LH HEADREST SUPPORT REAR SEATBACK FRAME REAR SEATBACK PAD REAR SEATBACK COVER TETHER ANCHOR COVER REAR SEAT RECLINING COVER INNER LH REAR SEAT RECLINING COVER INNER RH HOG RING 50 (510, 37) REAR SEAT PROTECTOR RECLINING COVER INNER RH HOG RING REAR SEAT CUSHION PAD RECLINING COVER INNER LH REAR SEAT CUSHION COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B142557E01 SE–49 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) REAR SEAT RECLINING CONTROL WIRE SUB-ASSEMBLY REAR NO. 1 SEAT LOCK CABLE ASSEMBLY FOLD SEAT LOCK CONTROL CABLE SUB-ASSEMBLY RELEASE HANDLE LH SE SCREW COVER REAR SEAT HINGE SUB-ASSEMBLY RH RECLINING COVER RH SEAT STAY REAR SEAT CUSHION FRAME E-RING REAR SEAT BELT INNER HINGE COVER PIN SPRING PROTECTOR GUIDE SPRING PIN E-RING 42 (430, 31) RECLINING COVER LH PROTECTOR PIN REAR SEAT HINGE SUB-ASSEMBLY LH REAR SEAT CUSHION UNDER COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120236E01 SE–40 SEAT – REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) INSTALLATION 1. SE INSTALL REAR NO. 2 SEAT ASSEMBLY LH (a) Install the headrests. (b) Install the seat. (c) Install the seat leg cover. SE–54 SEAT – POWER SEAT SWITCH POWER SEAT SWITCH Slide Switch Reclining Switch INSPECTION 1. Front Vertical Switch Lifter Switch RCLF E SE B RCLR INSPECT FRONT POWER SEAT SWITCH (a) Check the resistance between the terminals when each switch is operated. Standard resistance: Slide switch Tester Connection Switch Condition Specified Condition 1 (B) - 9 (SLDF) FRONT Below 1 Ω 4 (E) - 6 (SLDR) FRONT Below 1 Ω 4 (E) - 6 (SLDR) OFF Below 1 Ω 4 (E) - 9 (SLDF) OFF Below 1 Ω 1 (B) - 6 (SLDR) REAR Below 1 Ω 1 (E) - 6 (SLDF) REAR Below 1 Ω Front vertical switch FUP SLDF LDWN LUP SLDR FDWN Tester Connection Switch Condition Specified Condition 1 (B) - 10 (FUP) UP Below 1 Ω 4 (E) - 5 (FDWN) UP Below 1 Ω 4 (E) - 5 (FDWN) OFF Below 1 Ω B105970E02 4 (E) - 10 (FUP) OFF Below 1 Ω 1 (B) - 5 (FDWN) DOWN Below 1 Ω 4 (E) - 10 (FUP) DOWN Below 1 Ω Rear vertical switch Tester Connection Switch Condition Specified Condition 1 (B) - 7 (LUP) UP Below 1 Ω 4 (E) - 8 (LDWN) UP Below 1 Ω 4 (E) - 7 (LUP) OFF Below 1 Ω 4 (E) - 8 (LDWN) OFF Below 1 Ω 1 (B) - 8 (LDWN) DOWN Below 1 Ω 4 (E) - 7 (LUP) DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1 (B) - 3 (RCLF) FRONT Below 1 Ω 2 (RCLR) - 4 (E) FRONT Below 1 Ω 2 (RCLR) - 4 (E) OFF Below 1 Ω Reclining switch 3 (RCLF) - 4 (E) OFF Below 1 Ω 1 (B) - 2 (RCLR) REAR Below 1 Ω 3 (RCLF) - 4 (E) REAR Below 1 Ω If the result is not as specified, replace the switch. SE–55 SEAT – POWER SEAT SWITCH 2. Reclining Switch E Slide Switch RCLF RCLR B INSPECT FRONT POWER SEAT SWITCH RH (a) Inspect the front passenger side power seat switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: Slide switch Tester Connection Switch Condition Specified Condition 1 (B) - 9 (SLDF) FRONT Below 1 Ω 4 (B) - 6 (SLDR) FRONT Below 1 Ω 4 (B) - 6 (SLDR) OFF Below 1 Ω 4 (E) - 9 (SLDF) OFF Below 1 Ω 1 (B) - 6 (SLDR) REAR Below 1 Ω 4 (E) - 9 (SLDF) REAR Below 1 Ω Reclining switch SLDF SLDR B111877E01 Tester Connection Switch Condition Specified Condition 1 (B) - 3 (RCLF) FRONT Below 1 Ω 2 (RCLR) - 4 (E) FRONT Below 1 Ω 2 (RCLR) - 4 (E) OFF Below 1 Ω 3 (RCLF) - 4 (E) OFF Below 1 Ω 1 (B) - 2 (RCLR) REAR Below 1 Ω 3 (RCLF) - 4 (E) REAR Below 1 Ω If the result is not as specified, replace the switch. SE SE–56 Slide Motor: Counterclockwise SEAT – FRONT SEAT FRAME WITH ADJUSTER Clockwise FRONT SEAT FRAME WITH ADJUSTER INSPECTION 1. Driving Axis B073550E24 SE INSPECT FRONT SEAT ADJUSTER SUB-ASSEMBLY LH (a) Check operation of the slide motor. (1) Check if the rotates smoothly when the battery is connected to the slide motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the slide motor. Front Vertical Motor: Clockwise Counterclockwise Driving Axis B073550E25 (b) Check operation of the vertical motor. (1) Check if the rotates smoothly when the battery is connected to the vertical motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the vertical motor. Rear Vertical Motor: Clockwise Counterclockwise Driving Axis B073550E26 (c) Check operation of the rear vertical motor. (1) Check if the rotates smoothly when the battery is connected to the vertical motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the seat frame with adjuster. SE–57 SEAT – FRONT SEAT FRAME WITH ADJUSTER Reclining Motor: Counterclockwise (d) Check operation of the reclining motor. (1) Check if the rotates smoothly when the battery is connected to the reclining motor connector terminals OK Clockwise Driving Axis B073550E27 Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the reclining motor. Slide Motor: Counterclockwise 2. Clockwise Driving Axis B073550E24 INSPECT FRONT SEAT ADJUSTER SUB-ASSEMBLY RH (a) Check operation of the slide motor. (1) Check if the rotates smoothly when the battery is connected to the slide motor connector terminals. OK Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the slide motor. Reclining Motor: Counterclockwise Clockwise Driving Axis B073550E27 (b) Check operation of the reclining motor. (1) Check if the rotates smoothly when the battery is connected to the reclining motor connector terminals OK Measurement Condition Operational Direction Battery positive (+) → 2 Battery negative (-) → 1 Clockwise Battery positive (+) → 1 Battery negative (-) → 2 Counterclockwise If the result is not as specified, replace the reclining motor. SE SE–58 SEAT – FRONT POWER SEAT LUMBAR SWITCH HOLD RELEASE FRONT POWER SEAT LUMBAR SWITCH INSPECTION 1. SE E1 H B E2 R B068208E01 INSPECT FRONT POWER SEAT LUMBAR SWITCH (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Switch Position Specified Condition 1 (R) - 2 (E2) HOLD Below 1 Ω 3 (B) - 4 (H) HOLD Below 1 Ω 1 (R) - 2 (E2) OFF Below 1 Ω 4 (H) - 5 (E1) OFF Below 1 Ω 1 (R) - 3 (B) RELEASE Below 1 Ω 4 (H) - 5 (E1) RELEASE Below 1 Ω If the result is not as specified, replace the switch. SE–59 SEAT – LUMBAR SUPPORT ADJUSTER ASSEMBLY Counterclockwise LUMBAR SUPPORT ADJUSTER ASSEMBLY Clockwise INSPECTION 1. Driving Axis B068209E01 INSPECT LUMBAR SUPPORT ADJUSTER ASSEMBLY (a) Only on the driver side: (1) Check operation of the lumbar support adjuster motor. Standard Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the lumbar support adjuster assembly motor. SE SE–60 SEAT – SEAT HEATER SWITCH SEAT HEATER SWITCH INSPECTION 1. B065858 INSPECT SEAT HEATER SWITCH LH (a) Check the resistance between the terminals when the switch is operated. Standard resistance Tester Connection Switch Condition Specified Condition 3-4 ON (MAX) Below 1 Ω 5-6 ON (MAX) Below 1 Ω - OFF 10 kΩ or higher 4-5 ON (MIN) Below 1 Ω 1-2 Illumination circuit Below 1 Ω (b) Inspect the seat heater switch indicator. (1) Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1. (2) Push the seat heater switch ON and check that the indicator lights up. If the result is not as specified, replace the seat heater switch and inspect the circuits connected to the other parts. SE (c) Inspect the seat heater switch illumination. (1) Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 5. (2) Check that the illumination lights up. If the result is not as specified, replace the seat heater switch or bulb. B065621 2. B065858 INSPECT SEAT HEATER SWITCH RH (a) Check the resistance between the terminals when the switch is operated. Standard resistance Tester Connection Switch Condition Specified Condition 3-4 ON (MAX) Below 1 Ω 5-6 ON (MAX) Below 1 Ω - OFF 10 kΩ or higher 4-5 ON (MIN) Below 1 Ω 1-2 Illumination circuit Below 1 Ω (b) Inspect the seat heater switch indicator. (1) Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1. SEAT – SEAT HEATER SWITCH SE–61 (2) Push the seat heater switch ON and check that the indicator lights up. If the result is not as specified, replace the seat heater switch and inspect the circuits connected to the other parts. (c) Inspect the seat heater switch illumination. (1) Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 5. (2) Check that the illumination lights up. If the result is not as specified, replace the seat heater switch or bulb. B065621 SE SE–62 SEAT – FRONT SEATBACK HEATER FRONT SEATBACK HEATER INSPECTION 1. INSPECT FRONT SEATBACK HEATER LH (a) Check seatback heater resistance. Standard resistance Tester Connection Specified Condition 1-2 Below 1 Ω B065623E01 If the result is not as specified, replace the seatback cover assembly. 2. SE INSPECT FRONT SEATBACK HEATER RH (a) Check seatback heater resistance. Standard resistance Tester Connection Specified Condition 1-2 Below 1 Ω If the result is not as specified, replace the seatback cover assembly. B065623E01 SE–63 SEAT – FRONT SEAT CUSHION HEATER FRONT SEAT CUSHION HEATER A B INSPECTION 1. B065624E01 INSPECT FRONT SEAT CUSHION HEATER LH (a) Check the seat cushion heater resistance between the terminal. (1) Apply battery voltage and check the seat cushion heater. Standard resistance Measurement Condition Specified Condition A1 - B2 Below 1 Ω A4 - B2 Below 1 Ω A1 - A4 Below 1 Ω A2 - A3 Below 1 Ω B1 - B2 Below 1 Ω If the result is not as specified, replace the seat cushion cover assembly. 2. A B INSPECT FRONT SEAT CUSHION HEATER RH (a) Check the seat cushion heater resistance between the terminal. (1) Apply battery voltage and check the seat cushion heater. Standard resistance Measurement Condition Specified Condition A1 - B2 Below 1 Ω A4 - B2 Below 1 Ω A1 - A4 Below 1 Ω A2 - A3 Below 1 Ω B1 - B2 Below 1 Ω B065624E01 If the result is not as specified, replace the seat cushion cover assembly. SE SE–64 SEAT – SEAT HEATER CONTROL SEAT HEATER CONTROL INSPECTION 1. INSPECT FRONT SEAT HEATER CONTROL LH (a) Disconnect the seat heater control LH connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard Wire Harness SIde: No Pin Tester Connection No Pin 2. Wire Harness SIde: No Pin Specified Condition 6 - Body ground Constant Below 1 Ω 1-6 (Seat heater switch) OFF → ON 0 V → 10 to 14 V 4-6 Constant 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side or seat heater switch. B031234E03 SE Condition INSPECT FRONT SEAT HEATER CONTROL RH (a) Disconnect the seat heater control RH connector. (b) Measure the voltage and resistance according to the value(s) in the table below. Standard Tester Connection No Pin B031234E03 Condition Specified Condition 6 - Body ground Constant Below 1 Ω 1-6 (Seat heater switch) OFF → ON 0 V → 10 to 14 V 4-6 Constant 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side or seat heater switch. ED–4 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM OPERATION CHECK 1. ED INSPECT BASIC OPERATION (a) When the back door is partially closed, check that the motor operates so that the back door is fully closed (locked). (b) After the above step, check that the back door can be opened. (c) When the back door is partially closed and then the motor starts normal operation, push the back door opener switch and pull up the back door to open it. At this time, check that the motor starts reverse operation and then stops. (d) Immediately after the back door is partially closed (the motor has not started operation yet), push the back door opener switch to open the back door. Check that the motor does not operate at this time. ED–5 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM PROBLEM SYMPTOMS TABLE BACK DOOR CLOSER SYSTEM: Symptom Back door closer does not operate Suspected area See page 1. with Motor back door lock assembly (back door lock) ED-11 2. Multiplex network door ECU back (back door ECU) ED-11 3. Wire harness - ED ED–6 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM TERMINALS OF ECU 1. CHECK MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) B9 B8 B062706E04 (a) Disconnect the B8 and B9 ECU connectors, and check the voltage or continuity of each terminal of the wire harness side connectors. Symbols (Terminal No.) ED Wiring Color Condition Specified Condition BDR (B8-4) - Body Ground L-- Constant 10 to 14 V BECU (B8-5) - Body Ground L-R - - Constant 10 to 14 V GND (B8-3) - Body Ground W-B - - Constant Continuity No key inserted in ignition key cylinder → Key inserted No continuity → Continuity Back door opener switch OFF → ON No continuity → Continuity SIG (B8-6) - Body Ground B-- HSW+ (B9-10) - Body Ground V-W - - HSW- (B9-22) - Body Ground LG-R - - HALF (B9-6) - Body Ground R-G - - Back door OPEN → CLOSED Continuity → No continuity LSE (B9-21) - Body Ground B-R - - Constant Continuity If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the connectors, and check the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Color Condition Specified Condition L-B - - Back door OPEN → NOT COMPLETELY CLOSED → Motor in normal rotation (Right turn) → Motor in revers rotation (Left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → 10 to14 V → Below 1 V → Below 1 V ACT- (B9-14) - Body Ground L-R - - Back door OPEN → NOT COMPLETELY CLOSED → Motor in normal rotation (Right turn) → Motor in revers rotation (Left turn) → Operation completed (Back door CLOSED) Below 1 V → Below 1 V → Below 1 V → 10 to 14 V → Below 1 V FULL (B9-7) - Body Ground G-Y - - Back door CLOSED → OPEN 10 to 14 V → Below 1 V POS (B9-8) - Body Ground BR-W - - Back door OPEN → Closer in operation → CLOSED Below 1 V → 10 to 14 V → Below 1 V ACT+ (B9-15) - Body Ground If the result is not as specified, the vehicle may be defective. In this case, check the harness, connector and fuse between the ECU and battery. Then repair or replace it if necessary. ED–7 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM DIAGNOSIS SYSTEM 1. 2. 3. CG SG CANH SIL DESCRIPTION The ECU stores trouble codes when trouble occurs on the vehicle. The diagnostic system allows for reading of the trouble codes from the DLC3. Use the intelligent tester to check and solve the problem. CHECK BATTERY VOLTAGE (a) Check the battery voltage. Standard voltage: 10 to 14 V If the voltage is below 10 V, replace the battery before proceed to the next step. CHECK DLC3 (a) The vehicle's ECU uses ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. ED CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. Intelligent Tester CAN VIM DLC3 G039021E01 (b) Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch to the ON position and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or tester side. HINT: • If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual. ED–8 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM Intelligent Tester DTC CHECK / CLEAR 1. CAN VIM DLC3 G039021E01 2. ED CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) Read the DTCs by following the directions on the tester's screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) Erase the DTCs by following the directions on the tester's screen. HINT: Refer to the intelligent tester operator's manual for further details. ED–9 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the method to shorten the labor time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) According to the display on tester, read the DATA LIST. Item Measurement Item/ Display (Range) KEY SW(UNLK) Back door key lock and unlock SW signal/ ON or OFF ON: Back door lock key cylinder is turned to unlock OFF: Key is in back door lock key cylinder (Neutral position) - KEY SW(LOCK) Back door key lock and unlock SW signal/ ON or OFF ON: Back door lock key cylinder is turned to lock OFF: Key is in back door lock key cylinder (Neutral position) - HALF LATCH SW Back door half latch SW signal/ON or OFF ON: Back door is open OFF: Back door is closed - FULL LATCH SW Back door full latch SW (courtesy SW) signal/ON or OFF ON: Back door is closed OFF: Back door is open - DOOR HANDLE SW Back door opener SW signal/ON or OFF ON: Back door opener is pushed OFF: Back door opener is not pushed - LOCK STATUS Back door position SW signal/UNLOCK or LOCK UNLOCK: Back door is unlock LOCK: Back door is lock - Normal Condition 2. Item LATCH RELEASE Diagnostic Note PERFORM ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of troubleshooting is one of the method to shorten the labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the ignition switch ON. (c) According to the display on tester, perform the ACTIVE TEST. Test Details Back door lock latch is release ON/OFF Diagnostic Note - ED ED–10 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below. (Proceed to the page given for that circuit.) BACK DOOR CLOSER SYSTEM: DTC No. B2215 ED Detection Item Back Door Closer Switch Malfunction Trouble Area 1. with Motor back door lock assembly (back door lock) 2. Multiplex network door ECU back (back door ECU) 3. Wire harness See page ED-8 ENGINE HOOD / DOOR – FRONT DOOR ED–35 REASSEMBLY 1. INSTALL FRONT DOOR WIRE LH (a) Install the door wire with the 2 bolts. Torque: Reference 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: In order to prevent water leakage, be sure that the lip of the rubber grommet dose not turn up or is not deformed when installing the door wire. (b) Connect the door wire clips. 2. INSTALL FRONT DOOR CHECK ASSEMBLY LH (a) Apply MP grease to the sliding parts of the door check. (b) Install the door check to the door panel with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Apply adhesive to the bolt. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Install the door check to the body panel with the bolt. Torque: 30 N*m (306 kgf*cm, 22 in.*lbf) HINT: Install the door check so that rivet head is up. B062428 B062429E03 Bolt B062427E02 3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a "torx" socket wrench (T30), install the outside handle frame with the screw. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (b) Install the outside handle pad front and rear. 4. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH (a) Apply MP grease to the sliding and rotating parts of the door lock. (b) Install a new door lock wire harness packing. NOTICE: • If reusing the door lock that is removed, replace the packing in the connecting part with a new one. • Be careful that no grease and dirt will stick to the packing surface in the connecting part. • Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock. (c) Insert the outside handle link into the lock with the door motor, and then set it to the door panel. NOTICE: Make sure that the outside handle link is securely engaged with the lock assembly. ED ED–36 ENGINE HOOD / DOOR – FRONT DOOR (d) Apply adhesive to the 3 screws. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (e) Using a "torx" socket wrench (T30), install the door lock with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 42 in.*lbf) (f) Connect the door lock connector. B062426E01 ED Hole Plug 5. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (a) Using a "torx" socket wrench (T30), install the outside handle cover with the screw. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (b) Install the hole plug. 6. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH (a) Install the door frame with the bolt. Torque: 5.0 N*m (51 kgf*cm, 42 in.*lbf) 7. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Align the matchmarks on the regulator motor gear and regulator gear. (b) Using a "torx" driver (T25), install the door regulator motor with the 3 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: Never rotate the motor to the down direction until the window glass installation has done. 8. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Apply MP grease to the sliding and rotating parts of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. B061438E23 B062425E02 B062430 ENGINE HOOD / DOOR – FRONT DOOR ED–37 (b) Install the window regulator with the 6 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Connect the window regulator connector. NOTICE: Be careful not drop and deform the door window regulator. 9. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH NOTICE: Do not damage the door glass. B062424E01 (a) Install the glass run. (b) Insert the door glass into the door panel along the glass run, as shown in the illustration. (1) (2) ED B062423E14 B062422E01 (c) Install the door glass to the window regulator with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (d) Inspect operation of the power window. HINT: When the installation point of the door glass does not match, adjust the regulator position in the manual operation. (1) Connect the power window switch to the wire harness and turn the ignition switch ON. (2) Repeat UP and DOWN operation several times in the manual operation. 10. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (a) Install the No. 1 speaker bracket with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect the speaker connector. (c) Install the No. 2 speaker with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) B062421E01 ED–38 ENGINE HOOD / DOOR – FRONT DOOR 11. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Install the outer rear view mirror with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect the outer rear view mirror connector. B062419 12. INSTALL FRONT DOOR SERVICE HOLE COVER LH (a) Apply butyl tape to the door, as shown in the illustration. Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent (b) Install the service hole cover. Standard dimension Referance Point A ED Butyl Tape B B062414E01 Area Measurement A 6 mm (0.236 in.) B 2 mm (0.079 in.) HINT: • When installing the service hole cover, pull out the links and connectors through the service hole cover. • There should be no wrinkles or folds after attaching the service hole cover. • After attaching the service hole cover, check the sealing condition. ENGINE HOOD / DOOR – REAR DOOR ED–41 DISASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). Claw 1. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (a) Using a screwdriver, disengage the 3 claws. HINT: Tape the screwdriver tip before use. (b) Remove the inside handle bezel. 2. REMOVE REAR ARMREST ASSEMBLY LH (a) Disengage the 4 claws, remove the armrest assembly. HINT: Tape the screwdriver tip before use. Claw B062416E03 Claw Claw : Claw B062417E01 3. : Clips B062434E01 REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (a) Remove the cushion rubbers. (b) Remove the 2 screws. (c) Using a clip remover, disengage the 12 clips, remove the 12 clips. (d) Remove the trim board upward. HINT: In order to prevent the door from being damaged, cover the parts indicated by arrow marks in the illustration with tape. (e) Disconnect the 2 cables from the inside handle. (f) Remove the trim board. (g) Remove the inner weatherstrip. H006127E03 ED ED–42 ENGINE HOOD / DOOR – REAR DOOR B065761E01 ED 4. REMOVE REAR DOOR SERVICE HOLE COVER LH (a) Remove the rear door service hole cover LH. NOTICE: Remove the remaining tape on the door side. 5. REMOVE REAR SPEAKER ASSEMBLY (See page AV205) 6. REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH (See page ET-66) 7. REMOVE REAR DOOR GLASS WEATHERSTRIP OUTER (See page ET-32) 8. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched. (a) Open the door glass until the bolts appear in the service hole. (b) Remove the door glass from the glass bracket and lower the door glass into the door panel. NOTICE: Do not damage the door glass. HINT: Position the door glass toward the front as much as possible. (c) Remove the rear door glass run. (d) Remove the 2 bolts, screw and the division bar. B062435E01 (e) Rotate the division bar by 90° and pull it upward as shown in the illustration. 90q B063574E01 ENGINE HOOD / DOOR – REAR DOOR 9. B063661E01 B062437 ED–43 REMOVE REAR DOOR QUARTER WINDOW GLASS LH (a) Remove the quarter glass, as shown in the illustration. NOTICE: Do not damage the glass. (b) Remove the quarter window weatherstrip from the glass. 10. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH (a) Carefully pull up the glass out of the panel. HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched. 11. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Disconnect the window regulator connector. (b) Remove the 4 bolts and window regulator. NOTICE: When the bolts are removed, the rear door window regulator might drop and be deformed. HINT: Remove the window regulator through the service hole. 12. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Place matchmarks on the window regulator motor gear and regulator gear. (b) Using a "torx" driver (T25), remove the 3 screws and window regulator motor. 13. REMOVE REAR DOOR W/MOTOR LOCK ASSEMBLY LH (a) Disconnect the door lock connector. (b) Using a "torx" socket wrench (T30), remove the 3 screws and door lock. HINT: Remove the door lock through the service hole. (c) Remove the door lock wire harness packing. B062438E01 14. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH (a) Using a "torx" socket wrench (T30), loosen the screw and remove the outside handle cover. 15. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH (a) Pull and hold the release plate of the outside handle frame, as shown in the illustration. B057767 ED ED–44 ENGINE HOOD / DOOR – REAR DOOR (b) Pushing and pulling the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle. NOTICE: If the release plate is not pulled and held when removing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate. (c) Remove the 2 outside handle pad front and rear. (1) (2) B056613E13 16. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a "torx" socket wrench (T30), loosen the screw. (b) Slide the outside handle frame from to remove it. HINT: Remove the outside handle frame through the service hole. Bolt ED B062442E01 17. REMOVE REAR DOOR CHECK ASSEMBLY LH (a) Remove the 2 nuts, bolt and door check. HINT: Remove the door check through the service hole. B062429 18. REMOVE REAR DOOR WEATHERSTRIP LH (a) Using a clip remover, disengage the clip, remove the weatherstrip. HINT: If the clips are damaged, exchange them for new clips. ED–1 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM BACK DOOR CLOSER SYSTEM ENGINE HOOD / DOOR BODY PARTS LOCATION DRIVER SIDE JUNCTION BLOCK ASSEMBLY - BODY ECU UNLOCK WARNING SWITCH ASSEMBLY DOOR LOCK CONTROL SWITCH ED POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY - DOOR LOCK CONTROL SWITCH BACK DOOR OPENER SWITCH ASSEMBLY MULTIPLEX NETWORK DOOR ECU (BACK DOOR ECU) WITH MOTOR BACK DOOR LOCK ASSEMBLY (BACK DOOR LOCK) B120218E01 ED–2 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedures on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT 3 INSPECT COMMUNICATION MULTIPLEX COMMUNICATION SYSTEM (BEAN) ED (a) Check that there is no abnormality in the communication system by inspecting the communication function of the multiplex communication system with the intelligent tester. (1) (ECU unconnected, communication line abnormal) Without code outputs, proceed to A. (2) (ECU unconnected, communication line abnormal) With code outputs, proceed to B. B GO TO MULTIPLEX COMMUNICATION SECTION A 4 DIAGNOSTIC TROUBLE CODE CHECK (a) Check the diagnostic trouble code. (1) Without code outputs, proceed to A. (2) With code outputs, proceed to B. B Go to step 6 A 5 PROBLEM SYMPTOMS TABLE (a) Without applicable symptoms, proceed to A. (b) With applicable symptoms, proceed to B. B A Go to step 6 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM 6 ED–3 PERFORM TROUBLESHOOTING IN FOLLOWING METHOD, DEPENDING ON MALFUNCTION SYMPTOM (a) DATA LIST / ACTIVE TEST (See page ED-6) (1) Inspection with the intelligent tester (DATA LIST) (2) Inspection with the intelligent tester (ACTIVE TEST) (b) TERMINALS OF ECU (See page ED-4) NEXT 7 ADJUST, REPAIR OR REPLACE NEXT END ED ED–45 ENGINE HOOD / DOOR – REAR DOOR ADJUSTMENT HINT: • Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system and the curtain shield airbag system for normal operation. Then initialize both systems. • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSPECT REAR DOOR PANEL SUB-ASSEMBLY LH (a) Check that the clearance is within the standard value. D B A ED C E B062431E01 Standard clearance 2. Centering Bolt Standard Bolt B057104E01 Area Measurement A 5.0 +- 1.5 mm (0.197 +- 0.059 in.) B 5.6 +- 1.5 mm (0.024 +- 0.059 in.) C 8.8 +- 1.5 mm (0.343 +- 0.059 in.) D 160 mm (6.30 in.) E 4.5 +- 1.5 mm (0.177 +- 0.059 in.) ADJUST REAR DOOR PANEL SUB-ASSEMBLY LH (a) Adjust the rear door panel position. HINT: • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). ED–46 ENGINE HOOD / DOOR – REAR DOOR (1) Adjust the door forward/rearward and vertically by loosening the body side hinge bolts. (2) Tighten the body side hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B062432 (3) Horizontally and vertically adjust the door by loosening the door side hinge bolts. (4) Tighten the body side hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) ED B062433 (5) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic-faced hammer. (6) Tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) (7) Connect the negative (-) terminal cable from the battery. (8) Initialize both systems. (9) Check the SRS warning lamp. B062439E01 REASSEMBLY 1. Adhesive B062429E05 INSTALL REAR DOOR CHECK ASSEMBLY LH (a) Apply MP grease to the sliding part of the door check. (b) Install the door check to the door panel with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Apply adhesive to the bolt. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Install the door check to the body panel with the bolt. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) HINT: Install the door check so that rivet head is up. ENGINE HOOD / DOOR – REAR DOOR ED–47 2. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a "torx" socket wrench (T30), install the handle frame with the screw. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 3. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH (a) Install the outside handle pad front and rear. (b) Pull and hold the release plate of the outside handle frame, as shown in the illustration. Bolt B062442E02 ED B057767 (c) Pushing the outside handle in the arrow mark direction as shown in the illustration, install the outside handle. NOTICE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate. (2) (1) 4. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH (a) Using a "torx" socket wrench (T30), install the outside handle cover with the screw. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 5. INSTALL REAR DOOR WITH MOTOR LOCK ASSEMBLY LH (a) Apply MP grease to the sliding and rotating parts of the door lock. (b) Install a new door lock wire harness packing. NOTICE: • If reusing the door lock that is removed, replace the packing in the connecting part with a new one. • Be careful that no grease and dirt will stick to the packing surface in the connecting part. • Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock. B064044E14 ED–48 ENGINE HOOD / DOOR – REAR DOOR (c) Engage the lock with door motor with the release plate of the outside handle, and then set it to the door panel. NOTICE: Make sure that the release plate of the outside handle frame is securely engaged with the lock. (d) Apply adhesive to the 3 screws. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (e) Using a "torx" socket wrench (T30), install the door lock with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 42 in.*lbf) (f) Connect the door lock connector. 6. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Using a "torx" driver (T25), install the door window regulator motor with the 3 screws. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 7. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Apply MP grease to the sliding and rotating parts of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. B062438E01 ED B062440 (b) Install the door window regulator with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Be careful not to drop and deform the rear door window regulator. (c) Connect the window regulator connector. 8. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH NOTICE: Be careful not to drop and deform the front door window regulator. (a) Insert the rear door glass into the door panel. HINT: • Insert a shop rag inside the door panel to prevent the door glass from being scratched. • Position the door glass toward the front as much as possible. 9. INSTALL REAR DOOR QUARTER WINDOW GLASS LH (a) Install the quarter window weatherstrip to the door glass. NOTICE: Do not damage the glass. B062437 ED–49 ENGINE HOOD / DOOR – REAR DOOR (b) Install the door quarter window glass as shown in the illustration. B063661E02 10. INSTALL REAR DOOR WINDOW DIVISION BAR SUBASSEMBLY LH (a) Insert the division bar to the door panel, then rotate it by 90° as shown in the illustration. (b) Mount the door glass to the window regulator. 90° ED B063574E02 B062435E02 (c) Tighten the division bar with the 2 bolts and screw. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (d) Install the glass run. HINT: When the installation point of the door glass does not match, adjust the regulator position in manual operation. (1) Connect the power window switch to the wire harness and turn the ignition switch ON. (2) Repeat UP and DOWN operation several times in manual operation. 11. INSTALL REAR DOOR SERVICE HOLE COVER LH (a) Apply butyl tape to the door, as shown in the illustration. Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent (b) Install the service hole cover. Standard dimension Referance Point A B Butyl Tape B062441E01 Area Measurement A 6 mm (0.236 in.) B 2 mm (0.079 in.) HINT: • When installing the service hole cover, pull out the links and connectors through the service hole cover. • There should be no wrinkles or folds after attaching the service hole cover. • After attaching the service hole cover, check the sealing condition. ENGINE HOOD / DOOR – BACK DOOR ED–53 DISASSEMBLY HINT: A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). : Clip 1. REMOVE BACK DOOR TRIM BOARD (a) Remove the assist strap hole cover. (b) Remove the screw and assist strap. (c) Using a screwdriver, remove the back door trim cover. HINT: Tape the screwdriver tip before use. In order to prevent the back door from being damaged, cover the parts indicated by arrow marks in the illustration with tape. (d) Using a clip remover, remove the 10 clips and trim board. (e) Remove the inner weatherstrip. 2. REMOVE BACK DOOR SERVICE HOLE COVER LH (a) Remove the back door service hole cover LH. NOTICE: Remove the remaining tape on the back door side. B062858E01 3. B062865E02 REMOVE BACK DOOR GLASS (a) Remove the 5 screws and service hole cover. HINT: • Do not disconnect the multiplex network door ECU connector. • Fix the multiplex network door ECU with tape. • If the door lock protector are damaged, exchange it for new door lock protector. (b) Open the door glass until the bolts appear in the service hole. (c) Remove the door glass run. HINT: Since removing the glass run will make the glass loose, insert shop rug between the door glass and body panel. (d) Disconnect the window defogger connector. B062860E01 (e) Remove the 4 bolts and door glass. B062861E01 ED ED–54 ENGINE HOOD / DOOR – BACK DOOR (f) Remove the door glass as shown in the illustration. (g) Disconnect the rear window connector. (h) Remove the multiplex network door ECU. (2) (1) 4. REMOVE BACK DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER (See page ET-35) 5. REMOVE WITH MOTOR BACK DOOR LOCK ASSEMBLY (a) Disconnect the back door lock connector. B062862E01 (b) Remove the 2 back window regulator control wires. ED B063578E01 (c) Disengage the 2 claws and remove the lock protector as shown in the illustration. (d) Remove the 4 bolts and back door lock. HINT: Remove the door lock through the service hole. B062863 6. REMOVE BACK DOOR POWER WINDOW REGULATOR SUB-ASSEMBLY (a) Remove the 2 cushion rubbers. (b) Disconnect the window regulator connector. (c) Remove the 6 bolts, nut and window regulator. HINT: Remove the power window regulator through the service hole. 7. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH REAR (a) Remove the 2 nuts and window regulator motor. (b) Remove the 2 screws and cover plate. (c) Using needle nose pliers, remove the drum and wire guide from the motor. NOTICE: Do not use a screwdriver, etc. when removing them. B062864 B065134 ENGINE HOOD / DOOR – BACK DOOR 8. REMOVE REAR WIPER MOTOR ASSEMBLY (a) Remove the liner wiper step LH as shown in the illustration. (b) Remove the rear wiper motor assembly (See page WW-31). 9. REMOVE BACK DOOR LOCK CYLINDER (a) Disconnect the connector. (b) Remove the tailgate control switch. (c) Remove the 2 nuts and lock cylinder. HINT: Remove the back door lock cylinder assembly through the service hole. (2) Pull (1) Push B063660E01 ED–55 10. REMOVE BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE (See page ET-70) 11. REMOVE TELEVISION CAMERA ASSEMBLY (w/ Rear View Monitor System) (See page PM-16) 12. REMOVE BACK DOOR STOPPER LOWER (a) Remove the bolt and stopper lower. 13. REMOVE BACK DOOR LOWER STOPPER CUSHION (a) Remove the 2 bolts and stopper cushion. 14. REMOVE REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) (See page ET-19) 15. REMOVE CENTER STOP LIGHT ASSEMBLY (w/ Rear Spoiler) (See page LI-58) 16. REMOVE CENTER STOP LIGHT ASSEMBLY (w/o Rear Spoiler) (See page LI-58) ED ED–56 ENGINE HOOD / DOOR – BACK DOOR ADJUSTMENT 1. INSPECT BACK DOOR PANEL SUB-ASSEMBLY (a) Check that the clearance is within the standard value. B C A ED B062447E01 Standard clearance 2. Centering Bolt Standard Bolt B057104E01 Area Measurement A 6.5 +- 1.5 mm (0.296 +- 0.059 in.) B 10.0 +- 1.5 mm (0.394 +- 0.059 in.) C 15.0 +- 1.5 mm (0.591 +- 0.059 in.) ADJUST BACK DOOR PANEL SUB-ASSEMBLY (a) Adjust the back door panel position. HINT: • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). (1) Adjust the door horizontally and forward/ rearward by loosening the body side hinge nuts. (2) Tighten the body side hinge nuts after adjustment. Torque: 19.5 N*m (200 kgf*cm, 14 ft.*lbf) B062448 ENGINE HOOD / DOOR – BACK DOOR ED–57 (3) Horizontally and vertically adjust the back door by loosening the back door side hinge bolts. (4) Tighten the back door side hinge bolts after the adjustment. Torque: 19.5 N*m (200 kgf*cm, 14 ft.*lbf) B062857 (5) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic-faced hammer. (6) Tighten the striker mounting screws after the adjustment. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) ED B063576 (7) Adjust the door stopper, as shown in the illustration, so that the door can be opened/ closed smoothly. (8) Tighten the door stopper after the adjustment. Torque: 8.0 N*m (82 kgf*cm, 71 ft.*lbf) B063575E01 ED–58 ENGINE HOOD / DOOR – BACK DOOR REASSEMBLY ED 1. INSTALL CENTER STOP LIGHT ASSEMBLY (w/ Rear Spoiler) (See page ET-20) 2. INSTALL CENTER STOP LIGHT ASSEMBLY (w/o Rear Spoiler) 3. INSTALL REAR SPOILER SUB-ASSEMBLY (w/ Rear Spoiler) (See page ET-20) 4. INSTALL BACK DOOR LOWER STOPPER CUSHION (a) Install the lower stopper cushion with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 48 in.*lbf) 5. INSTALL BACK DOOR STOPPER LOWER (a) Install the stopper lower with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 6. INSTALL TELEVISION CAMERA ASSEMBLY (w/ Rear View Monitor System) (See page PM-16) 7. INSTALL BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE 8. INSTALL BACK DOOR LOCK CYLINDER (a) Install the lock cylinder with 2 the nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Install the tailgate control switch. 9. INSTALL REAR WIPER MOTOR ASSEMBLY (a) Install the rear wiper motor assembly (See page WW-33). (b) Install the liner wiper step LH. 10. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH REAR HINT: • To prevent the drum and cable from coming off, do not tilt the drum, subject it to shocks or use force on it. • If the cable comes off the drum, do not rewind the cable and do not reuse it. • After installing the window regulator, do not operate it by itself, because some types of regulator do not have a stopper. (a) Apply MP grease to the as shown in the illustration. MP Grease B062867E01 ENGINE HOOD / DOOR – BACK DOOR ED–59 (b) With the holding tool installed, match the holding tool with the motor housing. B062868 (c) Push down on the wire guide and drum, and insert the drum into the motor housing. NOTICE: If you can not insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum. ED B062869 (d) Install the cover plate with the 2 screws. Torque: 5.4 N*m (56 kgf*cm, 48 in.*lbf) (e) Install the window regulator motor with the window regulator. B062870 11. INSTALL BACK DOOR POWER WINDOW REGULATOR SUB-ASSEMBLY (a) Apply MP grease to the sliding and rotating parts of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. B063579 (b) Install the power regulator sub-assembly with the 6 bolts, nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Connect the window regulator connector. (d) Install the 2 cushion rubbers. B062864 ED–60 ENGINE HOOD / DOOR – BACK DOOR 12. INSTALL W/MOTOR BACK DOOR LOCK ASSEMBLY (a) Install the door lock with 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect the connector. (c) Install the door lock protector. B062863 (d) Install the 2 regulator control wires as shown in the illustration. ED B063578E01 13. INSTALL BACK DOOR GLASS (a) Insert the door glass as shown in the illustration. (1) (2) B062862E02 (b) Install the door glass with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Connect the rear window defogger connector. B062861 14. INSTALL BACK DOOR GLASS RUN (a) Install the door glass run. (b) Check that the glass run position as shown in the illustration. Align B063659E01 ENGINE HOOD / DOOR – BACK DOOR ED–61 15. INSTALL BACK DOOR SERVICE HOLE COVER (a) If replacing protector: Install the protector, as shown in the illustration. (b) Install the back door service hole cover with the 5 bolts. (c) Install the multiplexnetwork door ECU with the 2 bolts. (d) Connect the multiplexnetwork door ECU connector. Protector B062866E01 Referance Point Butyl Tape B062865E01 16. INSTALL BACK DOOR SERVICE HOLE COVER LH (a) Apply butyl tape to the door. Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent (b) Install the service hole cover, as shown in the illustration. HINT: • There should be no wrinkles or folds after attaching the service hole cover. • After attaching the service hole cover, check the sealing condition. ED ENGINE HOOD / DOOR – BACK DOOR SUPPORT ED–63 INSTALLATION 1. INSTALL BACK DOOR DUMPER STAY SUBASSEMBLY LH (a) Install the damper stay with the 3 bolts. Torque: Door side 19.5 N*m (200 kgf*cm, 14 ft.*lbf) Body side 17.5 N*m (180 kgf*cm, 13 ft.*lbf) ED ED–64 ENGINE HOOD / DOOR – BACK DOOR SUPPORT DISPOSAL HINT: Use the same procedures for the RH side and LH side. 1. a A b B B065104E15 ED DISPOSE OF BACK DOOR DUMPER STAY SUBASSEMBLY (a) Horizontally fix the stay in a vise with the piston-rod pulled out. (b) Wearing safety glasses, gradually cut a part between A and B as shown in the illustration using a metal saw to gradually release the gas. Specification Area Measurement a 80 mm (3.15 in.) b 20 mm (0.80 in.) CAUTION: Be careful to cover the area that is being cut as there is a possibility that metal debris could be blown out by the gas (the gas is colorless, odorless and harmless). ED–11 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM DTC B2215 Back Door Closer Switch Malfunction DESCRIPTION This DTC is output when the position switch in the back door malfunctions. This position switch detects the back door LOCK/UNLOCK and sends it to the back door ECU. DTC No. DTC Detection Condition Trouble Area • B2215 Back door does not operate • • with Motor back door lock assembly (back door lock) Multiplex network door ECU back (back door ECU) Wire harness WIRING DIAGRAM Multiplex Network Door ECU Back (Back Door ECU) B7 with Motor Back Door Lock Assembly (Back Door Lock) ED 4 BR-W 8 B9 POS 3 B-R 21 B9 LSE B064456E01 ED–12 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (MULTIPLEX NETWORK DOOR ECU - W/MOTOR BACK DOOR LOCK ASSEMBLY) (a) Disconnect the B7 back door lock and B9 back door ECU connectors. (b) Check the continuity between the terminals of the back door lock (B7) and back door ECU (B9) connectors. Standard (Check for open) Wire Harness Side: B7 Back Door Lock Symbols (Terminal No.) - (B7-4) - POS (B9-8) - (B7-3) - LSE (B9-21) NG B9 Back Door ECU Specified Condition Continuity REPAIR OR REPLACE HARNESS OR CONNECTOR ED B066168E01 OK 2 INSPECT WITH MOTOR BACK DOOR LOCK ASSEMBLY (a) Check operation of the door lock. (1) Using a screwdriver, push the latch in order to put the back door lock in the locked condition (full-latch position). (2) Connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2. Then, check operation of the latch. Standard: The latch turns to the open-latch position (3) Inspect motor operation when battery voltage is applied to the terminals. Standard Fuel-latch Open-latch B065423E01 Measurement Condition Specified Condition Battery positive (+) - Terminal 2 Battery negative (-) - Terminal 1 Clockwise (Motor in normal rotation) Battery positive (+) - Terminal 1 Battery negative (-) - Terminal 2 Counterclockwise (Motor in reverse rotation) ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM ED–13 (b) Check the back door courtesy switch continuity. (1) Check the continuity between the terminals of the courtesy switch. Standard Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Half-latch position 4-5 Continuity Full-latch position, Over-latch position 4-5 No continuity (c) Check the back door latch switch continuity. (1) Check the continuity between the terminals of the latch switch. Standard Open-latch Harf-latch Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Over-latch position 4-6 Continuity Half-latch position, Fulllatch position 4-6 No continuity (d) Check the position switch continuity. (1) Connect the battery positive (+) lead to connector terminal 1 and the negative (-) lead to connector terminal 2. Standard Full-latch Over-latch B062719E05 Door Lock Latch Position Terminal No. Specified Condition Any position other than motor stop position (Motor in operation) 3-4 Continuity Motor stop position (Gear in original position) 3-4 No continuity NG OK REPLACE MULTIPLEX NETWORK DOOR ECU REPLACE WITH MOTOR BACK DOOR LOCK ASSEMBLY ED ED–15 ENGINE HOOD / DOOR – HOOD HOOD ENGINE HOOD / DOOR BODY COMPONENTS WITH SPORT EDITION PACKAGE HOOD SUB-ASSEMBLY HOOD BULGE HOOD BULGE PLATE RIVET ED NUT HOOD AIR INTAKE GUIDE SCREW RIVET HOOD INSULATOR 5.5 (56, 49 in.*lbf) HOOD AIR INTAKE GUIDE NO. 1 RETAINER CLIP x11 5.5 (56, 49 in.*lbf) HOOD SUB-ASSEMBLY HOOD AUXILIARY CATCH HOOK ASSEMBLY RADIATOR GRILLE 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120194E01 ED–16 ENGINE HOOD / DOOR – HOOD HOOD TO RADIATOR SUPPORT SEAL AUXILIARY CATCH RELEASE LEVER ASSEMBLY 13 (130, 10) HOOD HINGE ASSEMBLY RH HOOD SUPPORT ASSEMBLY RH HOOD HINGE ASSEMBLY LH 8.0 (82, 71 in.*lbf) HOOD SUPPORT ASSEMBLY LH ED 13 (130, 10) 17.5 (180, 13) HOOD TO FRONT FENDER SEAL RH WITHOUT SECURITY SYSTEM 13 (130, 10) HOOD TO FRONT FENDER SEAL LH HOOD LOCK ASSEMBLY RADIATOR SUPPORT SEAL UPPER HOOD AUXILIARY CATCH HOOK WITH SECURITY SYSTEM HOOD LOCK ASSEMBLY HOOD LOCK RELEASE LEVER PROTECTOR 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B120195E01 ED–14 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM Back Door Closer does not Operate DESCRIPTION The back door ECU controls the back door closer. In response to the signals output from the switches in the back door lock, the back door closer drives the closer motor. WIRING DIAGRAM Multiplex Network Door ECU Back (Back Door ECU) Driver Side Junction Block Assembly 2 1F 2 L-O 6 DB1 4 B8 DBR L POWER 1 ED 1C Engine Room Junction L-W Block Assembly B7 with Motor Back Door Lock Assembly (Back Door Lock) 2 5 R-G 6 B9 HALF 2 6 G-Y 7 B9 FULL 1 4 BR-W 8 B9 POS 1 L-B 15 B9 ACT+ 2 L-R 14 B9 ACT- 3 B-R 21 B9 LSE J/B 2 ALT 1 2 B 2 2 B Battery B064457E01 ED–15 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM INSPECTION PROCEDURE 1 INSPECT BACK DOOR LOCK (a) Check that the back door fully closes (fully locked) when the door is closed by hand. NG IMPROPER FIT OF BACK DOOR, OR A FOREIGN OBJECT IS STUCK IN BACK DOOR OK 2 POWER SOURCE RESET (a) Disconnect the POWER DOOR 30A fuse and reconnect it. 10 seconds later, check that the back door closer is operational. OK ED NORMAL NG 3 INSPECT WITH MOTOR BACK DOOR LOCK ASSEMBLY (a) Check operation of the door lock. (1) Using a screwdriver, push the latch in order to put the back door lock in the locked condition (full-latch position). (2) Connect the positive (+) lead to terminal 1 and the negative (-) lead to terminal 2. Then, check operation of the latch. Standard: The latch turns to the open-latch position (3) Inspect motor operation when battery voltage is applied to the terminals. Standard Fuel-latch Open-latch B065423E01 Measurement Condition Specified Condition Battery positive (+) - Terminal 2 Battery negative (-) - Terminal 1 Clockwise (Motor in normal rotation) Battery positive (+) - Terminal 1 Battery negative (-) - Terminal 2 Counterclockwise (Motor in reverse rotation) ED–16 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM (b) Check the back door courtesy switch continuity. (1) Check the continuity between the terminals of the courtesy switch. Standard Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Half-latch position 4-5 Continuity Full-latch position, Over-latch position 4-5 No continuity (c) Check the back door latch switch continuity. (1) Check the continuity between the terminals of the latch switch. Standard Open-latch Harf-latch ED Door Lock Latch Position Terminal No. Specified Condition Open-latch position, Over-latch position 4-6 Continuity Half-latch position, Fulllatch position 4-6 No continuity (d) Check the position switch continuity. (1) Connect the battery positive (+) lead to connector terminal 1 and the negative (-) lead to connector terminal 2. Standard Full-latch Over-latch B062719E05 Door Lock Latch Position Terminal No. Specified Condition Any position other than motor stop position (Motor in operation) 3-4 Continuity Motor stop position (Gear in original position 3-4 No continuity OK NG REPLACE WITH MOTOR BACK DOOR LOCK ASSEMBLY ED–17 ENGINE HOOD / DOOR – BACK DOOR CLOSER SYSTEM 4 CHECK WIRE HARNESS (BACK DOOR LOCK - BACK BODY ECU) (a) Disconnect the B7 back door lock and B9 back door ECU connectors. (b) Check the continuity between the terminals of the back door lock (B7) and back door ECU (B9) connectors. Standard (Check for open) Wire Harness Side: B7 Back Door Lock Symbols (Terminal No.) Specified Condition - (B7-5) - HALF (B9-6) - (B7-6) - FULL (B9-7) - (B7-4) - POS (B9-8) - (B7-1) - ACT+ (B9-15) Continuity - (B7-2) - ACT- (B9-14) B9 Back Door ECU - (B7-3) - LSE (B9-21) OK REPLACE MULTIPLEX NETWORK DOOR ECU ED B066168E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR ENGINE HOOD / DOOR – HOOD SUPPORT ROD ED–23 HOOD SUPPORT ROD ENGINE HOOD / DOOR BODY COMPONENTS ED HOOD SUPPORT ASSEMBLY RH HOOD SUPPORT ASSEMBLY LH B120195E02 ED–24 ENGINE HOOD / DOOR – HOOD SUPPORT ROD REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). 1. B062405 ED REMOVE HOOD SUPPORT ASSEMBLY LH (a) Remove the 2 bolts and the hood support from the hood panel. HINT: While supporting the hood by hand, remove the hood support. (b) Remove the bolt and hood support from the vehicle body. ENGINE HOOD / DOOR – HOOD ED–17 DISASSEMBLY HINT: A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). 1. REMOVE RADIATOR GRILLE (a) Remove the 2 bolts and auxiliary catch release lever. (b) Remove the bolt and hood auxiliary catch hook. (c) Remove the 10 nuts and radiator grille. 2. REMOVE HOOD INSULATOR (a) Using a clip remover, remove the 11 clips and hood insulator. 3. REMOVE HOOD BULGE (for Sport Package) (a) Remove the screw and 5 nuts, as shown in the illustration. (b) Remove the hood bulge. (c) Remove the hood air intake guide No. 1 retainer. Retainer ED Screw B062402E01 (d) Using a drill of less than φ 4mm (0.16 in.), drill out the rivet heads and remove the hood bulge. Dimension (A): 5 mm (0.20 in.) (e) Gently and vertically put the drill onto the rivet, and cut the rivet flanges. (f) Remove the hood bulge plate and air intake guide. NOTICE: • Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. • Be careful with the cut rivet, because it is hot. (g) Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill. (h) Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the hood bulge. B062403 4. REMOVE HOOD SUPPORT ASSEMBLY LH (See page ED-24) 5. REMOVE HOOD SUPPORT ASSEMBLY RH (See page ED-24) 6. REMOVE HOOD SUB-ASSEMBLY (a) Remove the windshield washer hose. (b) Remove the 4 bolts and hood. 7. REMOVE HOOD HINGE ASSEMBLY LH (a) Remove the 2 bolts and hood hinge. 8. REMOVE HOOD HINGE ASSEMBLY RH (a) Remove the 2 bolts and hood hinge. ED–18 ENGINE HOOD / DOOR – HOOD 9. 10. REMOVE HOOD LOCK ASSEMBLY (a) Using a screwdriver, disengage the 4 clips. HINT: Tape the screwdriver tip before use. (b) Remove the hood lock release lever protector. NOTICE: Removing the protector damages the clips inside the protector, therefore the use of a new protector is necessary on installation. Protector : Clip REMOVE RADIATOR SUPPORT SEAL UPPER (a) Using a clip remover, remove the 8 clips and support seal. B062406E01 (c) Remove the 3 bolts and hood lock. (d) with Security system: Disconnect the connector. ED B063509 ED–25 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR ENGINE HOOD / DOOR BODY COMPONENTS FRONT DOOR OUTSIDE HANDLE COVER LH FRONT DOOR OUTSIDE HANDLE PAD FRONT FRONT DOOR GLASS RUN LH FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH ED HOLE PLUG FRONT DOOR GLASS SUB-ASSEMBLY LH FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH FRONT DOOR LOCK OPEN ROD FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH 8.0 (82, 71 in.*lbf) * 5.0 (51, 42 in.*lbf) 8.0 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) FRONT DOOR W/MOTOR LOCK ASSEMBLY LH DOOR LOCK WIRE HARNESS PACKING FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part * Precoated part B120196E01 ED–26 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR SERVICE HOLE COVER LH FRONT DOOR GLASS WEATHERSTRIP INNER LH FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH ED FRONT DOOR ARMLEST ASSEMBLY POWER MIRROR SWITCH DOOR INSIDE HANDLE NO. 2 BEZEL LH DOOR COURTESY LIGHT POWER WINDOW REGULATOR MASTER SWITCH FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH Non-reusable part B120197E02 ED–27 ENGINE HOOD / DOOR – FRONT DOOR OUTER REAR VIEW MIRROR ASSEMBLY LH 8.0 (82, 71 in.*lbf) FRONT DOOR WINDOW FRAME MOULDING REAR LH FRONT DOOR LOWER FRAME BRACKET GARNISH LH 8.0 (82, 71 in.*lbf) FRONT DOOR GLASS WEATHERSTRIP INNER LH CUSHION RUBBER ED 26 (265, 19) FRONT DOOR HINGE ASSEMBLY UPPER LH 5.5 (56, 49 in.*lbf) CUSHION RUBBER SPEAKER MOUNTING NO. 1 BRACKET FRONT NO. 2 SPEAKER ASSEMBLY 5.0 (51, 42 in.*lbf) FRONT DOOR HINGE ASSEMBLY LOWER LH 5.0 (51, 42 in.*lbf) 5.0 (51, 42 in.*lbf) * 30 (306, 22) DOOR CHECK 26 (265, 19) Clip FRONT NO. 1 SPEAKER ASSEMBLY Clip FRONT DOOR WEATHERSTRIP LH N*m (kgf*cm, ft.*lbf) : Specified torque * Precoated part B120198E01 ED–19 ENGINE HOOD / DOOR – HOOD ADJUSTMENT HINT: • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSPECT HOOD SUB-ASSEMBLY (a) Check that the clearance is within the standard value. A B ED B062397E01 Standard clearance 2. Centering Bolt Standard Bolt B057104E24 Area Measurement A 3.9 +- 1.5 mm (0.154 +- 0.059 in.) B 0.4 +- 1.5 mm (0.015 +- 0.059 in.) ADJUST HOOD SUB-ASSEMBLY (a) Horizontally adjust the hood. HINT: • Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). (1) Loosen the hood side hinge bolts. B062399 ED–20 ENGINE HOOD / DOOR – HOOD A (2) Adjust the clearance so that it will be in the standard value, by moving the hood. Standard (A): 3.9 +- 1.5 mm (0.154 +- 0.059 in.) (3) Tighten the hood side hinge bolts after the adjustment. Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf) Aligned B062398E01 (b) Adjust the height of the hood front end by the cushion rubber. (1) Adjust the cushion rubber so that the hood and the fender will be aligned. HINT: The cushion rubber goes up and down by turning it. ED Cushion Rubber B062400E01 Centering Bolt Standard Bolt B057104E24 Protector : Clip B062406E01 (c) Adjust the hood lock. HINT: • Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). (1) Using a clip remover, disengage the clips, remove the 8 radiator support seal upper clips. (2) Remove the radiator support seal upper. (3) Using a screwdriver, disengage the 4 clips. HINT: Tape the screwdriver tip before use. (4) Remove the hood lock release lever protector. NOTICE: Removing the protector damages the clips inside the protector, therefore the use of a new protector is necessary on the installation. ED–38 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR ENGINE HOOD / DOOR BODY COMPONENTS REAR DOOR LOCK W/ MOTOR ASSEMBLY LH REAR DOOR POWER WINDOW REGULATOR ASSEMBLY LH 8.0 (82, 71 in.*lbf) * 5.0 (51, 44 in.*lbf) 5.4 (55, 48 in.*lbf) DOOR LOCK WIRE HARNESS PACKING REAR DOOR SERVICE HOLE COVER LH ED POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 8.0 (82, 71 in.*lbf) REAR DOOR GLASS WEATHERSTRIP INNER LH DOOR INSIDE HANDLE NO. 2 BEZEL LH REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH REAR SPEAKER ASSEMBLY REAR DOOR ARMREST ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque REAR DOOR TRIM BOARD SUB-ASSEMBLY LH POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR Non-reusable part * Precoated part B120199E01 ENGINE HOOD / DOOR – REAR DOOR ED–39 REAR DOOR OUTSIDE HANDLE PAD FRONT REAR DOOR OUTSIDE HANDLE COVER LH REAR DOOR HANDLE ASSEMBLY OUTSIDE LH REAR DOOR WINDOW FRAME MOULDING FRONT LH REAR DOOR OUTSIDE HANDLE PAD REAR REAR DOOR WEATHERSTRIP LH ED REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 5.5 (56, 49 in.*lbf) REAR DOOR QUARTER WINDOW WETHERSTRIP LH REAR DOOR QUARTER GLASS SUB-ASSEMBLY LH 5.5 (56, 49 in.*lbf) REAR DOOR GLASS RUN LH REAR DOOR GLASS SUB-ASSEMBLY LH REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque B120200E01 ED–40 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR WEATHERSTRIP LH REAR DOOR HINGE ASSEMBLY UPPER LH 26 (265, 19) ED DOOR CHECK 5.5 (56, 49 in.*lbf) 26 (265, 19) * 36 (306, 22) 26 (265, 19) CHILD PROTECTOR LOCK HOLE PLUG REAR DOOR HINGE ASSEMBLY LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque * Precoated part B134257E01 ENGINE HOOD / DOOR – HOOD ED–21 (5) Adjust the hood lock position so that the striker will come in, by moving the striker. (6) Tighten the hood lock bolts after the adjustment. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) B062401 REASSEMBLY 1. INSTALL HOOD LOCK ASSEMBLY (a) with Security system: Connect the connector. (b) Install the hood lock assembly with the 3 bolts. (c) Adjust the hood lock position so that the striker will come in, by moving the striker (See page ED-18). (d) Tighten the hood lock bolts after the adjustment. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL HOOD HINGE ASSEMBLY LH (a) Install the hood hinge with the 2 bolts. Torque: 13.0 N*m (130 kgf*cm, 10 ft.*lbf) 3. INSTALL HOOD HINGE ASSEMBLY RH (a) Install the hood hinge with the 2 bolts. Torque: 13.0 N*m (130 kgf*cm, 10 ft.*lbf) 4. INSTALL HOOD SUB-ASSEMBLY (a) Install the hood with the 4 bolts. Torque: 13.0 N*m (130 kgf*cm, 10 ft.*lbf) 5. INSTALL HOOD SUPPORT ASSEMBLY LH (See page ED-24) 6. INSTALL HOOD SUPPORT ASSEMBLY RH (See page ED-24) 7. INSTALL HOOD BULGE (for Sport Package) (a) Install the hood bulge plate and hood air intake guide to the hood bulge. B063509 B062407 ED ED–22 ENGINE HOOD / DOOR – HOOD (b) Using a hand riveter or air riveter with nose piece, strike rivets into the hood bulge assembly. NOTICE: • If the rivet is not positioned perpendicularly, it will bend the mandrel. • Do not prize a riveter, because the riveter will be damaged and the mandrel will be bent. • Do not tilt the riveter when removing the rivet, because the materials are not tightened firmly. • Install the rivet while attaching the materials, because they are not tightened firmly. ED B127202 (c) Install the hood air intake guide No. 1 retainer with the screw and hood bulge assembly. (d) Install the hood bulge assembly to the hood with the 5 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Retainer 8. Screw B062402E01 INSTALL RADIATOR GRILLE (a) Install the radiator grille with the 12 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Install the hood auxiliary catch hook with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Install the auxiliary catch release lever with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) ED–50 ENGINE HOOD / DOOR – BACK DOOR BACK DOOR ENGINE HOOD / DOOR BODY COMPONENTS ED BACK DOOR GLASS RUN REAR SPOILER SUB-ASSEMBLY W/O REAR SPOILER STOP CENTER LAMP ASSEMBLY BACK DOOR GLASS WEATHERSTRIP OUTER B120201E02 ED–51 ENGINE HOOD / DOOR – BACK DOOR BACK DOOR DAMPER STAY SUB-ASSEMBLY RH BACK DOOR HINGE ASSEMBLY RH BACK DOOR HINGE ASSEMBLY LH 19.5 (200, 14) WASHER NOZZLE ASSEMBLY REAR WIPER ARM AND BLADE ASSEMBLY WIPER ARM HEAD CAP 19.5 (200, 14) 5.5 (56, 49 in.*lbf) 19.5 (200, 14) BACK DOOR LOCK CYLINDER 17.5 (180, 13) ED CUSHION 19.5 (200, 14) 5.5 (56, 49 in.*lbf) 8.0 (82, 71 in.*lbf) LINER WIPER STEP RH CUSHION BACK DOOR STOPPER LOWER RH 17.5 (180, 13) BACK DOOR LOWER STOPPER CUSHION RH BACK DOOR DUMPER STAY SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) BACK DOOR STOPPER LOWER LH TELEVISION CAMERA ASSEMBLY BACK DOOR LOWER STOPPER CUSHION LH BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120202E03 ED–52 ENGINE HOOD / DOOR – BACK DOOR BACK DOOR GLASS SUB-ASSEMBLY CONNECTOR 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) ED COVER PLATE POWER WINDOW REGULATOR MOTOR ASSEMBLY 8.0 (82, 71 in.*lbf) BACK DOOR POWER WINDOW REGULATOR ASSEMBLY MULTIPLEX NETWORK DOOR COMPUTER ASSEMBLY SERVICE HOLE COVER LH BACK DOOR GLASS WEATHERSTRIP INNER SERVICE HOLE COVER BACK DOOR LOCK ASSEMBLY 8.0 (82, 71 in.*lbf) BACK DOOR TRIM COVER BACK DOOR LOCK PROTECTOR SUB-ASSEMBLY ASSIST STRAP ASSEMBLY RH ASSIST STRAP HOLE COVER N*m (kgf*cm, ft.*lbf) : Specified torque BACK DOOR TRIM BOARD Non-reusable part B120203E03 ED–25 ENGINE HOOD / DOOR – HOOD SUPPORT ROD INSTALLATION 1. INSTALL HOOD SUPPORT ASSEMBLY LH (a) Install the hood support with the 2 bolts. Torque: 17.5 N*m (180 kgf*cm, 13 ft.*lbf) DISPOSAL 1. a A b B B065104E14 DISPOSE OF HOOD SUPPORT ASSEMBLY LH (a) Horizontally fix the stay in a vise with the piston-rod pulled out. (b) Wearing safety glasses, gradually cut a part between A and B as shown in the illustration using a metal saw to gradually release the gas. Specification Area Measurement a 80 mm (3.15 in.) b 20 mm (0.80 in.) CAUTION: Be careful to cover the area that is being cut as there is a possibility that metal debris could be blown out by the gas (the gas is colorless, odorless and harmless). ED ENGINE HOOD / DOOR – BACK DOOR SUPPORT ED–61 BACK DOOR SUPPORT ENGINE HOOD / DOOR BODY COMPONENTS ED BACK DOOR DUMPER STAY SUB-ASSEMBLY LH B120202E04 ED–62 ENGINE HOOD / DOOR – BACK DOOR SUPPORT REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). 1. B063577 ED REMOVE BACK DOOR DUMPER STAY SUBASSEMBLY LH (a) Remove the 2 bolts and damper stay from the door panel. HINT: While supporting the hood by hand, remove the hood support. (b) Loosen the bolt and remove the damper stay from the vehicle body. ED–28 ENGINE HOOD / DOOR – FRONT DOOR DISASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). 1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (a) Using a screwdriver, remove the lower frame bracket garnish. HINT: Tape the screwdriver tip before use. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (a) Using a screwdriver, disengage the 3 claws, and remove the inside handle bezel. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT ARMREST ASSEMBLY LH (a) Disengage the claws, and remove the armrest from the trim board. HINT: Tape the screwdriver tip before use. 4. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (a) Remove the 2 cushion rubbers. (b) Remove the 2 screws and clips. (c) Using a clip remover, remove the 11 clips. (d) Remove the trim board upward. HINT: In order to prevent the door from being damaged, cover the parts indicated by arrow marks in the illustration with tape. Clip : Clip B062415E01 Claw ED Claw B062416E02 Claw Claw : Claw B062417E01 : Claw B062418E01 ENGINE HOOD / DOOR – FRONT DOOR ED–29 (e) Disconnect the 2 cables from the inside handle as shown in the illustration. (f) Remove the inner weatherstrip. (g) Remove the 3 screws and power window master switch. H006127E01 (h) Using a screwdriver, disengage the 4 claws. HINT: Tape the screwdriver tip before use. (i) Remove the power mirror switch, as shown in the illustration. Claw ED B064057E01 5. REMOVE FRONT DOOR SERVICE HOLE COVER LH (a) Remove the front door service hole cover LH. NOTICE: Remove the remaining tape on the door side. 6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the outer rear view mirror connector. (b) Remove the 3 nuts and outer rear view mirror. NOTICE: When the nuts are removed, the outer rear view mirror might drop and be deformed. 7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-172) 8. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (a) Disconnect the speaker connector. (b) Remove the 2 bolts and No. 2 speaker. (c) Remove the 2 bolts and speaker mounting No. 1 bracket. 9. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (See page ET-63) B065760E01 B062419 B062421 10. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH (See page ET-27) ED–30 ENGINE HOOD / DOOR – FRONT DOOR 11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched. (a) Open the door glass until the bolts appear in the service holes. (b) Remove the 2 bolts and holding the door glass. B062422 (c) Remove the door glass, as shown in the illustration. NOTICE: • Do not damage the door glass. • When the bolts are removed, the door glass might drop and be deformed. (d) Remove the door glass run. (2) (1) ED B062423E12 B062424 12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH (a) Disconnect the window regulator connector. (b) Remove the 6 bolts and window regulator. NOTICE: When the bolts are removed, the window regulator might drop and be deformed. HINT: Remove the window regulator through the service hole. 13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Place matchmarks on the window regulator motor gear and regulator gear. (b) Using a "torx" driver (T25), remove the 3 screws and window regulator motor. 14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH (a) Remove the bolt and frame rear lower. B062425E01 ENGINE HOOD / DOOR – FRONT DOOR ED–31 15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (a) Remove the hole plug. (b) Using a "torx" socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed. Hole Plug B061438E22 16. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH (a) Disconnect the door lock connector. (b) Using a "torx" socket wrench (T30), remove the 3 screws and door lock. HINT: Remove the door lock through the service hole. (c) Remove the door lock wire harness packing. ED B062426 17. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH (a) Pushing and pulling the outside handle in the arrow mark direction in the illustration, remove the outside handle. (b) Remove the outside handle pad front and rear. (1) (2) B056613E13 18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a "torx" socket wrench (T30), loosen the screw. (b) Slide the outside handle frame from to remove it. HINT: Remove the outside handle frame through the service hole. Bolt B062427E01 19. REMOVE FRONT DOOR LOCK CHECK ASSEMBLY LH (a) Remove the 2 nuts, bolt and the door check. 20. REMOVE FRONT DOOR WEATHERSTRIP LH (a) Using a clip remover, disengage the clips and remove the weatherstrip. HINT: If the clips are damaged, exchange them for new clips. B062429 ED–32 ENGINE HOOD / DOOR – FRONT DOOR 21. REMOVE FRONT DOOR WIRE LH (a) Disconnect the door wire clips. (b) Remove the 2 bolts and door wire. B062428 ED ED–33 ENGINE HOOD / DOOR – FRONT DOOR ADJUSTMENT HINT: • Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning lamp, the side airbag system and the curtain shield airbag system for normal operation. Then initialize both systems. • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY LH (a) Check that the clearance is within the standard value. B A E ED C D B062408E01 Standard clearance 2. Centering Bolt Standard Bolt B057104E01 Area Measurement A 4.5 +- 1.5 mm (0.177 +- 0.059 in.) B 5.6 +- 1.5 mm (0.220 +- 0.059 in.) C 7.6 +- 1.5 mm (0.299 +- 0.059 in.) D 5.0 +- 1.5 mm (0.197 +- 0.059 in.) E 160 mm (6.30 in.) ADJUST FRONT DOOR PANEL SUB-ASSEMBLY LH (a) Adjust the front door panel position. HINT: • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (See page IP-6). ED–34 ENGINE HOOD / DOOR – FRONT DOOR (1) Put protective tape on the door panel and fender, as shown in the illustration. Protective Tape B064377E01 Clip Protector ED B064378E01 (2) Open the door, and remove the 5 clips. NOTICE: If the clips are damaged, replace them with new ones. (3) Remove the gap between the front fender side panel protector LH from the gap between the fender and door. HINT: If the clips are damaged, replace them with new ones. (4) Using SST, horizontally and vertically adjust the door by loosening the body side hinge bolts. SST 09812-00010, 09812-00020 (5) Tighten the body side hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B062409 (6) Adjust the door by loosening the door side hinge bolts forward/ rearward and vertically. (7) Tighten the door side hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (8) Install the front fender side panel protector LH with the 5 clips. B062410 B062411 (9) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic-faced hammer. (10) Tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) (11) Connect the negative (-) terminal cable from the battery. (12) Initialize both systems. (13) Check the SRS warning lamp. EXTERIOR – FRONT BUMPER ET–3 REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. REMOVE FRONT BUMPER ASSEMBLY (a) Using a clip remover, remove the 3 clips. (b) Remove the 4 bolts and 9 screws. (c) with Fog light: (1) Disconnect the fog light assembly connectors. B120252 (d) Using a screwdriver, disengage the 8 claws and remove the front bumper assembly. HINT: Tape the screwdriver tip before use. B120253 DISASSEMBLY 1. REMOVE FRONT BUMPER HOLE COVER LH (w/o Fog Light) (a) Disengage the 4 claws and remove the front bumper hole cover LH. 2. REMOVE FRONT BUMPER HOLE COVER RH (w/o Fog Light) HINT: Use the same procedures for the RH side and LH side. 3. REMOVE FRONT BUMPER HOLE COVER LH (w/ Fog Light) (See page LI-47) 4. REMOVE FRONT BUMPER HOLE COVER RH (w/ Fog Light) HINT: Use the same procedures for the RH side and LH side. B120254 ET ET–4 EXTERIOR – FRONT BUMPER 5. REMOVE FOG LIGHT ASSEMBLY LH (w/ Fog Light) (See page LI-37) 6. REMOVE FOG LIGHT ASSEMBLY RH (w/ Fog Light) HINT: Use the same procedures for the RH side and LH side. 7. REMOVE RADIATOR GRILLE LOWER (a) Remove the 2 bolts. (b) Disengage the 13 claws and remove the radiator grille lower. 8. REMOVE FRONT BUMPER COVER 9. REMOVE FRONT BUMPER REINFORCEMENT PLATE (a) Remove the 3 bolts and front bumper reinforcement plate. B120255 ET B120256 10. REMOVE FRONT BUMPER SIDE MOUNTING BRACKET LH (a) Remove the bolt, 2 nuts and front bumper side mounting bracket LH. 11. REMOVE FRONT BUMPER SIDE MOUNTING BRACKET RH HINT: Use the same procedures for the RH side and LH side. B120257 12. REMOVE FRONT BUMPER SIDE SUPPORT LH (a) Using a screwdriver, remove the 2 screws and front bumper side support LH. HINT: Tape the screwdriver tip before use. 13. REMOVE FRONT BUMPER SIDE SUPPORT RH HINT: Use the same procedures for the RH side and LH side. B120258 EXTERIOR – FRONT BUMPER ET–5 14. REMOVE FRONT BUMPER ENERGY ABSORBER (a) Remove the front bumper energy absorber. B120259 15. REMOVE FRONT BUMPER REINFORCEMENT SUBASSEMBLY (a) Remove the 4 nuts and front bumper reinforcement sub-assembly. B120260 REASSEMBLY 1. INSTALL FRONT BUMPER REINFORCEMENT SUBASSEMBLY (a) Install the front bumper reinforcement sub-assembly with the 4 nuts. Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 2. INSTALL FRONT BUMPER ENERGY ABSORBER 3. INSTALL FRONT BUMPER SIDE SUPPORT LH (a) Install the front bumper side support LH with the 2 screws. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 4. INSTALL FRONT BUMPER SIDE SUPPORT RH HINT: Use the same procedures for the RH side and LH side. 5. INSTALL FRONT BUMPER SIDE MOUNTING BRACKET LH (a) Install the front bumper side mounting bracket LH with the bolt and 2 nuts. Torque: Bolt 8.0 N*m (82 kgf*cm, 71 in.*lbf) Nut 5.0 N*m (51 kgf*cm, 44 in.*lbf) B120260 B120258 B120257 ET ET–6 EXTERIOR – FRONT BUMPER 6. INSTALL FRONT BUMPER SIDE MOUNTING BRACKET RH HINT: Use the same procedures for the RH side and LH side. 7. INSTALL FRONT BUMPER REINFORCEMENT PLATE (a) Install the front bumper reinforcement plate with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 8. INSTALL FRONT BUMPER COVER (a) Install the radiator grille lower with the 13 claws. (b) Install the 2 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) 9. INSTALL RADIATOR GRILLE LOWER B120256 10. INSTALL FOG LIGHT ASSEMBLY LH (See page LI-50) ET B120255 11. INSTALL FOG LIGHT ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side. 12. INSTALL FRONT BUMPER HOLE COVER LH (w/o Fog Light) (See page LI-51) 13. INSTALL FRONT BUMPER HOLE COVER RH (w/o Fog Light) HINT: Use the same procedures for the RH side and LH side. 14. INSTALL FRONT BUMPER HOLE COVER LH (w/ Fog Light) 15. INSTALL FRONT BUMPER HOLE COVER RH (w/ Fog Light) INSTALLATION 1. B120253 INSTALL FRONT BUMPER ASSEMBLY (a) Install the front bumper assembly with the 8 claws. (b) with Fog light: (1) Connect the fog light assembly connectors. EXTERIOR – FRONT BUMPER ET–7 (c) Install the 4 bolts and 9 screws. Torque: Bolt 8.0 N*m (82 kgf*cm, 71 in.*lbf) Screw 3.0 N*m (31 kgf*cm, 27 in.*lbf) (d) Install the 3 clips. Screw Screw Bolt B120252E02 2. CONNECT BATTERY NEGATIVE TERMINAL 3. VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT 4. VEHICLE PREPARATION FOR FOG LIGHT AIM ADJUSTMENT 5. INSPECT FOG LIGHT AIMING LI-47 6. ADJUST FOG LIGHT AIMING LI-47 7. PERFORM INITIALIZATION Some systems need initialization when disconnecting the cable from the negative battery terminal. ET ET–10 EXTERIOR – REAR BUMPER REAR BUMPER STEP CUSHION REAR BUMPER PROTECTOR RH REAR BUMPER PROTECTOR LH REAR BUMPER COVER ET Non-reusable part B120289E01 REMOVAL 1. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH (a) Using a clip remover, remove the 2 clips. (b) Remove the 7 screws and quarter panel mudguard sub-assembly rear LH. 2. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR RH HINT: Use the same procedures for the RH side and LH side. 3. REMOVE REAR BUMPER ASSEMBLY (a) Using a clip remover, remove the 2 clips. (b) Remove the 8 bolts and 4 screws. B120261 B120262 EXTERIOR – REAR BUMPER ET–11 (c) Disengage the 6 claws and remove the rear bumper assembly. B120263 DISASSEMBLY 1. REMOVE REAR BUMPER STEP CUSHION (a) Remove the 6 rear bumper stop cushions. ET B120264 2. REMOVE REAR BUMPER PROTECTOR LH (a) Remove the rear bumper protector LH. 3. REMOVE REAR BUMPER PROTECTOR RH HINT: Use the same procedures for the RH side and LH side. 4. REMOVE REAR BUMPER COVER 5. REMOVE REAR BUMPER RETAINER UPPER LH (a) Remove the 2 screws. (b) Using a screwdriver, disengage the claw and remove the rear bumper retainer upper LH. HINT: Tape the screwdriver tip before use. 6. REMOVE REAR BUMPER RETAINER UPPER RH HINT: Use the same procedures for the RH side and LH side. B120265 B120266 ET–12 EXTERIOR – REAR BUMPER 7. REMOVE REAR BUMPER END RETAINER LH (a) Remove the screw. (b) Using a screwdriver, disengage the claw and remove the rear bumper end retainer LH. HINT: Tape the screwdriver tip before use. 8. REMOVE REAR BUMPER END RETAINER RH HINT: Use the same procedures for the RH side and LH side. 9. REMOVE REAR BUMPER BAR REINFORCEMENT LH (a) Remove the screw and rear bumper bar reinforcement LH. B120267 10. REMOVE REAR BUMPER BAR REINFORCEMENT RH HINT: Use the same procedures for the RH side and LH side. B120268 ET 11. REMOVE REAR BUMPER ENERGY ABSORBER (a) Remove the rear bumper energy absorber. B120269 12. REMOVE REAR BUMPER SIDE MOUNTING BRACKET LH (a) Remove the bolt and rear bumper side mounting bracket LH. 13. REMOVE REAR BUMPER SIDE MOUNTING BRACKET RH HINT: Use the same procedures for the RH side and LH side. B120270 14. REMOVE REAR BUMPER REINFORCEMENT NO. 2 (a) Remove the bolt and No. 2 rear bumper reinforcement. 15. REMOVE REAR BUMPER REINFORCEMENT NO. 1 HINT: Use the same procedures for the RH side and LH side. B120271 ET–1 EXTERIOR – FRONT BUMPER FRONT BUMPER EXTERIOR BODY COMPONENTS FRONT BUMPER SIDE MOUNTING BRACKET RH 8.0 (82, 71 in.*lbf) FRONT BUMPER SIDE MOUNTING BRACKET LH FRONT BUMPER SIDE SUPPORT RH 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 3.0 (31, 27 in.*lbf) FRONT BUMPER REINFORCEMENT PLATE ET 58 (591, 43) 58 (591, 43) FRONT BUMPER ENERGY ABSORBER 3.0 (31, 27 in.*lbf) FRONT BUMPER SIDE SUPPORT LH FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 3.0 (31, 27 in.*lbf) FRONT BUMPER ASSEMBLY 3.0 (31, 27 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque 8.0 (82, 71 in.*lbf) B120174E01 ET–2 EXTERIOR – FRONT BUMPER FRONT BUMPER COVER 7.5 (77, 66 in.*lbf) RADIATOR GRILLE LOWER ET without Fog Light: without Fog Light: FRONT BUMPER HOLE COVER RH with Fog Light: FOG LIGHT ASSEMBLY RH FRONT BUMPER HOLE COVER RH FRONT BUMPER HOLE COVER LH with Fog Light: FOG LIGHT ASSEMBLY LH FRONT BUMPER HOLE COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque B120288E01 EXTERIOR – REAR BUMPER ET–13 REASSEMBLY 1. INSTALL REAR BUMPER REINFORCEMENT NO. 2 (a) Install the No. 2 rear bumper reinforcement with the bolt. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 2. INSTALL REAR BUMPER REINFORCEMENT NO. 1 HINT: Use the same procedures for the RH side and LH side. 3. INSTALL REAR BUMPER SIDE MOUNTING BRACKET LH (a) Install the rear bumper side mounting bracket LH with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 4. INSTALL REAR BUMPER SIDE MOUNTING BRACKET RH HINT: Use the same procedures for the RH side and LH side. 5. INSTALL REAR BUMPER ENERGY ABSORBER 6. INSTALL REAR BUMPER BAR REINFORCEMENT LH (a) Install the rear bumper bar reinforcement LH with the screw. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 7. INSTALL REAR BUMPER BAR REINFORCEMENT RH HINT: Use the same procedures for the RH side and LH side. 8. INSTALL REAR BUMPER END RETAINER LH (a) Install the rear bumper end retainer LH with the screw and claw. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 9. INSTALL REAR BUMPER END RETAINER RH HINT: Use the same procedures for the RH side and LH side. B120271 B120270 B120268 B120267 10. INSTALL REAR BUMPER RETAINER UPPER LH (a) Install the rear bumper retainer upper LH with the 2 screws and claw. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 11. INSTALL REAR BUMPER RETAINER UPPER RH HINT: Use the same procedures for the RH side and LH side. 12. INSTALL REAR BUMPER COVER B120266 ET ET–14 EXTERIOR – REAR BUMPER 13. INSTALL REAR BUMPER PROTECTOR LH (a) Install a new rear bumper protector LH. 14. INSTALL REAR BUMPER PROTECTOR RH HINT: Use the same procedures for the RH side and LH side. B120265 15. INSTALL REAR BUMPER STEP CUSHION (a) Install 6 new rear bumper stop cushions. B120264 ET INSTALLATION 1. INSTALL REAR BUMPER ASSEMBLY (a) Install the rear bumper assembly with the 6 claws. B120263 (b) Install the 8 bolts and 4 screws. Torque: Bolt 8.0 N*m (82 kgf*cm, 71 in.*lbf) Screw 5.0 N*m (51 kgf*cm, 44 in.*lbf) (c) Install the 2 clips. Bolt Screw Bolt Screw B120262E01 2. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 3. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR RH ET–8 EXTERIOR – REAR BUMPER REAR BUMPER EXTERIOR BODY COMPONENTS REAR BUMPER RETAINER UPPER RH ET 3.0 (31, 27 in.*lbf) 3.0 (31, 27 in.*lbf) REAR BUMPER END RETAINER RH 3.0 (31, 27 in.*lbf) 3.0 (31, 27 in.*lbf) REAR BUMPER END RETAINER LH REAR BUMPER RETAINER UPPER LH 8.0 (82, 71 in.*lbf) REAR BUMPER SIDE MOUNTING BRACKET RH 8.0 (82, 71 in.*lbf) REAR BUMPER SIDE MOUNTING BRACKET LH N*m (kgf*cm, ft.*lbf) : Specified torque B120175E01 ET–9 EXTERIOR – REAR BUMPER REAR BUMPER REINFORCEMENT NO. 1 REAR BUMPER ENERGY ABSORBER REAR BUMPER REINFORCEMENT NO. 2 25 (255, 18) 25 (255, 18) QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR LH QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR RH REAR BUMPER BAR REINFORCEMENT RH 5.0 (51, 44 in.*lbf) REAR BUMPER BAR REINFORCEMENT LH 8.0 (82, 71 in.*lbf) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 8.0 (82, 71 in.*lbf) REAR BUMPER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B134260E01 ET EXTERIOR – ROOF RACK ET–23 INSTALLATION 1. INSTALL ROOF RACK BAR JOINT NO. 2 (a) Using a torx wrench (T25), install the 8 screws to the roof rack bar joint. 2. INSTALL ROOF RACK LEG COVER FRONT LH (a) Install the rack leg with the 2 screws. 3. INSTALL ROOF RACK LEG COVER FRONT RH (a) Install the rack leg with the 2 screws. 4. INSTALL ROOF RACK ASSEMBLY (a) Using a white gasoline, clean the bolt and thread. (b) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Adhesive B064237E01 (c) Install the roof rack assembly with the 8 bolts. B063613 5. INSTALL ROOF RACK LEG COVER REAR LH (a) Install the leg cover with the 4 claws and clip. 6. INSTALL ROOF RACK LEG COVER REAR RH (a) Install the leg cover with the 4 claws and clip. 7. INSTALL ROOF RACK LEG COVER FRONT LH (a) Install the leg cover with the 4 claws and clip. 8. INSTALL ROOF RACK LEG COVER FRONT RH (a) Install the leg cover with the 4 claws and clip. B063612 B063611 ET ET–15 EXTERIOR – NAME PLATE NAME PLATE REPLACEMENT 1. REPLACE NAME PLATE Front Fender Emblem (Left, Right) Back Door Name Plate Front Fender Emblem (Left) 309.0 (12.165) Front Fender Emblem (Right) 309.0 (12.165) 83.0 (3.268) 83.0 (3.268) 302.0 (11.890) 306.5 (12.067) 167.5 (6.594) 167.5 (6.594) 83.0 (3.268) 302.0 (11.890) 302.0 (11.890) 306.5 (12.067) 83.0 (3.268) 304.0 (11.968) 304.0 (11.968) 302.0 (11.890) mm (in.) B134208E01 ET ET–16 EXTERIOR – NAME PLATE Front Fender Emblem (Left) Front Fender Emblem (Right) 262.0 (10.315) 262.0 (10.315) 83.0 (3.268) 302.0 (11.890) 83.0 (3.268) 304.0 (11.968) 315.0 (12.401) ET 6.0 (0.236) 83.0 (3.268) 304.0 (11.968) 408.0 (16.063) 6.0 (0.236) 302.0 (11.890) 307.0 (12.087) 288.0 (11.339) 26.0 (1.024) 302.0 (11.890) 308.5 (12.146) 176.0 (6.923) 304.0 (11.968) 381.0 (14.000) 176.0 (6.923) 83.0 (3.268) 26.0 (1.024) 302.0 (11.890) 306.5 (12.067) 308.5 (12.146) 304.0 (11.968) mm (in.) B134209E01 ET–17 EXTERIOR – NAME PLATE Front Fender Emblem (Left) 193.5 (7.618) Front Fender Emblem (Right) 26.0 (1.024) 286.5 (11.280) 83.0 (3.268) 176.0 (6.92) 26.0 (1.024) 302.0 (11.890) 304.5 (11.988) 306.5 (12.067) 304.0 (11.968) Back Door Name Plate 171.5 (6.752) ET 142.0 (5.591) 48.0 (1.890) 226.5 (8.917) 131.0 (5.157) 34.0 (1.339) B134210E01 EXTERIOR – FRONT DOOR GLASS WEATHERSTRIP ET–27 REMOVAL HINT: On the RH side, use the same procedures as on the LH side. Screw Protective Tape Tape B062951E01 1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-28) 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-28) 4. REMOVE FRONT ARMREST ASSEMBLY LH (See page ED-28) 5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-28) 6. REMOVE FRONT DOOR SERVICE HOLE COVER LH (See page ED-29) 7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (See page ED-29) 8. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (See page ET-63) 9. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH (a) Put protective tape under the glass weatherstrip assembly. (b) Remove the screw. (c) Using a screwdriver or moulding remover, disengage the claw and remove the glass weatherstrip. HINT: Tape the screwdriver tip before use. ET ET–28 EXTERIOR – FRONT DOOR GLASS WEATHERSTRIP INSTALLATION ET 1. INSTALL FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH (a) Install the glass weatherstrip with the claw and screw. 2. INSTALL FRONT DOOR WINDOW FRAME MOULDING REAR LH 3. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (See page ED-37) 4. INSTALL FRONT DOOR SERVICE HOLE COVER LH (See page ED-37) 5. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH 6. INSTALL FRONT ARMREST ASSEMBLY LH 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH 8. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH 9. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY ET–18 EXTERIOR – REAR SPOILER REAR SPOILER EXTERIOR BODY COMPONENTS REAR SPOILER CLIP NO. 1 2.5 (25, 22 in.*lbf) REAR SPOILER REAR SPOILER CLIP NO. 1 7.0 (71, 62 in.*lbf) 7.0 (71, 62 in.*lbf) ET CENTER STOP LIGHT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120176E01 EXTERIOR – REAR SPOILER ET–19 REMOVAL 1. REMOVE REAR SPOILER (a) Remove the 2 grommets, 2 bolts and spoiler. (b) Disconnect the center stop light connector. 2. REMOVE CENTER STOP LIGHT ASSEMBLY (a) Remove the 2 bolts and stop light assembly. 3. REMOVE REAR SPOILER CLIP NO. 1 (a) Use a drill which tip is less than φ 4 mm (0.16 in.). (b) Tape the drill tip as shown in the illustration. Dimension (A): 5 mm (0.20 in.) HINT: In order not to drill too deeply, tape the drill tip. (c) Gently and vertically place the drill tip onto the rivet, cut the rivet flanges, and then remove the rivet. NOTICE: • Placing the drill tip strongly will turn the rivet together with the drill, and so the rivet will not be cut. • Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself. • Be careful in undertaking this task as the cut rivet is hot. (d) Remove the 2 spoiler clips from the back door panel. B063789 B063787 A B064660E01 INSTALLATION 1. B064661 INSTALL REAR SPOILER CLIP NO. 1 (a) Using an air riveter or hand riveter with nose piece, strike waterproof rivets of φ 4 mm into the body panel to install the 2 rear spoiler clips No. 1 to the back door panel. NOTICE: If the rivet is not positioned perpendicularly, it will bend the mandrel. ET ET–20 EXTERIOR – REAR SPOILER 2. INSTALL CENTER STOP LIGHT ASSEMBLY (a) Install the stop light assembly with the 2 bolts. Torque: 2.5 N*m (25 kgf*cm, 22 in.*lbf) 3. INSTALL REAR SPOILER (a) Connect the center stop light connector. (b) Install the spoiler with the 2 bolts and 2 grommets. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) B063787 B063789 ET ET–32 EXTERIOR – REAR DOOR GLASS WEATHERSTRIP REMOVAL HINT: On the RH side, use the same procedures as on the LH side. ET Screw Protective Tape Tape B062582E01 1. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR 2. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-41) 3. REMOVE REAR ARMREST ASSEMBLY LH (See page ED-41) 4. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-41) 5. REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH (See page ET-66) 6. REMOVE REAR DOOR GLASS WEATHERSTRIP OUTER (a) Remove the screw. (b) Put protective tape under the glass weatherstrip. (c) Using a screwdriver or moulding remover, disengage the claw and remove glass weatherstrip. HINT: Tape the screwdriver tip before use. EXTERIOR – REAR DOOR GLASS WEATHERSTRIP ET–33 INSTALLATION 1. INSTALL REAR DOOR GLASS WEATHERSTRIP OUTER 2. INSTALL REAR DOOR WINDOW FRAME MOULDING FRONT LH 3. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH 4. INSTALL REAR ARMREST ASSEMBLY LH 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH 6. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR (a) Install the glass weatherstrip with the claw and screw. ET ET–21 EXTERIOR – ROOF RACK ROOF RACK EXTERIOR BODY COMPONENTS ROOF RACK LEG COVER FRONT RH ROOF CARRIER BAR RH REAR ROOF RACK LEG LH ROOF RACK LEG COVER REAR RH ROOF RACK BRACKET REAR ROOF RACK LEG RH ROOF RACK BRACKET FRONT ROOF RACK LEG LH ROOF RACK LEG COVER FRONT LH ROOF RACK BRACKET ROOF CARRIER BAR LH FRONT ROOF RACK LEG RH ROOF RACK LEG COVER REAR LH ROOF RACK BRACKET ROOF RACK PLATE ET REAR ROOF RACK BAR NO. 2 ROOF CARRIER CAP ROOF RACK BAR JOINT NO. 2 FRONT ROOF RACK BAR B134207E01 ET–22 EXTERIOR – ROOF RACK REMOVAL HINT: A bolt without torque specification is a standard bolt (See page SS-1). 1. REMOVE ROOF RACK LEG COVER FRONT LH (a) Using a screwdriver, disengage the 4 claws and clip, and remove the leg cover. HINT: Tape the screwdriver tip before use. 2. REMOVE ROOF RACK LEG COVER FRONT RH (a) Using a screwdriver, disengage the 4 claws and clip, and remove the leg cover. HINT: Tape the screwdriver tip before use. 3. REMOVE ROOF RACK LEG COVER REAR LH (a) Using a screwdriver, disengage the 4 claws and clip, and remove the leg cover. HINT: Tape the screwdriver tip before use. 4. REMOVE ROOF RACK LEG COVER REAR RH (a) Using a screwdriver, disengage the 4 claws and clip, and remove the leg cover. HINT: Tape the screwdriver tip before use. 5. REMOVE ROOF RACK ASSEMBLY (a) Remove the 4 bolts and the roof rack assembly. 6. REMOVE ROOF RACK LEG COVER FRONT LH (a) Remove the 2 screws and rack leg. 7. REMOVE ROOF RACK LEG COVER FRONT RH (a) Remove the 2 screws and rack leg. 8. REMOVE ROOF RACK BAR JOINT NO. 2 (a) Using a torx wrench (T25), remove the 8 screws the roof rack bar joint. B063611 ET B063612 B063613 EXTERIOR – BACK DOOR GLASS WEATHERSTRIP ET–35 REMOVAL 1. REMOVE BACK DOOR TRIM PANEL ASSEMBLY (a) Remove the assist strap hole cover. (b) Remove the assist strap assembly RH. (c) Remove the back door trim panel. 2. REMOVE BACK DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER (a) Put protective tape under the glass weatherstrip. (b) Using a screwdriver or moulding remover, disengage the claw and remove the glass weatherstrip outer. HINT: • Tape the screwdriver tip before use. • Put the screwdriver on either edge of the door glass weatherstrip. Protective Tape Tape ET B062583E01 ET–36 EXTERIOR – BACK DOOR GLASS WEATHERSTRIP INSTALLATION ET 1. INSTALL BACK DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER (a) Install the glass weatherstrip outer with the claw. 2. INSTALL BACK DOOR TRIM PANEL ASSEMBLY ET–24 EXTERIOR – FRONT DOOR GLASS WEATHERSTRIP FRONT DOOR GLASS WEATHERSTRIP EXTERIOR BODY COMPONENTS FRONT DOOR OUTSIDE HANDLE PAD FRONT FRONT DOOR OUTSIDE HANDLE COVER LH FRONT DOOR GLASS RUN LH FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH ET FRONT DOOR OUTSIDE HANDLE PAD REAR HOLE PLUG FRONT DOOR LOCK OPEN ROD FRONT DOOR GLASS SUB-ASSEMBLY LH FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) 5.0 (51, 42 in.*lbf) 8.0 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH DOOR LOCK WIRE HARNESS PACKING FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part B120196E03 EXTERIOR – FRONT DOOR GLASS WEATHERSTRIP ET–25 FRONT DOOR SERVICE HOLE COVER LH FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH FRONT DOOR GLASS WEATHERSTRIP INNER LH FRONT ARMREST ASSEMBLY LH ET POWER MIRROR SWITCH DOOR INSIDE HANDLE NO. 2 BEZEL LH DOOR COURTESY LIGHT FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY Non-reusable part B120197E07 ET–26 EXTERIOR – FRONT DOOR GLASS WEATHERSTRIP FRONT DOOR WINDOW FRAME MOULDING REAR LH OUTER REAR VIEW MIRROR ASSEMBLY LH FRONT DOOR LOWER FRAME BRACKET GARNISH LH 8.0 (82, 71 in.*lbf) FRONT DOOR GLASS WEATHERSTRIP INNER LH CUSHION RUBBER 26 (265, 19) ET FRONT DOOR HINGE ASSEMBLY UPPER LH CUSHION RUBBER 5.5 (56, 49 in.*lbf) DOOR CHECK FRONT NO. 2 SPEAKER ASSEMBLY 5.0 (51, 42 in.*lbf) SPEAKER MOUNTING NO. 1 BRACKET 30 (306, 22) 5.0 (51, 42 in.*lbf) 26 (265, 19) 5.0 (51, 42 in.*lbf) FRONT DOOR HINGE ASSEMBLY LOWER LH FRONT NO. 1 SPEAKER ASSEMBLY CLIP CLIP FRONT DOOR WEATHERSTRIP LH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B120198E03 ET–38 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING REMOVAL HINT: On the RH side, use the same procedures as on the LH side. without Roof Rack 1. REMOVE ROOF RACK ASSEMBLY LH (w/ Roof Rack) HINT: (See page ET-22) 2. REMOVE ROOF DRIP SIDE MOULDING COVER FRONT LH (w/o Roof Rack) (a) Using a screwdriver, disengage the 2 claws and remove the moulding cover. HINT: Tape the screwdriver tip before use. 3. REMOVE WINDSHIELD MOULDING OUTSIDE LH (a) Put protective tape around the windshield moulding. (b) Pull out the windshield moulding by hand. NOTICE: • Be careful not to damage the windshield moulding. • If the windshield moulding is damaged, exchange it for a new one. 4. REMOVE WINDSHIELD OUTSIDE MOULDING FASTENER NO. 1 (a) Put protective tape around the fastener. (b) Using a screwdriver, disengage the 3 clips and pull out the fastener by hand. HINT: Tape the screwdriver tip before use. NOTICE: • Be careful not to damage the windshield and fastener. • If the windshield and fastener are damaged, exchange them for a new one. Claw B062586E01 ET Protective Tape B062955E01 Protective Tape B062959E01 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ET–39 5. REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER NO. 2 LH (a) Put protective tape around the moulding. (b) Pull out the moulding by hand. NOTICE: Be careful not to damage the moulding. 6. REMOVE ROOF DRIP SIDE MOULDING END COVER REAR LH (w/o Roof Rack) (a) Using a screwdriver, disengage the 2 claws and remove the moulding end cover. HINT: Tape the screwdriver tip before use. 7. REMOVE ROOF DRIP SIDE FINISH MOULDING REAR LH (a) Put protective tape around the moulding. (b) Pull out the moulding by hand. NOTICE: • Be careful not to damage the moulding. • Do not remove the clips. • In case that the clips are damaged or removed accidentally, exchange them into supplied ones. 8. REMOVE ROOF RACK BRACKET FRONT LH (w/o Roof Rack) (a) Remove the 2 bolts and bracket. 9. REMOVE ROOF RACK BRACKET NO. 1 REAR LH (w/ o Roof Rack) (a) Remove the 2 bolts and bracket. Protective Tape B062957E01 Claw B062586E02 Protective Tape Clip B062958E01 B062588 ET EXTERIOR – REAR DOOR GLASS WEATHERSTRIP ET–29 REAR DOOR GLASS WEATHERSTRIP EXTERIOR BODY COMPONENTS REAR DOOR POWER WINDOW REGULATOR ASSEMBLY LH REAR DOOR LOCK WITH MOTOR ASSEMBLY LH 5.0 (51, 44 in.*lbf) 5.4 (55, 48 in.*lbf) DOOR LOCK WIRE HARNESS PACKING 8.0 (82, 71 in.*lbf) POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 8.0 (82, 71 in.*lbf) REAR DOOR GLASS WEATHERSTRIP INNER LH REAR DOOR SERVICE HOLE COVER LH DOOR INSIDE HANDLE NO. 2 BEZEL LH REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH REAR SPEAKER ASSEMBLY REAR DOOR ARMREST ASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR Precoated part B120199E03 ET ET–30 EXTERIOR – REAR DOOR GLASS WEATHERSTRIP REAR DOOR OUTSIDE HANDLE PAD FRONT REAR DOOR OUTSIDE HANDLE COVER LH REAR DOOR HANDLE ASSEMBLY OUTSIDE LH REAR DOOR WINDOW FRAME MOULDING FRONT LH REAR DOOR OUTSIDE HANDLE PAD REAR ET REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH REAR DOOR WEATHERSTRIP LH 5.5 (56, 49 in.*lbf) REAR DOOR QUARTER WINDOW WEATHERSTRIP LH REAR DOOR GLASS SUBASSEMBLY LH REAR DOOR QUARTER GLASS SUB-ASSEMBLY LH 5.5 (56, 49 in.*lbf) REAR DOOR GLASS RUN LH REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120200E02 ET–31 EXTERIOR – REAR DOOR GLASS WEATHERSTRIP REAR DOOR WEATHERSTRIP LH 26 (265, 19) DOOR CHECK REAR DOOR HINGE ASSEMBLY UPPER LH 5.5 (56, 49 in.*lbf) 26 (265, 19) 30 (306, 22) 26 (265, 19) CHILD PROTECTOR LOCK HOLE PLUG REAR DOOR HINGE ASSEMBLY LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B134257E02 ET ET–40 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING INSTALLATION Primer M 1. Primer M A B065596E01 INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NO. 1 (a) Using a brush, coat the exposed part of the body on the vehicle side with Primer M. Dimension (A): 40 mm (3.125 in.) NOTICE: • Dry the primer coating for 3 minutes or more. • Do not coat the adhesive with Primer M. • Do not keep any of the opened Primer M for later use. (1) Using a heat light, heat the body and moulding. Heating temperature: Body 40 to 60 °C (104 to 140°F) Moulding 20 to 30 °C (68 to 86°F) NOTICE: Do not heat the moulding and body excessively. ET Alignment mark A A A-A Clip 2.5 mm (0.098 in.) Clip Adhesive tape B063875E01 (b) Apply new adhesive tape to the clip as shown in the illustration. (1) Attach the clip to the protrusion on the vehicle body with adhesive tape. EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ET–41 2. INSTALL WINDSHIELD MOULDING OUTSIDE LH (a) Install the moulding as shown in the illustration. (1) Install the middle of the moulding onto the front edge of the roof. (2) Install the rear end of the moulding along the side edge of the roof. (3) Install the front end of the moulding along the side edge of the windshield. 3. INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER NO. 2 LH (a) Install the moulding as shown in the illustration. (1) Aligning the front end of the moulding with the alignment mark on the body, install the moulding. 4. INSTALL ROOF DRIP SIDE FINISH MOULDING REAR LH (a) Install the moulding as shown in the illustration. 2 1 3 Push Front Edge Of Roof B063877E01 Alignment mark Moulding B063874E01 Moulding Clip B063873E01 ET EXTERIOR – BACK DOOR GLASS WEATHERSTRIP ET–33 BACK DOOR GLASS WEATHERSTRIP EXTERIOR BODY COMPONENTS REAR SPOILER SUB-ASSEMBLY BACK DOOR GLASS RUN ET WITHOUT REAR SPOILER STOP CENTER LIGHT ASSEMBLY BACK DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER B120201E03 ET–34 EXTERIOR – BACK DOOR GLASS WEATHERSTRIP REAR WIPER ARM AND BLADE ASSEMBLY BACK DOOR HINGE ASSEMBLY RH BACK DOOR DAMPER STAY SUB-ASSEMBLY RH BACK DOOR HINGE ASSEMBLY LH 19.5 (200, 14) WASHER NOZZLE ASSEMBLY WIPER ARM HEAD CAP 19.5 (200, 14) 5.5 (56, 49 in.*lbf) BACK DOOR LOCK CYLINDER ASSEMBLY 19.5 (200, 14) 17.5 (180, 13) 19.5 (200, 14) CUSHION ET 8.0 (82, 71 in.*lbf) LINER WIPER STEP RH 5.5 (56, 49 in.*lbf) CUSHION BACK DOOR STOPPER LOWER RH 17.5 (180, 13) BACK DOOR LOWER STOPPER CUSHION RH BACK DOOR DUMPER STAY SUB-ASSEMBLY LH BACK DOOR STOPPER LOWER LH 8.0 (82, 71 in.*lbf) TELEVISION CAMERA ASSEMBLY BACK DOOR LOWER STOPPER CUSHION LH BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120202E05 ET–36 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ROOF DRIP SIDE FINISH MOULDING EXTERIOR BODY COMPONENTS WITHOUT ROOF RACK ROOF DRIP SIDE MOULDING END COVER REAR LH ROOF RACK BRACKET NO. 1 REAR LH ROOF DRIP SIDE MOULDING COVER FRONT LH 10 (102, 7.4) ROOF RACK BRACKET FRONT LH ET WINDSHIELD MOULDING OUTSIDE LH RETAINER BRACKET RETAINER BRACKET ROOF DRIP SIDE FINISH MOULDING CLIP NO. 1 ROOF DRIP SIDE FINISH MOULDING CENTER NO. 2 LH WINDSHIELD OUTSIDE FASTENER NO. 1 ROOF DRIP SIDE FINISH MOULDING REAR LH N*m (kgf*cm, ft.*lbf) : Specified torque B134211E01 ET–37 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING WITH ROOF RACK REAR ROOF RACK COVER ROOF RACK ASSEMBLY LH FRONT ROOF RACK COVER 31 (316, 22) WINDSHIELD MOULDING OUTSIDE LH ET RETAINER BRACKET RETAINER BRACKET ROOF DRIP SIDE FINISH MOULDING CLIP NO. 1 ROOF DRIP SIDE FINISH MOULDING CENTER NO. 2 LH WINDSHIELD OUTSIDE FASTENER NO. 1 REAR ROOF DRIP SIDE FINISH MOULDING N*m (kgf*cm, ft.*lbf) : Specified torque B134212E01 ET–48 EXTERIOR – OUTSIDE MOULDING REMOVAL 1. REMOVE FRONT DOOR OUTSIDE MOULDING SUBASSEMBLY HINT: When installing the front door outside moulding assembly, heat the vehicle body and front door outside moulding assembly using a heat light. Heating temperature: Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Remove the nut. ET B120273 (b) Using a heat light, heat the front door outside moulding sub-assembly. (c) Using a knife, cut the double-sided tape. NOTICE: • If reusing the moulding, be careful not to damage the moulding. • Do not damage the body. (d) Disengage the 11 clips and remove the front door outside moulding sub-assembly. NOTICE: If the clips are damaged, exchange them for new clips. Double-sided Tape B120274E01 2. REMOVE NO. 3 OUTSIDE MOULDING CLIP (a) Remove the 2 No. 3 outside moulding clips. 3. REMOVE NO. 4 OUTSIDE MOULDING CLIP (a) Remove the 9 No. 4 outside moulding clips. 4. REMOVE FRONT DOOR OUTSIDE MOULDING PAD UPPER (a) Remove the front door outside moulding pad upper. ET–49 EXTERIOR – OUTSIDE MOULDING 5. REMOVE NO. 3 OUTSIDE MOULDING RETAINER (a) Put a 4.0 mm (0.16 in.) drill bit into a drill. (b) Tape the 4.0 mm (0.16 in.) drill bit without covering the portion that is 5.0 mm (0.20 in.) from the tip. HINT: Tape the 4.0mm (0.16 in.) drill bit to prevent the drill bit from going too deep. (c) Lightly press the drill against the rivets, drill off the flanges of the rivets, and remove the 3 rivets. NOTICE: • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. • Do not pry the rivets with the drill, because this may cause damage to the installation holes of the rivets or the drill bit. • Be careful of the drilled rivets as they may become hot. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. (e) Remove the No. 3 outside moulding retainer from the front door outside moulding. 6. REMOVE FRONT DOOR OUTSIDE MOULDING 7. REMOVE REAR DOOR OUTSIDE MOULDING SUBASSEMBLY HINT: When installing the rear door outside moulding assembly, heat the vehicle body and rear door outside moulding assembly using a heat light. Heating temperature: 5.0 mm (0.20 in.) B120275E01 Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. ET ET–50 EXTERIOR – OUTSIDE MOULDING (a) Put a 4.0 mm (0.16 in.) drill bit into a drill. (b) Tape the 4.0 mm (0.16 in.) drill bit without covering the portion that is 5.0 mm (0.20 in.) from the tip. HINT: Tape the 4.0mm (0.16 in.) drill bit to prevent the drill bit from going too deep. (c) Lightly press the drill against the rivets, drill off the flanges of the rivets, and remove the 3 rivets. NOTICE: • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. • Do not pry the rivets with the drill, because this may cause damage to the installation holes of the rivets or the drill bit. • Be careful of the drilled rivets as they may become hot. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. 5.0 mm (0.20 in.) B120276E01 ET (e) Using a heat light, heat the rear door outside moulding sub-assembly. (f) Using a knife, cut the double-sided tape. NOTICE: • If reusing the moulding, be careful not to damage the moulding. • Do not damage the body. (g) Disengage the 10 clips and remove the rear door outside moulding sub-assembly. NOTICE: If the clips are damaged, exchange them for new clips. Double-sided Tape B120277E01 8. REMOVE NO. 3 OUTSIDE MOULDING CLIP (a) Remove the 4 No. 3 outside moulding clips. 9. REMOVE NO. 4 OUTSIDE MOULDING CLIP (a) Remove the 6 No. 4 outside moulding clips. 10. REMOVE WHEEL HOUSE SEAL FRONT (a) Remove the wheel house seal front. 11. REMOVE NO. 1 BODY OUTSIDE MOULDING PAD (a) Remove the No. 1 body outside moulding pad. 12. REMOVE NO. 1 REAR DOOR MOULDING PAD (a) Remove the No. 1 rear door moulding pad. 13. REMOVE REAR DOOR OUTSIDE MOULDING PAD UPPER (a) Remove the rear door outside moulding pad upper. ET–51 EXTERIOR – OUTSIDE MOULDING 5.0 mm (0.20 in.) B120278E01 14. REMOVE NO. 5 OUTSIDE MOULDING RETAINER (a) Put a 4.0 mm (0.16 in.) drill bit into a drill. (b) Tape the 4.0 mm (0.16 in.) drill bit without covering the portion that is 5.0 mm (0.20 in.) from the tip. HINT: Tape the 4.0mm (0.16 in.) drill bit to prevent the drill bit from going too deep. (c) Lightly press the drill against the rivets, drill off the flanges of the rivets, and remove the 6 rivets. NOTICE: • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through. • Do not pry the rivets with the drill, because this may cause damage to the installation holes of the rivets or the drill bit. • Be careful of the drilled rivets as they may become hot. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas. (e) Remove the No. 5 outside moulding retainer from the rear door outside moulding. 15. REMOVE REAR DOOR OUTSIDE MOULDING 16. REMOVE FRONT BODY MUDGUARD (a) Remove the 4 screws, 3 clips and front body mudguard. 17. REMOVE STEP SUB-ASSEMBLY (a) Remove the 6 bolts. (b) with Step light: Disconnect the step light wiring connector. (c) Remove the step sub-assembly. 18. REMOVE ROCKER PANEL MOULDING SUBASSEMBLY HINT: When installing the rocker panel moulding sub-assembly, heat the vehicle body and rocker panel moulding subassembly using a heat light. Heating temperature: Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Remove the 2 screws and 4 clips. (b) Using a heat light, heat the rocker panel moulding sub-assembly. (c) Using a knife, cut the double-sided tape. NOTICE: • If reusing the moulding, be careful not to damage the moulding. • Do not damage the body. ET ET–52 EXTERIOR – OUTSIDE MOULDING (d) Disengage the 8 clips and remove the rocker panel moulding sub-assembly. NOTICE: If the clips are damaged, exchange them for new clips. Double-sided Tape B120279E01 ET 19. REMOVE NO. 1 OUTSIDE MOULDING CLIP (a) Remove the 3 No. 1 outside moulding clips. 20. REMOVE NO. 2 OUTSIDE MOULDING CLIP (a) Remove the 5 No. 2 outside moulding clips. 21. REMOVE NO. 1 ROCKER PANEL MOULDING PROTECTOR (a) Remove the No. 1 rocker panel moulding protector. 22. REMOVE ROCKER PANEL MOULDING FRONT 23. REMOVE DISCONNECT BATTERY NEGATIVE TERMINAL 24. REMOVE FRONT BUMPER ASSEMBLY HINT: (See page ET-3) 25. REMOVE FRONT BUMPER SIDE SUPPORT HINT: (See page ET-3) 26. REMOVE FRONT WHEEL OPENING EXTENSION SUB-ASSEMBLY (a) Remove the 2 screws. (b) Disengage the 12 clips and remove the front wheel opening extension sub-assembly. NOTICE: If the clips are damaged, exchange them for new clips. B120280 27. REMOVE NO. 1 OUTSIDE MOULDING CLIP (a) Remove the 3 No. 1 outside moulding clips. 28. REMOVE NO. 2 OUTSIDE MOULDING CLIP (a) Remove the 9 No. 2 outside moulding clips. EXTERIOR – OUTSIDE MOULDING ET–53 29. REMOVE FRONT FENDER OUTSIDE MOULDING PAD (a) Remove the front fender outside moulding pad. 30. REMOVE BODY OUTSIDE MOULDING PAD (a) Remove the body outside moulding pad. 31. REMOVE FRONT WHEEL OPENING OR ARCH MOULDING EXTENSION 32. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH (See page ET-10) 33. REMOVE QUARTER PANEL MUDGUARD SUBASSEMBLY REAR RH (See page ET-10) 34. REMOVE REAR BUMPER ASSEMBLY (See page ET10) 35. REMOVE REAR QUARTER OUTSIDE MOULDING SUB-ASSEMBLY (a) Remove the 2 screws. (b) Disengage the 5 clips and remove the rear quarter outside moulding sub-assembly. NOTICE: If the clips are damaged, exchange them for new clips. B120281 36. REMOVE NO. 3 OUTSIDE MOULDING CLIP (a) Remove the 2 No. 3 outside moulding clips. 37. REMOVE NO. 4 OUTSIDE MOULDING CLIP (a) Remove the 3 No. 4 outside moulding clips. 38. REMOVE NO. 1 QUARTER PANEL MOULDING PAD (a) Remove the No. 1 quarter panel moulding pad. 39. REMOVE REAR QUARTER OUTSIDE MOULDING ET ET–54 EXTERIOR – OUTSIDE MOULDING INSTALLATION B120281 ET 1. INSTALL REAR QUARTER OUTSIDE MOULDING 2. INSTALL NO. 1 QUARTER PANEL MOULDING PAD (a) Install a new No. 1 quarter panel moulding pad. 3. INSTALL NO. 4 OUTSIDE MOULDING CLIP 4. INSTALL NO. 3 OUTSIDE MOULDING CLIP 5. INSTALL REAR QUARTER OUTSIDE MOULDING SUB-ASSEMBLY (a) Install the rear quarter outside moulding subassembly with the 5 clips. (b) Install the 2 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 6. INSTALL REAR BUMPER ASSEMBLY (See page ET14) 7. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR RH 8. INSTALL QUARTER PANEL MUDGUARD SUBASSEMBLY REAR LH 9. INSTALL FRONT WHEEL OPENING OR ARCH MOULDING EXTENSION 10. INSTALL BODY OUTSIDE MOULDING PAD (a) Install a new body outside moulding pad. 11. INSTALL FRONT FENDER OUTSIDE MOULDING PAD (a) Install a new front fender outside moulding pad. 12. INSTALL NO. 2 OUTSIDE MOULDING CLIP 13. INSTALL NO. 1 OUTSIDE MOULDING CLIP 14. INSTALL FRONT WHEEL OPENING EXTENSION SUB-ASSEMBLY (a) Install the front wheel opening extension subassembly with the 12 clips. (b) Install the 2 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 15. INSTALL FRONT BUMPER SIDE SUPPORT HINT: (See page ET-6) B120280 16. INSTALL FRONT BUMPER ASSEMBLY (See page ET-6) 17. INSTALL CONNECT BATTERY NEGATIVE TERMINAL 18. VEHICLE PREPARATION FOR FOG LIGHT AIM 19. PREPARATION FOR FOG LIGHT AIMING 20. INSPECT FOG LIGHT AIMING 21. ADJUST FOG LIGHT AIMING ET–55 EXTERIOR – OUTSIDE MOULDING 22. PERFORM INITIALIZATION Some systems need initialization when disconnecting the cable from the negative battery terminal. 23. INSTALL ROCKER PANEL MOULDING FRONT 24. INSTALL NO. 1 ROCKER PANEL MOULDING PROTECTOR (a) Install a new No. 1 rocker panel moulding protector. 25. INSTALL NO. 2 OUTSIDE MOULDING CLIP 26. INSTALL NO. 1 OUTSIDE MOULDING CLIP 27. INSTALL ROCKER PANEL MOULDING SUBASSEMBLY HINT: When installing the rocker panel moulding sub-assembly, heat the vehicle body and rocker panel moulding subassembly using a heat light. Heating temperature: Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the rocker panel moulding sub-assembly. (If reusing the rocker panel moulding sub-assembly.) (1) Using a heat light, heat the rocker panel moulding sub-assembly. (2) Remove the double-sided tape from the rocker panel moulding sub-assembly. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the rocker panel moulding sub-assembly. (c) Install the rocker panel moulding sub-assembly. (1) Using a heat light, heat the vehicle body and rocker panel moulding sub-assembly. (2) Remove the peeling paper from the face of the rocker panel moulding sub-assembly. HINT: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the rocker panel moulding sub-assembly with the 8 clips. (4) Install the 2 screws and 4 clips. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) ET ET–56 EXTERIOR – OUTSIDE MOULDING Double-sided Tape B120279E01 ET 28. INSTALL STEP SUB-ASSEMBLY (a) with Step light: Connect the step light wiring connector. (b) Install the step sub-assembly with the 6 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 29. INSTALL FRONT BODY MUDGUARD 30. INSTALL REAR DOOR OUTSIDE MOULDING ET–57 EXTERIOR – OUTSIDE MOULDING 31. INSTALL NO. 5 OUTSIDE MOULDING CLIP (a) Using an air riveter or hand riveter with a nose piece, install the No. 5 outside moulding retainer with 6 new rivets. HINT: If the rivet cannot be cut, pull it again and cut it. NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet. 32. INSTALL REAR DOOR OUTSIDE MOULDING PAD UPPER (a) Install a new rear door outside moulding pad upper. INCORRECT Riveter 33. INSTALL NO. 1 REAR DOOR MOULDING PAD (a) Install a new No. 1 rear door moulding pad. 34. INSTALL NO. 1 OUTSIDE MOULDING PAD (a) Install a new No. 1 body outside moulding pad. 35. INSTALL WHEEL HOUSE SEAL FRONT (a) Install a new wheel house seal front. 36. INSTALL NO. 4 OUTSIDE MOULDING CLIP 37. INSTALL NO. 3 OUTSIDE MOULDING CLIP Mandrel INCORRECT Riveter INCORRECT Riveter INCORRECT Riveter B146493E01 38. INSTALL REAR DOOR OUTSIDE MOULDING SUBASSEMBLY HINT: When installing the rear door outside moulding assembly, heat the vehicle body and rear door outside moulding assembly using a heat light. Heating temperature: Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. ET ET–58 EXTERIOR – OUTSIDE MOULDING (b) Clean the rear door outside moulding sub-assembly. (If reusing the rear door outside moulding subassembly.) (1) Using a heat light, heat the rear door outside moulding sub-assembly. (2) Remove the double-sided tape from the rear door outside moulding sub-assembly. (3) Wipe off any tape adhesive residue with cleaner. (4) Apply new double-sided tape to the rear door outside moulding sub-assembly. Double-sided Tape B120277E01 ET (c) Install the rear door outside moulding sub-assembly. (1) Using a heat light, heat the vehicle body and rear door outside moulding sub-assembly. (2) Remove the peeling paper from the face of the rear door outside moulding sub-assembly. HINT: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the rear door outside moulding subassembly with the 10 clips. EXTERIOR – OUTSIDE MOULDING ET–59 (4) Using an air riveter or hand riveter with a nose piece, install 3 new rivets. HINT: If the rivet cannot be cut, pull it again and cut it. NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet. 39. INSTALL FRONT DOOR OUTSIDE MOULDING INCORRECT Riveter Mandrel INCORRECT Riveter INCORRECT Riveter INCORRECT Riveter B146494E01 ET ET–60 EXTERIOR – OUTSIDE MOULDING 40. INSTALL NO. 3 OUTSIDE MOULDING RETAINER (a) Using an air riveter or hand riveter with a nose piece, install the No. 3 outside moulding retainer with 3 new rivets. HINT: If the rivet cannot be cut, pull it again and cut it. NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding. • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet. 41. INSTALL FRONT DOOR OUTSIDE MOULDING PAD UPPER (a) Install a new front door outside moulding pad upper. 42. INSTALL NO. 4 OUTSIDE MOULDING CLIP ET INCORRECT Riveter 43. INSTALL NO. 3 OUTSIDE MOULDING CLIP 44. INSTALL FRONT DOOR OUTSIDE MOULDING SUBASSEMBLY HINT: When installing the front door outside moulding assembly, heat the vehicle body and front door outside moulding assembly using a heat light. Heating temperature: Mandrel Item Temperature Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) INCORRECT Riveter INCORRECT Riveter Riveter INCORRECT B146495E01 NOTICE: Do not heat the vehicle body and moulding excessively. (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body surface. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with cleaner. (b) Clean the front door outside moulding subassembly. (If reusing the front door outside moulding sub-assembly.) (1) Using a heat light, heat the front door outside moulding sub-assembly. (2) Remove the double-sided tape from the front door outside moulding sub-assembly. (3) Wipe off any tape adhesive residue with cleaner. EXTERIOR – OUTSIDE MOULDING ET–61 (4) Apply new double-sided tape to the front door outside moulding sub-assembly. (c) Install the front door outside moulding subassembly. (1) Using a heat light, heat the vehicle body and front door outside moulding sub-assembly. (2) Remove the peeling paper from the face of the front door outside moulding sub-assembly. HINT: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the front door outside moulding subassembly with the 11 clips. Double-sided Tape B120274E01 (4) Install the nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) ET B120273 ET–42 EXTERIOR – OUTSIDE MOULDING OUTSIDE MOULDING EXTERIOR BODY COMPONENTS ET 3.0 (31, 27 in.*lbf) 3.0 (31, 27 in.*lbf) FRONT BUMPER SIDE SUPPORT 3.0 (31, 27 in.*lbf) 5.0 (51, 44 in.*lbf) 8.0 (82, 71 in.*lbf) FRONT WHEEL OPENING EXTENSION SUB-ASSEMBLY FRONT BUMPER ASSEMBLY FRONT BODY MUDGUARD N*m (kgf*cm, ft.*lbf) : Specified torque B120182E01 EXTERIOR – OUTSIDE MOULDING ET–43 FRONT FENDER OUTSIDE MOULDING PAD NO. 1 OUTSIDE MOULDING CLIP BODY OUTSIDE MOULDING PAD NO. 2 OUTSIDE MOULDING CLIP ET FRONT WHEEL OPENING OR ARCH MOULDING EXTENSION Non-reusable part B134261E01 ET–44 EXTERIOR – OUTSIDE MOULDING RIVET ET 5.0 (51, 44 in.*lbf) REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120290E01 ET–45 EXTERIOR – OUTSIDE MOULDING REAR DOOR OUTSIDE MOULDING PAD UPPER NO. 1 REAR DOOR MOULDING PAD FRONT DOOR OUTSIDE MOULDING PAD UPPER NO. 3 OUTSIDE MOULDING CLIP NO. 4 OUTSIDE MOULDING CLIP NO. 3 OUTSIDE MOULDING CLIP WHEEL HOUSE SEAL FRONT NO. 4 OUTSIDE MOULDING CLIP RIVET RIVET RIVET NO. 3 OUTSIDE MOULDING RETAINER REAR DOOR OUTSIDE MOULDING FRONT DOOR OUTSIDE MOULDING Non-reusable part B134262E01 ET ET–46 EXTERIOR – OUTSIDE MOULDING 5.0 (51, 44 in.*lbf) ET 5.0 (51, 44 in.*lbf) ROCKER PANEL MOULDING SUB-ASSEMBLY STEP SUB-ASSEMBLY 5.0 (51, 44 in.*lbf) NO. 2 OUTSIDE MOULDING CLIP NO. 1 OUTSIDE MOULDING CLIP NO. 1 ROCKER PANEL MOULDING PROTECTOR ROCKER PANEL MOULDING FRONT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120291E01 ET–47 EXTERIOR – OUTSIDE MOULDING QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR RH QUARTER PANEL MUDGUARD SUB-ASSEMBLY REAR LH 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) ET 8.0 (82, 71 in.*lbf) REAR BUMPER ASSEMBLY 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 8.0 (82, 71 in.*lbf) REAR QUARTER OUTSIDE MOULDING SUB-ASSEMBLY NO. 4 OUTSIDE MOULDING CLIP NO. 1 QUARTER PANEL MOULDING PAD NO. 3 OUTSIDE MOULDING CLIP REAR QUARTER OUTSIDE MOULDING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B120292E01 ET–66 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING REMOVAL HINT: On the RH side, use the same procedures as on the LH side. 1. Screw Claw Push Claw B065260E01 REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH (a) Remove the screw. (b) Using a heat light, heat the moulding to 40 to 60°C (104 to 140°F). NOTICE: Do not heat the moulding excessively. (c) Disengage the 2 claws by pushing the moulding and remove the moulding. NOTICE: If reusing the moulding, take cake not to damage the moulding. INSTALLATION 1. Caulking Sponge Non-woven Fabric ET Adhesive Tape (2) INSTALL REAR DOOR WINDOW FRAME MOULDING FRONT LH (a) Using a shop rag, remove the adhesive tape from the moulding. (1) Clean the contact surface of the body with a of shop rag saturated with white gasoline. (b) Clean the outer circumference of the moulding with white gasoline. (c) Apply new adhesive tape to the moulding, as shown in the illustration. Dimension: A (1) (1) 50.0 mm (1.969 in.), (2) 330 mm (12.992 in.) Adhesive Tape B 5.0 mm (0.197 in.) A C (1) 1.2 mm (0.047 in.), (2) 0.8 mm (0.031 in.) (d) Using a heat light, heat the body and moulding. Heating temperature: Caulking Sponge B C Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) B062961E01 NOTICE: Do not heat the body and moulding excessively. (e) Remove the moulding release sheet from the moulding face. HINT: Be careful for dirt or foreign objects not to stick to the adhered part when peeling off the moulding release sheet. (f) Engage the 2 claws and install the moulding. NOTICE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. ET–62 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING FRONT DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS FRONT DOOR WINDOW FRAME MOULDING REAR LH OUTER REAR VIEW MIRROR ASSEMBLY LH FRONT DOOR LOWER FRAME BRACKET GARNISH LH 8.0 (82, 71 in.*lbf) FRONT DOOR GLASS WEATHERSTRIP INNER LH CUSHION RUBBER 26 (265, 19) ET FRONT DOOR HINGE ASSEMBLY UPPER LH CUSHION RUBBER 5.5 (56, 49 in.*lbf) DOOR CHECK 5.0 (51, 42 in.*lbf) FRONT NO. 2 SPEAKER ASSEMBLY SPEAKER MOUNTING NO. 1 BRACKET 30 (306, 22) 26 (265, 19) 5.0 (51, 42 in.*lbf) 5.0 (51, 42 in.*lbf) FRONT DOOR HINGE ASSEMBLY LOWER LH FRONT NO. 1 SPEAKER ASSEMBLY CLIP CLIP FRONT DOOR WEATHERSTRIP LH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B134213E01 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING ET–63 REMOVAL HINT: On the RH side, use the same procedures as on the LH side. 1. Screw Claw Push Claw B065259E01 REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (a) Remove the screw. (b) Using a heat light, heat the moulding to 40 to 60°C (104 to 140°F). NOTICE: Do not heat the moulding excessively. (c) Disengage the 2 claws by pushing the moulding and remove the moulding. NOTICE: If reusing the moulding, take care not to damage the moulding. INSTALLATION Non-woven Fabric 1. Caulking Sponge (1) Adhesive Tape (2) INSTALL FRONT DOOR WINDOW FRAME MOULDING REAR LH (a) Using a shop rag, remove the adhesive tape from the moulding. (1) Clean the contact surface of the body with shop rag saturated with white gasoline. (b) Clean the outer circumference of the moulding with white gasoline. (c) Apply new adhesive tape to the moulding, as shown in the illustration. Dimension: A (1) 330 mm (12.992 in.), (2) 265.0 mm (10.433 in.) Adhesive Tape B 5.0 mm (0.197 in.) A C (1) 0.8 mm (0.031 in.), (2) 1.2 mm (0.197 in.) (d) Using a heat light, heat the body and moulding. Heating temperature: Caulking Sponge B C Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) B062960E01 NOTICE: Do not heat the body and moulding excessively. (e) Remove the moulding release sheet from the moulding face. HINT: Be careful for dirt or foreign objects not to stick to the adhered part when peeling off the moulding release sheet. (f) Engage the 2 claws and install the moulding. NOTICE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. ET EXTERIOR – SIDE STEP ET–69 INSTALLATION 1. INSTALL SIDE STEP BRACKET (a) Install the 3 brackets with the 6 bolts. Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 2. REMOVE LH STEP SUB-ASSEMBLY (a) Install the step sub-assembly with the 6 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) ET ET–64 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING REAR DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS REAR DOOR OUTSIDE HANDLE PAD FRONT REAR DOOR OUTSIDE HANDLE COVER LH REAR DOOR HANDLE ASSEMBLY OUTSIDE LH REAR DOOR WINDOW FRAME MOULDING FRONT LH REAR DOOR OUTSIDE HANDLE PAD REAR ET REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH REAR DOOR WEATHERSTRIP LH 5.5 (56, 49 in.*lbf) REAR DOOR QUARTER WINDOW WEATHERSTRIP LH REAR DOOR GLASS SUBASSEMBLY LH REAR DOOR QUARTER GLASS SUB-ASSEMBLY LH 5.5 (56, 49 in.*lbf) REAR DOOR GLASS RUN LH REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120200E03 ET–65 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING REAR DOOR WEATHERSTRIP LH 26 (265, 19) DOOR CHECK REAR DOOR HINGE ASSEMBLY UPPER LH 8.5 (87, 75 in.*lbf) 26 (265, 19) 30 (306, 22) 26 (265, 19) CHILD PROTECTOR LOCK HOLE PLUG REAR DOOR HINGE ASSEMBLY LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B134257E03 ET EXTERIOR – BACK DOOR GARNISH ET–71 INSTALLATION 1. INSTALL BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE (a) Install the garnish with the 2 clips and 6 nuts. 2. INSTALL BACK DOOR SERVICE HOLE COVER LH (a) Install the service hole cover LH. (b) Install the back door trim panel. (c) Install the assist strap assembly RH. (d) Install the assist strap hole cover. ET ET–67 EXTERIOR – SIDE STEP SIDE STEP EXTERIOR BODY COMPONENTS ET LH STEP SUB-ASSEMBLY 19.5 (199, 14) NO. 3 SIDE STEP BRACKET NO. 1 SIDE STEP BRACKET NO. 2 SIDE STEP BRACKET 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B146598E01 ET–68 EXTERIOR – SIDE STEP REMOVAL HINT: On the RH side, use the same procedures as on the LH side. ET 1. REMOVE LH STEP SUB-ASSEMBLY (a) Remove the 6 bolts holding the side step assembly to the side step brackets. (b) with Step light: Disconnect the step light wiring connector. (c) Remove the side step assembly. 2. REMOVE SIDE STEP BRACKET (a) Remove the 6 bolts and 3 brackets. EXTERIOR – BACK DOOR GARNISH ET–69 BACK DOOR GARNISH EXTERIOR BODY COMPONENTS CLIP BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE ET B134214E01 ASSIST STRAP HOLE COVER ASSIST STRAP ASSEMBLY RH SERVICE HOLE COVER LH BACK DOOR TRIM BOARD BACK DOOR TRIM COVER Non-reusable part B134215E03 ET–70 EXTERIOR – BACK DOOR GARNISH REMOVAL ET 1. REMOVE BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE (a) Remove the assist strap hole cover. (b) Remove the assist strap assembly RH. (c) Remove the back door trim panel. (d) Remove the service hole cover LH. 2. REMOVE BACK DOOR SERVICE HOLE COVER LH (a) Remove the 6 nuts. (b) Disengage the 2 clips by pulling the garnish, and remove the garnish. INTERIOR – ROOF HEADLINING IR–7 REMOVAL HINT: A bolt without torque specification is a standard bolt (See page SS-2). 1. REMOVE TONNEAU COVER RETRACTOR SUBASSEMBLY 2. REMOVE REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) HINT: See page SE-36 3. REMOVE NO. 3 SEAT LEG COVER NO. 2 (for 50/50 Split Seat Type) 4. REMOVE REAR NO. 2 SEAT LOCK ASSEMBLY LH (for 50/50 Split Seat Type) (a) Remove the 2 bolts and seat lock. 5. REMOVE REAR NO. 2 SEAT LOCK ASSEMBLY RH (for 50/50 Split Seat Type) (a) Remove the 2 bolts and seat lock. 6. REMOVE SEAT ANCHOR RAIL NO. 4 (for 50/50 Split Seat Type) (a) Using a screwdriver, remove the 2 covers, 2 bolts and anchor rail. HINT: Tape the screwdriver tip before use. B076091 7. REMOVE BACK DOOR WEATHERSTRIP 8. REMOVE DECK BOARD SUB-ASSEMBLY (a) Remove the 2 bolts and the deck board subassembly. 9. REMOVE DECK BOARD ASSEMBLY (a) Remove the 2 bolts and the deck board assembly. B063596 10. REMOVE REAR FLOOR MAT SUPPORT PLATE REAR (a) Remove the 5 bolts and mat support plate. B063594 IR IR–8 INTERIOR – ROOF HEADLINING 11. REMOVE DECK FLOOR BOX LH (a) Using a screwdriver, disengage the claws and remove the cover. HINT: Tape the screwdriver tip before use. (b) Remove the bolt, deck floor box and luggage hold belt striker. B063597 12. REMOVE DECK FLOOR BOX RH HINT: Use the same procedures described for the LH side. 13. REMOVE DECK TRIM COVER REAR (a) Using a screwdriver, pry out the trim cover. HINT: Tape the screwdriver tip before use. 14. REMOVE DECK TRIM SIDE BOARD UPR LH (a) Remove the screw and side board. 15. REMOVE DECK TRIM SIDE BOARD UPR RH (a) Remove the screw and side board. 16. REMOVE SIDE TRIM BOX ASSEMBLY LH (a) Remove the screw and side trim box. 17. REMOVE SIDE TRIM BOX ASSEMBLY RH (a) Remove the screw and side trim box. IR Plate Cover Claw B064791E01 Claw B Claw C Claw A Claw D 18. REMOVE QUARTER SCUFF PLATE INSIDE LH (for 50/50 Split Seat Type) (a) Using a screwdriver, disengage the 4 claws and covers. HINT: Tape the screwdriver tip before use. (b) Remove the 2 bolts and scuff plate. 19. REMOVE QUARTER SCUFF PLATE INSIDE RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. 20. REMOVE REAR DOOR SCUFF PLATE LH (a) Using a screwdriver, disengage the claw labeled A, claw labeled B, 2 claws labeled C and claw labeled D. Remove the scuff plate. HINT: Tape the screwdriver tip before use. 21. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedure described for the LH side. B076924E01 INTERIOR – ROOF HEADLINING Claw B Claw D Claw E 22. REMOVE FRONT DOOR SCUFF PLATE LH (a) Using a screwdriver, disengage the claw labeled A, claw labeled B, 4 claws labeled C, claw labeled D and claw labeled E. Remove the scuff plate. HINT: Tape the screwdriver tip before use. 23. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure described for the LH side. Claw A Claw C IR–9 B076922E02 24. REMOVE COWL SIDE TRIM BOARD LH (a) Remove the cap nut. (b) Using a screwdriver, disengage the 2 claws and remove the trim board. HINT: Tape the screwdriver tip before use. Claw 25. REMOVE COWL SIDE TRIM BOARD RH HINT: Use the same procedure described for the LH side. B076923E03 26. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 27. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 28. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 29. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 30. REMOVE DECK TRIM COVER REAR 31. REMOVE REAR FLOOR CARPET ASSEMBLY Clip Clip Clip Clip B063598E02 32. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (a) Remove the screw and deck trim cover. (b) Remove the 3 screws and clips. (c) Using a screwdriver, disengage the 6 clips and remove the side panel. HINT: Tape the screwdriver tip before use. 33. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH HINT: Use the same procedure described for the LH side. IR IR–10 INTERIOR – ROOF HEADLINING 34. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (for 50/50 Split Seat Type) (a) Remove the bolt and 3 screws. (b) Using a screwdriver, remove the 5 clips and side panel. HINT: Tape the screwdriver tip before use. Clip Clip B076092E01 Clip B A A B B B063599E03 IR Clip A Clip B B076093E01 Claw A B A Clip A Claw B 35. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. 36. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER LH (a) Remove the screw and tonneau cover hook. (b) Remove the 3 bolts and clip. (c) Using a screwdriver, disengage the 9 clips and remove the side garnish. HINT: Tape the screwdriver tip before use. 37. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH HINT: Use the same procedure described for the LH side. 38. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER LH (for 50/50 Split Seat Type) (a) Remove the rear No. 2 shoulder anchor bolt. (b) Remove the 3 screws, disengage the 4 clips labeled A and 5 clips labeled B. (c) Using a screwdriver, disengage the 4 claws and remove the side garnish. HINT: Tape the screwdriver tip before use. 39. REMOVE ROOF SIDE GARNISH ASSEMBLY INNER RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. 40. REMOVE CENTER PILLAR GARNISH LOWER LH (a) Using a screwdriver, disengage the 6 claws labeled A and 2 claws labeled B. Remove the 2 clips and pillar garnish. HINT: Tape the screwdriver tip before use. 41. REMOVE CENTER PILLAR GARNISH LOWER RH HINT: Use the same procedure described for the LH side. A B064143E01 INTERIOR – ROOF HEADLINING 42. REMOVE CENTER PILLAR GARNISH UPPER LH (a) Remove the bolt and disconnect the front seat outer belt (floor anchor side). (b) Remove the 2 bolts. (c) Using a screwdriver, disengage the 6 claws and clip, and remove the pillar garnish. HINT: Tape the screwdriver tip before use. Clip Claw B063595E01 Clip B Clip A Claw Claw IR–11 43. REMOVE CENTER PILLAR GARNISH UPPER RH HINT: Use the same procedure described for the LH side. 44. REMOVE FRONT PILLAR GARNISH LH (a) Using a screwdriver, remove the 2 assist grip plugs. HINT: Tape the screwdriver tip before use. (b) Remove the 2 bolts. (c) Using a screwdriver, disengage the claw. Remove the clip labeled A, clip labeled B and pillar garnish. HINT: Tape the screwdriver tip before use. B063600E03 120 mm 700 mm Adhesive Tape (d) Pull the garnish upward, and remove the pillar garnish from the instrument panel. (e) w/ Curtain shield airbag: Protect the curtain shield airbag LH. (1) Thoroughly cover the airbag with cloth or nylon of 700 mm (27.56 in.) x 120 mm (4.72 in.) and fix the ends of the cover with adhesive tape, as shown in the illustration. NOTICE: Cover the curtain shield airbag with the protection cover as soon as the front pillar garnish is removed. 45. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedure described for the LH side. 46. REMOVE INNER REAR VIEW MIRROR ASSEMBLY Adhesive Tape Protective Cover B065292E08 IR IR–12 INTERIOR – ROOF HEADLINING Claw Clip 47. REMOVE ROOF CONSOLE BOX ASSEMBLY (a) Using a moulding remover, disengage the 3 claws and 2 clips. HINT: Tape the screwdriver tip before use. (b) Disconnect the map light switch connector and sliding roof switch connector, and remove the console box. Claw Clip B063602E02 48. REMOVE INTERIOR LIGHT ASSEMBLY NO. 1 (a) Using a screwdriver, disengage the 4 claws and remove the interior light lens. HINT: Tape the screwdriver tip before use. Protective Tape B120248E01 (b) Using a screwdriver, disengage the 4 claws and remove the 2 covers. HINT: Tape the screwdriver tip before use. IR Protective Tape B120249E03 Protective Tape B120250E01 (c) Using a screwdriver, disengage the 4 claws. HINT: Tape the screwdriver tip before use. INTERIOR – ROOF HEADLINING IR–13 (d) Remove the No. 1 roof wire from the claw of the interior light. (e) Using a screwdriver, disengage the 4 claws and remove the interior light switch base and the interior light. 49. REMOVE DOME LIGHT ASSEMBLY (w/ RSE) HINT: See page AV-177 Protective Tape 50. REMOVE TELEVISION DISPLAY ASSEMBLY (w/ RSE) HINT: See page AV-176 B120251E01 51. REMOVE VISOR ASSEMBLY LH (a) Remove the 2 screws and visor assembly. (b) Remove the 2 screws and visor sub-assembly. 52. REMOVE VISOR ASSEMBLY RH HINT: Use the same procedure described for the LH side. 53. REMOVE VISOR HOLDER (a) Remove the screw and visor holder. B063601 IR IR–14 INTERIOR – ROOF HEADLINING with Sliding Roof Clip without Sliding Roof Clip 54. REMOVE ROOF HEADLINING ASSEMBLY (a) Disengage the 4 clips and remove the headlining. B064607E02 IR without Sliding Roof INSTALLATION Double-stick Tape 1. INSTALL ROOF HEADLINING ASSEMBLY (a) Align the marking, and then install the wire harness with tape. HINT: Be careful for dirt or foreign objects not to stick to the adhered part when peeling off the double-stick tape. (b) Attach the roof wire harness along the adhered part. NOTICE: Roof wire harness should be attached securely. (c) Install the roof headlining with the 4 clips. 2. INSTALL VISOR HOLDER (a) Install the screw and visor holder. with Sliding Roof (without RSE) Double-stick Tape with Sliding Roof (with RSE) Double-stick Tape B120287E01 INTERIOR – ROOF HEADLINING 3. INSTALL VISOR ASSEMBLY LH (a) Install the 2 screws and visor sub-assembly. (b) Install the 2 screws and visor assembly. 4. INSTALL VISOR ASSEMBLY RH HINT: Use the same procedure described for the LH side. 5. INSTALL INTERIOR LIGHT ASSEMBLY NO. 1 (a) Install interior light switch base and the interior light, and engage the 4 claws. (b) Install the No. 1 roof wire to the claw of the interior light. (c) Engage the 4 claws. (d) Install the 2 covers and engage the 4 claws. (e) Install the interior light lens and engage the 4 claws. 6. INSTALL DOME LIGHT ASSEMBLY (w/ RSE) HINT: See page AV-177 7. INSTALL TELEVISION DISPLAY ASSEMBLY (w/ RSE) HINT: See page AV-177 8. INSTALL ROOF CONSOLE BOX ASSEMBLY (a) Install the console box and reconnect the map light switch connector and sliding roof switch connector. (b) Engage the 3 claws and 2 clips. B063601 Claw Claw 9. Clip Clip INSTALL INNER REAR VIEW MIRROR ASSEMBLY B063602E02 Clip B Clip A IR–15 Claw 10. INSTALL FRONT PILLAR GARNISH LH (a) Install the clip labeled A, clip labeled B and pillar garnish, and engage the claw. (b) Install 2 bolts. (c) Install the 2 assist grip plugs. 11. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedure described for the LH side. Claw B063600E03 12. INSTALL CENTER PILLAR GARNISH UPPER LH (a) Install the pillar garnish and engage the 6 claws. (b) Install the 2 bolts. IR IR–16 INTERIOR – ROOF HEADLINING (c) Install the front seat outer belt (floor anchor side) and install the bolt. 13. INSTALL CENTER PILLAR GARNISH UPPER RH HINT: Use the same procedure described for the LH side. Clip Claw B063595E01 Claw A 14. INSTALL CENTER PILLAR GARNISH LOWER LH (a) Install the 2 clips and pillar garnish. And engage the 6 claws labeled A and 2 claws labeled B. B A Clip A Claw B A B064143E01 IR 15. INSTALL CENTER PILLAR GARNISH LOWER RH HINT: Use the same procedure described for the LH side. 16. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER LH (a) Install the side garnish and engage the 9 clips. (b) Install the 3 bolts and clip. (c) Install the tonneau cover hook and the screw. 17. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH HINT: Use the same procedure described for the LH side. 18. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER LH (for 50/50 Split Seat Type) (a) Install the side garnish and engage the 4 screws. (b) Engage the 4 clips labeled A and 5 clips labeled B, and install the 3 screws. (c) Install the rear No. 2 shoulder anchor bolt. 19. INSTALL ROOF SIDE GARNISH ASSEMBLY INNER RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. Clip A Clip B B076093E01 20. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (a) Install the side panel and engage the 6 clips. (b) Install the 3 screws and clips. (c) Install the screw and deck trim cover. Clip Clip Clip 21. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH HINT: Use the same procedure described for the LH side. 22. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (for 50/50 Split Seat Type) (a) Install the side panel and the 5 clips. Clip B063598E02 INTERIOR – ROOF HEADLINING IR–17 (b) Install the 3 screws and the bolt. Clip Clip 23. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. 24. INSTALL REAR FLOOR CARPET ASSEMBLY 25. INSTALL DECK TRIM COVER REAR B076092E01 26. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 27. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 28. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 29. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 30. INSTALL COWL SIDE TRIM BOARD LH (a) Install the trim board and engage the 2 claws. (b) Install the cap nut. Claw 31. INSTALL COWL SIDE TRIM BOARD RH HINT: Use the same procedure described for the LH side. B076923E03 32. INSTALL FRONT DOOR SCUFF PLATE LH (a) Install the scuff plate. Engage the claw labeled A, claw labeled B, 4 claws labeled C, claw labeled D and claw labeled E. Claw B Claw D Claw E Claw A Claw C B076922E02 34. INSTALL REAR DOOR SCUFF PLATE LH (a) Install the scuff plate. Engage the claw labeled A, claw labeled B, 2 claws labeled C and claw labeled D. Claw B Claw C Claw A 33. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure described for the LH side. Claw D B076924E01 35. INSTALL REAR DOOR SCUFF PLATE RH HINT: Use the same procedure described for the LH side. IR IR–18 INTERIOR – ROOF HEADLINING Plate Cover Claw 36. INSTALL QUARTER SCUFF PLATE INSIDE LH (for 50/50 Split Seat Type) (a) Install the scuff plate and the 2 bolts. (b) Engage the 4 claws and covers. 37. INSTALL QUARTER SCUFF PLATE INSIDE RH (for 50/50 Split Seat Type) HINT: Use the same procedure described for the LH side. B064791E01 38. INSTALL SIDE TRIM BOX ASSEMBLY LH (a) Install the side trim box and the screws. 39. INSTALL SIDE TRIM BOX ASSEMBLY RH (a) Install the side trim box and the screws. 40. INSTALL DECK TRIM SIDE BOARD UPR LH (a) Install the side board and the screw. 41. INSTALL DECK TRIM SIDE BOARD UPR RH (a) Install the side board and the screw. 42. INSTALL DECK TRIM COVER REAR (a) Install the trim cover. 43. INSTALL DECK FLOOR BOX LH (a) Install the deck floor box, luggage hold belt and bolt. (b) Install the cover and the claws. IR 44. INSTALL DECK FLOOR BOX RH HINT: Use the same procedure described for the LH side. B063597 45. INSTALL REAR FLOOR MAT SUPPORT PLATE REAR (a) Install the mat support plate and 5 bolts. B063594 46. INSTALL DECK BOARD ASSEMBLY (a) Install the deck board assembly and the 2 bolts. 47. INSTALL DECK BOARD SUB-ASSEMBLY (a) Install the deck board sub-assembly and the 2 bolts. 48. INSTALL BACK DOOR WEATHERSTRIP 49. INSTALL SEAT ANCHOR RAIL NO. 4 (for 50/50 Split Seat Type) (a) Install the 2 covers, 2 bolts and anchor rail. B063596 50. INSTALL REAR NO. 2 SEAT LOCK ASSEMBLY LH (a) Install the seat lock and 2 bolts. INTERIOR – ROOF HEADLINING IR–19 51. INSTALL REAR NO. 2 SEAT LOCK ASSEMBLY RH (a) Install the seat lock and 2 bolts. 52. INSTALL NO. 3 SEAT LEG COVER NO. 2 (for 50/50 Split Seat Type) 53. INSTALL REAR NO. 2 SEAT ASSEMBLY (for 50/50 Split Seat Type) HINT: See page SE-38 B076091 54. INSTALL TONNEAU COVER RETRACTOR SUBASSEMBLY IR INTERIOR – FRONT FLOOR FOOTREST IR–1 FRONT FLOOR FOOTREST REMOVAL 1. REMOVE FRONT FLOOR FOOTREST (a) Using a screwdriver, disengage 2 clips and remove the footrest. HINT: Tape the screwdriver tip before use. B062589 IR IR–2 INTERIOR – FRONT FLOOR FOOTREST INSTALLATION 1. IR INSTALL FRONT FLOOR FOOTREST (a) Install the footrest clips by engaging the claws with the footrest. HINT: Before the installation, check that the part of footrest to be engaged with the clips is not damaged. NOTICE: If it is damaged, replace it with a new one. IR–2 INTERIOR – ROOF HEADLINING ROOF HEADLINING INTERIOR BODY COMPONENTS REAR DOOR OPENING TRIM WEATHERSTRIP RH CENTER PILLAR GARNISH UPPER RH DECK TRIM COVER REAR ASSIST GRIP ASSEMBLY ROOF SIDE GARNISH ASSEMBLY INNER RH TONNEAU COVER HOOK IR COVER FRONT PILLAR GARNISH RH DECK FLOOR BOX RH COVER SIDE DECK TRIM PANEL ASSEMBLY RH COVER FRONT DOOR SCUFF PLATE RH COVER REAR DOOR SCUFF PLATE RH COVER DECK TRIM COVER NO. 1 CENTER PILLAR GARNISH LOWER RH DECK TRIM COVER NO. 1 FRONT DOOR OPENING TRIM WEATHERSTRIP RH DECK BOARD SUB-ASSEMBLY B120186E09 IR–3 INTERIOR – ROOF HEADLINING BACK DOOR WEATHERSTRIP REAR FLOOR MAT SUPPORT PLATE REAR DECK TROM COVER REAR RH REAR FLOOR CARPET ASSEMBLY DECK TROM COVER REAR LH COVER LUGGAGE HOLD BELT STRIKER DECK TRIM COVER REAR CENTER PILLAR GARNISH UPPER LH COVER 42 (430, 31) DECK FLOOR BOX LH 42 (430, 31) COVER ASSIST GRIP ASSEMBLY TONNEAU COVER HOOK ROOF SIDE GARNISH ASSEMBLY INNER LH FRONT PILLAR GARNISH LH SIDE DECK TRIM PANEL ASSEMBLY LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR SCUFF PLATE LH REAR DOOR OPENING TRIM WEATHERSTRIP LH REAR DOOR SCUFF PLATE LH CENTER PILLAR GARNISH LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque B120187E07 IR IR–4 INTERIOR – ROOF HEADLINING with REAR NO. 2 SEAT: ROOF SIDE GARNISH ASSEMBLY INNER RH NO. 3 SEAT LEG COVER NO. 2 CUP HOLDER REAR FLOOR SEAT LOCK COVER COVER QUARTER SCUFF PLATE INSIDE RH REAR DOOR SCUFF PLATE RH REAR NO. 2 SEAT LOCK ASSEMBLY RH SEAT ANCHOR RAIL NO. 4 DECK TRIM SIDE PANEL ASSEMBLY RH IR REAR FLOOR CARPET ASSEMBLY ROOF SIDE GARNISH ASSEMBLY INNER LH NO. 3 SEAT LEG COVER NO. 2 ROPE HOOK ROPE HOOK CUP HOLDER REAR FLOOR MAT SUPPORT PLATE REAR REAR NO. 2 SEAT LOCK ASSEMBLY LH QUARTER TRIM JACK COVER COVER DECK TRIM SIDE PANEL ASSEMBLY LH QUARTER SCUFF PLATE INSIDE LH REAR DOOR SCUFF PLATE LH B120188E02 IR–5 INTERIOR – ROOF HEADLINING ASSIST GRIP ASSEMBLY COAT HOOK RH ROOF HEADLINING ASSEMBLY FRONT ASSIST GRIP PLUG VISOR SUBASSEMBLY RH INTERIOR LIGHT ASSEMBLY NO. 1 INTERIOR LIGHT ASSEMBLY NO. 1 ROOF CONSOLE BOX ASSEMBLY VISOR SUBASSEMBLY LH COAT HOOK LH VISOR ASSEMBLY RH ASSIST GRIP ASSEMBLY VISOR HOLDER FRONT ASSIST GRIP PLUG VISOR HOLDER VISOR ASSEMBLY LH FRONT ASSIST GRIP PLUG B120189E04 IR IR–6 INTERIOR – ROOF HEADLINING with SLIDING ROOF: ROOF HEADLINING ASSEMBLY with RSE: TELEVISION DISPLAY ASSEMBLY IR ROOF HEADLINING ASSEMBLY DOME LIGHT ASSEMBLY DOME LIGHT LENS ROOF CONSOLE BOX ASSEMBLY B134268E01 RF–3 SLIDING ROOF – SLIDING ROOF SYSTEM PROBLEM SYMPTOMS TABLE SLIDING ROOF SYSTEM: Symptom AUTO function does not operate Sliding roof system does not operate Sliding roof system stops operation halfway Suspected area See page Sliding roof motor assembly RF-2 1. POWER fuse - 2. POWER relay - 3. Sliding roof housing assembly RF-6 4. Sliding roof motor switch assembly RF-7 5. Sliding roof motor assembly RF-2 6. Wire harness RF-7 1. Sliding roof motor assembly RF-2 2. Wire harness RF-7 3. Sliding roof housing assembly RF-6 RF RF–4 SLIDING ROOF – SLIDING ROOF SYSTEM ON-VEHICLE INSPECTION 1. INSPECT WINDOW LOCK SWITCH (a) Check that operation of the door glasses except the driver side door glass, the back door glass and the roof glass are disabled when the window lock switch of the power window master switch is pressed. (b) Check that the door glasses, the back door glass and the roof glass can be operated when the window lock switch is pressed again. 2. INSPECT AUTO SLIDE-OPEN/CLOSE FUNCTION (a) Check that the sliding roof switch can operate the roof glass as follows while the tilt-UP / DOWN function is not operating: Result Condition •Ignition switch ON •Window lock switch OFF Switch Switch Operation SLIDE OPEN TILT UP Pressed more than 0.3 sec. Roof Glass Fully open Fully closed HINT: The roof glass stops partway when the sliding roof switch is pushed on either side during AUTO operation. 3. RF INSPECT AUTO TILT UP/DOWN FUNCTION (a) Check that the sliding roof switch can operate the roof glass as follows while the slide-OPEN/CLOSE function is not operating: Result Condition •Ignition switch ON •Window lock switch OFF Switch Switch Operation TILT UP SLIDE OPEN Pressed more than 0.3 sec. Roof Glass Fully tilted up Fully closed HINT: The roof glass stops partway when the sliding roof switch is pushed on either side during AUTO operation. 4. INSPECT SLIDING ROOF OPERATION FUNCTION AFTER IGNITION SWITCH OFF (a) Under both of the following conditions, check that the door glasses, the back door glass and the roof glass can be operated even after the ignition switch is turned OFF: • Within 43 seconds after the ignition switch is turned OFF • The driver side door is closed 5. CHECK DEFLECTOR OPERATION (a) Check deflector AUTO operation. (1) Run the vehicle with the sliding roof fully open, and check that the deflector lowers (AUTO DOWN) as the vehicle speed increases and rises (AUTO UP) as the vehicle speed decreases. SLIDING ROOF – SLIDING ROOF SYSTEM RF–5 (2) Check that the deflector lowers according to the vehicle speeds when the sliding roof has been fully opened while the vehicle is running. (b) Check that the sliding roof automatically tilts UP/ DOWN depending on the vehicle speed. (1) Conditions that enable the sliding roof to automatically tilt DOWN: • Sliding roof in fully open position • Sliding roof in UP position • Vehicle speed 80 km/h (50 mph) or less (during acceleration) (2) Conditions that enable the sliding roof to automatically tilts UP: • Sliding roof in fully open position • Sliding roof in DOWN position • Vehicle speed 60 km/h (37 mph) or less (during deceleration) 6. INSPECT JAM PROTECTION FUNCTION HINT: The jam protection function prevents any part of your body from getting caught by accident between the vehicle body and the roof glass during roof glass operation. Operative condition: • AUTO CLOSE • AUTO CLOSE during sliding roof operation after the ignition switch is turned OFF • AUTO TILT-DOWN • AUTO TILT-DOWN during sliding roof operation after the ignition switch is turned OFF CAUTION: • Do not check this function using a part of your body such as a hand. Also, pay thorough attention that nothing gets caught by accident in this process. • If checking this function with something thin (less than 5 mm [0.20 in.]) inserted between the glass and vehicle body, this function may not operate. (a) When the slide-OPEN/CLOSE function is operating: Check that the roof glass opens by approximately 200 mm (7.87 in.) right when something gets caught between the vehicle body and the roof glass during roof glass operation. B065141 RF RF–6 SLIDING ROOF – SLIDING ROOF SYSTEM (b) When the tilt-UP/DOWN function is operating: Check that the roof glass fully tilts up when something gets caught between the vehicle body and the roof glass during roof glass operation. 7. B065142 RF INSPECT FAIL-SAFE FUNCTION (a) If the roof glass is not closed because the jam protection function operates improperly, perform following operation. Then, you can close the roof glass using the manual operation function. (1) Press the sliding roof switch on TILT UP side and hold it for 10 seconds after the jam protection function operates. Then you can use the manual operation function. RF–8 SLIDING ROOF – SLIDING ROOF HOUSING INSTALLATION 1. INSTALL ROOF WIND DEFLECTOR PANEL ASSEMBLY 2. INSTALL SLIDING ROOF DRIVE CABLE SUBASSEMBLY 3. ADJUST FULLY CLOSED POSITION (a) Using a screwdriver, slide the drive cable of the sliding roof to align the matchmarks. HINT: Tape the screwdriver tip before use. 4. INSTALL ROOF DRIP CHANNEL REAR 5. INSTALL SUNSHADE TRIM KNOB (a) Install the trim knob with the 2 screws. 6. INSTALL SUNSHADE TRIM SUB-ASSEMBLY 7. INSTALL SLIDING ROOF SUNSHADE STOPPER 8. INSTALL SLIDING ROOF HOUSING SUB-ASSEMBLY (a) Install the housing sub-assembly with the 6 nuts. (b) Install the 4 brackets with the 8 bolts. (c) Connect the 4 drain hoses. 9. INSTALL SLIDING ROOF DRIVE GEAR SUBASSEMBLY (a) Install the drive gear with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Connect the sliding roof motor switch connector. Matchmarks B064332E01 RF B063617 10. ADJUST SLIDING ROOF GLASS SUB-ASSEMBLY (a) Check the difference in level between the sliding roof (weatherstrip) and roof panel. Dimension (Circumference: 0 +- 2.0 mm (0 +- 0.079 in.) B063346 (b) Check the difference in level between the sliding roof (glass) and roof panel front end and rear end. NOTICE: The clearance should be even all around. B063347 11. INSTALL SLIDING ROOF GLASS SUB-ASSEMBLY (a) Using a "torx" wrench T25, loosen a screw to adjust the sliding roof panel position. When the adjustment has been done, tighten the screw there. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (b) Reset the sliding roof drive gear (See page RF-2). SLIDING ROOF – SLIDING ROOF HOUSING RF–9 (c) Check the sliding roof operation function (See page RF-2). HINT: If the jam protection function is not activated, reset the sliding roof drive gear again. 12. CHECK FOR WATER LEAK (a) Adjusting the sliding roof, check that there is no water leak. If a leak is found, readjust the sliding roof. 13. INSTALL ROOF HEADLINING ASSEMBLY HINT: See page IR-14 RF SLIDING ROOF – SLIDING ROOF SYSTEM RF–1 SLIDING ROOF SYSTEM SLIDING ROOF BODY PARTS LOCATION SLIDING ROOF HOUSING RF SLIDING ROOF MOTOR SWITCH SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF CONTROL ECU) B120205E02 RF–2 SLIDING ROOF – SLIDING ROOF SYSTEM INITIALIZATION 1. RF RESET SLIDING ROOF MOTOR (a) If the AUTO operation function does not operate, reset the sliding roof motor using either of the following ways. (1) Press the sliding roof switch on TILT UP side and hold it. When the roof glass stops at the fully tilted-up position, the reset of the motor is completed. (2) Fully open the roof glass, press the sliding roof switch on SLIDE OPEN side and hold it for 10 seconds. 10 seconds later, the reset of the motor is completed. HINT: If the battery terminal is disconnected or after the jam protection function has operated, the ECU of the sliding roof motor may not detect the position of the roof glass. If the AUTO operation function is still disabled even if the sliding roof motor is reset, the hall IC (built in the sliding roof motor assembly) for detecting the roof glass position may malfunction. RF–5 SLIDING ROOF – SLIDING ROOF HOUSING SLIDING ROOF HOUSING SLIDING ROOF BODY COMPONENTS 4.0 (40, 35 in.*lbf) SLIDING ROOF GLASS SUB-ASSEMBLY SLIDING ROOF SIDE GARNISH RH SLIDING ROOF GUIDE RAIL COVER RH SUNSHADE TRIM SLIDING ROOF GUIDE RAIL COVER LH SLIDING ROOF SIDE GARNISH LH RF SUNSHADE TRIM KNOB SLIDING ROOF SUNSHADE STOPPER ROOF WIND DEFLECTOR PANEL SUB-ASSEMBLY SLIDING ROOF DRIVE CABLE SUB-ASSEMBLY SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY 5.4 (55, 48 in.*lbf) SLIDING ROOF HOUSING SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B120206E02 RF–6 SLIDING ROOF – SLIDING ROOF HOUSING REMOVAL HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. 1. REMOVE ROOF HEADLINING ASSEMBLY HINT: See page IR-7 2. REMOVE SLIDING ROOF GUIDE RAIL COVER LH (a) Using a screwdriver, pry out the rail cover. HINT: Tape the screwdriver tip before use. 3. REMOVE SLIDING ROOF GUIDE RAIL COVER RH HINT: Use the same procedures described above for the LH side. 4. REMOVE SLIDING ROOF SIDE GARNISH LH (a) Using screwdriver, pry out the garnish. HINT: Tape the screwdriver tip before use. 5. REMOVE SLIDING ROOF SIDE GARNISH RH HINT: Use the same procedures described above for the LH side. 6. REMOVE SLIDING ROOF GLASS SUB-ASSEMBLY (a) Using a "torx" wrench (T25), remove the 4 screws. (b) Pull the glass upward to remove it. 7. REMOVE SLIDING ROOF HOUSING SUB-ASSEMBLY (a) Disconnect the 4 drain hoses from the housing. (b) Remove the 8 bolts and 4 brackets. (c) Remove the 6 nuts and housing sub-assembly. 8. REMOVE SLIDING ROOF DRIVE GEAR SUBASSEMBLY (a) Disconnect the sliding roof motor switch connector. (b) Remove the 2 bolts and the drive gear subassembly. 9. REMOVE SLIDING ROOF SUNSHADE STOPPER (a) Using a screwdriver, remove the sliding roof sunshade stopper. HINT: Tape the screwdriver tip before use. RF B063615 B063617 10. REMOVE SUNSHADE TRIM SUB-ASSEMBLY RF–7 SLIDING ROOF – SLIDING ROOF HOUSING 11. REMOVE SUNSHADE TRIM KNOB (a) Remove the 2 screws and trim knob. 12. REMOVE ROOF DRIP CHANNEL REAR (a) Slide the drip channel backward and remove it. 13. REMOVE SLIDING ROOF DRIVE CABLE SUBASSEMBLY (a) Using a screwdriver, slide the drive cable backward and remove it. HINT: Tape the screwdriver tip before use. 14. REMOVE ROOF WIND DEFLECTOR PANEL SUBASSEMBLY INSPECTION 1. B064673 INSPECT SLIDING ROOF MOTOR SWITCH ASSEMBLY (a) Remove the sliding roof motor switch (See page IR7). (b) Check the continuity between the terminals when operating the switch. Standard resistance Terminals No. Switch Operation Specified Condition 1-3 TILT UP is pressed Below 1 Ω 2-3 SLIDE OPEN is pressed Below 1 Ω 1, 2 - 3 OFF 10 kΩ or higher If the result is not as specified, replace the switch. 2. B059681 INSPECT HARNESS AND CONNECTOR (FOR SLIDING ROOF MOTOR ASSEMBLY) (a) Disconnect the sliding roof motor connector (See page IR-7). (b) Check the connector terminals of the wire harness side connector. Standard Terminals No. Condition Specified Condition 8 - Body ground Constant Below 1 Ω 9-8 Ignition switch ON 10 to 14 V 10 - 8 Constant 10 to 14 V 1-8 Constant Below 1 Ω 7-8 TILT UP is pressed Below 1 Ω 6-8 SLIDE OPEN is pressed Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. RF MP–3 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the multiplex communication system. • The intelligent tester should be used in step 2. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CHECK FOR DTC (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result Result B DTC does not reoccur A DTC reoccurs B GO TO DTC CHART A 3 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (See page MP-4). NEXT 4 ADJUST, REPAIR OR REPLACE NEXT 5 NEXT END CONFIRMATION TEST Proceed to MP MP–4 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM TERMINALS OF ECU 1. CHECK DRIVER SIDE JUNCTION BLOCK ASSEMBLY (BODY ECU) (a) Disconnect the 1B, 1E, 1F, 1H and 1L J/B connectors. Vehicle Rear Side Vehicle Front Side 1F 1E 1B Body ECU 1F 1E 1B 1L 1H MP B065658E01 (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BECU (1F-12) - Body ground W-R - Body ground Power source (+B) Always 10 to 14 V BECU (1B-4) - Body ground W-R - Body ground Power source (+B) Always 10 to 14 V BECU (1L-4) - Body ground W-R - Body ground Power source (+B) Always 10 to 14 V BDR1 (1E-9) - Body ground G-W - Body ground Power source (+B) Always 10 to 14 V GND1 (1H-2) - Body ground W-B - Body ground Ground for main power supply Always Below 1 Ω GND2 (1H-2) - Body ground W-B - Body ground Ground for main power supply Always Below 1 Ω MP–5 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 2. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK THEFT WARNING ECU ASSEMBLY (THEFT DETERRENT ECU) (a) Disconnect the T5 connector. T5 B050657E08 (b) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition +B1 (T5-2) - Body ground W-R - Body ground Power source (+B) Always 10 to 14 V +B2 (T5-3) - Body ground W-L - Body ground Power source (+B) Always 10 to 14 V W-B - Body ground Ground for main power supply Always Below 1 Ω E (T5-29) - Body ground 3. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) (a) Disconnect the B8 connector. B8 B062706E05 (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition BDR (B8-4)- Body ground L - Body ground Power source (+B) Always 10 to 14 V BECU (B8-5) - Body ground L-R - Body ground Power source (+B) Always 10 to 14 V GND (B8-3) - Body ground W-B - Body ground Ground for main power supply Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MP MP–6 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DIAGNOSIS SYSTEM CG SG SIL 1. DESCRIPTION (a) The network gateway ECU controls the functions of the multiplex communication system on the vehicle. Data of the multiplex communication system and the Diagnostic Trouble Codes (DTC) can be read through the Data Link Connector 3 (DLC3) of the vehicle. 2. CHECK DLC3 (a) The vehicle's ECU uses the ISO 1565-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAEJ 1962 and matches the ISO 15765-4 format. BAT E106867E03 Symbols (Terminal No.) SIL (7) - SG (5) Terminal Description Bus "+" line Condition During transmission Specified Condition Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V MP 3. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) The BEAN communication line consists of 2 systems: One is a system with a loop-shaped line that the back door ECU is united with the body ECU present in the center of the line. Another is a system that the body ECU and the theft deterrent ECU are connected alone. Since the line for the back door ECU is loopshaped, the communication can be maintained by the line that is not open even if part of the line become open for some reason. In the case that there is a short-circuit (bus-down) in the line, however, all the BEAN communication becomes impossible in the system and some DTCs are output. HINT: • When bus-down occurs, communication from the related ECU stops. Therefore, DTC cannot be output, so perform a DTC (SAE code) inspection using the intelligent tester. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 4. MP–7 • The theft deterrent ECU and the back door ECU have a single communication line. Therefore, if the line has a short-circuit (bus-down), the BEAN communication will be impossible and DTCs will not be output, either. COMMUNICATION FUNCTION INSPECTION (a) Inspect the battery voltage. Standard voltage: 10 to 14 V (b) Inspect the diagnosis monitor code output. (1) Check a diagnosis code for the body ECU by connecting the intelligent tester to the DLC3 and turning the ignition switch ON. (2) When the display shows diagnostic codes of the ECU unconnected and the communication bus defective, perform the inspection depending on the troubleshooting. HINT: When other diagnostic code is output, refer to the diagnostic code table and check the applicable section. DTC CHECK / CLEAR Intelligent Tester 1. DLC3 A066288E02 2. CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (c) Enter the following menus: DIAGNOSIS/OBD/ MOBD/BODY/DTC INFO. (d) Check the DTCs on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (c) Erase the DTCs by following the prompts on the tester screen. (d) Enter the following menus: DIAGNOSIS/OBD/ MOBD/BODY/DTC INFO. HINT: Refer to the intelligent tester operator's manual for further details. MP MP–8 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART If malfunction code is displayed during DTC check, check the circuit corresponding to the code in the table below. Proceed to the page given for the circuit. MULTIPLEX COMMUNICATION SYSTEM DTC No. MP Detection Item Trouble Area See page B1214 Short to B+ in Door System Communication Bus Malfunction 1. Theft warning ECU assembly (Theft deterrent ECU) 2. Multiplex network door ECU back (Back door ECU) 3. Wire harness 4. Instrument panel junction block assembly (Body ECU) MP-9 B1215 Short to GND in Door System Communication Bus Malfunction 1. Theft warning ECU assembly (Theft deterrent ECU) 2. Multiplex network door ECU back (Back door ECU) 3. Wire harness 4. Instrument panel junction block assembly (Body ECU) MP-9 B1269 Theft Deterrent ECU Communication Stop 1. Theft warning ECU assembly (Theft deterrent ECU) 2. Wire harness MP-14 B1287 Back Door ECU Communication Stop 1. Multiplex network door ECU back (Back door ECU) 2. Wire harness MP-18 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–9 DTC B1214 Short to B+ in Door System Communication Bus Malfunction DTC B1215 Short to GND in Door System Communication Bus Malfunction DESCRIPTION B1214 and B1215 are output when +B and the body ground is short-circuited on the communication bus. Detecting this condition disables all the BEAN communication and outputs some DTCs. DTC No. B1214 B1215 DTC Detection Condition Door system communication circuit and +B battery system short Door system communication circuit and body ground short Trouble Area • • • • Theft warning ECU assembly (Theft deterrent ECU) Multiplex network door ECU back (Back door ECU) Wire harness Instrument panel junction block assembly (Body ECU) • • • • Theft warning ECU assembly (Theft deterrent ECU) Multiplex network door ECU back (Back door ECU) Wire harness Instrument panel junction block assembly (Body ECU) MP MP–10 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM Instrument Panel Junction Block Assembly (Body ECU) 26 MPX3 B6 23 MPX2 B4 BR-R BR-Y A14 IE1 B J19 J/C BR-R B 9 BD1 BR-Y R 1 B8 MPX2 31 T5 MPX1 MP Theft Warning ECU Assembly (Theft deterrent ECU) Multiplex Network Door ECU Back (Back door ECU) B065155E02 INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (A ECU) (a) Check whether the output of the DTC stops when the A ECU connector is disconnected. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–11 Body ECU Communication Circuit Communication Circuit Communication Circuit A ECU B ECU (Back Door ECU) (Theft deterrent ECU) B063900E01 NOTICE: Disconnect the connectors in the operational sequence, and start the next step after the connector in connected. HINT: In this case, the A ECU in the represents the back door ECU. OK: When the output of the DTC stops, the disconnected A ECU is abnormal. OK REPLACE A ECU NG 2 CHECK DIAGNOSTIC TROUBLE CODE (B ECU) (a) Check whether the output of the DTC stops when the B ECU connector is disconnected. MP MP–12 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Body ECU Communication Circuit Communication Circuit Communication Circuit A ECU B ECU (Back Door ECU) (Theft deterrent ECU) B065156E01 OK: Neither DTC B1214 nor DTC B1215 is output. NOTICE: Disconnect the connectors in the operational sequence, and start the next step after the connector in connected. HINT: In this case, the B ECU in the represents the theft deterrent ECU. OK: When the output of the DTC stops, the disconnected B ECU is abnormal. MP OK REPLACE B ECU NG 3 CHECK WIRE HARNESS BETWEEN BODY ECU AND A ECU OR B ECU (a) Disconnect the A ECU, B ECU and body ECU connectors. (b) Check the wire harness (MPX line) between the A ECU, B ECU and body ECU. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–13 Body ECU Communication Circuit MPX Line MPX Line Communication Circuit Communication Circuit A ECU B ECU (Back Door ECU) (Theft deterrent ECU) B063902E01 (1) Turn the ignition switch ON. (2) Check the voltage between the wire harness (MPX line) and body ground. Standard voltage MPX line - Body ground Specified Condition Body ECU or A ECU (Back door ECU) - Body ground Below 1 V Body ECU or B ECU (Theft deterrent ECU) - Body ground Below 1 V If the output voltage is not Below 1V, the wire harness (MPX line) may be short-circuited with +B. (3) Check the resistance of the wire harness (MPX lines) and body ground. Standard resistance MPX line - Body ground Specified Condition Body ECU or A ECU (Back door ECU) - Body ground 10 kΩ or higher Body ECU or B ECU (Theft deterrent ECU) - Body ground 10 kΩ or higher If there is Below 1 Ω, the wire harness (MPX line) and body ground may be short-circuited with the body ground. NG REPAIR OR REPLACE WIRE HARNESS BETWEEN BODY ECU AND A ECU OR B ECU OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–1 MULTIPLEX COMMUNICATION SYSTEM COMMUNICATION MULTIPLEX COMMUNICATION SYSTEM PARTS LOCATION THEFT WARNING ECU ASSEMBLY (THEFT DETERRENT ECU) MP INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - BODY ECU MULTIPLEX NETWORK DOOR ECU BACK (BACK DOOR ECU) C131375E01 MP–2 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM SYSTEM DIAGRAM 1. MULTIPLEX COMMUNICATION SYSTEM (BEAN) DESCRIPTION (a) The BEAN communication line is used to control the following items: • Instrument panel junction block assembly (Body ECU) • Theft warning ECU assembly (Theft deterrent ECU) • Multiplex network door ECU back (Back door ECU) If there is a short-circuit (bus-down) in the line, communication to the system that had a short-circuit (bus-down) will be disabled and the DTC concerning the system will be output from the multiplex network body ECU. Instrument Panel Junction Block Assembly (Body ECU) 26 MPX3 B6 MP BR-Y 23 MPX2 B4 BR-R A14 IE1 B J19 J/C BR-R B 9 BD1 BR-Y R 31 T5 MPX1 Theft Warning ECU Assembly (Theft deterrent ECU) 1 B8 MPX2 Multiplex Network Door ECU Back (Back door ECU) B065155E01 MP–14 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1269 Theft Deterrent ECU Communication Stop DESCRIPTION DTC B1269 is output when the communication between the theft deterrent ECU and the body ECU stops for more than 10 seconds. DTC No. B1269 MP DTC Detection Condition Theft deterrent ECU communication stop Trouble Area • • Theft warning ECU assembly (Theft deterrent ECU) Wire harness MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–15 WIRING DIAGRAM Theft Warning ECU Assembly (Theft Deterrent ECU) Instrument Panel Junction Block Assembly Engine Room R/B Passenger Side J/B W-R ECU-B 2 1 4 1B 2 2 W-R W 4 1L W-R B 3E B 3E 2 T5 +B1 SECU/HORN ALT 2 1 J/B 2 1 2 1 1C 2 10 1K 3 T5 +B2 W-L B MPX3 2 26 B6 J19 J/C BR-Y B BR-Y B 31 T5 MPX1 L-W 2 2 1 MP J24 J/C Short Pin W-B 2 A 29 T5 E B Battery II B065157E01 MP–16 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (BODY ECU - THEFT DETERRENT ECU) (a) Check the wire harness between the body ECU and theft deterrent ECU. (1) Disconnect the B6 and T5 connectors. (2) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B6 Instrument Panel Junction Block Assembly (Body ECU) Tester Connection Condition Specified Condition MPX3 (B6-26) - MPX1 (T5-31) Always Below 1 Ω NG T5 Theft Warning ECU Assembly (Theft Deterrent ECU) REPAIR OR REPLACE HARNESS OR CONNECTOR B064050E01 MP OK 2 INSPECT THEFT WARNING ECU ASSEMBLY (a) Disconnect the T5 connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side T5 Theft Warning ECU Assembly (Theft Deterrent ECU) B065163E01 OK Tester Connection Condition Specified Condition +B1 (T5-2) - Body ground Always 10 to 14 V +B2 (T5-3) - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3 MP–17 INSPECT THEFT WARNING ECU ASSEMBLY (a) Disconnect the T5 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T5 Theft Warning ECU Assembly (Theft Deterrent ECU) Tester Connection Condition Specified Condition E (T5-29) - Body ground Always Below 1 Ω NG B065163E01 REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE THEFT WARNING ECU ASSEMBLY MP MP–18 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1287 Back Door ECU Communication Stop DESCRIPTION B1287 is output when the communication between the multiplex network door ECU back (back door ECU) and multiplex network body ECU stops for more than 10 seconds. DTC No. B1287 MP DTC Detection Condition Back door ECU communication stop Trouble Area • • Multiplex network door ECU back (Back door ECU) Wire harness MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–19 WIRING DIAGRAM Multiplex Network Door ECU Back (Back Door ECU) Instrument Panel Junction Block Assembly Engine Room R/B W-R ECU-B 2 1 2 2 4 1B 2 1 1C 12 1F W-R 7 BD1 L-R 1 1F L-O 6 BD1 L 5 B8 BECU W ALT 2 1 J/B 21 2 Power 1 2 4 B8 BDR B BR-R 23 MPX2 B4 2 A14 IE1 BR-R 9 1 R BD1 B8 MPX2 MP L-W Short Pin 2 2 1 A J41 2 J/C A J40 W-B 10 BD1 W-B 3 B8 GND W-B B Battery BL B065158E01 MP–20 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (BODY ECU - BACK DOOR ECU) (a) Check the wire harness between the body ECU and back door ECU. (1) Disconnect the B4 and B8 connectors. (2) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B4 Instrument Panel Junction Block Assembly (Body ECU) Tester Connection Condition Specified Condition MPX2 (B4-23) - MPX2 (B8-1) Always Below 1 Ω NG B8 Multiplex Network Door ECU Back (Back Door ECU) REPAIR OR REPLACE HARNESS OR CONNECTOR B064051E02 MP OK 2 INSPECT MULTIPLEX NETWORK DOOR ECU (BACK DOOR ECU) (a) Disconnect the B8 connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B8 Multiplex Network Door ECU Back (Back Door ECU) B065162E01 OK Tester Connection Condition Specified Condition BECU (B8-5) - Body ground Always 10 to 14 V BDR (B8-4) - Body ground Always 10 to 14 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3 MP–21 INSPECT MULTIPLEX NETWORK DOOR ECU (BACK DOOR ECU) (a) Disconnect the B8 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B8 Multiplex Network Door ECU Back (Back Door ECU) B065162E01 Tester Connection Condition Specified Condition GND (B8-3) - Body ground Always Below 1 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MULTIPLEX NETWORK DOOR ECU (BACK DOOR ECU) MP CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–3 PARTS LOCATION MASTER CYLINDER SOLENOID (SKID CONTROL ECU) CA CAN J/C STEERING ANGLE SENSOR ECM DLC3 YAW RATE SENSOR C131374E01 CA–4 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM SYSTEM DIAGRAM Serial Communication Line (SIL) Skid Control ECU DLC3 CAN J/C ECM 120 Ω +- 10% 120 Ω +- 10% : CAN Main Bus Line (CAN-H) : CAN Main Bus Line (CAN-L) Steering Angle Sensor Yaw Rate Sensor CA : CAN Sub Bus Line (CAN-H) : CAN Sub Bus Line (CAN-L) C134075E01 HINT: • The skid control ECU stores DTCs and performs DTC communication by receiving information from the steering angle sensor and yaw rate sensor. These sensors cannot store DTCs or perform DTC communication. • The ECM uses the CAN communication system to perform DTC communication instead of the conventional serial communication line (SIL). CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TR... Last Modified: 4-26-2007 1.6 D Service Category: Power Source/Network Section: Networking Model Year: 2007 Model: 4Runner Doc ID: RM0000022YR008X Title: CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TROUBLESHOOTING (2007 4Runner) HOW TO PROCEED WITH TROUBLESHOOTING NOTICE: z DTCs for the CAN communication system as follows: z U0073/94, U0123/62, U0124/95, U0126/63, U0100/65. Refer to troubleshooting of each system if DTCs regarding the CAN communication system are not output. 1. CHECK AND CLEAR DTCs NEXT 2. CHECK CAN BUS LINE NEXT 3. CHECK USING INTELLIGENT TESTER VIA CAN VIM (a) Select the "BUS CHECK" . Result: PROCEED TO A RESULT A All ECUs and sensors connected to the CAN communication system are displayed. B An ECU or sensor not connected to the CAN communication system is displayed. C A few ECUs or sensors not connected to the CAN communication system are displayed. B COMMUNICATION STOP MODE TABLE C CHECK FOR AN OPEN IN ONE SIDE OF THE CAN SUB BUS LINE CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH TR... 4. CHECK DTC COMBINATION TABLE (a) Confirm trouble according to the combination of output DTCs regarding the CAN communication system. HINT: Previous CAN communication system DTCs may be the cause if CAN communication system DTCs are output and all ECUs and sensors connected to the CAN communication system are displayed on the intelligent tester's "BUS CHECK" screen via the CAN VIM. NEXT 5. CIRCUIT INSPECTION NEXT 6. IDENTIFICATION OF PROBLEM NEXT 7. REPAIR OR REPLACE NEXT 8. CONFIRMATION TEST NEXT END CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: CAN Bus Line (2007 4Runner) Last Modified: 4-26-2007 1.6 J Service Category: Power Source/Network Section: Networking Model Year: 2007 Model: 4Runner Doc ID: RM000002AG0006X Title: CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: CAN Bus Line (2007 4Runner) CAN Bus Line DESCRIPTION When any DTC of the CAN communication system is output, first measure the resistance between the terminals of the DLC3 and the yaw rate sensor connector to specify the trouble area. WIRING DIAGRAM CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: CAN Bus Line (2007 4Runner) INSPECTION PROCEDURE PROCEDURE 1. CHECK CAN BUS WIRE (MAIN BUS LINE FOR DISCONNECTION, BUS LINES FOR SHORT CIRCUIT) (a) Measure the resistance according to the value(s) in the table below. Standard resistance: CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: CAN Bus Line (2007 4Runner) TESTER CONNECTION CONDITION D1-6 (CANH) - D114 (CANL) D1-6 (CANH) - D114 (CANL) D1-6 (CANH) - D114 (CANL) NGA NGB z z z z z z SPECIFIED VALUE RESULT IG switch OFF Stop light switch OFF 54 to 69 Ω OK IG switch OFF Stop light switch OFF 69 Ω or higher NG-A Below 54 Ω NG-B IG switch OFF Stop light switch OFF CHECK CAN MAIN BUS LINE FOR DISCONNECTION CHECK CAN BUS LINES FOR SHORT CIRCUIT OK 2. CHECK CAN BUS LINE FOR SHORT TO +B (a) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION CONDITION SPECIFIED VALUE D1-6 (CANH) - D1-16 (BAT) z z IG switch OFF Stop light switch 1 MΩ or higher OFF D1-14 (CANL) - D1-16 (BAT) z IG switch OFF NG z Stop light switch 1 MΩ or higher OFF CHECK CAN BUS LINE FOR SHORT TO +B CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: CAN Bus Line (2007 4Runner) 3. CHECK CAN BUS LINE FOR SHORT TO GND (a) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION CONDITION D1-4 (CG) - D1-6 (CANH) z D1-4 (CG) - D1-14 (CANL) z z z SPECIFIED VALUE IG switch OFF Stop light switch OFF 3 kΩ or higher IG switch OFF Stop light switch OFF 3 kΩ or higher NG CHECK CAN BUS LINE FOR SHORT TO GND OK GO TO HOW TO PROCEED WITH TROUBLESHOOTING CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... Last Modified: 4-26-2007 1.6 U Service Category: Power Source/Network Section: Networking Model Year: 2007 Model: 4Runner Doc ID: RM0000022YT008X Title: CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4Runner) TERMINALS OF ECU HINT: This section describes the standard CAN values for all CAN related components. 1. CAN J/C (a) CAN J/C connectors. HINT: z z The connectors connected to the CAN J/C can be distinguished by the colors of the bus lines and the connecting side of the connector. J48, J49, J50 and J51 are interchangeable. CAN J/C CONNECTORS COLOR (CAN-H SIDE) COLOR (CAN-L SIDE) ECM (J51) L LG DLC3 (J50) P V Steering angle sensor (J49) B Y ("A" SIDE, WITH EARTH TERMINAL) CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... Yaw rate sensor (J48) W CAN J/C CONNECTORS R COLOR (CAN-H SIDE) COLOR (CAN-L SIDE) B W ("B" SIDE, WITHOUT EARTH TERMINAL) Skid control ECU (J47) (b) The terminals of the CAN J/C connectors. TERMINAL TERMINAL SYMBOL 1 CANH 2 CANL (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS SPECIFIED VALUE CANH - CANL 108 to 132 Ω 2. DLC3 (a) Check DLC3. (1) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS TERMINAL CONDITION SPECIFIED CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... DESCRIPTION VALUE D1-6 (CANH) HIGH-level CAN IG switch OFF, - D1-14 bus line - LOWstop light 54 to 69 Ω (CANL) level CAN bus line switch OFF D1-6 (CANH) - D1-16 (BAT) HIGH-level CAN IG switch OFF, bus line - Battery stop light positive switch OFF 1 MΩ or higher D1-14 (CANL) - D116 (BAT) LOW-level CAN IG switch OFF, bus line - Battery stop light positive switch OFF 1 MΩ or higher D1-6 (CANH) -D1-4 (CG) HIGH-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher D1-14 (CANL) - D14 (CG) LOW-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher 3. SKID CONTROL ECU (a) Check the skid control ECU harness side connector (S28). (1) Disconnect the connector (S28) from the skid control ECU. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS WIRING TERMINAL CONDITION SPECIFIED COLOR DESCRIPTION VALUE S28-11 (CANH) S28-25 (CANL) B-W HIGH-level CAN bus line - LOW-level CAN bus line S28-11 (CANH) S28-32 (GND1) B - W-B HIGH-level CAN bus line - Ground S28-25 (CANL) S28-32 (GND1) W - WB S28-11 IG switch OFF, stop light switch OFF IG switch OFF, stop light switch 108 to 132 Ω 3 kΩ or higher OFF LOW-level CAN bus line - Ground IG switch OFF, stop light switch OFF HIGH-level IG switch 3 kΩ or higher CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... (CANH) S28-31 (+BS) S28-25 (CANL) S28-31 (+BS) B-Y CAN bus line - Battery positive OFF, stop light switch OFF 1 MΩ or higher W-Y LOW-level CAN bus line - Battery positive IG switch OFF, stop light switch OFF 1 MΩ or higher 4. STEERING SENSOR (a) Check the harness side connector (S11) of the steering sensor. (1) Disconnect the connector (S11) from the steering sensor. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS WIRING TERMINAL CONDITION SPECIFIED COLOR DESCRIPTION VALUE S11-3 (CANH) S11-11 (CANL) S11-3 (CANH) S11-2 (ESS) S11-11 (CANL) S11-2 (ESS) S11-3 (CANH) S11-9 (BAT) S11-11 (CANL) S11-9 (BAT) 5. YAW RATE SENSOR B-Y HIGH-level CAN bus line - LOW-level CAN bus line IG switch OFF, stop light switch OFF 108 to 132 Ω B - W-B HIGH-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher Y - W-B LOW-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher B - W-B HIGH-level CAN bus line - Battery positive IG switch OFF, stop light switch OFF 1 MΩ or higher Y - W-B LOW-level CAN bus line - Battery positive IG switch OFF, stop light switch OFF 1 MΩ or higher CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... (a) Check the yaw rate sensor harness side connector (Y1). (1) Disconnect the connector (Y1) from the yaw rate sensor. (2) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS WIRING TERMINAL CONDITION SPECIFIED COLOR DESCRIPTION VALUE Y1-3 (CANH) Y1-2 (CANL) HIGH-level CAN bus line - LOW-level CAN bus line IG switch OFF, stop 54 to 69 Ω light switch OFF Y1-3 W - W(CANH) B Y1-1 (GND) LOW-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher Y1-2 (CANL) R - W-B Y1-1 (GND) LOW-level CAN bus line - Ground IG switch OFF, stop light switch OFF 3 kΩ or higher W-O LOW-level CAN bus line - Battery positive IG switch OFF, stop light switch OFF 1 MΩ or higher R-O LOW-level CAN bus line - Battery positive IG switch OFF, stop light switch OFF 1 MΩ or higher Y1-3 (CANH) D1-16 (BAT) Y1-2 (CANL) D1-16 (BAT) Y-R 6. ECM (a) Measure the resistance according to the value(s) in the table below. Standard resistance: CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU (2007 4R... TERMINAL E7-33 (CANH) - E7-34 (CANL) CONDITION z z SPECIFIED VALUE IG switch OFF Stop light switch OFF 108 to 132 Ω (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TERMINALS E7-33 (CANH) E7-34 (CANL) E7-33 (CANH) E4-7 (E01) E7-34 (CANL) E4-7 (E01) E7-33 (CANH) E8-3 (BATT) E7-34 (CANL) E8-3 (BATT) WIRING COLOR CONDITION z L - LG z L - W-B (2UZ-FE) z L - BR (1GR-FE) z LG - W-B (2UZ-FE) z LG - BR (1GR-FE) z z L-L z z LG - L z IG switch OFF Stop light switch OFF SPECIFIED VALUE 108 to 132 Ω IG switch OFF Stop light switch OFF 3 kΩ or higher IG switch OFF Stop light switch OFF 3 kΩ or higher IG switch OFF Stop light switch OFF 1 MΩ or higher IG switch OFF Stop light switch OFF 1 MΩ or higher CA–46 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Check CAN Bus Line for Short to GND DESCRIPTION A short to GND is suspected in the CAN bus line when there is continuity between terminals 4 (CG) and 6 (CANH) or terminals 4 (CG) and 14 (CANL) of the DLC3. Symptom Trouble Area • • • • • • There is continuity between terminals 4 (CG) and 6 (CANH) or terminals 4 (CG) and 14 (CANL) of the DLC3. Short to GND in CAN bus line ECM Skid control ECU Steering angle sensor Yaw rate sensor CAN J/C WIRING DIAGRAM Y1 Yaw Rate Sensor CAN J/C ECM Center J/B B 3F B 3F W-B CANH W-B GND 1 CANL B 3F W 1 J48 1 J51 L R 2 J48 2 J51 LG 3 2 S11 Steering Angle Sensor CANH W-B CA 2 B 1 J49 Y 2 J49 3 ESS CANL 11 Skid Control ECU A J15 J/C A J15 11 CANH S28 25 CANL S28 B 11 IC2 1 B J47 W 22 IC2 W 32 GND2 S28 2 J47 33 CANH E7 34 E7 CANL W-B (2UZ-FE) 7 BR (1GR-FE) E4 E01 D1 DLC3 1 J50 P 2 J50 V 6 CANH CANL 14 1 J52 4 W-B CG W-B E J22 J/C W-B W-B A A J24 J/C II A J37 J/C IK W-B E A W-B J5 J/C IG J5 J/C EA IH IG EE G036696E01 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–47 INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO GND (DLC3 SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the DLC3 sub bus line connector (J50) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal P J50 V G031933E33 DLC3: D1 CG (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL D1-4 (CG) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher G026206E75 NG REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CONNECT CONNECTOR (a) Reconnect the DLC3 sub bus line connector (J50) to the CAN J/C. NEXT CA CA–48 3 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND (SKID CONTROL ECU SUB BUS LINE) (a) Disconnect the skid control ECU sub bus line connector (J47) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CAN J/C “B” Side (without Earth Terminal) Wire Harness View: B J47 W G031932E97 DLC3: D1 CG (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CA CANL D1-4 (CG) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher G026206E75 OK Go to step 10 NG 4 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CA–49 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 5 CHECK CAN BUS LINE FOR SHORT TO GND (YAW RATE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the yaw rate sensor sub bus line connector (J48) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal W J48 R G031933E34 DLC3: D1 CG (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL D1-4 (CG) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher G026206E75 OK Go to step 12 NG 6 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA CA–50 7 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND (STEERING ANGLE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the steering angle sensor sub bus line connector (J49) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal B J49 Y G031933E35 DLC3: D1 CG (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CA CANL D1-4 (CG) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher G026206E75 OK Go to step 14 NG 8 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CA–51 CHECK CAN BUS LINE FOR SHORT TO GND (ECM MAIN BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the ECM main bus line connector (J51) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal L J51 LG G031933E32 DLC3: D1 CG (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL D1-4 (CG) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher G026206E75 OK Go to step 16 NG REPLACE CAN J/C 10 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CA CA–52 11 DLC3: CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND (SKID CONTROL ECU SUB BUS LINE) D1 CG (a) Disconnect the skid control ECU connector (S28). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL G026206E75 D1-4 (CG) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher REPLACE MASTER CYLINDER SOLENOID NG REPAIR OR REPLACE SKID CONTROL ECU SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 12 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. CA NEXT 13 DLC3: CHECK CAN BUS LINE FOR SHORT TO GND (YAW RATE SENSOR SUB BUS LINE) D1 CG (a) Disconnect the yaw rate sensor connector (Y1). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL G026206E75 D1-4 (CG) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher REPLACE YAW RATE SENSOR NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) CA–53 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 14 CONNECT CONNECTOR (a) Reconnect the steering angle sub bus line connector (J49) to the CAN J/C. NEXT 15 DLC3: CHECK CAN BUS LINE FOR SHORT TO GND (STEERING ANGLE SENSOR SUB BUS LINE) D1 CG (a) Disconnect the steering angle sensor connector (S11). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL G026206E75 D1-4 (CG) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher REPLACE STEERING ANGLE SENSOR NG REPAIR OR REPLACE STEERING ANGLE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 16 CONNECT CONNECTOR (a) Reconnect the ECM main bus line connector (J51) to the CAN J/C. NEXT 17 DLC3: CHECK CAN BUS LINE FOR SHORT TO GND (ECM MAIN BUS LINE) D1 CG (a) Disconnect the ECM connector (E7). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL G026206E75 D1-4 (CG) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher REPLACE ECM CA CA–54 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM NG REPAIR OR REPLACE ECM MAIN BUS LINE OR CONNECTOR (CAN-H, CAN-L) CA CA–55 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Open in One Side of CAN Sub Bus Line DESCRIPTION If 2 or more ECUs and/or sensors do not appear on the intelligent tester's "BUS CHECK" screen via the CAN VIM, one side of the CAN sub-bus line may be open. (One side of the CAN-H [sub-bus line]/CAN-L [sub-bus line] of the ECU and/or sensor is open.) Symptom Trouble Area 2 or more ECUs and/or sensors do not appear on the intelligent tester's "BUS CHECK" screen via the CAN VIM. • • • • • • One side of the CAN sub-bus line is open Skid control ECU Steering angle sensor Yaw rate sensor ECM CAN J/C WIRING DIAGRAM Y1 Yaw Rate Sensor CAN J/C ECM CANH CANL W 1 J48 1 J51 L R 2 J48 2 J51 LG 3 2 33 CANH E7 34 E7 CA S11 Steering Angle Sensor CANH CANL CANL Skid Control ECU B 1 J49 1 J47 B 11 IC2 B 11 S28 CANH Y 2 J49 2 J47 W 22 IC2 W 25 S28 CANL P 1 J50 V 2 J50 3 11 D1 DLC3 CANH CANL 6 14 G036694E01 CA–56 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK OPEN IN ONE SIDE OF CAN SUB BUS LINE (SKID CONTROL ECU SUB BUS LINE) CAN J/C “B” Side (with Earth Terminal) Wire Harness View: B (a) Disconnect the skid control ECU sub bus line connector (J47) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. (b) Connect the intelligent tester via the CAN VIM to the DLC3. (c) Turn the ignition switch ON. (d) Select "BUS CHECK" on the intelligent tester display via the CAN VIM (See page CA-13). Result J47 Proceed to W G031932E98 Result A "ABS/VSC/TRAC" does not appear B 2 or more ECUs and/or sensors do not appear A Go to step 8 B CA 2 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT 3 CHECK OPEN IN ONE SIDE OF CAN SUB BUS LINE (STEERING ANGLE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: Earth Terminal B J49 (a) Disconnect the steering angle sensor sub bus line connector (J49) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. (b) Connect the intelligent tester via the CAN VIM to the DLC3. (c) Turn the ignition switch ON. (d) Select "BUS CHECK" on the intelligent tester display via the CAN VIM (See page CA-13). Result Proceed to Y A G031933E35 Result "STEERING SENSOR" does not appear CA–57 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Proceed to B A Result 2 or more ECUs and/or sensors do not appear Go to step 10 B 4 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT 5 CHECK OPEN IN ONE SIDE OF CAN SUB BUS LINE (YAW RATE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: Earth Terminal W J48 (a) Disconnect the yaw rate sensor sub bus line connector (J48) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. (b) Connect the intelligent tester via the CAN VIM to the DLC3. (c) Turn the ignition switch ON. (d) Select "BUS CHECK" on the intelligent tester display via the CAN VIM (See page CA-13). Result Proceed to R G031933E34 B Result A "YAW /DECELERAT" does not appear B 2 or more ECUs and/or sensors do not appear Go to step 12 A 6 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA CA–58 7 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK OPEN IN ONE SIDE OF CAN BUS LINE (YAW RATE SENSOR SUB BUS LINE) Yaw Rate Sensor Connector Front View: Y1 (a) Disconnect the yaw rate sensor connector (Y1). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection CANL Y1-2 (CANL) - Y1-3 (CANH) G026359E63 NG • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK REPLACE YAW RATE SENSOR 8 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CA 9 CHECK OPEN IN ONE SIDE OF CAN SUB BUS LINE (SKID CONTROL ECU SUB BUS LINE) Skid Control ECU Connector Front View: S28 CANH (a) Disconnect the skid control ECU connector (S28). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection S28-11 (CANH) - S28-25 (CANL) CANL E069126E55 NG OK REPLACE MASTER CYLINDER SOLENOID • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPAIR OR REPLACE SKID CONTROL ECU SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) CA–59 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 10 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT 11 CHECK OPEN IN ONE SIDE OF CAN SUB BUS LINE (STEERING ANGLE SENSOR SUB BUS LINE) (a) Disconnect the steering angle sensor connector (S11). (b) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: CANH Tester connection S11-3 (CANH) - S11-11 (CANL) S11 CANL G027814E07 NG • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPAIR OR REPLACE STEERING ANGLE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK REPLACE STEERING ANGLE SENSOR CA 12 CHECK CAN J/C (a) Disconnect connectors (J47), (J48), (J49), (J50) and (J51) from the CAN J/C. (b) Measure the resistance according to the value(s) in the table below. Standard resistance CAN J/C “A” Side (with Earth Terminal): CANH Tester connection 1 (CANH) - 2 (CANL) CANL Earth Terminal CAN J/C “B” Side (without Earth Terminal): CANH CANL G026214E16 NG • • Condition Specified value IG switch OFF Stop light switch OFF 108 to 132 Ω REPLACE CAN J/C CA–60 OK REPLACE ECM CA CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–1 CAN COMMUNICATION SYSTEM PRECAUTION 1. 2. 3. F045104 HANDLING PRECAUTIONS ON STEERING SYSTEM (a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in hazardous driving. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM (a) This vehicle is equipped with an SRS (Supplemental Restraint System), such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page RS-1). WIRE HARNESS REPAIR (a) After repairing the wire bus line with solder, wrap the repaired part with vinyl tape. NOTICE: • The CANL bus line and CANH bus line must be installed together all the time. When installing, make sure to twist them. • The difference in length of the CANL bus line and CANH bus line should be within 100 mm (3.93 in.). • Untwisted parts around the connector should be within 80 mm (3.15 in.). (b) Do not perform bypass wiring between the connectors. NOTICE: If you perform bypass wiring, the characteristic of the twisted wire harness will be lost. Bypass Wire F045105E11 4. F045106 CONNECTOR HANDLING (a) When inserting tester probes into a connector, insert them from the back of the connector. CA CA–2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (b) If it is impossible to check resistance from the back of the connector, use a repair wire to check it. Repair Wire F045107E16 CA CA–15 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM DIAGNOSIS SYSTEM 1. Trouble Mode Skid control ECU communication stop mode DTC COMBINATION TABLE NOTICE: Complete "CHECK CAN BUS LINE" (See page RS-1) to confirm that there is no malfunction in the CAN bus line, and then perform troubleshooting according to the following DTC combination table. (a) Confirm the trouble mode according to the combination of output DTCs. U0100/65 U0073/94 U0123/62 U0124/95 U0126/63 { { { { { Yaw rate sensor communication stop mode - - { { - Steering sensor communication stop mode - - - - { ECM communication stop mode (*2) { - - - - 2. HINT: • Previous CAN communication system DTCs may be the cause if CAN communication system DTCs are output and all ECUs an sensors connected to the CAN communication system are displayed on the intelligent tester's "BUS CHECK" screen via the CAN VIM. • U0073/94, U0123/62, U0124/95, U0126/63 and U0100/65 are the DTCs in the CAN communication system. • The above table shows combinations of these DTCs. • {..... DTCs that are being output. • - ...... DTCs that are not being output. BUS CHECK HINT: The ECUs and sensors that are properly connected to the CAN communication system can be displayed using the intelligent tester via the CAN VIM. (a) Select "BUS CHECK" from the "OBD/MOBD MENU" screen. G032145 CA CA–16 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (b) Press "ENTER" on the intelligent tester via the CAN VIM. G030152 3. G032144 DTC No. CA (c) The screen displays the ECUs and sensors that are properly connected to the CAN communication system. HINT: There is a communication stop in the system of any properly connected ECUs or sensors that are not displayed (See page CA-7). DTC TABLE BY ECU HINT: If CAN communication system DTCs are output, trouble cannot be determined only by the DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING" (See page CA-6). (a) Skid Control ECU HINT: DTC communication uses the SIL line. Detection Item U0073/94 Control Module Communication Bus Off U0100/65 Lost Communication With ECM/PCM "A" U0123/62 Lost Communication With Yaw Rate Sensor Module U0124/95 Lost Communication With Lateral Acceleration Sensor Module U0126/63 Lost Communication With Steering Angle Sensor Module (b) ECM HINT: The ECM is connected to the CAN communication system but CAN communication system DTCs are not output. CA–17 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM FAIL-SAFE CHART 1. FAIL-SAFE FUNCTION (a) When communication fails in any of the CAN bus lines (communication lines) due to a short circuit or any other causes, the fail-safe function, which is specified for each system, operates to prevent the system from malfunctioning. (b) This function operates for each system when communication is impossible. (For further details, see the pages for each system.) Function ECM Skid Control ECU Steering Angle Sensor Yaw Rate Sensor Action when unable to communicate DTC detection (Driver detectable) VSC Control (Controls VSC/ TRC engine output) - Rx Tx Tx VSC function stops Detectable (Light comes on) VSC Control (Controls VSC/ TRC engine output) Rx or Tx Tx or Rx - - VSC function stops Detectable (Light comes on) HINT: • Rx: Reception from each ECU (sensor). • Tx: Transmission to each ECU (sensor). CA CA–18 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Skid Control ECU Communication Stop Mode DESCRIPTION Detection Item Symptom • SKID CONTROL ECU COMMUNICATION STOP MODE • Trouble Area "ABS/VSC/TRAC" is not displayed on the "BUS CHECK" screen of the intelligent tester via the CAN VIM. DTCs are output from each ECU in skid control ECU communication stop mode as shown in the "DTC COMBINATION TABLE" (See page CA-13). • • Power source or inside the skid control ECU Skid control ECU sub bus line or connector WIRING DIAGRAM Skid Control ECU CAN J/C ECM CANH CANL 33 E7 L 1 J51 1 J47 B 11 IC2 B 11 S28 CANH 34 E7 LG 2 J51 2 J47 W 22 IC2 W 25 S28 CANL Driver Side J/B CA L-Y ECU-IG 2 1C J4 J/C 12 1E B-R F W-L AM1 2 F 46 S28 IG1 Engine Room R/B I18 Ignition SW 4 IG1 B-R ALT AM1 2 2 1 2 1 2 B 2 2 32 S28 GND2 B W-B Battery EA G036690E01 CA–19 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (SKID CONTROL ECU SUB BUS LINE) Skid Control ECU Connector Front View: S28 CANH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the skid control ECU connector (S28). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection S28-11 (CANH) - S28-25 (CANL) CANL • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω E069126E55 NG REPAIR OR REPLACE SKID CONTROL ECU SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CHECK WIRE HARNESS (IG, GND2) Skid Control ECU Connector Front View: (a) Measure the resistance according to the value(s) in the table below. Standard resistance S28 IG1 GND2 E069126E56 Tester connection Condition Specified value S28-32 (GND2) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified value S28-46 (IG1) - Body ground IG switch ON 10 to 14 V NG OK REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–20 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Steering Angle Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom • STEERING ANGLE SENSOR COMMUNICATION STOP MODE Trouble Area "STEERING SENSOR" is not displayed on the "BUS CHECK" screen of the intelligent tester via the CAN VIM. DTCs are output from each ECU in steering angle sensor communication stop mode as shown in the "DTC COMBINATION TABLE" (See page CA-13). • • • Power source or inside the steering angle sensor Steering angle sensor sub bus line or connector WIRING DIAGRAM S11 Steering Angle Sensor CAN J/C ECM CANH CANL 33 E7 L 34 E7 LG 1 J51 1 J49 B 2 J51 2 J49 Y 3 11 CANH CANL Driver Side J/B ECU-IG 2 1C CA J20 J/C 28 1J B-R A J12 B-R G G J/C A J13 B-R A J15 W-B 1 IG1 I18 Ignition SW L-Y A J15 W-L 4 IG1 AM1 2 J/C 2 ESS Engine Room R/B ALT 2 B 2 1 AM1 2 1 2 W-B 2 2 B A J5 J/C Battery IG G036691E01 CA–21 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (STEERING ANGLE SENSOR SUB BUS LINE) (a) Turn the ignition switch to the LOCK position. (b) Disconnect the steering angle sensor connector (S11). (c) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: CANH Tester connection S11-3 (CANH) - S11-11 (CANL) S11 CANL • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω G027814E07 NG REPAIR OR REPLACE STEERING ANGLE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CHECK WIRE HARNESS (IG1, ESS) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Steering Angle Sensor Wire Harness View: ESS IG1 S11 G027814E08 Tester connection Condition Specified value S11-2 (ESS) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified value S11-1 (IG1) - Body ground IG switch ON 10 to 14 V NG OK REPLACE STEERING ANGLE SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–22 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom • YAW RATE SENSOR COMMUNICATION STOP MODE Trouble Area "YAW/DECELERAT" is not displayed on the "BUS CHECK" screen of the intelligent tester via the CAN VIM. DTCs are output from each ECU in yaw rate sensor communication stop mode as shown in the "DTC COMBINATION TABLE" (See page CA-13). • • • Power source or inside the yaw rate sensor Yaw rate sensor sub bus line or connector WIRING DIAGRAM Y1 Yaw Rate Sensor CAN J/C ECM CANH CANL 33 E7 L 34 E7 LG 1 J51 1 J48 W 2 J51 2 J48 R 3 2 CANH CANL Driver Side J/B ECU-IG 2 1C CA 28 1J J20 J/C B-R G A J12 B-R G J/C A J12 B-R B 3F W-B 5 IG1 Center J/B I18 Ignition SW L-Y B 3F W-L 4 IG1 AM1 2 ALT B 2 1 GND B 3F Engine Room R/B 2 1 AM1 2 1 2 2 W-B 2 W-B B A A J24 J/C J37 J/C Battery II IK G036692E01 CA–23 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (YAW RATE SENSOR SUB BUS LINE) Yaw Rate Sensor Connector Front View: Y1 CANH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the yaw rate sensor connector (Y1). (c) Measure the resistance according to the value(s) in the table below. Standard resistance CANL Tester connection Y1-2 (CANL) - Y1-3 (CANH) • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω G026359E63 NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CHECK WIRE HARNESS (IG, GND) Yaw Rate Sensor Connector Front View: Y1 GND IG G026359E64 (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified value Y1-1 (GND) - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester connection Condition Specified value Y1-5 (IG) - Body ground IG switch ON 10 to 14 V NG OK REPLACE YAW RATE SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR CA CA–24 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CAN Bus Line DESCRIPTION When any DTC of the CAN communication system is output, first measure the resistance between the terminals of the DLC3 and the yaw rate sensor connector to specify the trouble area. WIRING DIAGRAM Y1 Yaw Rate Sensor CAN J/C ECM CANH CANL W 1 J48 1 J51 L R 2 J48 2 J51 LG 3 2 33 CANH E7 34 E7 Skid Control ECU S11 Steering Angle Sensor CANH CANL CANL B 1 J49 1 J47 B 11 IC2 B 11 S28 CANH Y 2 J49 2 J47 W 22 IC2 W 25 S28 CANL 3 11 D1 DLC3 CA 1 J50 P 2 J50 V 6 14 CANH CANL Engine Room R/B ALT 2 B 2 1 OBD 2 1 2 2 C14 IC4 O O 16 BAT J22 J/C 2 W-B B W-B E E 4 CG A J5 J/C Battery IG G036689E01 CA–25 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 DLC3: CHECK CAN BUS WIRE (MAIN BUS LINE FOR DISCONNECTION, BUS LINES FOR SHORT CIRCUIT) D1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection Condition • D1-6 (CANH) D1-14 (CANL) CANL • • G026206E73 D1-6 (CANH) D1-14 (CANL) • • D1-6 (CANH) D1-14 (CANL) • Specified value Result IG switch OFF Stop light switch OFF 54 to 69 Ω OK IG switch OFF Stop light switch OFF 69 Ω or higher NG-A IG switch OFF Stop light switch OFF Below 54 Ω NG-B NG-A CHECK CAN MAIN BUS LINE FOR DISCONNECTION NG-B CHECK CAN BUS LINES FOR SHORT CIRCUIT OK 2 DLC3: CA CHECK CAN BUS LINE FOR SHORT TO +B D1 (a) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-16 (BAT) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher BAT CANL D1-14 (CANL) - D1-16 (BAT) G026206E74 NG OK CHECK CAN BUS LINE FOR SHORT TO +B CA–26 3 DLC3: CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND D1 CG (a) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-4 (CG) - D1-6 (CANH) CANL D1-4 (CG) - D1-14 (CANL) Specified value IG switch OFF Stop light switch OFF 3 kΩ or higher • • IG switch OFF Stop light switch OFF 3 kΩ or higher G026206E75 NG CHECK CAN BUS LINE FOR SHORT TO GND OK GO TO HOW TO PROCEED WITH TROUBLESHOOTING CA Condition • • CA–27 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CAN Main Bus Line for Disconnection DESCRIPTION The CAN main bus line and DLC3 sub bus line may have a disconnection when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is more than 69 Ω. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is more than 69 Ω. • • • CAN main bus line ECM CAN J/C WIRING DIAGRAM D1 DLC3 CANH CAN J/C P 6 1 J50 ECM 1 J51 L 33 CANH E7 CA CANL V 14 2 J50 2 J51 LG 34 E7 CANL G036693E01 CA–28 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 DLC3: CHECK DLC3 D1 (a) Measure the resistance according to the value(s) in the table below. Result CANH Tester connection Condition • D1-6 (CANH) D1-14 (CANL) CANL • • G026206E73 D1-6 (CANH) D1-14 (CANL) • Specified value Result IG switch OFF Stop light switch OFF 108 to 132 Ω A IG switch OFF Stop light switch OFF 132 Ω or higher B NOTICE: When the measured value is 132 Ω or more and a CAN communication system diagnostic code is output, there may be a fault other than a disconnection of the DLC3 sub bus line. For that reason, troubleshooting should be performed again from "How to Proceed with Troubleshooting" after repairing the trouble area. B CA REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) A 2 CHECK CAN MAIN BUS LINE FOR DISCONNECTION (ECM - CAN J/C) (a) Disconnect the connector (E7) from the ECM. (b) Measure the resistance according to the value(s) in the table below. Standard resistance ECM Wire Harness View: Tester connection E7-33 (CANH) - E7-34 (CANL) E7 CANL NG • • Condition Specified value IG switch OFF Stop light switch OFF 108 to 132 Ω CANH G038051E01 OK REPLACE ECM CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3 CA–29 CHECK CAN J/C CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the CAN main bus line connector (J51) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal L J51 LG G031933E32 CAN J/C “A” Side (with Earth Terminal): CANH (b) Measure the resistance according to the value in the table below. Standard resistance Between the terminals where the connector (J51) was connected CANH - CANL CANL • • Condition Specified value IG switch OFF Stop light switch OFF 108 to 132 Ω G026370E04 NG REPLACE CAN J/C OK REPAIR OR REPLACE CAN BUS MAIN WIRE OR CONNECTOR (CAN J/C - ECM) CA CA–30 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Check CAN Bus Lines for Short Circuit DESCRIPTION The CAN bus lines are considered to be shorted when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. • • • • • • Short in CAN bus lines Skid control ECU Steering angle sensor Yaw rate sensor ECM CAN J/C WIRING DIAGRAM Y1 Yaw Rate Sensor CAN J/C ECM CANH CANL CA W 1 J48 1 J51 L R 2 J48 2 J51 LG 3 2 33 CANH E7 34 E7 S11 Steering Angle Sensor CANH CANL CANL Skid Control ECU B 1 J49 1 J47 B 11 IC2 B 11 S28 CANH Y 2 J49 2 J47 W 22 IC2 W 25 S28 CANL P 1 J50 V 2 J50 3 11 D1 DLC3 CANH CANL 6 14 G036694E01 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–31 INSPECTION PROCEDURE 1 CHECK CAN BUS LINES FOR SHORT CIRCUIT (DLC3 SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the DLC3 sub bus line connector (J50) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal P J50 V G031933E33 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL NG G026206E73 • • Condition Specified value IG switch OFF Stop light switch OFF 1 MΩ or more REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CONNECT CONNECTOR (a) Reconnect the DLC3 sub bus line connector (J50) to the CAN J/C. NEXT CA CA–32 3 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (SKID CONTROL ECU SUB BUS LINE) (a) Disconnect the skid control ECU sub bus line connector (J47) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CAN J/C “B” Side (without Earth Terminal) Wire Harness View: B J47 W G031932E97 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CA CANL OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω Go to step 10 G026206E73 NG 4 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 5 CA–33 CHECK CAN BUS LINES FOR SHORT CIRCUIT (YAW RATE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the yaw rate sensor sub bus line connector (J48) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal W J48 R G031933E34 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω Go to step 12 G026206E73 NG 6 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA CA–34 7 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (STEERING ANGLE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the steering angle sensor sub bus line connector (J49) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal B J49 Y G031933E35 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CA CANL OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω Go to step 14 G026206E73 NG 8 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CA–35 CHECK CAN BUS LINES FOR SHORT CIRCUIT (ECM MAIN BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the ECM main bus line connector (J51) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal L J51 LG G031933E32 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL OK • • Condition Specified value IG switch OFF Stop light switch OFF 108 to 132 Ω Go to step 16 G026206E73 NG REPLACE CAN J/C 10 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CA CA–36 11 DLC3: CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (SKID CONTROL ECU SUB BUS LINE) D1 (a) Disconnect the skid control ECU connector (S28). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL G026206E73 OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPLACE MASTER CYLINDER SOLENOID NG REPAIR OR REPLACE SKID CONTROL ECU SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 12 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA 13 DLC3: CHECK CAN BUS LINES FOR SHORT CIRCUIT (YAW RATE SENSOR SUB BUS LINE) D1 (a) Disconnect the yaw rate sensor connector (Y1). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL G026206E73 OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPLACE YAW RATE SENSOR NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR 14 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT CA–37 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 15 DLC3: CHECK CAN BUS LINES FOR SHORT CIRCUIT (STEERING ANGLE SENSOR SUB BUS LINE) D1 (a) Disconnect the steering angle sensor connector (S11). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL G026206E73 OK • • Condition Specified value IG switch OFF Stop light switch OFF 54 to 69 Ω REPLACE STEERING ANGLE SENSOR NG REPAIR OR REPLACE STEERING ANGLE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 16 CONNECT CONNECTOR (a) Reconnect the ECM main bus line connector (J51) to the CAN J/C. NEXT CA 17 DLC3: CHECK CAN BUS LINES FOR SHORT CIRCUIT (ECM MAIN BUS LINE) D1 (a) Disconnect the ECM connector (E7). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-6 (CANH) - D1-14 (CANL) CANL G026206E73 OK • • Condition Specified value IG switch OFF Stop light switch OFF 108 to 132 Ω REPLACE ECM NG REPAIR OR REPLACE ECM MAIN BUS LINE OR CONNECTOR (CAN-H, CAN-L) CA–38 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Check CAN Bus Line for Short to +B DESCRIPTION A short to +B is suspected in the CAN bus line when there is continuity between terminals 16 (BAT) and 6 (CANH) or terminals 16 (BAT) and 14 (CANL) of the DLC3. Symptom There is continuity between terminals 16 (BAT) and 6 (CANH) or 16 (BAT) and 14 (CANL) of the DLC3. CA Trouble Area • • • • • Short to +B in CAN bus line ECM Skid control ECU Steering angle sensor Yaw rate sensor CA–39 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM S11 Steering Angle Sensor CAN J/C ECM Center J/B B 3E W-R CANH B 3E W-R 9 CANL 4 1B 1 J49 1 J51 L Y 2 J49 2 J51 LG 3 BAT Driver Side J/B 4 1L B 11 33 CANH E7 34 E7 3 E8 BATT Y1 Yaw Rate Sensor W-R W 1 J48 R 2 J48 11 IC2 B 1 J47 1 J50 P 22 IC2 W 2 J47 2 J50 V CANH Skid Control ECU 3 CANL 2 11 CANH S28 B 25 CANL S28 W 31 S28 +BS CANL D1 DLC3 6 14 L CANH CANL BAT O 16 Y Engine Room R/B CA ECU-B 2 Short Pin 1 2 B 1 2 W 2 2 OBD ALT 2 1 2 1 2 O 2 C14 IC4 2 B ABS SOL 2 1 2 2 EF1 1 2 2 Y L C4 IC4 Battery G036695E01 CA–40 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO +B (DLC3 SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the DLC3 sub bus line connector (J50) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal P J50 V G031933E33 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-16 (BAT) - D1-6 (CANH) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher BAT CA CANL D1-16 (BAT) - D1-14 (CANL) G026206E74 NG REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CONNECT CONNECTOR (a) Reconnect the DLC3 sub bus line connector (J50) to the CAN J/C. NEXT CA–41 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3 CHECK CAN BUS LINE FOR SHORT TO +B (SKID CONTROL ECU SUB BUS LINE) (a) Disconnect the skid control ECU sub bus line connector (J47) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. CAN J/C “B” Side (without Earth Terminal) Wire Harness View: B J47 W G031932E97 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-16 (BAT) - D1-6 (CANH) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher BAT CANL D1-16 (BAT) - D1-14 (CANL) G026206E74 OK Go to step 10 NG 4 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT CA CA–42 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 5 CHECK CAN BUS LINE FOR SHORT TO +B (YAW RATE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the yaw rate sensor sub bus line connector (J48) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal W J48 R G031933E34 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-16 (BAT) - D1-6 (CANH) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher BAT CA CANL D1-16 (BAT) - D1-14 (CANL) G026206E74 OK Go to step 12 NG 6 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA–43 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 7 CHECK CAN BUS LINE FOR SHORT TO +B (STEERING ANGLE SENSOR SUB BUS LINE) CAN J/C “A” Side (with Earth Terminal) Wire Harness View: (a) Disconnect the steering angle sensor sub bus line connector (J49) from the CAN J/C. NOTICE: • Before disconnecting the connector, make a note of where it is connected. • Reconnect the connector to its original position. Earth Terminal B J49 Y G031933E35 DLC3: D1 (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection D1-16 (BAT) - D1-6 (CANH) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher BAT CANL D1-16 (BAT) - D1-14 (CANL) CA G026206E74 OK Go to step 14 NG 8 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT 9 DLC3: CHECK CAN BUS LINE FOR SHORT TO +B (ECM MAIN BUS LINE) D1 (a) Disconnect the ECM connector (E7). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection BAT CANL G026206E74 D1-16 (BAT) - D1-6 (CANH) D1-16 (BAT) - D1-14 (CANL) Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher CA–44 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM OK REPLACE ECM NG REPAIR OR REPLACE ECM MAIN BUS LINE OR CONNECTOR (CAN-H, CAN-L) 10 CONNECT CONNECTOR (a) Reconnect the skid control ECU sub bus line connector (J47) to the CAN J/C. NEXT 11 DLC3: CHECK CAN BUS LINE FOR SHORT TO +B (SKID CONTROL ECU SUB BUS LINE) D1 (a) Disconnect the skid control ECU connector (S28). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection BAT CANL G026206E74 CA D1-16 (BAT) - D1-6 (CANH) D1-16 (BAT) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher REPLACE MASTER CYLINDER SOLENOID NG REPAIR OR REPLACE SKID CONTROL ECU SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 12 CONNECT CONNECTOR (a) Reconnect the yaw rate sensor sub bus line connector (J48) to the CAN J/C. NEXT CA–45 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 13 DLC3: CHECK CAN BUS LINE FOR SHORT TO +B (YAW RATE SENSOR SUB BUS LINE) D1 (a) Disconnect the yaw rate sensor connector (Y1). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection BAT CANL G026206E74 D1-16 (BAT) - D1-6 (CANH) D1-16 (BAT) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher REPLACE YAW RATE SENSOR NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 14 CONNECT CONNECTOR (a) Reconnect the steering angle sensor sub bus line connector (J49) to the CAN J/C. NEXT 15 DLC3: CA CHECK CAN BUS LINE FOR SHORT TO +B (STEERING ANGLE SENSOR SUB BUS LINE) D1 (a) Disconnect the steering angle sensor connector (S11). (b) Measure the resistance according to the value(s) in the table below. Standard resistance CANH Tester connection BAT CANL G026206E74 D1-16 (BAT) - D1-6 (CANH) D1-16 (BAT) - D1-14 (CANL) OK Condition Specified value • • IG switch OFF Stop light switch OFF 1 MΩ or higher • • IG switch OFF Stop light switch OFF 1 MΩ or higher REPLACE STEERING ANGLE SENSOR NG REPAIR OR REPLACE STEERING ANGLE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) 1GR-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRS002X Title: 1GR-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell (Maintenance-Free Battery). (1) If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. (b) Check the electrolyte quantity of each cell (Except Maintenance-Free Battery). (1) If under the lower level, add distilled water. 2. CHECK BATTERY SPECIFIC GRAVITY (a) Except Maintenance-Free Battery: Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20°C (68°F) HINT: If the specific gravity is less than specification, charge the battery. 3. CHECK BATTERY VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. (b) Turn the ignition switch OFF and turn off the electrical systems. (c) Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) 1GR-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) HINT: If the voltage is less than specification, charge the battery. (d) Check the indicator as shown in the illustration. HINT: z z z Blue: OK White: Charging Necessary Red: Insufficient Water 4. CHECK BATTERY TERMINAL (a) Check that the battery terminals are not loose or corroded. 5. CHECK FUSIBLE LINK AND FUSES (a) Check the fusible link, H-fuses and fuses for continuity. 6. INSPECT FAN AND GENERATOR V BELT (a) Visually check the belt for excessive wear, frayed cords etc. HINT: z z If any defect has been found, replace the fan and generator V belt. Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Check that it fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. 7. VISUALLY CHECK GENERATOR WIRING (a) Check that the wiring is in good condition. 1GR-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) 8. LISTEN FOR ABNORMAL NOISES FROM GENERATOR (a) Check that there is no abnormal noise from the generator while the engine is running. 9. INSPECT CHARGE WARNING LIGHT CIRCUIT (a) Turn the ignition switch ON. Check that the charge warning light comes on. (b) Start the engine. Check that the light goes off. HINT: If the light does not operate as specified, troubleshoot the charge warning light circuit. 10. INSPECT CHARGING CIRCUIT WITHOUT LOAD (a) If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer's instructions. (b) If a tester is not available, connect a voltmeter to the charging circuit as follows. (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator. (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative (-) lead of the voltmeter. (c) Check the charging circuit. (1) With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V HINT: z z If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: 11. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "HI". (b) Check the reading on the ammeter. 1GR-FE CHARGING: CHARGING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Standard amperage: 30 A or more HINT: z z If the ammeter reading is less than standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than standard amperage. 1GR-FE CHARGING: CHARGING SYSTEM: PARTS LOCATION (2007 4Runner) Last Modified: 4-26-2007 1.6 R Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRR002X Title: 1GR-FE CHARGING: CHARGING SYSTEM: PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION 1GR-FE CHARGING: CHARGING SYSTEM: PARTS LOCATION (2007 4Runner) 1GR-FE CHARGING: CHARGING SYSTEM: PRECAUTION (2007 4Runner) Last Modified: 4-26-2007 1.6 L Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BSC002X Title: 1GR-FE CHARGING: CHARGING SYSTEM: PRECAUTION (2007 4Runner) PRECAUTION 1. PRECAUTION (a) Check that the battery cables are connected to the correct terminals. (b) Disconnect the battery cables when the battery is given a quick charge. (c) Do not perform tests with a high voltage insulation resistance tester. (d) Never disconnect the battery while the engine is running. (e) Check that the charging cable is tightened on terminal B of the generator and the fuse box. (f) Do not perform inspection of the generator in which terminal F is connected to the other terminal. 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Title: 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002BSD002X 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE CHARGING: GENERATOR: COMPONENTS (2007 4Runner) 1GR-FE CHARGING: GENERATOR: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRW002X Title: 1GR-FE CHARGING: GENERATOR: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE GENERATOR PULLEY SST: 09820-63010 09820-06010 09820-06020 SST 1-A and B 09820-06010 SST 2 09820-06020 (a) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) NOTICE: Check that SST is secured to the rotor shaft. (b) Mount SST 2 in a vise. (c) Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2. (d) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn. 1GR-FE CHARGING: GENERATOR: DISASSEMBLY (2007 4Runner) (e) Remove the generator from SST 2. (f) Turn SST 1-B, and remove SST 1-A and B. (g) Remove the pulley nut and pulley. 2. REMOVE GENERATOR REAR END COVER (a) Place the generator on the pulley. (b) Remove the 3 nuts and rear end cover. 3. REMOVE TERMINAL INSULATOR (a) Remove the terminal insulator. 1GR-FE CHARGING: GENERATOR: DISASSEMBLY (2007 4Runner) 4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY (a) Remove the plate seal. (b) Remove the 2 nuts and brush holder. (c) Remove the plate seal. 5. REMOVE GENERATOR COIL ASSEMBLY (a) Remove the 4 bolts. (b) Using SST, remove the coil. SST: 09950-40011 09951-04020 09952-04010 09953-04020 09954-04010 09955-04071 1GR-FE CHARGING: GENERATOR: DISASSEMBLY (2007 4Runner) 09957-04010 09958-04011 6. REMOVE GENERATOR ROTOR ASSEMBLY (a) Remove the washer and rotor. 1GR-FE CHARGING: GENERATOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRU002X Title: 1GR-FE CHARGING: GENERATOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using vernier calipers, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than minimum, replace the brush holder. 2. INSPECT GENERATOR ROTOR ASSEMBLY (a) Check the rotor open circuit. (1) Using an ohmmeter, measure the resistance between the slip rings. Resistance: 2.3 to 2.7 Ω at 20°C (68°F) If the resistance is not as specified, replace the rotor. (b) Check the rotor ground. (1) Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. (c) Inspect slip rings. (1) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. 1GR-FE CHARGING: GENERATOR: INSPECTION (2007 4Runner) (2) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than minimum, replace the rotor. 3. INSPECT GENERATOR ROTOR BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. 4. REMOVE GENERATOR ROTOR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST: 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (Inside). 5. INSTALL GENERATOR ROTOR BEARING (a) Place the rotor on the pulley. 1GR-FE CHARGING: GENERATOR: INSPECTION (2007 4Runner) (b) Install the bearing cover (Inside). (c) Using SST and a press, press in a new bearing. SST: 09820-00031 (d) Using SST, push in the bearing cover (outside). SST: 09285-76010 6. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check the bearing is not rough or worn. If necessary, replace the bearing. 7. REMOVE GENERATOR DRIVE END FRAME BEARING (a) Remove the 4 screws and retainer plate. 1GR-FE CHARGING: GENERATOR: INSPECTION (2007 4Runner) (b) Using SST, tap out the bearing. SST: 09950-60010 09951-00250 SST: 09950-70010 09951-07100 8. INSTALL GENERATOR DRIVE END FRAME BEARING (a) Using SST and a press, press in a new bearing. SST: 09950-60010 09951-00470 SST: 09950-70010 09951-07100 (b) Install the retainer plate with the 4 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in·lbf) 1GR-FE CHARGING: GENERATOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRT002X Title: 1GR-FE CHARGING: GENERATOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL GENERATOR ASSEMBLY (a) Install the generator assembly with the 2 bolts. Torque: 43 N·m (438 kgf·cm, 32 ft·lbf) (b) Install the wire harness clamp bracket with the 2 bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf) (c) Connect the wire harness. (1) Connect the wire harness to the terminal B and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (2) Connect the connector to the generator assembly. (3) Install the wire harness stay with the bolt. Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf) 2. INSTALL BATTERY 3. INSTALL FAN AND GENERATOR V BELT 4. INSTALL ENGINE NO. 1 UNDER COVER SUB-ASSEMBLY (a) Install the engine under cover sub-assembly No. 1 with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 5. INSTALL V-BANK COVER 1GR-FE CHARGING: GENERATOR: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRX002X Title: 1GR-FE CHARGING: GENERATOR: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL GENERATOR ROTOR ASSEMBLY (a) Place the drive end frame on the rotor. (b) Install the rotor and washer. 2. INSTALL GENERATOR COIL ASSEMBLY (a) Using SST and a press, press in the coil carefully. SST: 09285-76010 (b) Install the 4 bolts. Torque: 5.8 N·m (59 kgf·cm, 51 in·lbf) 3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY (a) Install the plate seal (Inside). (b) Place the brush holder with the pin facing upward. NOTICE: Be careful of the brush holder installing direction. (c) Install the 2 screws. Torque: 1.8 N·m (18 kgf·cm, 16 in·lbf) 1GR-FE CHARGING: GENERATOR: REASSEMBLY (2007 4Runner) (d) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside). 4. INSTALL TERMINAL INSULATOR 5. INSTALL GENERATOR REAR END COVER (a) Install the rear end cover with the 3 nuts. Torque: 4.6 N·m (47 kgf·cm, 41 in·lbf) 6. INSTALL GENERATOR PULLEY SST: 09820-63010 09820-06010 09820-06020 SST 1-A and B 09820-06010 SST 2 09820-06020 (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) NOTICE: Check that SST is secured to the rotor shaft. (c) Mount SST 2 in a vise. (d) Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2 1GR-FE CHARGING: GENERATOR: REASSEMBLY (2007 4Runner) (e) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration. Torque: 111 N·m (1,125 kgf·cm, 81 ft·lbf) (f) Remove the generator from SST 2. (g) Turn SST 1-B, and remove SST 1-A, B. (h) Turn the pulley, and check that the pulley moves smoothly. 1GR-FE CHARGING: GENERATOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Power Source/Network Section: Battery/Charging Model Year: 2007 Model: 4Runner Doc ID: RM000002BRV002X Title: 1GR-FE CHARGING: GENERATOR: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE V-BANK COVER 2. REMOVE ENGINE NO. 1 UNDER COVER SUB-ASSEMBLY (a) Remove the 4 bolts and engine under cover sub-assembly No. 1. 3. REMOVE FAN AND GENERATOR V BELT 4. REMOVE BATTERY 5. REMOVE GENERATOR ASSEMBLY (a) Disconnect the wire harness. (1) Remove the bolt and wire harness stay. (2) Disconnect the connector from the generator assembly. (3) Remove the terminal cap and nut. (4) Disconnect the wire harness from the terminal B. (b) Remove the 2 bolts and wire harness clamp bracket from the generator assembly. (c) Remove the 2 bolts and generator assembly. 1GR-FE CHARGING: GENERATOR: REMOVAL (2007 4Runner) 1GR-FE COOLING: COOLANT: REPLACEMENT (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM0000017DS009X Title: 1GR-FE COOLING: COOLANT: REPLACEMENT (2007 4Runner) REPLACEMENT 1. DRAIN ENGINE COOLANT CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (a) Remove the service hole cover from the engine under cover. (b) Install a vinyl hose onto the drain on the radiator side. (c) Fix the vinyl hose with tape. (d) Loosen the 3 drain plugs on the engine and radiator, and drain the coolant. (e) Remove the radiator cap. (f) Drain the coolant from the reservoir tank. (g) Tighten the 3 drain plugs. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (h) Remove the vinyl hose from the radiator. 2. ADD ENGINE COOLANT 1GR-FE COOLING: COOLANT: REPLACEMENT (2007 4Runner) (a) Slowly fill the system with engine coolant. Capacity: 9.8 liters (10.4 Us qts, 8.6 Imp. qts) HINT: z z z z Use of improper coolants may damage the engine cooling system. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids). New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50 % and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTICE: Do not substitute plain water for engine coolant. (b) Install the radiator cap securely. (c) Bleed the cooling system. (1) Open the heater water valve while warming up the engine. (2) Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine. (d) Stop the engine and wait until the coolant cools down. (e) Add coolant into the reservoir until the coolant level is FULL. 3. INSPECT ENGINE COOLANT LEAK (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm 2 17.1 psi), then check for leakage. 1GR-FE COOLING: COOLING SYSTEM: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BGY006X Title: 1GR-FE COOLING: COOLING SYSTEM: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FLUID COUPLING ASSEMBLY (a) Check the fluid coupling for damage or silicon oil leaks. If necessary, replace the fluid coupling. 1GR-FE COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000000V1Q027X Title: 1GR-FE COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKAGE (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (b) Fill the radiator with coolant and attach a radiator cap tester. (c) Warm up the engine. (d) Pump it to 118 kPa (1.2 kgf/cm 2, 17.1 psi), then check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and cylinder head. (e) Reinstall the radiator cap. 2. INSPECT ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant should be between the LOW and FULL lines when the engine is cold. If low, check for leakage and add Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line. 3. INSPECT ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator. (b) Check for any excessive deposits of rust or scale around the radiator cap and radiator filler hole; 1GR-FE COOLING: COOLING SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) the coolant should be free of oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. 1GR-FE COOLING: RADIATOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Title: 1GR-FE COOLING: RADIATOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002BGH006X 1GR-FE COOLING: RADIATOR: COMPONENTS (2007 4Runner) 1GR-FE COOLING: RADIATOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BGG007X Title: 1GR-FE COOLING: RADIATOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL RADIATOR ASSEMBLY (a) Insert the tabs of the radiator support through the radiator service holes. (b) Install the radiator assembly with the 4 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 2. INSTALL FAN SHROUD (a) Insert the tabs in the slots shown in the illustration, attach the fan shroud with the 3 bolts. Torque: 5.0 N·m (51 kgf·cm, 44 in·lbf) 3. ADD ENGINE COOLANT 4. INSPECT ENGINE COOLANT LEAK 1GR-FE COOLING: RADIATOR: ON-VEHICLE CLEANING (2007 4Runner) Last Modified: 4-26-2007 1.6 N Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000000V1Y01MX Title: 1GR-FE COOLING: RADIATOR: ON-VEHICLE CLEANING (2007 4Runner) ON-VEHICLE CLEANING 1. INSPECT FINS FOR BLOCKAGE (a) If the fins are clogged, wash them with water or a steam cleaner, then dry them with compressed air. NOTICE: z z z If the distance between the steam cleaner and core is too small, there is a possibility of damaging the fins, so keep to the following injection distances. INJECTION PRESSURE KPA (KG/CM 2, PSI) INJECTION DISTANCE MM (IN.) 2,942 to 4,903 (30 to 50, 427 to 711) 300 (11.811) 4,903 to 7,845 (50 to 80, 711 to 1,138) 500 (19.685) If the fins are bent, straighten them with a screwdriver or pliers. Be careful not to expose electronic components to water. 1GR-FE COOLING: RADIATOR: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000000XYW023X Title: 1GR-FE COOLING: RADIATOR: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT RADIATOR CAP SUB-ASSEMBLY NOTICE: If the radiator cap is contaminated, rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing the following steps [A} and [B], keep the tester at an angle of 30° or more above the horizontal. z z z (a) Using a radiator cap tester, slowly pump and check that air comes from the vacuum valve [A]. Pumping speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air does not come from the vacuum valve, replace the reservoir cap. (b) Pump the tester, then measure the relief valve opening pressure [B]. Pumping speed: 1 push every second NOTICE: The above pumping speed is for the first pumping only (in order to close the vacuum valve). After the first pumping, the pumping speed can be reduced. HINT: Use the tester's maximum reading as the opening pressure. Standard opening pressure: 93 to 123 kPa (0.95 to 1.25 kgf*cm 2, 13.5 to 17.8 psi) Minimum opening pressure: 78 kPa (0.8 kgf*cm 2, 11.4 psi) If the opening pressure is less than the minimum, replace the radiator cap. 1GR-FE COOLING: RADIATOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BGI007X Title: 1GR-FE COOLING: RADIATOR: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support upper. 3. SEPARATE FAN SHROUD (a) Disconnect the reserve tank hose from the radiator. (b) Disconnect the radiator hose No. 1 from the radiator. (c) Disconnect the oil cooler inlet hose from the radiator. (d) Disconnect the oil cooler outlet hose from the radiator. (e) Disconnect the radiator hose No. 2 from the radiator. (f) Remove the 3 bolts, and separate the fan shroud. HINT: Temporarily put the separated fan shroud at an appropriate location in the engine room. 4. REMOVE RADIATOR ASSEMBLY 1GR-FE COOLING: RADIATOR: REMOVAL (2007 4Runner) (a) Remove the 4 bolts and radiator. 5. REMOVE RADIATOR SUPPORT NO.1 (a) Remove the 1 radiator support No. 1. 6. REMOVE RADIATOR SUPPORT NO.2 (a) Remove the 3 radiator support No. 2. 7. REMOVE RADIATOR SUPPORT NO.1 BUSH (a) Remove the 4 radiator support No. 1 bush. 1GR-FE COOLING: THERMOSTAT: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Title: 1GR-FE COOLING: THERMOSTAT: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002BG7002X 1GR-FE COOLING: THERMOSTAT: COMPONENTS (2007 4Runner) 1GR-FE COOLING: THERMOSTAT: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000000V1K00RX Title: 1GR-FE COOLING: THERMOSTAT: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT WATER INLET WITH THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. (a) Immerse the thermostat in water, then gradually heat the water. (b) Check the valve opening temperature of the thermostat. Valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve lift: 8.0 mm (0.31 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the 1GR-FE COOLING: THERMOSTAT: INSPECTION (2007 4Runner) thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperature (below 40°C (104° F)). If not fully closed, replace the thermostat. 1GR-FE COOLING: THERMOSTAT: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BG9002X Title: 1GR-FE COOLING: THERMOSTAT: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL WATER INLET WITH THERMOSTAT (a) Install a new gasket to the water inlet with thermostat. (b) Install the water inlet with thermostat with the 3 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 2. CONNECT RADIATOR OUTLET, NO.2 HOSE CLAMP OR CLIP 3. ADD ENGINE COOLANT 4. INSPECT ENGINE COOLANT LEAK 5. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 1GR-FE COOLING: THERMOSTAT: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BG8002X Title: 1GR-FE COOLING: THERMOSTAT: REMOVAL (2007 4Runner) REMOVAL HINT: If the thermostat was not installed, cooling efficiency would be harmed. Even if the engine tends to overheat, do not remove the thermostat. 1. DRAIN ENGINE COOLANT 2. REMOVE V-BANK COVER 3. DISCONNECT RADIATOR OUTLET, NO.2 HOSE CLAMP OR CLIP 4. REMOVE WATER INLET WITH THERMOSTAT (a) Remove the 3 nuts, water inlet with thermostat and gasket. 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Title: 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002BG4002X 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: COMPONENTS (2007 4Runner) 1GR-FE COOLING: WATER PUMP: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000000V1G00PX Title: 1GR-FE COOLING: WATER PUMP: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT WATER PUMP ASSEMBLY (a) Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump assembly. (b) Turn the pulley and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump assembly. 1GR-FE COOLING: WATER PUMP: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BG2002X Title: 1GR-FE COOLING: WATER PUMP: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 17 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) 2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 3. INSTALL COOLER COMPRESSOR ASSEMBLY 4. INSTALL GENERATOR ASSEMBLY 5. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the 2 idler pulleys with the 2 bolts. Torque: 39 N·m (398 kgf·cm, 29 ft·lbf) 6. INSTALL WATER INLET (a) Install a new O-ring to the water outlet pipe. (b) Install a new gasket to the water pump. (c) Apply soapy water to the O-ring. (d) Install the water inlet with the 5 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 1GR-FE COOLING: WATER PUMP: INSTALLATION (2007 4Runner) (e) Connect the 5 water by-pass hoses. (f) Connect the 2 radiator hoses. (g) Connect the 2 oil cooler hoses (with oil cooler). 7. INSTALL AIR CLEANER ASSEMBLY 8. CONNECT VENTILATION HOSE NO.2 9. INSTALL FAN WITH FLUID COUPLING (a) Put the fan pulley to the water pump. (b) Put the fan with fluid coupling and fan shroud together. (c) Temporarily install the 4 fluid coupling nuts. (d) Tighten the 2 fan shroud bolts and radiator reserve tank bolt. Torque: 5.0 N·m (51 kgf·cm, 44 in·lbf) (e) Connect the reserve tank hose. (f) Fasten the 2 oil cooler hoses with the hose clamp. 10. INSTALL FAN AND GENERATOR V BELT 11. FULLY TIGHTEN FAN WITH FLUID COUPLING (a) Tighten the 4 fluid coupling bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) 12. INSTALL RADIATOR SUPPORT SEAL UPPER 13. ADD ENGINE COOLANT 14. INSPECT ENGINE COOLANT LEAK 15. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 1GR-FE COOLING: WATER PUMP: INSTALLATION (2007 4Runner) 16. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Install the engine under cover with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 1GR-FE COOLING: WATER PUMP: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Cooling Model Year: 2007 Model: 4Runner Doc ID: RM000002BG5002X Title: 1GR-FE COOLING: WATER PUMP: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Remove the 4 bolts and engine under cover. 2. DRAIN ENGINE COOLANT 3. REMOVE V-BANK COVER 4. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 5. LOOSEN FAN WITH FLUID COUPLING (a) Loosen the 4 fluid coupling bolts. 6. REMOVE FAN AND GENERATOR V BELT 7. REMOVE FAN WITH FLUID COUPLING (a) Unfasten the hose clamp, and then separate the 2 oil cooler hoses from the fan shroud. (b) Disconnect the radiator reserve tank hose. 1GR-FE COOLING: WATER PUMP: REMOVAL (2007 4Runner) (c) Remove the 2 fan shroud bolts and radiator reserve tank bolt. (d) Remove the 4 fluid coupling nuts, and then remove the fan with fluid coupling and fan shroud together. (e) Remove the fan pulley. 8. DISCONNECT VENTILATION HOSE NO.2 9. REMOVE AIR CLEANER ASSEMBLY 10. REMOVE WATER INLET (a) Disconnect the 2 oil cooler hoses (with oil cooler). (b) Disconnect the 2 radiator hoses. (c) Disconnect the 5 water by-pass hoses. 1GR-FE COOLING: WATER PUMP: REMOVAL (2007 4Runner) (d) Remove the 5 bolts and water inlet. (e) Remove the O-ring from the water outlet pipe. (f) Remove the gasket from the water pump. 11. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the 2 bolts and 2 idler pulleys. 12. REMOVE GENERATOR ASSEMBLY 13. SEPARATE COOLER COMPRESSOR ASSEMBLY 14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 15. REMOVE WATER PUMP ASSEMBLY (a) Remove the 17 bolts, water pump and gasket. 1GR-FE EMISSION CONTROL: AIR FUEL RATIO SENSOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292S002X Title: 1GR-FE EMISSION CONTROL: AIR FUEL RATIO SENSOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (for Bank 1 and Bank 2) (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: TERMINAL NO. RESISTANCE 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 2°C (68°F) 1 (HT) - 4 (AF-) No continuity If the resistance is not as specified, replace the sensor. 1GR-FE EMISSION CONTROL: CANISTER: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292Q001X Title: 1GR-FE EMISSION CONTROL: CANISTER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE EMISSION CONTROL: CANISTER: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE EMISSION CONTROL: CANISTER: COMPONENTS (2007 4Runner) 1GR-FE EMISSION CONTROL: CANISTER: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292P001X Title: 1GR-FE EMISSION CONTROL: CANISTER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL CHARCOAL CANISTER ASSEMBLY (a) Install the charcoal canister with the 3 bolts. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) (b) Connect the purge line hose to the charcoal canister. (c) Connect the connector to the pump module. (d) Connect the canister outlet hose No. 2 to the charcoal canister. (e) Connect the fuel tank hose to the charcoal canister. 2. INSTALL CHARCOAL CANISTER NO. 2 FILTER (a) Install the charcoal canister with a bolt. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) (b) Connect the canister outlet hose to the fuel tank filler pipe. (c) Connect the canister outlet hose No. 2 to the charcoal canister. 3. INSTALL SPARE TIRE 1GR-FE EMISSION CONTROL: CANISTER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292R001X Title: 1GR-FE EMISSION CONTROL: CANISTER: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE SPARE TIRE 2. REMOVE CHARCOAL CANISTER NO. 2 FILTER (a) Disconnect the canister outlet hose No. 2 from the charcoal canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (b) Disconnect the canister outlet hose from the fuel tank filler pipe. (c) Remove a bolt and the charcoal canister filter. 3. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the fuel tank vent hose from the charcoal 1GR-FE EMISSION CONTROL: CANISTER: REMOVAL (2007 4Runner) canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (b) Disconnect the canister outlet hose No. 2 from the charcoal canister. (1) Deeply push the connector inside. (2) Pinch portion A. (3) Pull out the connector. (c) Disconnect the connector from the pump module. (d) Disconnect the purge line hose from the charcoal canister. (e) Remove the 3 bolts and the charcoal canister from the body. 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: ON-VEHICLE INSPECTION ... Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292O002X Title: 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT AIR-FUEL RATIO COMPENSATION SYSTEM (a) Measure voltage between terminals of the ECM. Standard voltage: TERMINAL CONDITION VOLTAGE A1A+ ←→ E1 IG switch ON 3.3 V A1A- ←→ E1 IG switch ON 3.0 V A2A+ ←→ E1 IG switch ON 3.3 V A2A- ←→ E1 IG switch ON 3.0 V CAUTION: Connect test leads from the back side of the ECM connector. HINT: Voltage between terminals of the ECM is kept constant regardless of the voltage of A/F sensor. (b) Connect the intelligent tester to the DLC3. (c) Select "DATA MONITOR" - "A/FS B1 S1", "A/FS B2 S1" and "O2S B1 S2" to display the monitor. (d) Warm up the A/F sensor with the engine speed at 2, 500 rpm for approx. 2 minutes. (e) Keep the engine speed at 2,500 rpm and confirm that the displays of "A/FS B1 S1" and "A/FS B2 S1" are similar to the illustration on the left. CAUTION: The illustration differs from the real display. 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: ON-VEHICLE INSPECTION ... HINT: Only intelligent tester displays the waveform of A/F sensor. (f) Confirm that the displays of "O2S B1 S2" changes between 0 V to 1 V with the engine speed at 2,500 rpm. 2. INSPECT FUEL CUT OFF RPM (a) Increase the engine speed to at least 3,500 rpm. (b) Use a sound scope to check for injector operating noise. (c) Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. Fuel cut off rpm: 2,500 rpm Fuel return rpm: 1,200 rpm 3. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS (a) Check for cracks, leaks or damage. HINT: Separation of the engine oil dipstick, oil filter cap, PCV hose, etc. may causes an engine failure or engine malfunctions. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause an engine failure or engine malfunctions. 4. CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank . 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: ON-VEHICLE INSPECTION ... (b) Apply pressure to the fuel tank and make the internal pressure of the air pressure 4 kPa (41 gf/cm 2 , 0.58 psi). (c) Check that the internal pressure in the fuel tank is maintained for 1 minute. (d) Check the connections for each hose and pipe. (e) Check the installed parts on the fuel tank. If there is no abnormality, replace the fuel tank and filler pipe. (f) Reconnect the vent line hose to the fuel tank. 5. INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE (a) Fill the fuel tank with fuel enough. (b) Disconnect the vent line hose from the fuel tank . 2 (c) Apply 4 kPa (41 gf/cm , 0.58 psi) to the vent port of the fuel tank. (d) Remove the fuel tank cap, and check that the pressure inside the tank drops. If pressure does not drop, replace the fuel tank assembly. (e) Reconnect the vent line hose to the fuel tank. 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: ON-VEHICLE INSPECTION ... 6. CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister . (b) Check that there is ventilation in the air inlet line. (c) Reconnect the air inlet line hose to the charcoal canister. 7. INSPECT VAPOR PRESSURE SENSOR (a) Inspect the power source voltage of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Using a voltmeter, measure the voltage between connector terminals VC and E2 on the wiring harness side of the ECM. Voltage: 4.5 to 5.5 V (3) Turn the ignition switch OFF. (b) Inspect the power output of the vapor pressure sensor. (1) Turn the ignition switch ON. (2) Remove the fuel tank cap. (3) Using a voltmeter, measure the voltage between connector terminals PTNK and E2 on the wiring harness side of the ECM. Voltage: 3.0 to 3.6 V (4) Reinstall the fuel tank cap. 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION (2007 4R... Last Modified: 4-26-2007 1.6 R Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292N002X Title: 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION (2007 4R... ILLUSTRATION 1GR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION (2007 4R... 1GR-FE EMISSION CONTROL: HEATED OXYGEN SENSOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Emission Control Model Year: 2007 Model: 4Runner Doc ID: RM00000292T002X Title: 1GR-FE EMISSION CONTROL: HEATED OXYGEN SENSOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT HEATED OXYGEN SENSOR (for Bank 1 and Bank 2) (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: TERMINAL NO. RESISTANCE 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) 1 (HT) - 4 (E1) No Continuity If the resistance is not as specified, replace the sensor. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BR6002X Title: 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CAMSHAFT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BR5002X Title: 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL CAMSHAFT NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Align the mark link (yellow) with the timing mark (1-dot mark) of the camshaft timing gear as shown in the illustration. (b) Apply new engine oil to the thrust portions and journals of the camshafts. (c) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. (d) Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (e) Temporarily install the camshaft timing gear set bolt. (f) Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration. (g) Install the 4 bearing caps in their proper locations. (h) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (i) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (j) Rotate the No. 1 camshaft clockwise using a wrench so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (k) Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear. (l) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) 2. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears. (c) Tighten the No. 2 chain tensioner bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) 3. INSTALL NO. 2 CAMSHAFT NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder facing upward as shown in the illustration. (b) Install the 4 bearing caps in their proper locations. (c) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (d) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (e) Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (f) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (g) Remove the pin from the No. 2 chain tensioner. 4. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Align the mark link (yellow) with the timing mark (2-dot mark) of the camshaft timing gear as shown in the illustration. (b) Apply new engine oil to the thrust portions and journals of the camshafts. (c) Temporarily put the No. 1 chain on the No. 2 chain of 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) the camshaft timing gear. (d) Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 3 camshaft, and insert the No. 3 camshaft into the camshaft timing gear. (e) Temporarily install the camshaft timing gear set bolt. (f) Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration. (g) Install the 4 bearing caps in their proper locations. (h) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (i) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (j) Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear. (k) Hold the hexagonal portion of the No. 3 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) 5. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (b) Temporarily install the camshaft timing gear and No. 3 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears. (c) Tighten the chain tensioner No. 3 bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 6. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear. (b) Temporarily install the camshaft timing gear set bolt. (c) Install the 4 bearing caps in their proper locations. (d) Apply a light coat of engine oil to the threads of the bearing cap bolts. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (e) Using several steps, install and tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (f) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (g) Remove the pin from the No. 3. chain tensioner (h) Release the chain tension between the camshaft timing gear (RH bank) and crankshaft timing gear by turning the crankshaft pulley clockwise slightly. 7. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. (b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (c) Install the chain tensioner with the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) (d) Remove the bar from the chain tensioner. (e) Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (f) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover. (g) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. 8. SET NO. 1 CYLINDER TO TDC / COMPRESSION 9. INSPECT VALVE CLEARANCE 10. ADJUST VALVE CLEARANCE 11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) of the cylinder head, timing chain cover and cylinder head cover. (b) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Install the seal washers to the bolts. (d) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. (b) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Install the seal washers to the bolts. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) (d) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 13. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 14. INSTALL INTAKE AIR SURGE TANK (a) Install a new gasket to the intake air surge tank. (b) Using the socket hexagon wrench 8, install the intake air surge tank with the 4 bolts. Torque: 28 N·m (286 kgf·cm, 21 ft·lbf) (c) Install the 2 intake air surge tank nuts. Torque: 28 N·m (286 kgf·cm, 21 ft·lbf) (d) Install the 2 surge tank stays with the 4 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) (e) Install the oil baffle plate with the bolt. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (f) Install the throttle body bracket with the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) (g) Install the 3 wire harness clamps and hose clamp. (h) Connect the throttle body with motor connector. (i) Connect the 2 VSV connectors. (j) Connect the ventilation hose. (k) Connect the fuel vapor feed hose. (l) Connect the 2 water by-pass hoses. 15. INSTALL AIR CLEANER ASSEMBLY 16. CONNECT NO. 2 VENTILATION HOSE 17. ADD ENGINE COOLANT 18. CHECK FOR ENGINE COOLANT LEAKAGE 1GR-FE ENGINE MECHANICAL: CAMSHAFT: INSTALLATION (2007 4Runner) 19. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 20. INSPECT IGNITION TIMING 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BR7002X Title: 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE V-BANK COVER 3. DISCONNECT NO. 2 VENTILATION HOSE 4. REMOVE AIR CLEANER ASSEMBLY 5. REMOVE INTAKE AIR SURGE TANK (a) Disconnect the 2 water by-pass hoses. (b) Disconnect the fuel vapor feed hose. (c) Disconnect the ventilation hose. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) (d) Disconnect the 2 VSV connectors. (e) Disconnect the throttle body with motor connector. (f) Separate the 3 wire harness clamps and hose clamp. (g) Remove the 2 bolts and throttle body bracket. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) (h) Remove the bolt and oil baffle plate. (i) Remove the 4 bolts and 2 surge tank stays. (j) Remove the 2 nuts. (k) Using a socket hexagon wrench 8, remove the 4 bolts, intake air surge tank and gasket. 6. REMOVE IGNITION COIL ASSEMBLY 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket. 8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) 9. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. (b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) (c) Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears. 10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY NOTICE: z z Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. (a) Remove the 4 bolts, timing chain cover plate and gasket. (b) While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. (c) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (d) Remove the 2 bolts and chain tensioner. 11. REMOVE NO. 2 CAMSHAFT NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) While raising up the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (c) Separate the camshaft timing gear from the No. 2 camshaft. (d) Rotate the camshaft counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face upward as shown in the illustration. (e) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (f) Remove the 4 bearing caps and No. 2 camshaft. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) 12. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear. 13. REMOVE CAMSHAFT NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTICE: z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. (b) Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. (c) Rotate the No. 1 camshaft counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face downward as shown in the illustration. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) (d) Using several steps, loosen and remove the 8 bearing cap bolts in the sequence as shown in the illustration. (e) Remove the 4 bearing caps. (f) Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with No. 2 chain. (g) Tie the No. 1 chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. 14. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY NOTICE: 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (c) Separate the camshaft timing gear from the No. 4 camshaft. (d) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (e) Remove the 4 bearing caps and No. 4 camshaft. 15. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) 16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Release the chain tension between the camshaft timing gear (LH bank) and crankshaft timing gear by turning the crankshaft pulley counterclockwise slightly. (b) Hold the hexagonal portion of the No. 3 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTICE: z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. (c) Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. 1GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL (2007 4Runner) (d) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (e) Remove the 4 bearing caps. (f) Remove the camshaft timing gear set bolt with the No. 3 camshaft lifted up, and then remove the No. 3 camshaft and camshaft timing gear with No. 2 chain. (g) Tie the No. 1 chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BZD002X Title: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BZC002X Title: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the outside thread diameter of the bolt. Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BZB002X Title: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL NO. 2 CYLINDER HEAD GASKET (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. (b) Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward. NOTICE: z z Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head. 2. INSTALL CYLINDER HEAD LH (a) Place the cylinder head on the cylinder head gasket. (b) Install the 8 cylinder head bolts. HINT: z The cylinder head bolts are tightened in 2 successive steps (Procedures "A" and "B"). z If any cylinder head bolt is broken or deformed, replace it. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration (Procedure "A"). Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the washers into the cylinder head. (4) Mark the front side of each cylinder head bolt with paint. (5) Retighten the cylinder head bolts 180° as shown (Procedure "B"). (6) Check that the painted marks are now at 180° opposite to the engine front. (c) Install the 2 cylinder head bolts. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Using several steps, install and tighten the 2 cylinder head bolts uniformly in the sequence as shown in the illustration. Torque: 30 N·m (306 kgf·cm, 22 ft·lbf) (d) Install the ground cable with the bolt. Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf) 3. INSTALL CYLINDER HEAD GASKET (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (b) Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward. NOTICE: z z Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head. 4. INSTALL CYLINDER HEAD SUB-ASSEMBLY (a) Place the cylinder head on the cylinder head gasket. (b) Install the 8 cylinder head bolts. HINT: z The cylinder head bolts are tightened in 2 successive steps (Procedures "A" and "B"). z If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Using several steps, tighten each bolt uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration (Procedure "A"). Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) NOTICE: Do not drop the washers into the cylinder head. (4) Mark the front side of each cylinder head bolt with paint. (5) Retighten the cylinder head bolts 180° as shown (Procedure "B"). (6) Check that the painted marks are now at 180° opposite to the engine front. (c) Install the ground cables with the 2 bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf) 5. INSTALL CAMSHAFTS (for Bank 2) NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Set the crankshaft position. (1) Install the crankshaft pulley set bolt, and turn the crankshaft, and set the crankshaft set key at the left horizontal position. NOTICE: Setting the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. (b) Apply new engine oil to the thrust portions and journals of the camshafts. (c) Place the 2 camshafts onto the cylinder head with the cam lobes of No. 2 cylinder facing each correct direction as shown in the illustration. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (d) Install the 8 bearing caps in their proper locations. (e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (f) Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) 6. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Install the No. 3 chain tensioner with the bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) 7. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) (a) Align the mark links (yellow) with the timing marks (1dot mark and 2-dot mark) of the camshaft timing gears as shown in the illustration. (b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts. (c) Temporarily install the 2 camshaft timing gear bolts. NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (e) Remove the pin from the No. 3 tensioner. 8. INSTALL NO. 1 CHAIN VIBRATION DAMPER (a) Install the No. 1 chain vibration damper with the 2 bolts. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 9. INSTALL NO. 2 CAMSHAFT BEARING (a) Install the No. 2 camshaft bearing to the cylinder head. NOTICE: Clean the backside of the bearing and the contact surface of the cylinder head and prevent oil from adhering to them. 10. INSTALL CAMSHAFTS (for Bank 1) NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Set the crankshaft position. (1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. (b) Apply new engine oil to the thrust portions and journals of the camshafts. (c) Place the 2 camshafts onto the cylinder head with the 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) cam lobes of No. 1 cylinder facing each direction as shown in the illustration. (d) Install the 8 bearing caps in their proper locations. (e) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (f) Using several steps, install and tighten the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (g) Turn the camshafts clockwise until the knock pin comes to 90° position to the cylinder head. 11. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Install the No. 2 chain tensioner with the bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 12. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) Align the mark links (yellow) with the timing marks (1dot mark) of the camshaft timing gears as shown in the illustration. (b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts. (c) Temporarily install the 2 camshaft timing gear bolts. NOTICE: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (e) Remove the pin from the No. 2 tensioner. 13. INSTALL WATER BY-PASS JOINT RR (a) Install a new O-ring to the water outlet pipe. (b) Apply soapy water to the O-ring. (c) Install 2 new gaskets and water by-pass joint RR with the 2 bolts and 4 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (d) Connect the heater hose. (e) Connect the engine coolant temperature sensor connector. 14. INSTALL INTAKE MANIFOLD (a) Set a new gasket on each cylinder head. NOTICE: z Align the port holes of the gasket and cylinder head. z Be careful of the installation direction. (b) Set the intake manifold on the cylinder heads. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (c) Install and tighten the 10 bolts uniformly in several steps. Torque: 26 N·m (265 kgf·cm, 19 ft·lbf) (d) Connect the 6 fuel injector connectors. 15. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 16. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Set a new gasket to the LH cylinder head with the oval shape facing backward. NOTICE: Be careful of the installation direction. (b) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 30 N·m (306 kgf·cm, 22 ft·lbf) (c) Connect the A/F sensor connector. 18. INSTALL NO. 2 MANIFOLD STAY (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 19. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY 20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Set a new gasket to the RH cylinder head with the oval shape facing forward. NOTICE: Be careful of the installation direction. (b) Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps. Torque: 30 N·m (306 kgf·cm, 22 ft·lbf) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: INSTALLATION (2007 4Runner) (c) Connect the A/F sensor connector. 21. INSTALL MANIFOLD STAY (a) Install the manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 22. INSTALL EXHAUST PIPE ASSEMBLY FRONT 23. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it to the oil filler tube. (b) Push in the oil filler tube end into the oil pan lower tube. (c) Install the oil filler tube with the bolt. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (d) Install the ATF level gauge. 24. INSTALL NO. 1 COOL AIR INLET (a) Install the cool air inlet with air cleaner hose with the 2 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 25. INSTALL CHAIN SUB-ASSEMBLY HINT: 26. ADD ENGINE OIL 27. ADD ENGINE COOLANT 28. CHECK FOR ENGINE OIL LEAKAGE 29. CHECK FOR ENGINE COOLANT LEAKAGE 30. CHECK FOR FUEL LEAKAGE 31. CHECK FOR EXHAUST GAS LEAKAGE 32. INSPECT ENGINE IDLE SPEED 33. INSPECT COMPRESSION 34. INSPECT CO/HC 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BZE002X Title: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. DRAIN ENGINE COOLANT 3. DRAIN ENGINE OIL 4. REMOVE CHAIN SUB-ASSEMBLY HINT: 5. REMOVE NO. 1 COOL AIR INLET (a) Remove the 2 bolts and cool air inlet with air cleaner hose. 6. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (a) Remove the ATF level gauge. (b) Remove the bolt and pull out the oil filler tube. (c) Remove the O-ring from the oil filler tube. 7. REMOVE EXHAUST PIPE ASSEMBLY FRONT HINT: 8. REMOVE MANIFOLD STAY (a) Remove the 3 bolts and manifold stay. 9. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Disconnect the A/F sensor connector. (b) Remove the 6 nuts, exhaust manifold and gasket. 10. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY 11. REMOVE NO. 2 MANIFOLD STAY 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) (a) Remove the 3 bolts and No. 2 manifold stay. 12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Disconnect the A/F sensor connector. (b) Remove the 6 nuts, exhaust manifold and gasket. 13. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 14. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 15. REMOVE INTAKE MANIFOLD (a) Disconnect the 6 fuel injector connectors. (b) Remove the 10 bolts, intake manifold and 2 gaskets. 16. REMOVE WATER BY-PASS JOINT RR (a) Disconnect the engine coolant temperature sensor connector. (b) Disconnect the heater hose. (c) Remove the 2 bolts, 4 nuts, water by-pass joint RR and 2 gaskets. (d) Remove the O-ring from the water outlet pipe. 17. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) (a) While raising the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain. NOTICE: z Be careful not to damage the cylinder head and valve z lifter with the wrench. Do not disassemble the camshaft timing gear assembly. 18. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 2 chain tensioner. 19. REMOVE CAMSHAFTS (for Bank 1) NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Rotate the camshafts counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration. 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) (b) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. (c) Remove the 8 bearing caps and 2 camshafts. 20. REMOVE NO. 2 CAMSHAFT BEARING 21. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and No. 1 chain vibration damper. 22. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) (a) While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain. NOTICE: 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. 23. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 3 chain tensioner. 24. REMOVE CAMSHAFTS (for Bank 2) NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. (b) Remove the 8 bearing caps and 2 camshafts. 25. REMOVE CYLINDER HEAD SUB-ASSEMBLY (a) Remove the 2 bolts and separate the 2 ground cables. (b) Using several steps, loosen the 8 cylinder head bolts on 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE: z Be careful not to drop the plate washers into the cylinder z head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. (c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. 26. REMOVE CYLINDER HEAD GASKET 27. REMOVE CYLINDER HEAD LH (a) Remove the bolt and separate the ground cable. (b) Using several steps, remove the 2 cylinder head bolts on the cylinder head in the sequence as shown in the illustration. (c) Using several steps, loosen the 8 cylinder head bolts on the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE: z Be careful not to drop the plate washers into the cylinder 1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL (2007 4Runner) head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. z (d) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. 28. REMOVE NO. 2 CYLINDER HEAD GASKET 1GR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002CXS002X Title: 1GR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000017LB003X Title: 1GR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT DRIVE BELT (a) Visually check the drive belt for excessive wear frayed cords, etc. If any defect is found, replace the drive belt HINT: Cracks on the rib side of a drive belt are considered acceptable. HINT: If the drive belt has chunks missing from the ribs, it should be replaced. 1GR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000017L9004X Title: 1GR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FAN AND GENERATOR V BELT (a) While turning the belt tensioner counterclockwise, align with its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner. (b) Install the V-ribbed belt. (c) While turning the belt tensioner counterclockwise, remove the bar. (d) If it is hard to install the V-ribbed belt, perform the following procedure. (1) Put the V-ribbed belt on all parts except the P/S pump, as shown in the illustration. (2) While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump. 2. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Install the No. 1 engine under cover with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 1GR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION (2007 4Runner) 1GR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000017LA004X Title: 1GR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Remove the 4 bolts, then remove the No. 1 engine under cover sub-assembly. 2. REMOVE FAN AND GENERATOR V BELT (a) While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V-ribbed belt from the belt tensioner. 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B5K002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B5J002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 2. INSTALL SPARK PLUG Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 3. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 4. INSTALL OIL FILLER CAP HOUSING (a) Install a new gasket and oil filler cap housing with the 2 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 5. INSTALL OIL FILLER CAP SUB-ASSEMBLY 6. INSTALL WATER BY-PASS JOINT RR 7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 8. INSTALL INTAKE MANIFOLD 9. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (a) Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 10. INSTALL WATER INLET 11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 12. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 13. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 14. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION (2007 4Runner) (a) Install the engine mounting bracket with engine mounting insulator with the 3 bolts. Torque: 43 N·m (438 kgf·cm, 32 ft·lbf) 15. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket with engine mounting insulator with the 4 bolts. Torque: 43 N·m (438 kgf·cm, 32 ft·lbf) 16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 18. INSTALL NO. 2 VENTILATION HOSE 19. INSTALL VENTILATION HOSE 20. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 21. INSTALL HEATER WATER INLET HOSE A 22. INSTALL RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP 23. INSTALL NO. 1 RADIATOR HOSE 24. INSTALL ENGINE WIRE 25. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY 26. INSTALL ENGINE ASSEMBLY (a) Attach the engine sling device and hang the engine with the chain block. (b) Lower the engine into the engine room carefully. (c) Attach the engine mounting brackets to the frame brackets. (d) Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts. Torque: 38 N·m (387 kgf·cm, 28 ft·lbf) (e) Remove the 4 bolts and 2 engine hangers. 27. INSTALL NO. 2 ENGINE WIRE (a) Install the ground cable to the cylinder block. Torque: 13 N·m (133 kgf·cm, 9 ft·lbf) 28. INSTALL ENGINE WIRE (a) Connect the front differential connector. (b) Insert the engine wire to the cabin space, and install the grommet. 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION (2007 4Runner) (c) Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire. (d) Install the glove compartment door. (e) Install the cowl side trim board RH. (f) Install the front door scuff plate RH. 29. INSTALL INTAKE AIR SURGE TANK 30. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 31. CONNECT HEATER WATER INLET HOSE B 32. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 33. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 34. INSTALL COOLER COMPRESSOR 35. INSTALL GENERATOR ASSEMBLY 36. INSTALL VANE PUMP ASSEMBLY 37. INSTALL FAN PULLEY 38. INSTALL FAN WITH FLUID COUPLING (a) Temporarily install the fan with fluid coupling with the 4 nuts. 39. INSTALL FAN AND GENERATOR V BELT 40. FULLY TIGHTEN FAN WITH FLUID COUPLING 41. INSTALL FAN SHROUD (a) Put the fan shroud into the engine room. (b) Connect the 2 oil cooler hoses with the hose clamp. 42. INSTALL RADIATOR ASSEMBLY 43. INSTALL RADIATOR SUPPORT SEAL UPPER 44. INSTALL AIR CLEANER ASSEMBLY 45. CONNECT NO. 2 VENTILATION HOSE 46. INSTALL HOOD SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION (2007 4Runner) (a) Install the hood with the 4 bolts. Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) (b) Tighten the 2 hood supports. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) (c) Connect the windshield washer hose. 47. ADJUST HOOD SUB-ASSEMBLY 48. INSTALL BATTERY 49. ADD ENGINE OIL 50. ADD ENGINE COOLANT 51. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: 52. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: 53. CHECK FOR ENGINE COOLANT LEAKAGE 54. CHECK FOR FUEL LEAKAGE 55. CHECK FOR ENGINE OIL LEAKAGE 56. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 57. INSPECT IGNITION TIMING 58. INSPECT ENGINE IDLE SPEED 59. INSPECT CO/HC 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B5L002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: 3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: 4. DRAIN ENGINE COOLANT 5. DRAIN ENGINE OIL 6. REMOVE BATTERY 7. REMOVE HOOD SUB-ASSEMBLY (a) Disconnect the windshield washer hose. (b) Separate the 2 hood supports. (c) Remove the 4 bolts and hood. 8. REMOVE V-BANK COVER 9. REMOVE NO. 2 VENTILATION HOSE 10. REMOVE AIR CLEANER ASSEMBLY 11. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 12. REMOVE RADIATOR ASSEMBLY 13. REMOVE FAN SHROUD 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) (a) Unfasten the hose clamp, and disconnect the 2 oil cooler hoses from the fan shroud. (b) Remove the fan shroud. 14. LOOSEN FAN WITH FLUID COUPLING 15. REMOVE FAN AND GENERATOR V BELT 16. REMOVE FAN WITH FLUID COUPLING (a) Remove the 4 bolts and fan with fluid coupling. 17. REMOVE FAN PULLEY 18. SEPARATE VANE PUMP ASSEMBLY 19. REMOVE GENERATOR ASSEMBLY 20. SEPARATE COOLER COMPRESSOR 21. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 22. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 23. DISCONNECT HEATER WATER INLET HOSE B 24. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 25. REMOVE INTAKE AIR SURGE TANK 26. SEPARATE ENGINE WIRE (a) Remove the front door scuff plate RH . (b) Remove the cowl side trim board RH . (c) Remove the glove compartment door . (d) Disconnect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire before pulling out the engine wire into the engine room. (e) Disconnect the front differential connector. 27. SEPARATE NO. 2 ENGINE WIRE (a) Disconnect the ground cable from the cylinder block. 28. REMOVE ENGINE ASSEMBLY (a) Install the 2 engine hangers with the 4 bolts as shown in 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) the illustration. Part No.: Engine hanger No. 1: 12281-31070 Engine hanger No. 2: 12282-31050 Bolt: 91671-10825 Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) (b) Attach the engine sling device and hang the engine with the chain block. (c) Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets. (d) Lift the engine out of the vehicle carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. (e) Place the engine onto a working bench. 29. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY 30. REMOVE ENGINE WIRE 31. REMOVE NO. 1 RADIATOR HOSE 32. REMOVE RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP 33. REMOVE HEATER WATER INLET HOSE A 34. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 35. REMOVE VENTILATION HOSE 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) 36. REMOVE NO. 2 VENTILATION HOSE 37. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (a) Remove the 6 nuts, exhaust manifold and gasket. 38. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (a) Remove the 6 nuts, exhaust manifold and gasket. 39. INSPECT EXHAUST MANIFOLD FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) If warpage is greater than the maximum, replace the exhaust manifold. HINT: Maximum warpage of each installation surface: HINT: 0.3 mm (0.012 in.) 40. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH (a) Remove the 4 bolts and engine mounting bracket with engine mounting insulator. 41. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH (a) Remove the 3 bolts and engine mounting bracket with engine mounting insulator. 42. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the 2 bolts and 2 idler pulleys. 43. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (a) Remove the bolt and idler pulley. 44. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 45. REMOVE WATER INLET 46. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (a) Remove the 3 bolts, 2 nuts, oil filter bracket and gasket. 1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL (2007 4Runner) 47. REMOVE INTAKE MANIFOLD 48. INSPECT INTAKE MANIFOLD FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank. Maximum warpage: Intake air surge tank side 0.8 mm (0.031 in.) Cylinder head side 0.2 mm (0.008 in.) If warpage is greater than the maximum, replace the intake manifold. 49. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the 2 bolts and 2 camshaft timing oil control valves. 50. REMOVE WATER BY-PASS JOINT RR 51. REMOVE OIL FILLER CAP SUB-ASSEMBLY 52. REMOVE OIL FILLER CAP HOUSING (a) Remove the 2 nuts, oil filler cap housing and gasket. 53. REMOVE IGNITION COIL ASSEMBLY 54. REMOVE SPARK PLUG 55. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 56. REMOVE PARTIAL ENGINE ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4L002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4K002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST: 09226-10010 2. INSTALL CRANKSHAFT PULLEY HINT: SST: 09213-54015 91651-60855 SST: 09330-00021 3. INSTALL FAN WITH FLUID COUPLING 4. INSTALL FAN AND GENERATOR V BELT 5. FULLY TIGHTEN FAN WITH FLUID COUPLING 6. INSTALL RADIATOR SUPPORT SEAL UPPER 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (a) Connect the cable to the negative battery terminal. Torque: 3.9 N·m (40 kgf·cm, 35 in·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: INSTALLATION (2007 4Runner) 8. CHECK FOR ENGINE OIL LEAKAGE 9. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Install the engine under cover with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 10. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4M002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: REMOVAL (2007 4Runner) REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE V-BANK COVER 3. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (a) Remove the 4 bolts and engine under cover. 5. LOOSEN FAN WITH FLUID COUPLING 6. REMOVE FAN AND GENERATOR V BELT 7. REMOVE FAN WITH FLUID COUPLING 8. REMOVE CRANKSHAFT PULLEY HINT: SST: 09213-54015 91651-60855 SST: 09330-00021 SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05030 9. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver, pry out the oil seal. 1GR-FE ENGINE MECHANICAL: ENGINE FRONT OIL SEAL: REMOVAL (2007 4Runner) NOTICE: Be careful not to damage the crankshaft. Wrap the tip of the screwdriver with tape. 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4W002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4V002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST: 09223-78010 2. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Using SST, hold the crankshaft. SST: 09213-54015 91651-60855 SST: 09330-00021 (b) Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: INSTALLATION (2007 4Runner) (c) Install the front spacer, drive plate and rear spacer on the crankshaft. (d) Using several steps, install and tighten the 8 mounting bolts uniformly in the sequence as shown in the illustration. Torque: 83 N·m (846 kgf·cm, 61 ft·lbf) 3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: 4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: 5. CHECK FOR ENGINE OIL LEAKAGE 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002B4X002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) HINT: 2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) HINT: 3. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Using SST, hold the crankshaft. SST: 09213-54015 91651-60855 SST: 09330-00021 (b) Remove the 8 bolts, front spacer, drive plate and rear spacer. 4. REMOVE ENGINE REAR OIL SEAL 1GR-FE ENGINE MECHANICAL: ENGINE REAR OIL SEAL: REMOVAL (2007 4Runner) (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BK4002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BK5002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) DISASSEMBLY HINT: z z z Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new ones. 1. REMOVE NO. 1 ENGINE HANGER (a) Remove the 2 bolts and No. 1 engine hanger. 2. REMOVE NO. 2 ENGINE HANGER (a) Remove the 2 bolts and No. 2 engine hanger. 3. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the bolt and pull out the oil level gauge guide. (b) Remove the O-ring from the oil level gauge guide. 4. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY (a) Remove the 2 water drain cocks. 5. REMOVE VVT SENSOR (a) Remove the 2 bolts and 2 VVT sensors. 6. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and crankshaft position sensor. 7. REMOVE OIL CONTROL VALVE FILTER 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) (a) Remove the plug, filter and gasket from each cylinder head. 8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket. 9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder head cover and gasket. (b) Remove the ventilation valve from the cylinder head cover. 10. REMOVE CRANKSHAFT PULLEY (a) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) (b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. (c) Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST: 09213-54015 91651-60855 SST: 09330-00021 (d) Using the pulley set bolt and SST, remove the crankshaft pulley. SST: 09950-50013 09951-05010 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 09952-05010 09953-05020 09954-05030 11. REMOVE OIL PAN DRAIN PLUG (a) Remove the drain plug and gasket. 12. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove the 10 bolts and 2 nuts. (b) Insert the blade of SST between the oil pan and No. 2 oil pan, and cut off applied sealer and remove the No. 2 oil pan. SST: 09032-00100 NOTICE: z z Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan. Be careful not to damage the No. 2 oil pan flange. 13. REMOVE OIL STRAINER SUB-ASSEMBLY (a) Remove the 2 nuts, oil strainer and gasket. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 14. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 17 bolts and 2 nuts. (b) Remove the 4 stud bolts. (c) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. (d) Remove the O-ring from the oil pump. 15. REMOVE WATER PUMP ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) (a) Remove the 17 bolts, water pump and gasket. 16. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (a) Remove the 15 bolts and 2 nuts. (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. (c) Remove the O-ring from the LH cylinder head. 17. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using a screwdriver, pry out the oil seal. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) NOTICE: Be careful not to damage the oil pump assembly. Wrap the tip of the screwdriver with tape. 18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY NOTICE: z z Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. (a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. (b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (c) Remove the 2 bolts and chain tensioner. 19. REMOVE CHAIN TENSIONER SLIPPER 20. REMOVE NO. 1 IDLE GEAR SHAFT (a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 21. REMOVE NO. 2 CHAIN VIBRATION DAMPER (a) Remove the 2 No. 2 chain vibration dampers. 22. REMOVE CHAIN SUB-ASSEMBLY 23. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 24. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and No. 1 chain vibration damper. 25. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) While raising the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain. NOTICE: z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. 26. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 2 chain tensioner. 27. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) (a) While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain. NOTICE: z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. 28. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (a) Remove the bolt and No. 3 chain tensioner. 29. REMOVE CAMSHAFTS NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Remove the camshafts of the RH bank. (1) Rotate the camshafts counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration. (2) Using several steps, loosen and remove the 16 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) bearing cap bolts uniformly in the sequence as shown in the illustration. (3) Remove the 8 bearing caps and 2 camshafts. (b) Remove the camshafts of the LH bank. (1) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration. (2) Remove the 8 bearing caps and 2 camshafts. 30. REMOVE NO. 1 CAMSHAFT BEARING 31. REMOVE NO. 2 CAMSHAFT BEARING 32. REMOVE CYLINDER HEADS (a) Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration. (b) Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) NOTICE: Be careful not to drop the plate washers into the cylinder head. Cylinder head warpage or cracking could result from removing bolts in incorrect order. z z (c) Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. (d) Remove the RH and LH cylinder head gaskets. 33. REMOVE NO. 1 WATER OUTLET PIPE (a) Separate the knock sensor wire. (b) Remove the 3 bolts and water outlet pipe. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 34. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connectors. (b) Remove the 2 bolts and 2 knock sensors. 35. REMOVE ENGINE REAR OIL SEAL RETAINER (a) Remove the 5 bolts and 2 nuts. (b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap. 36. REMOVE ENGINE REAR OIL SEAL (a) Using a screwdriver and hammer, tap out the oil seal. 37. REMOVE VALVE LIFTER HINT: Arrange the valve lifter in the correct order. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 38. REMOVE VALVE HINT: Arrange the valves, inner compression springs, valve spring retainers and valve spring retainer locks in the correct order. (a) Place the cylinder head on a wooden block. (b) Using SST, compress the inner compression spring and remove the 2 valve spring retainer locks. SST: 09202-70020 09202-00010 (c) Remove the valve, inner compression spring, valve spring and valve spring retainer. 39. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seat by blowing air. 40. REMOVE VALVE STEM OIL O SEAL OR RING (a) Using needle-nose pliers, remove the valve stem oil seal. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 41. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.30 mm (0.0059 to 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) 42. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembling. (b) Remove the 2 connecting rod cap bolts. (c) Clean the crank pin, bearing and connecting rod. (d) Check the crank pin and bearing for pits and scratches. (e) Lay a strip of Plastigage across the crank pin. (f) Check that the protrusion of the connecting rod cap is facing the correct direction. (g) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. (h) Tighten the bolts alternately with the specified torque. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (i) Mark the front side of each connecting cap bolt with paint. (j) Retighten the cap bolts 90° as shown in the illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, connecting rod cap and lower bearing. (l) Measure the Plastigage at its widest point. Standard oil clearance: 0.026 to 0.046 mm (0.0010 to 0.0018 in.) Maximum oil clearance: 0.066 mm (0.0025 in.) NOTICE: Completely remove the Plastigage. (m) If replacing a bearing, replace it with one that has the same number marked on the connecting rod. There are 4 sizes of standard bearings, marked "1 ", "2", "3" and "4" accordingly. HINT: Standard bearing center wall thickness 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) MARK MM (IN.) "1" 1.484 to 1.487 (0.0584 to 0.0585) "2" 1.487 to 1.490 (0.0585 to 0.0587) "3" 1.490 to 1.493 (0.0587 to 0.0588) "4" 1.493 to 1.496 (0.0588 to 0.0589) 43. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push in the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: z z Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. 44. REMOVE CONNECTING ROD BEARING 45. REMOVE PISTON RING SET (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ring by hand. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 46. REMOVE PISTON PIN HOLE SNAP RING (a) Using a screwdriver, pry out the 2 snap rings. 47. REMOVE WITH PIN PISTON SUB-ASSEMBLY (a) Gradually heat the piston to approx. 80°C (176°F). (b) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: z z The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. 48. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the pair of the thrust washers or a crankshaft. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) HINT: Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 49. REMOVE CRANKSHAFT (a) Using several steps, loosen and remove the 8 main bearing cap bolts and seal washers uniformly in the sequence as shown in the illustration. (b) Using several steps, loosen and remove the 16 main bearing cap bolts uniformly in the sequence as shown in the illustration. (c) Using a screwdriver, pry out the main bearing caps. Remove the 4 main bearing caps and lower bearings. NOTICE: z z Pull up the main bearing cap while turning it little by little to the right and the left. Be careful not to damage the joint surfaces of the cylinder block and the main bearing cap. 50. REMOVE CRANKSHAFT THRUST WASHER SET 51. REMOVE CRANKSHAFT BEARING 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY (2007 4Runner) 52. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm socket hexagon wrench, remove the 3 oil nozzles. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BK3002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT CAMSHAFTS (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum runout: 0.06 mm (0.0024 in.) If the runout is greater than the maximum, replace the camshaft. (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 44.168 to 44.268 mm (1.7389 to 1.7428 in.) Exhaust 44.580 to 44.680 mm (1.7551 to 1.7591 in.) Minimum cam lobe height: Intake 44.018 mm (1.7330 in.) Exhaust 44.430 mm (1.7492 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. 2. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Fix the intake camshaft with a vise. NOTICE: Be careful not to damage the camshaft. (b) Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the camshaft timing gear assembly with the bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (c) Confirm the camshaft timing gear assembly is locked. (d) Release the lock pin. (1) Cover 4 oil paths of the cam journal with a masking tape as shown in the illustration. HINT: One of the 2 grooves on the cam journal is for retards (upper) and the other is for advances (lower). Each groove has 2 oil 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with tape. (2) Prick a hole in the tape placed on the advance side path. Prick a hole in the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. (3) Apply about 200 kPa (2.0 kgf/cm 2) of air pressure to the two broken paths (the advance side path and the retard side path). NOTICE: Cover the paths with a shop rag to avoid oil splashing. (4) Confirm that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard path. HINT: When the lock pin is released, the camshaft timing gear rotates in the advance direction. (5) When the camshaft timing gear comes to the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path. NOTICE: The camshaft timing assembly gear occasionally shifts to the retard side abruptly, if air compression of the advanced side path is released first. It often results in the breakage of the lock pin. (e) Check for smooth revolution. (1) Except the position where the lock pin meets at the most retard angle, turn the camshaft timing gear assembly back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 31° NOTICE: Be sure to perform this check by hand, instead of air pressure. (f) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked at the most retarded position. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (g) Remove the set bolt and camshaft timing gear assembly. NOTICE: Be sure not to remove the other 3 bolts. 3. INSPECT CYLINDER HEAD SET BOLT (a) Using vernier calipers, measure the outside thread diameter of the bolt. Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 in.) Minimum outside diameter: 10.7 mm (0.421 in.) 4. INSPECT CHAIN SUB-ASSEMBLY (a) Using a spring scale, pull the chain sub assembly with a force of 147 N (15.0 kgf, 33.1 lbf) and measure the length of the chain sub assembly by vernier calipers. Maximum chain elongation: 146.8 mm (5.780 in.) NOTICE: Perform the same measurements by pulling at random in 3 or more places to obtain an average length. If the elongation is greater than the maximum, replace the chain. 5. INSPECT NO. 2 CHAIN SUB-ASSEMBLY (a) Using a spring scale, pull the chain sub assembly with a force of 147 N (15.0 kgf, 33.1 lbf) and measure the length of the chain sub assembly by vernier calipers. Maximum chain elongation: 146.8 mm (5.780 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) NOTICE: Perform the same measurements by pulling at random in 3 or more places to obtain an average length. If the elongation is greater than the maximum, replace the chain. 6. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY (a) Put the No. 1 chain on the larger gear of the camshaft timing gear assembly. (b) Using vernier calipers, measure the timing gear with the chain. Minimum gear diameter (with chain): 115.5 mm (4.547 in.) NOTICE: The vernier calipers must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and camshaft timing gear assembly. (c) Put the No. 2 chain on the smaller gear of the camshaft timing gear assembly. (d) Using vernier calipers, measure the timing gear with the chain. Minimum gear diameter (with chain): 73.1 mm (2.878 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) NOTICE: The vernier calipers must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 2 chain and camshaft timing gear assembly. 7. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET (a) Put the No. 2 chain on the camshaft timing gear. (b) Using vernier calipers, measure the camshaft timing gear diameter with the chain . Minimum gear diameter (with chain): 73.1 mm (2.878 in.) NOTICE: The vernier calipers must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 2 chain and the camshaft timing gear. 8. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET (a) Put the No. 1 chain on the crankshaft timing gear. (b) Using vernier calipers, measure the crankshaft timing gear diameter with the chain. Minimum gear diameter (with chain): 61.0 mm (2.402 in.) NOTICE: The vernier calipers must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and crankshaft timing gear. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) 9. INSPECT NO. 1 IDLE GEAR (a) Put the No. 1 chain on the idle gear. (b) Using vernier calipers, measure the idle gear with the chain. Minimum gear diameter (with chain): 61.0 mm (2.402 in.) NOTICE: The vernier calipers must contact the chain rollers for the measuring. If the diameter is less than the minimum, replace the No. 1 chain and idle gear. 10. INSPECT IDLE GEAR SHAFT OIL CLEARANCE (a) Using a micrometer, measure the idle gear shaft diameter. Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 in.) (b) Using a caliper gauge, measure the inside diameter of the idle gear. Idle gear inside diameter: 23.02 to 23.03 mm (0.9063 to 0.9067 in.) (c) Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement. Standard oil clearance: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) 0.020 to 0.043 mm (0.0008 to 0.0017 in.) Maximum oil clearance: 0.093 mm (0.0037 in.) 11. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with your finger. 12. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly. (b) Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the No. 2 chain tensioner. 13. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY (a) Check that the plunger moves smoothly. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (b) Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the No. 3 chain tensioner. 14. INSPECT CHAIN TENSIONER SLIPPER (a) Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the chain tensioner slipper. 15. INSPECT NO. 1 CHAIN VIBRATION DAMPER (a) Measure the worn depth of the No. 1 chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the No. 1 chain vibration damper. 16. INSPECT NO. 2 CHAIN VIBRATION DAMPER (a) Measure the worn depth of the No. 2 chain vibration damper. Maximum depth: 1.0 mm (0.039 in.) If the depth is greater than the maximum, replace the No. 2 chain vibration damper. 17. CLEAN CYLINDER HEAD SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (a) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. (b) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the combustion chambers. (c) Using a valve guide bushing brush and solvent, clean all the valve guide bushes. (d) Using a soft brush and solvent, thoroughly clean the cylinder head. 18. INSPECT CYLINDER HEAD SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (a) Inspect warpage. (1) Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and manifolds. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than the maximum, replace the cylinder head. (b) Inspect cranks. (1) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 19. CLEAN VALVE (a) Using a gasket scraper, chip off any carbon from the valve head. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (b) Using a wire brush, thoroughly clean the valve. 20. INSPECT VALVE (a) Inspect the valve stem diameter. (1) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: INTAKE EXHAUST 5.470 to 5.485 mm 5.465 to 5.480 mm (0.2154 to 0.2159 in.) (0.2152 to 0.2158 in.) (b) Inspect the valve face angle. (1) Grind the valve enough to remove pits and carbon. (2) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° (c) Inspect the valve head margin thickness. (1) Using vernier calipers, check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. (d) Inspect the overall length. (1) Using vernier calipers, check the overall length. Standard overall length: INTAKE EXHAUST 106.95 mm (4.2106 in.) 105.80 mm (4.1654 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Minimum overall length: INTAKE EXHAUST 106.40 mm (4.1890 in.) 105.30 mm (4.1457 in.) If the overall length is less than the minimum, replace the valve. (e) Inspect the valve stem tip. (1) Check the surface of the valve stem tip for wear. NOTICE: Do not grind off more than the minimum length. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. 21. CLEAN VALVE SEAT (a) Using a 45° carbide cutter, resurface the valve seats. (b) Clean the valve seats. 22. INSPECT VALVE SEAT (a) Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve against the valve seat. NOTICE: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Do not rotate the valve. (c) Check the valve face and seat according to the following procedure. (1) If prussian blue appears around the entire face, the valve is centered. If not, replace the valve. (2) If prussian blue appears around the entire valve seat, the guide and face are centered. If not, resurface the valve seat. (3) Check that the seat contacts the middle of the valve face with the width below. Standard width: 1.0 to 1.4 mm (0.039 to 0.055 in.) 23. REPAIR VALVE SEAT NOTICE: Take off a cutter gradually to make the intake valve seat smooth. (a) If the seating is too high to the valve face, use 30° and 45° cutters to correct the seat. (b) Intake side: If the seating is too low to the valve face, use 60° and 45° cutters to correct the seat. (c) Exhaust side: If the seating is too low to the valve face, use 75° and 45° cutters to correct the seat. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (d) Handrub the valve and valve seat with an abrasive compound. (e) After handrubbing, clean the valve and valve seat. 24. INSPECT INNER COMPRESSION SPRING (a) Inspect squareness. (1) Using a steel square, measure the squareness of the inner compression spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the inner compression spring. (b) Inspect free length. (1) Using vernier calipers, measure the free length of the inner compression spring. Free length: 47.80 mm (1.8819 in.) If the free length is not as specified, replace the inner compression spring. (c) Inspect tension. (1) Using a spring tester, measure the tension of the inner compression spring at the specified installed length. Installed tension: 186.2 to 205.8 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.3 mm (1.311 in.) If the installed tension is not as specified, replace the 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) inner compression spring. 25. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the valve guide bush. Inside diameter: 5.51 to 5.53 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement (Step 8) from the valve guide bush inside diameter measurement. Standard overall length: INTAKE EXHAUST 0.025 to 0.060 mm 0.030 to 0.065 mm (0.0010 to 0.0024 in.) (0.0012 to 0.0026 in.) Minimum overall length: INTAKE EXHAUST 0.08 mm (0.0031 in.) 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the valve and valve guide bush. 26. REMOVE VALVE GUIDE BUSH (a) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F). 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (b) Place the cylinder head on a wooden block. (c) Using SST, tap out the valve guide bush. SST: 09201-10000 SST: 09201-01055 SST: 09950-70010 09951-07100 27. INSTALL VALVE GUIDE BUSH (a) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Bush bore diameter: 10.295 to 10.315 mm (0.4053 to 0.4061 in.) If the bush bore diameter of the cylinder head is greater than 10.315 mm (0.4061 in.), machine the bush bore to the dimension of 10.345 to 10.365 mm (0.4073 to 0.4081 in.). Valve guide bush diameter STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) (b) Gradually heat the cylinder head to 80 to 100°C (176 to 212°F). 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (c) Place the cylinder head on a wooden block. (d) Using SST, tap in a new valve guide bush to the specified protrusion height. SST: 09201-10000 SST: 09201-01055 SST: 09950-70010 09951-07100 Protrusion height: 9.3 to 9.7 mm (0.366 to 0.382 in.) (e) Using a sharp 5.5 mm reamer, ream the valve guide bush to obtain the standard specified clearance between the valve guide bush and valve stem. Standard overall length: INTAKE EXHAUST 0.025 to 0.060 mm 0.030 to 0.065 mm (0.0010 to 0.0024 in.) (0.0012 to 0.0026 in.) 28. INSPECT VALVE LIFTER (a) Using a micrometer, measure the valve lifter diameter. Valve lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) 29. INSPECT VALVE LIFTER OIL CLEARANCE 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) Subtract the valve lifter diameter measurement (Step 16) from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than the maximum, replace the valve lifter. If necessary, replace the cylinder head. 30. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the camshaft bearing caps, camshaft bearings and camshaft journals. (b) Install the camshaft bearing . (c) Place the camshaft on the cylinder head. (d) Lay a strip of Plastigage across each of the camshaft journals. (e) Install the camshaft bearing caps . NOTICE: Do not turn the camshafts. (f) Remove the camshaft bearing caps . (g) Measure the Plastigage at its widest point. Standard oil clearance (Cylinder head RH): 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) NO. 1 (INTAKE) NO. 1 (EXHAUST) OTHERS 0.008 to 0.038 mm 0.040 to 0.079 mm 0.025 to 0.062 mm (0.0003 to 0.0015 in.) (0.0016 to 0.0031 in.) (0.0010 to 0.0024 in.) Standard oil clearance (Cylinder head LH): NO. 1 OTHERS 0.040 to 0.079 mm 0.025 to 0.062 mm (0.0016 to 0.0031 in.) (0.0010 to 0.0024 in.) Maximum oil clearance (Cylinder head RH): NO. 1 (INTAKE) OTHERS 0.07 mm (0.0028 in.) 0.10 mm (0.0039 in.) Maximum oil clearance (Cylinder head LH): 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft bearings and/or camshaft. If necessary, replace the camshaft bearing caps and cylinder head together. Reference: Cylinder head journal bore diameter Camshaft bearing center wall thickness (Mark "2") Camshaft journal diameter (h) Remove the Plastigage completely. (i) Remove the camshafts. (j) Remove the camshaft bearing. 31. INSPECT CAMSHAFT THRUST CLEARANCE 40.009 to 40.017 mm (1.5752 to 1.5755 in.) 2.004 to 2.008 mm (0.0789 to 0.0791 in.) 35.971 to 35.985 mm (1.4165 to 1.4167 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (a) Install the camshafts . (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.04 to 0.09 mm (0.0016 to 0.0035 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshafts. If necessary, replace the camshaft bearing caps and cylinder head as a set. 32. INSPECT CYLINDER BLOCK FOR FLATNESS (a) Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head gasket. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than the maximum, replace the cylinder block. 33. INSPECT CYLINDER BORE 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.132 mm (3.7060 in.) If the average diameter of 4 positions is greater than the maximum, replace the cylinder block. 34. INSPECT WITH PIN PISTON SUB-ASSEMBLY (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 27.7 mm (1.091 in.) from the piston head. Piston diameter: 93.910 to 93.920 mm (3.6972 to 3.6976 in.) 35. INSPECT PISTON OIL CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.080 to 0.102 mm (0.0031 to 0.0040 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block. 36. INSPECT CONNECTING ROD SUB-ASSEMBLY (a) Using a rod aligner and feeler gauge, check the connecting rod alignment. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If misalignment is greater than the maximum, replace the connecting rod assembly. (2) Check twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than the maximum, replace the connecting rod assembly. 37. INSPECT PISTON PIN OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the piston pin hole. Piston pin hole inside diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) HINT: Piston pin hole inside diameter MARK MM (IN.) A 22.001 to 22.004 (0.8662 to 0.8663) B 22.005 to 22.007 (0.8663 to 0.8664) C 22.008 to 22.010 (0.8665 to 0.8665) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) HINT: Piston pin diameter MARK MM (IN.) A 21.997 to 22.000 (0.8660 to 0.8661) B 22.001 to 22.003 (0.8661 to 0.8663) C 22.004 to 22.006 (0.8663 to 0.8664) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (c) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) HINT: Bushing inside diameter MARK MM (IN.) A 22.005 to 22.008 (0.8663 to 0.8665) B 22.009 to 22.011 (0.8665 to 0.8666) C 22.012 to 22.014 (0.8666 to 0.8667) (d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.040 mm (0.0016 in.) (e) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and piston pin together. (f) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (g) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the connecting rod and piston pin together. 38. REMOVE CONNECTING ROD SMALL END BUSH (a) Using SST and a press, press out the bushing. SST: 09222-30010 39. INSTALL CONNECTING ROD SMALL END BUSH (a) Align the oil holes of a new bushing and the connecting rod. (b) Using SST and a press, press in the bushing. SST: 09222-30010 (c) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance between the bushing and piston pin. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) HINT: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Check that the piston pin fits at a normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with a thumb. 40. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Ring groove clearance: No. 1 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil 0.07 to 0.15 mm (0.0028 to 0.0060 in.) 41. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110mm (4.33 in.) from the top of the cylinder block. (b) Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.) No. 2 0.40 to 0.50 mm (0.0157 to 0.0197 in.) Oil (Side rail) 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum end gap: No. 1 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) 1.0 mm (0.039 in.) No. 2 1.1 mm (0.043 in.) Oil (Side rail) 1.0 mm (0.039 in.) 42. INSPECT CONNECTING ROD BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. 43. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 10.0 to 10.2 mm (0.393 to 0.402 in.) If the diameter is less than the minimum, replace the bolt. 44. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (b) Using a micrometer, measure the diameter of each main journal. Diameter: 71.988 to 72.000 mm (2.8342 to 2.8346 in.) (c) Check each main journal for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) (d) Using a micrometer, measure the diameter of each crank pin. Diameter: 55.992 to 56.000 mm (2.2044 to 2.2047 in.) (e) Check each crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) 45. INSPECT CRANKSHAFT OIL CLEARANCE HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. (a) Clean each main journal and bearing. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing or its contact surface. (c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 bottom bearings. NOTICE: Do not apply engine oil to the bearing or its contact surface. HINT: A number marked on each main bearing cap indicates the installation position. (d) Place the crankshaft on the cylinder block. (e) Lay a strip of Plastigage across each journal. (f) Examine the front marks and numbers and install the bearing caps on the cylinder block. (g) Apply a light coat of engine oil to the threads of the bearing cap bolts. (h) Temporarily install the 8 main bearing cap bolts to the inside positions. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) (i) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.). (j) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. (k) Apply a light coat of engine oil to the threads of the main bearing cap bolts. (l) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 61 N·m (622 kgf·cm, 45 ft·lbf) (m) Mark the front side of the bearing cap bolts with paint. (n) Retighten the bearing cap bolts 90° in the sequence as shown. (o) Check that the painted mark is now at a 90° angle to the front. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) NOTICE: Do not turn the crankshaft. (p) Install the 8 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 26 N·m (262 kgf·cm, 19 ft·lbf) (q) Remove the main bearing caps. (r) Measure the Plastigage at its widest point. Standard oil clearance: 0.018 to 0.030 mm (0.0007 to 0.0012 in.) Maximum clearance: 0.046 mm (0.0018 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. NOTICE: Completely remove the Plastigage. (s) If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for appropriate bearing number. There are 5 sizes of standard bearings, marked "1", "2", "3", "4" and "5" accordingly. Journal bearings HINT: CYLINDER BLOCK (A) + CRANKSHAFT USE BEARING 0-5 "1" 6 - 11 "2" 12 - 17 "3" 18 - 23 "4" 24 - 28 "5" 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) EXAMPLE HINT: Cylinder block "11" (A) + Crankshaft "06" (B) = Total number 17 (Use bearing "3") ITEM Cylinder block main journal bore diameter (A) Crankshaft main journal diameter (B) MARK MM (IN.) "00" 77.000 (3.0315) "01" 77.001 (3.0315) "02" 77.002 (3.0316) "03" 77.003 (3.0316) "04" 77.004 (3.0317) "05" 77.005 (3.0317) "06" 77.006 (3.0317) "07" 77.007 (3.0318) "08" 77.008 (3.0318) "09" 77.009 (3.0319) "10" 77.010 (3.0319) "11" 77.011 (3.0319) "12" 77.012 (3.0320) "13" 77.013 (3.0320) "14" 77.014 (3.0320) "15" 77.015 (3.0321) "16" 77.016 (3.0321) "00" 71.999 to 72.000 (2.8346 to 2.8346) "01" 71.998 to 71.999 (2.8346 to 2.8346) "02" 71.997 to 71.998 (2.8345 to 2.8346) "03" 71.996 to 71.997 (2.8345 to 2.8346) "04" 71.995 to 71.996 (2.8344 to 2.8345) "05" 71.994 to 71.995 (2.8344 to 2.8344) "06" 71.993 to 71.994 (2.8343 to 2.8344) "07" 71.992 to 71.993 (2.8343 to 2.8343) "08" 71.991 to 71.992 (2.8343 to 2.8343) "09" 71.990 to 71.991 (2.8343 to 2.8343) "10" 71.989 to 71.990 (2.8342 to 2.8343) "11" 71.988 to 71.989 (2.8342 to 2.8342) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSPECTION (2007 4Runner) Standard bearing center wall thickness "1" 2.488 to 2.491 (0.0980 to 0.0981) "2" 2.491 to 2.494 (0.0981 to 0.0982) "3" 2.494 to 2.497 (0.0982 to 0.0983) "4" 2.497 to 2.500 (0.0982 to 0.0984) "5" 2.500 to 2.503 (0.0984 to 0.0985) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM000002BK6002X Title: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL STUD BOLT (a) Install the stud bolts as shown in the illustration. Torque: 11 N·m (112 kgf·cm, 8.1 ft·lbf) Torque: 4.5 N·m (46 kgf·cm, 40 in·lbf) Torque: 4.0 N·m (41 kgf·cm, 35 in·lbf) 2. INSTALL STRAIGHT PIN (a) Using a plastic-faced hammer, tap in the straight pin. Standard protrusion: 22.5 to 23.5 mm (0.886 to 0.925 in.) for pin A 10.5 to 11.5 mm (0.413 to 0.453 in.) for pin B 8.5 to 9.5 mm (0.335 to 0.374 in.) for pin C 5.5 to 6.5 mm (0.217 to 0.256 in.) for pin D 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 3. INSTALL TIGHT PLUG (a) Apply adhesive around the tight plugs. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (b) Using SST, install the tight plugs as shown in the illustration. SST: 09950-60010 09951-00350 SST: 09950-70010 09951-07150 Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 4. INSTALL OIL JET (a) Using a screwdriver and hammer, tap in the oil jet. 5. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY (a) Using a 5 mm socket hexagon wrench, install the 3 oil nozzles. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 6. INSTALL PISTON PIN HOLE SNAP RING (a) Using a screwdriver, install a new snap ring on one side of the piston pin hole. HINT: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Check that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston. 7. INSTALL WITH PIN PISTON SUB-ASSEMBLY (a) Gradually heat the piston to about 80°C (176°F). (b) Coat the piston pin with engine oil. (c) Align the front marks of the piston and connecting rod, and push in the piston pin with a thumb. 8. INSTALL PISTON PIN HOLE SNAP RING (a) Using a screwdriver, install a new snap ring on the other side of the piston pin hole. HINT: Be sure that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 9. INSTALL PISTON RING SET (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings. NOTICE: Install the No. 2 compression ring with the painted mark facing upward. (c) Position the piston rings so that the ring ends are as shown. 10. INSTALL CONNECTING ROD BEARING (a) Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the contact surface of the connecting rod and prevent oil from adhering to them. 11. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (a) Clean each main journal and bearing. (b) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. (c) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. HINT: The number marked on each main bearing cap indicates the installation position. 12. INSTALL CRANKSHAFT (a) Apply engine oil to the upper bearing and install the crankshaft on the cylinder block. (b) Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block. (1) Push the crankshaft toward the front (rear) side. (2) Install the 2 upper thrust washers with the oil grooves facing outward. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (c) Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward. (d) Examine the front marks and numbers and install the bearing caps on the cylinder block. (e) Apply a light coat of engine oil to the threads of the bearing cap bolts. (f) Temporarily install the 8 main bearing cap bolts to the inside positions. (g) Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.). (h) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. (i) Apply a light coat of engine oil to the threads of the main bearing cap bolts. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (j) Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 61 N·m (622 kgf·cm, 45 ft·lbf) (k) Mark the front side of the bearing cap bolts with paint. (l) Retighten the bearing cap bolts 90° in the sequence as shown. (m) Check that the painted mark is now at a 90° angle to the front. (n) Check that the crankshaft turns smoothly. (o) Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 26 N·m (262 kgf·cm, 19 ft·lbf) 13. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Check the positions of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: z z Clean the backside of the bearing and the contact surface of the connecting rod cap and prevent oil from adhering to them. Match the numbered connecting rod cap with the connecting rod. (d) Check that the protrusion of the connecting rod cap is facing the correct direction. (e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. (f) Tighten the bolts alternately with the specified torque. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (g) Mark the front side of each connecting cap bolt with paint. (h) Retighten the cap bolts 90° as shown. (i) Check that the crankshaft turns smoothly. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 14. INSTALL RING PIN (a) Using a plastic-faced hammer, tap in new ring pins until it reaches the specified protrusion height. Specified protrusion height: 2.7 to 3.3 mm (0.106 to 0.130 in.) 15. INSTALL STRAIGHT PIN (a) Using a plastic-faced hammer, tap in new straight pins until it reaches the specified protrusion height. Specified protrusion height: A 17.5 to 19.5 mm (0.689 to 0.768 in.) B 7.5 to 8.5 mm (0.295 to 0.335 in.) C 7.0 to 9.0 mm (0.276 to 0.354 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 16. INSTALL STUD BOLT (a) Using the torx socket wrench E5 and E7, install the stud bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 4.0 N·m (41 kgf·cm, 35 in·lbf) Torque: 20 N·m (199 kgf·cm, 14 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 17. INSTALL UNION (a) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Using a deep socket wrench 12, install the unions. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 18. INSTALL TIGHT PLUG (a) Apply adhesive around the tight plug. (b) Using SST, tap in the tight plugs to the specified depth. SST: 09950-60010 09951-00250 SST: 09950-70010 09951-07150 Specified depth: 1.5 mm (0.059 in.) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 19. INSTALL WITH HEAD STRAIGHT SCREW PLUG (a) Using a straight hexagon wrench 14, install a new gasket and straight screw plug. Torque: 80 N·m (816 kgf·cm, 59 ft·lbf) 20. INSTALL VALVE STEM OIL O SEAL OR RING HINT: The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (a) Apply a light coat of engine oil to the valve guide bush. (b) Using SST, push in a new valve stem oil seal. SST: 09201-41020 21. INSTALL VALVE SPRING SEAT (a) Install the valve spring seat. 22. INSTALL VALVE (a) Apply engine oil to the valve as shown in the illustration. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Place the cylinder head on a wooden block. (c) Install the valve, inner compression spring and valve spring retainer. (d) Using SST, compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem. SST: 09202-70020 09202-00010 (e) Using a pin punch 5, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 23. INSTALL VALVE LIFTER (a) Apply engine oil to the valve stem end and valve lifter, and install the valve lifter to the valve stem. (b) Check that the valve lifter rotates smoothly by hand. 24. INSTALL ENGINE REAR OIL SEAL 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST: 09223-78010 (b) Apply MP grease to the oil seal lip. 25. INSTALL ENGINE REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block. (b) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied. (c) Install the oil seal retainer with the 5 bolts and 2 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 26. INSTALL KNOCK SENSOR (a) Install the 2 knock sensors with the 2 bolts as shown in the illustration. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Connect the knock sensor connectors. 27. INSTALL NO. 1 WATER OUTLET PIPE (a) Install the water outlet pipe with the 3 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 28. INSTALL CYLINDER HEAD GASKET (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. (b) Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) NOTICE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward. NOTICE: z z Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head. 29. INSTALL CYLINDER HEAD SUB-ASSEMBLY (a) Place the RH cylinder head on the cylinder head gasket. (b) Install the 8 cylinder head bolts and plate washers. HINT: z z The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B"). If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration (Procedure "A"). Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) NOTICE: Do not drop the washers into the cylinder head. (4) Mark the front side of each cylinder head bolt with paint. (5) Retighten the cylinder head bolts by 180° as shown (Procedure "B"). (6) Check that the painted marks are now at 180° opposite to the engine front. 30. INSTALL NO. 2 CYLINDER HEAD GASKET (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block. (b) Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward. NOTICE: z z Be careful of the installation direction. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 31. INSTALL CYLINDER HEAD LH (a) Place the LH cylinder head on the cylinder head gasket. (b) Install the 8 cylinder head bolts and plate washers. HINT: z z The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B"). If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the plate washer to the cylinder head bolt. (3) Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration (Procedure "A"). Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTICE: Do not drop the washers into the cylinder head. (4) Mark the front side of each cylinder head bolt with paint. (5) Retighten the cylinder head bolts by 180° as shown (Procedure "B"). (6) Check that the painted marks are now at 180° opposite to the engine front. (c) Install the 2 cylinder head bolts. (1) Apply a light coat of engine oil to the threads of the cylinder head bolts. (2) Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 30 N·m (306 kgf·cm, 22 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) 32. INSTALL NO. 1 CAMSHAFT BEARING (a) Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing. NOTICE: z z Install the bearing while aligning it with the oil hole in the bearing cap. Clean the backside of the bearing and the contact surface of the bearing cap and prevent oil from adhering to them. 33. INSTALL NO. 2 CAMSHAFT BEARING (a) Install the No. 2 camshaft bearing to the cylinder head. NOTICE: Clean the backside of the bearing and the bearing surface of the cylinder head. 34. INSTALL CAMSHAFTS NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Set the crankshaft position. (1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position. NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle. (b) Apply new engine oil to the thrust portion and journal of the camshafts. (c) Install the camshaft of the RH bank. (1) Place the 2 camshafts onto the RH cylinder head with the cam lobes of No. 1 cylinder facing each direction 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) as shown in the illustration. (2) Install the 8 bearing caps in their proper locations. (3) Apply a light coat of engine oil to the threads of the bearing cap bolts. (4) Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (5) Turn the camshafts clockwise with a wrench until the camshaft knock pin comes 90° position to the cylinder head. (d) Install the camshafts of the LH bank. (1) Place the 2 camshafts onto the LH cylinder head with the cam lobes of No. 2 cylinder facing as shown in the illustration. (2) Install the 8 bearing caps in their proper locations. (3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (4) Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) 35. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Install the No. 2 chain tensioner with the bolt. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 36. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1) (a) Align the mark links (yellow) with the timing marks (1dot mark) of the camshaft timing gears as shown in the illustration. (b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts. (c) Temporarily install the 2 camshaft timing gear bolts. NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (e) Remove the pin from the No. 2 chain tensioner. 37. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (b) Install the No. 3 chain tensioner with the bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 38. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2) (a) Align the mark links (yellow) with the timing marks (1dot mark and 2-dot mark) of the camshaft timing gears as shown in the illustration. (b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (c) Temporarily install the 2 camshaft timing gear bolts. NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. (d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (e) Remove the pin from the No. 3 chain tensioner. 39. INSTALL NO. 1 CHAIN VIBRATION DAMPER (a) Install the No. 1 chain vibration damper with the 2 bolts. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 40. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET (a) Align the timing gear set key with the key groove of the 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) timing gear. (b) Install the timing gear onto the crankshaft with the gear facing inward as shown in the illustration. 41. INSTALL CHAIN TENSIONER SLIPPER 42. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. (b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (c) Install the chain tensioner with the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 43. INSTALL CHAIN SUB-ASSEMBLY (a) Set the No. 1 cylinder to the TDC / compression. (1) Align the timing marks of the camshaft timing gears and bearing caps. (2) Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Align the mark link (yellow) with the timing mark of the crankshaft timing gear. (c) Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain. 44. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Instal the 2 No. 2 chain vibration dampers. 45. INSTALL NO. 1 IDLE GEAR SHAFT (a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (b) Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTICE: Be careful of the idle gear direction. (c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N·m (612 kgf·cm, 44 ft·lbf) (d) Remove the bar from the chain tensioner. 46. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST: 09226-10010 (b) Apply MP grease to the oil seal lip. 47. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Install a new O-ring to the LH cylinder head as shown in the illustration. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (c) Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent (d) Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration. Seal packing: Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: z z Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. Do not apply seal packing to the "A" as shown in the illustration. (e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place. (f) Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) NOTICE: z z Pay attention not to wrap the chain and slipper over the timing chain cover seal line. After installing the timing chain cover, install the water pump within 15 minutes. HINT: Each bolt length is as follows: HINT: A: 25 mm (0.98 in.) HINT: B: 55 mm (2.17 in.) 48. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 17 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) 49. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. (b) Install the 4 stud bolts. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Torque: 4.0 N·m (41 kgf·cm, 35 in·lbf) (c) Install a new O-ring to the oil pump. (d) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) HINT: Each bolt length is as follows: HINT: A: 25 mm (0.98 in.) HINT: B: 45 mm (1.77 in.) HINT: C: 14 mm (0.55 in.) 50. INSTALL OIL STRAINER SUB-ASSEMBLY (a) Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 51. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan. (b) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (c) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 52. INSTALL OIL PAN DRAIN PLUG (a) Install the drain plug and a new gasket. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 53. INSTALL CRANKSHAFT PULLEY (a) Using SST, install the pulley set bolt. SST: 09213-54015 91651-60855 SST: 09330-00021 Torque: 250 N·m (2,549 kgf·cm, 184 ft·lbf) 54. SET NO. 1 CYLINDER TO TDC / COMPRESSION 55. INSPECT VALVE CLEARANCE 56. ADJUST VALVE CLEARANCE 57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. (b) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing:: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Install the gasket to the cylinder head cover. (d) Install the seal washers to the bolts. (e) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 58. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. (b) Apply adhesive to the threads of the ventilation valve. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (c) Install the ventilation valve to the cylinder head cover. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) (d) Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, the cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (e) Install the gasket to the cylinder head cover. (f) Install the seal washers to the bolts. (g) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 59. INSTALL OIL CONTROL VALVE FILTER (a) Check that no foreign objects are present on the mesh part of the 2 filters. (b) Install 2 new gaskets to each new plug. (c) Insert the filters to the plugs. (d) Apply adhesive to 2 or 3 threads of the plugs. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (e) Install the plugs to each cylinder head. Torque: 62 N·m (632 kgf·cm, 46 ft·lbf) 60. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the crankshaft position sensor with the bolt. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 61. INSTALL VVT SENSOR (a) Apply a light coat of engine oil to the O-ring of each VVT sensor. (b) Install the 2 VVT sensors with the 2 bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf) 62. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (a) Apply adhesive to 2 or 3 threads of the drain cocks end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (b) After applying the specified torque, rotate the drain cock clockwise as shown in the illustration. Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) NOTICE: z z z z Install the drain cock within 3 minutes after applying adhesive. Do not expose the drain cock to coolant within 1 hour after installing. Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque. Do not loosen the drain cock after setting it correctly. 63. INSTALL OIL LEVEL GAUGE GUIDE (a) Install a new O-ring to the oil level gauge guide. (b) Apply a light coat of engine oil to the O-ring. (c) Push in the oil level gauge guide end into the guide hole of the oil pan. (d) Install the oil level gauge guide with the bolt. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 64. INSTALL NO. 2 ENGINE HANGER 1GR-FE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (2007 4Runner) (a) Install the engine hanger with the 2 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 65. INSTALL NO. 1 ENGINE HANGER (a) Install the engine hanger with the 2 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000017L8004X Title: 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT ENGINE COOLANT HINT: 2. INSPECT ENGINE OIL HINT: 3. INSPECT BATTERY HINT: 4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 5. INSPECT DRIVE BELT 6. INSPECT IGNITION TIMING NOTICE: z Turn all electrical systems OFF. z Operate the inspection when the cooling fan motor is turned OFF. (a) Warm up the engine. (b) When using the intelligent tester. (1) Connect the intelligent tester to the DLC3. (2) Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / IGN ADVANCE. (3) Inspect the ignition timing during idling. Ignition timing: 7 to 24°CA BTDC during idling (Transmission in neutral 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) position) (4) Check that the ignition timing advances immediately when the engine speed is increased. (c) When not using intelligent tester. (1) Using SST, connect the terminals 13 (TC) and 4 (CG) of the DLC3. SST: 09843-18040 NOTICE: Be sure not to connect the terminals wrongly. It causes breakage of the engine. (2) Remove the air cleaner cap sub-assembly. (3) Pull out the wire harness as shown in the illustration. (4) Connect the tester probe of a timing light to the wire of the ignition coil connector for No. 1 cylinder. NOTICE: z z Use a timing light that detects the first signal. After checking, be sure to wrap the wire harness with tape. (5) Inspect the ignition timing during idling. Ignition timing: 8 to 12°CA BTDC during idling (Transmission in neutral position) (6) Remove the SST from the DLC3. (7) Inspect the ignition timing during idling. Ignition timing: 7 to 24°CA BTDC during idling (Transmission in neutral position) (8) Disconnect the timing light from the engine. (9) Install the air cleaner cap sub-assembly. 7. INSPECT ENGINE IDLING SPEED 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) NOTICE: z Turn all the electrical systems OFF. z Operate the inspection when the cooling fan motor is turned OFF. (a) Warm up the engine. (b) When using the intelligent tester: (1) Connect the intelligent tester to the DLC3. (2) Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / ENGINE SPD. (3) Inspect the engine idling speed. Idling speed: 650 to 750 rpm (Transmission in neutral position) (c) When not using the intelligent tester: (1) Using SST, connect the terminal 8 (TAC) of the DLC3. SST: 09843-18030 (2) Race the engine speed at 2,500 rpm for approximately 90 seconds. (3) Inspect the engine idling speed. Idling speed: 650 to 750 rpm (Transmission in neutral position) 8. INSPECT COMPRESSION (a) Warm up and stop the engine. (b) Remove the V-bank cover. (c) Remove the air cleaner assembly. (d) Remove the intake air surge tank . (e) Remove the 6 ignition coils. (f) Remove the 6 spark plugs. (g) Disconnect the 6 injector connectors. (h) Inspect the cylinder compression pressure. (1) Insert a compression gage into the spark plug hole (Procedure "A"). SST: 09992-00500 (2) Fully open the throttle (Procedure "B"). 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) (3) While cranking the engine, measure the compression pressure (Procedure "C"). Compression pressure: 1,300 kPa (13.3 kgf/cm 2, 189 psi) Minimum pressure: 1,000 kPa (10.2 kgf/cm 2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm 2, 15 psi) NOTICE: z z z Use a fully-charged battery so the engine speed can be increased to 250 rpm or more. Inspect the other cylinders in the same way. Measure the compression in as short a time as possible. (4) Repeat procedures "A" through "C" for each cylinder. (5) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat procedures "A" through "C" for cylinders with low compression. z z If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket. (i) Connect the 6 injector connectors. (j) Install the 6 spark plugs. (k) Install the 6 ignition coils. (l) Install the intake air surge tank . (m) Install the air cleaner assembly. (n) Install the V-bank cover. 9. INSPECT CO/HC HINT: This check is to determine whether or not the idle CO/HC complies with regulations. (a) Start the engine. (b) Run the engine at 2,500 rpm for approximately 180 seconds. 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) (c) Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Immediately check the CO/HC concentration during idling and/or at 2,500 rpm. HINT: z z Complete the measurement within 3 minutes. When carrying out the 2 modes (idling and 2,500 rpm) test, the measurement orders are prescribed by the applicable local regulations. (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check the A/F sensor and heated oxygen sensor operation. (2) See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO HC SYMPTOM CAUSES 1. Faulty ignition: { Normal High Rough idling { Incorrect timing Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders 1. Vacuum leaks: Low High Rough idling { (Fluctuating HC reading) { { PCV hoses Intake manifold Throttle body 2. Lean mixture causing misfire High High Rough idling (Black smoke from exhaust) 1. Restricted air filter 2. Faulty EFI systems: { Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter { Faulty ECM { { 1GR-FE ENGINE MECHANICAL: ENGINE: ON-VEHICLE INSPECTION (2007 4Runner) { { Faulty injectors Faulty throttle position sensor 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000029WU002X Title: 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: COMPONENTS (2007 4Runner) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000029WS002X Title: 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL CHAIN TENSIONER SLIPPER 2. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. (b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (c) Install the chain tensioner with the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 3. INSTALL CHAIN SUB-ASSEMBLY (a) Set the No. 1 cylinder to the TDC / compression. (1) Align the timing marks of the camshaft timing gears and bearing caps. (2) Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) (b) Align the mark link (yellow) with the timing mark of the crankshaft timing gear. (c) Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain. 4. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Instal the 2 No. 2 chain vibration dampers. 5. INSTALL NO. 1 IDLE GEAR SHAFT (a) Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft. (b) Temporarily install the No. 1 idle gear shaft and No. 1 idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block. NOTICE: Be careful of the idle gear direction. (c) Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft. Torque: 60 N·m (612 kgf·cm, 44 ft·lbf) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) (d) Remove the bar from the chain tensioner. 6. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 7. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 8. INSTALL VVT SENSOR 9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 12. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 13. INSTALL INTAKE AIR SURGE TANK 14. INSTALL OIL PAN SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. (b) Install a new O-ring to the oil pump. (c) Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (d) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) HINT: Each bolt length is as follows: HINT: A: 25 mm (0.98 in.) HINT: B: 45 mm (1.77 in.) HINT: C: 14 mm (0.55 in.) (e) Install the 4 housing bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (f) Install the flywheel housing under cover. 15. INSTALL OIL STRAINER SUB-ASSEMBLY (a) Install a new gasket and the oil strainer with the 2 nuts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) 16. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and No. 2 oil pan. (b) Apply a continuous bead of seal packing (diameter 3: to 4 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: Install the No. 2 oil pan within 3 minutes after applying seal packing. After installing it, the No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied. (c) Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 17. INSTALL CRANKSHAFT PULLEY (a) Using SST, install the pulley set bolt. SST: 09213-54015 91651-60855 SST: 09330-00021 Torque: 250 N·m (2,549 kgf·cm, 184 ft·lbf) 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) 18. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (a) Install the idler pulley with the bolt. Torque: 54 N·m (551 kgf·cm, 40 ft·lbf) HINT: "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley. 19. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Install the 2 idler pulleys with the 2 bolts. Torque: 39 N·m (398 kgf·cm, 29 ft·lbf) 20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (a) Temporarily install the V-ribbed belt tensioner with the 5 bolts. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) (b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) (c) Tighten the other bolts. Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 33 mm (1.30 in.) 21. INSTALL COOLER COMPRESSOR ASSEMBLY 22. INSTALL GENERATOR ASSEMBLY 23. INSTALL VANE PUMP ASSEMBLY (a) Install the vane pump with the 2 bolts. Torque: 43 N·m (438 kgf·cm, 32 ft·lbf) NOTICE: Do not hit the pulley to other parts when installing the vane pump. (b) Connect the P/S oil pressure switch connector. 24. INSTALL WATER INLET 25. INSTALL OIL LEVEL GAUGE GUIDE (a) Install a new O-ring to the oil level gauge guide. (b) Apply a light coat of engine oil to the O-ring. (c) Push in the oil level gauge guide end into the guide hole of the oil pan. (d) Install the oil level gauge guide with the bolt. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (e) Install the oil level gauge. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: INSTALLATION (2007 4Runner) 26. INSTALL AIR CLEANER ASSEMBLY 27. CONNECT NO. 2 VENTILATION HOSE 28. INSTALL FLUID COUPLING ASSEMBLY 29. INSTALL FAN AND GENERATOR V BELT 30. FULLY TIGHTEN FLUID COUPLING ASSEMBLY 31. INSTALL RADIATOR SUPPORT SEAL UPPER 32. INSTALL BATTERY 33. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT HINT: 34. INSTALL POWER STEERING LINK ASSEMBLY HINT: 35. ADD ENGINE OIL 36. ADD ENGINE COOLANT 37. CHECK FOR ENGINE OIL LEAKS 38. CHECK FOR ENGINE COOLANT LEAKS 39. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 40. INSPECT IGNITION TIMING 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000029WT002X Title: 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE POWER STEERING LINK ASSEMBLY HINT: 2. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (for 4WD) HINT: 3. DRAIN ENGINE COOLANT 4. DRAIN ENGINE OIL 5. REMOVE BATTERY 6. REMOVE V-BANK COVER 7. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 8. LOOSEN FLUID COUPLING ASSEMBLY 9. REMOVE FAN AND GENERATOR V BELT 10. REMOVE FLUID COUPLING ASSEMBLY 11. DISCONNECT NO. 2 VENTILATION HOSE 12. REMOVE AIR CLEANER ASSEMBLY 13. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the oil level gauge. (b) Remove the bolt and pull out the oil level gauge guide. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) (c) Remove the O-ring from the oil level gauge guide. 14. REMOVE WATER INLET 15. SEPARATE VANE PUMP ASSEMBLY (a) Disconnect the P/S oil pressure switch connector. (b) Remove the 2 bolts, and separate the vane pump. NOTICE: Do not hit the pulley to other parts when separating the vane pump. HINT: The vane pump is suspended securely. 16. REMOVE GENERATOR ASSEMBLY 17. SEPARATE COOLER COMPRESSOR ASSEMBLY 18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (a) Remove the 5 bolts and V-ribbed belt tensioner. 19. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the 2 bolts and 2 idler pulleys. 20. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (a) Remove the bolt and idler pulley. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) 21. REMOVE CRANKSHAFT PULLEY (a) Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST: 09213-54015 91651-60855 SST: 09330-00021 (b) Using the pulley set bolt and SST, remove the crankshaft pulley. SST: 09950-50013 09951-05010 09952-05010 09953-05020 09954-05030 22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (a) Remove the 10 bolts and 2 nuts. (b) Insert the blade of SST between the oil pan and No. 2 oil pan, cut off applied sealer and remove the No. 2 oil pan. SST: 09032-00100 NOTICE: z z Be careful not to damage the contact surfaces of the oil pan and No. 2 oil pan. Be careful not to damage the No. 2 oil pan flange. 23. REMOVE OIL STRAINER SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) (a) Remove the 2 nuts, oil strainer and gasket. 24. REMOVE OIL PAN SUB-ASSEMBLY (a) Remove the 4 housing bolts. (b) Remove the flywheel housing under cover. (c) Remove the 17 bolts and 2 nuts. (d) Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration. NOTICE: 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) Be careful not to damage the contact surfaces of the cylinder block and oil pan. (e) Remove the O-ring from the oil pump. 25. REMOVE INTAKE AIR SURGE TANK 26. REMOVE IGNITION COIL ASSEMBLY 27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 29. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the 2 oil control valve connectors. (b) Remove the 2 bolts and 2 camshaft timing oil control valves. 30. REMOVE VVT SENSOR 31. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 33. SET NO. 1 CYLINDER TO TDC / COMPRESSION 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) (a) Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block. (b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. 34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY NOTICE: z z Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first. (a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. 1GR-FE ENGINE MECHANICAL: TIMING CHAIN: REMOVAL (2007 4Runner) (b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (c) Remove the 2 bolts and chain tensioner. 35. REMOVE CHAIN TENSIONER SLIPPER 36. REMOVE NO. 1 IDLE GEAR SHAFT (a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft. 37. REMOVE NO. 2 CHAIN VIBRATION DAMPER (a) Remove the 2 No. 2 chain vibration dampers. 38. REMOVE CHAIN SUB-ASSEMBLY 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) Last Modified: 4-26-2007 1.6 N Service Category: Engine/Hybrid System Section: Engine Mechanical Model Year: 2007 Model: 4Runner Doc ID: RM0000029VW002X Title: 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. DRAIN ENGINE COOLANT 2. REMOVE V-BANK COVER 3. DISCONNECT NO. 2 VENTILATION HOSE 4. REMOVE AIR CLEANER ASSEMBLY 5. REMOVE INTAKE AIR SURGE TANK 6. REMOVE IGNITION COIL ASSEMBLY 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 9. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. (b) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. 10. INSPECT VALVE CLEARANCE (a) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. (b) Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. (c) Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.29 to 0.39 mm (0.011 to 0.015 in.) (2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter. 11. ADJUST VALVE CLEARANCE (a) Set the No. 1 cylinder to the TDC /compression. (1) Turn the crankshaft pulley, and align the notch with the timing mark "0" of the timing chain cover. (2) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above. (3) Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears. (b) Remove the No. 1 chain tensioner assembly. NOTICE: z z Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40° from the TDC first. (1) Remove the 4 bolts, timing chain cover plate and gasket. (2) While rotating the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration. (3) While rotating the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (4) Remove the 2 bolts and chain tensioner. (c) Remove the No. 2 camshaft. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) the following steps should be carried out. (1) While raising the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (2) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (3) Separate the camshaft timing gear from the No. 2 camshaft. (4) Rotate the camshaft counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face upward as shown in the illustration. (5) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (6) Remove the 4 bearing caps and No. 2 camshaft. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (d) Remove the No. 2 chain tensioner assembly. (1) Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear. (e) Remove the camshaft. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt. NOTICE: z z Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the camshaft timing gear assembly. (2) Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear. (3) Rotate the No. 1 camshaft counterclockwise using a wrench so that the cam lobes of the No. 1 cylinder face upward as shown in the illustration. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (4) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (5) Remove the 4 bearing caps. (6) Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with No. 2 chain. (7) Tie the No. 1 chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. (f) Remove the No. 4 camshaft sub-assembly. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) While pushing down the No. 3 chain tensioner, insert 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) a pin of φ1.0 mm (0.039 in.) into the hole to fix it. (2) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. (3) Separate the camshaft timing gear from the No. 4 camshaft. (4) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (5) Remove the 4 bearing caps and No. 4 camshaft. (g) Remove the No. 3 chain tensioner assembly. (1) Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear. (h) Remove the No. 3 camshaft sub-assembly. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. (2) Remove the 4 bearing caps. (3) Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear and No. 2 chain. (4) Tie the No. 1 chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. (i) Remove the valve lifters. (j) Determine the size of the valve lifter to be installed according to the following formulas or charts. (1) Using a micrometer, measure the thickness of the removed lifter. (2) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. T: 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) Thickness of removed lifter A: Measured valve clearance N: Thickness of new lifter Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) (3) Select a new lifter with a thickness as close as possible to the calculated value. HINT: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). (k) Install the No. 3 camshaft sub-assembly. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Align the mark link (yellow) with the timing mark (2dot mark) of the camshaft timing gear as shown in the illustration. (2) Apply new engine oil to the thrust portions and journals of the camshafts. (3) Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (4) Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration. (5) Install the 4 bearing caps in their proper locations. (6) Apply a light coat of engine oil to the threads of the bearing cap bolts. (7) Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (8) Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear. (l) Install the No. 3 chain tensioner assembly. (1) While pushing in the tensioner, insert a pin of φ1.0 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) mm (0.039 in.) into the hole to fix it. (2) Temporarily install the camshaft timing gear and No. 3 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears. (3) Tighten the No. 3 chain tensioner bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) (m) Install the No. 4 camshaft sub-assembly. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Align the knock pin hole on the camshaft timing gear with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear. (2) Temporarily install the camshaft timing gear set bolt. (3) Install the 4 bearing caps in their proper locations. (4) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (5) Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (6) Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (7) Remove the pin from the No. 3 chain tensioner. (n) Install the camshaft. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Align the mark link (yellow) with the timing mark (1dot mark) of the camshaft timing gear as shown in the illustration. (2) Apply new engine oil to the thrust portions and journals of the camshafts. (3) Temporarily put the No. 1 chain on the No. 2 chain of 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) the camshaft timing gear. (4) Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear. (5) Temporarily install the camshaft timing gear set bolt. (6) Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration. (7) Install the 4 bearing caps in their proper locations. (8) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (9) Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (10) Rotate the No. 1 camshaft clockwise using the hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap. (11) Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear. (12) Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (o) Install the No. 2 chain tensioner assembly. (1) While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (2) Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears. (3) Tighten the No. 2 chain tensioner bolt. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) (p) Install the No. 2 camshaft. NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (1) Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of No. 1 cylinder facing upward as shown in the illustration. (2) Install the 4 bearing caps in their proper locations. (3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. (4) Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (5) Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear. (6) Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt. Torque: 100 N·m (1,020 kgf·cm, 74 ft·lbf) (7) Remove the pin from the No. 2 chain tensioner. (q) Install the No. 1 chain tensioner assembly. (1) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. (2) While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate. (3) Install the chain tensioner with the 2 bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) (4) Remove the bar from the chain tensioner. 1GR-FE ENGINE MECHANICAL: VALVE CLEARANCE: ADJUSTMENT (2007 4Runner) (5) Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (6) Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover. (7) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. 12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 14. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 15. INSTALL INTAKE AIR SURGE TANK 16. INSTALL AIR CLEANER ASSEMBLY 17. CONNECT NO. 2 VENTILATION HOSE 18. ADD ENGINE COOLANT 19. CHECK FOR ENGINE COOLANT LEAKS 20. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 21. INSPECT IGNITION TIMING 1GR-FE EXHAUST: EXHAUST PIPE: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Title: 1GR-FE EXHAUST: EXHAUST PIPE: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002B1I001X 1GR-FE EXHAUST: EXHAUST PIPE: COMPONENTS (2007 4Runner) 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1H001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 2. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) 3. INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 4. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install 2 new gaskets and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 5. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using a vernier caliper, measure the free length to the 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) compression spring. Minimum length: 40.5 mm (4.5645 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with the 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 6. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 7. INSPECT EXHAUST GAS LEAK 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1J001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE EXHAUST PIPE ASSEMBLY TAIL (a) Remove the 2 bolts, exhaust pipe support and tail pipe. 2. REMOVE EXHAUST PIPE ASSEMBLY CENTER (a) Remove the 2 bolts and 2 compression springs. (b) Remove the 4 exhaust pipe supports and exhaust pipe center. 3. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and No. 2 exhaust front pipe assembly. 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 5. REMOVE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 nuts and exhaust pipe assembly front. 6. REMOVE HEATED OXYGEN SENSOR (for Bank 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Title: 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000000PE200UX 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL INJECTOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL INJECTOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM000000WQQ00UX Title: 1GR-FE FUEL: FUEL INJECTOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FUEL INJECTOR ASSEMBLY (a) Check the resistance. (1) Using an ohmmeter, measure the resistance between the terminals. Standard: TESTER CONNECTION SPECIFIED CONDITION 1-2 11.6 to 12.4 Ω at 20°C (68°F) If the result is not as specified, replace the fuel injector. (b) Check the injection volume. NOTICE: z z Perform the test in a well-ventilated area and watch out for flames. Handle the fuel tube connector carefully. (1) Prepare a new fuel tube. HINT: Part No. 23801-31070 (2) Using a cutter knife, cut the fuel tube protector. Tear the protector by hand, then remove the fuel tube connector. NOTICE: 1GR-FE FUEL: FUEL INJECTOR: INSPECTION (2007 4Runner) If the protector is cut too deeply with the cutter, the Oring of the fuel tube connector will be damaged. (3) Install the fuel tube connector into SST (hose), then connect the tube connector to the fuel pipe. SST: 09268-41047 95336-08070 CAUTION: Connect the fuel tube connector (quick type) after observing the precautions. (4) Remove the pressure regulator . (5) Install the O-ring onto the fuel inlet of the pressure regulator. (6) Connect SST (hose) to the fuel inlet of the pressure regulator with another SST (union) and the 2 bolts. SST: 09268-41047 95336-08070 09268-41091 Torque: 7.5 N·m (80 kgf·cm, 66 in·lbf) (7) Connect the fuel return hose to the fuel outlet of the pressure regulator. (8) Install a new O-ring onto the injector. (9) Connect SST (adaptor and hose) to the injector and hold the injector and union with SST (clamp). SST: 09268-41047 95336-08070 SST: 09268-41140 SST: 09268-41400 (10) Set the injector in a graduated cylinder. CAUTION: Install a suitable vinyl tube onto the injector to prevent gasoline splashes. (11) Connect the intelligent tester to the DLC3. (12) Turn the ignition switch to ON. (13) Turn the intelligent tester ON. (14) Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / ACTIVE TEST / FUEL PUMP / SPD / ON. (15) Install SST onto the fuel injector. SST: 09842-30080 1GR-FE FUEL: FUEL INJECTOR: INSPECTION (2007 4Runner) (16) Connect SST to the battery, then measure the injection volume for 15 seconds. Perform the inspection 2 or 3 times, then calculate the average. Standard:: INJECTION VOLUME 76 to 91 cm 3 (4.6 to 5.5 cu in.) per 15 seconds DIFFERENCE BETWEEN EACH FUEL INJECTOR 15 cm 3 (0.9 cu in.) or less NOTICE: Always do the switching at the battery side. If the result is not as specified, replace the fuel injector. (c) Check the fuel leakage. (1) When checking the injection volume, remove SST from the battery. Inspect the fuel leakage from the fuel injector. SST: 09842-30080 Standard: 1 drop or less every 12 minutes. If the result is not as specified, replace the fuel injector. 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM000000Q4600VX Title: 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FUEL INJECTOR (a) Install a new insulator onto each fuel injector. (b) Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto each fuel injector. (c) While turning the fuel injector left and right, install it onto the fuel delivery pipe. (d) Position the fuel injector connector facing outward. 2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Place the fuel delivery pipe together with the 6 fuel injectors on the intake manifold. 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) (b) Provisionally install the 6 bolts, which are used to hold the fuel delivery pipe, onto the intake manifold. (c) Check that the fuel injectors rotate smoothly. HINT: If the fuel injectors do not rotate smoothly, replace the O-ring. (d) Position the fuel injector connector facing outward. (e) Tighten the 6 bolts, which are used to hold the fuel delivery pipe, to the intake manifold. Torque: 15 N·m (153 kgf·cm, 11 ft·lbf) (f) Connect the 6 fuel injector connectors. 3. CONNECT FUEL PIPE SUB-ASSEMBLY (a) Push the tube connector into the pipe until the tube connector makes a "click" sound. NOTICE: z z Check if there is any damage or foreign objects on the connected part of the fuel pipe. After connecting, check that the pipe and connector are securely connected by pulling them. (b) Install the fuel pipe clamp. 4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (a) Push the tube connector into the pipe until the tube connector makes a "click" sound. NOTICE: z z Check if there is any damage or foreign objects on the connected part of the fuel pipe. After connecting, check that the pipe and connector are securely connected by pulling them. (b) Install the fuel pipe clamp. 5. INSTALL INTAKE AIR SURGE TANK (a) Install a new gasket and the intake air surge tank with the 2 nuts. Torque: 28 N·m (286 kgf·cm, 21 ft·lbf) (b) Using an 8 mm socket hexagon wrench, install the 4 bolts. Torque: 28 N·m (286 kgf·cm, 21 ft·lbf) 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) (c) Install the 3 upper bolts which are used to secure the 2 surge tank stays and throttle body bracket. Torque: 21 N·m (214 kgf·cm, 16 ft·lbf) (d) Install the 3 wire harness clamps and hose clamp. (e) Connect the throttle motor connector. (f) Connect the 2 VSV connectors. (g) Connect the ventilation hose. 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) (h) Connect the fuel vapor feed hose. (i) Connect the No. 4 water by-pass hose. (j) Connect the No. 5 water by-pass hose. 6. INSTALL AIR CLEANER ASSEMBLY 7. CONNECT NO. 2 VENTILATION HOSE (a) Connect the No. 2 ventilation hose. 1GR-FE FUEL: FUEL INJECTOR: INSTALLATION (2007 4Runner) 8. INSTALL V-BANK COVER 9. CONNECT BATTERY NEGATIVE TERMINAL Torque: 3.9 N·m (40 kgf·cm, 35 in·lbf) 10. ADD ENGINE COOLANT 11. CHECK FOR ENGINE COOLANT LEAKAGE 12. CHECK FOR FUEL LEAK 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM000000Q4800WX Title: 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. DRAIN ENGINE COOLANT 4. REMOVE V-BANK COVER 5. DISCONNECT NO. 2 VENTILATION HOSE (a) Disconnect the No. 2 ventilation hose. 6. REMOVE AIR CLEANER ASSEMBLY 7. REMOVE INTAKE AIR SURGE TANK (a) Disconnect the No. 5 water by-pass hose. 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) (b) Disconnect the No. 4 water by-pass hose. (c) Disconnect the fuel vapor feed hose. (d) Disconnect the ventilation hose. (e) Disconnect the 2 VSV connectors. 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) (f) Disconnect the throttle motor connector. (g) Remove the 3 wire harness clamps and hose clamp. (h) Remove the 3 upper bolts which are used to secure the 2 surge tank stays and throttle body bracket. (i) Using an 8 mm socket hexagon wrench, remove the 4 bolts. (j) Remove the 2 nuts, then remove the intake air surge tank and gasket. 8. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) (a) Remove the fuel pipe clamp. (b) Pinch the tube connector, and then pull the fuel pipe out of the pipe as shown in the illustration. NOTICE: z z z z z z Remove any dirt and foreign objects from the fuel tube connector before performing this work. Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube. Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube. If the fuel tube connector and pipe are stuck, push and pull to release them. 9. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) (a) Remove the fuel pipe clamp. (b) Pinch the tube connector, and then pull the fuel pipe out of the pipe as shown in the illustration. NOTICE: z z z z z z Remove any dirt and foreign objects from the fuel tube connector before performing this work. Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube. Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube. If the fuel tube connector and pipe are stuck, push and pull to release them. 10. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (a) Disconnect the 6 fuel injector connectors. (b) Remove the 6 bolts and fuel delivery pipe together with the 6 fuel injectors. NOTICE: Be careful not to drop the injectors when removing the fuel delivery pipe. 1GR-FE FUEL: FUEL INJECTOR: REMOVAL (2007 4Runner) 11. REMOVE FUEL INJECTOR (a) Pull the 6 injectors out of the delivery pipe. 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S1002X Title: 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM000000UJZ00NX Title: 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto the fuel pressure pulsation damper. (b) Install the fuel pressure pulsation damper onto the fuel delivery pipe. (c) Install the clip. 2. INSTALL V-BANK COVER 3. CHECK FOR FUEL LEAK 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM000000UK100NX Title: 1GR-FE FUEL: FUEL PRESSURE PULSATION DAMPER: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. REMOVE V-BANK COVER 3. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (a) Remove the clip. (b) Pull the fuel pressure pulsation damper out of the fuel delivery pipe. 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028RW002X Title: 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PRESSURE REGULATOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000015Y3004X Title: 1GR-FE FUEL: FUEL PRESSURE REGULATOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY (a) Install the vacuum hose. (b) Apply a light coat of spindle oil or gasoline to a new O-ring and install it onto the fuel pressure regulator. (c) Install the fuel pressure regulator with the 2 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 2. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 3. INSTALL AIR CLEANER ASSEMBLY 4. CONNECT NO. 2 VENTILATION HOSE (a) Connect the No. 2 ventilation hose. 5. INSTALL V-BANK COVER 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N·m (40 kgf·cm, 35 in·lbf) 1GR-FE FUEL: FUEL PRESSURE REGULATOR: INSTALLATION (2007 4Runner) 7. CHECK FOR FUEL LEAK 1GR-FE FUEL: FUEL PRESSURE REGULATOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000015Y5004X Title: 1GR-FE FUEL: FUEL PRESSURE REGULATOR: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE V-BANK COVER 4. DISCONNECT NO. 2 VENTILATION HOSE (a) Disconnect the No. 2 ventilation hose. 5. REMOVE AIR CLEANER ASSEMBLY 6. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY 7. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY (a) Remove the 2 bolts, then remove the fuel pressure regulator. (b) Remove the vacuum hose. 1GR-FE FUEL: FUEL PRESSURE REGULATOR: REMOVAL (2007 4Runner) 1GR-FE FUEL: FUEL PUMP RESISTOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S9002X Title: 1GR-FE FUEL: FUEL PUMP RESISTOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FUEL PUMP RESISTOR (a) Inspect the fuel pump resistor resistance. (1) Using an ohmmeter, measure the resistance between terminal. Standard resistance: 0.70 - 0.76 Ω at 20°C (68°F) 1GR-FE FUEL: FUEL PUMP: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Title: 1GR-FE FUEL: FUEL PUMP: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM0000028S6003X 1GR-FE FUEL: FUEL PUMP: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL PUMP: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S7003X Title: 1GR-FE FUEL: FUEL PUMP: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE VAPOR PRESSURE SENSOR (a) Remove the tube joint clip, and pull out the vapor pressure sensor. 2. REMOVE FUEL SENDER GAGE ASSEMBLY (a) Disconnect the fuel sender gage connector. (b) Unlock the fuel sender gage, and slide it to remove. 3. REMOVE FUEL PUMP ASSEMBLY WITH FILTER (a) Using a screwdriver, disconnect the 4 snap-claws from the claw holes, and remove the sub tank. NOTICE: Do not damage the sub tank. 1GR-FE FUEL: FUEL PUMP: DISASSEMBLY (2007 4Runner) (b) Disconnect the fuel pump connector. (c) Using a small screwdriver, disconnect the 4 claws from the claw holes, and remove the fuel pump with filter. (d) Remove the fuel pump O-ring from the fuel pump. (e) Remove the fuel pump spacer from the fuel pump. 4. REMOVE FUEL PUMP FILTER (a) Using a small screwdriver, pry out the clip. (b) Pull out the fuel pump filter from the fuel pump. 1GR-FE FUEL: FUEL PUMP: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S5003X Title: 1GR-FE FUEL: FUEL PUMP: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FUEL PUMP (a) Inspect the fuel pump resistance. (1) Using an ohmmeter, measure the resistance between terminals 4 and 5. Standard resistance: 0.2 - 3.0 Ω at 20°C (68°F) (b) Inspect fuel pump operation. (1) Apply the battery voltage to both terminals. Check that the pump operates. NOTICE: z z z These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep fuel pump as far away from the battery as possible. Always do the switching at the battery side. 1GR-FE FUEL: FUEL PUMP: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S4002X Title: 1GR-FE FUEL: FUEL PUMP: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY 1GR-FE FUEL: FUEL PUMP: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028S8002X Title: 1GR-FE FUEL: FUEL PUMP: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL FUEL PUMP FILTER (a) Install the fuel pump filter with a new clip. 2. INSTALL FUEL PUMP ASSEMBLY WITH FILTER (a) Install a fuel pump spacer to the fuel pump. (b) Apply a light coat of gasoline to a new O-ring, and install it to the fuel pump. (c) Apply a light coat of gasoline to the O-ring again, and install the fuel pump to the fuel filter. (d) Install the sub tank. (1) Apply a light coat of gasoline to a new O-ring, and install it to the fuel suction tube assembly. (2) Apply a light coat of gasoline to the O-ring again, and install the sub tank to the fuel filter. 3. INSTALL FUEL SENDER GAGE ASSEMBLY (a) Lock the fuel sender gage. 1GR-FE FUEL: FUEL PUMP: REASSEMBLY (2007 4Runner) (b) Connect the fuel sender gage connector. 4. INSTALL VAPOR PRESSURE SENSOR (a) Install the vapor pressure sensor with the tube joint clip. NOTICE: z z z z Check that there is no scratch or foreign objects on the connecting parts. Check that the fuel tube joint connector is fully inserted. Check that the tube joint clip is on the collar of the fuel tub joint. After installing the tube joint clip, check if the fuel tube joint connector is securely connected by pulling it. 1GR-FE FUEL: FUEL PUMP: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028T5002X Title: 1GR-FE FUEL: FUEL PUMP: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY 1GR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028RV002X Title: 1GR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION AND FUEL LEAK (a) When using the intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Turn the ignition switch ON and intelligent tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the intelligent tester. (4) Please refer to the intelligent tester operator's manual for further details. (b) When not using the intelligent tester (1) Remove the circuit opening relay. (2) Using a service wire, connect terminals FP and +B of the relay block. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance to the fuel system. (d) Turn the ignition switch OFF. (e) Disconnect the intelligent tester from the DLC3. 2. CHECK FUEL PRESSURE (a) Prepare for inspection. (1) Prepare a new fuel tube, and take out the fuel tube connector from the tube. 1GR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) HINT: Part No. 23801-31070 (b) Prevent gasoline from spilling out . (c) Disconnect the EFI fuel pipe clamp . (d) Disconnect the fuel pipe No. 1 from the fuel main tube. (e) Install SST (pressure gauge) as shown in the illustration by using the SSTs and a fuel tube connector. SST: 09268-31011 90467-13001 95336-08070 SST: 09268-45014 09268-41200 09268-41220 09268-41250 90467-13001 (f) Wipe off any splattered gasoline. (g) Start the engine. (h) Measure the fuel pressure at idle. Fuel pressure: 281 - 287 kPa (2.87 - 2.93 kgf/cm 2, 40.8 - 41.7 psi) (i) Stop the engine. (j) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm 2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. 1GR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) (k) After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery carefully, remove the SST and fuel tube connector to prevent gasoline from the splashing. (l) Reconnect the fuel tube to the fuel main tube. (m) Install the EFI fuel pipe clamp. (n) Check for fuel leak. 1GR-FE FUEL: FUEL SYSTEM: PRECAUTION (2007 4Runner) Last Modified: 4-26-2007 1.6 L Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028RU002X Title: 1GR-FE FUEL: FUEL SYSTEM: PRECAUTION (2007 4Runner) PRECAUTION 1. PRECAUTION (a) Before starting on the work for the fuel system inspection and repair, disconnect the negative (-) terminal cable from the battery. (b) Do not smoke or work near fire when handling the fuel system. (c) Keep gasoline away from rubber or leather parts. 2. WORK FOR PREVENT GASOLINE FROM SPILLING OUT CAUTION: z z Take precaution for preventing gasoline from spilling out before removing the fuel system parts. As there is the remained pressure in the fuel line after working for prevent gasoline from spilling out, prevent it from splashing inside the vehicle compartment by covering them with a shop rag. (a) Remove the circuit opening relay from the engine room relay block. (b) Start the engine. After the engine stopped, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system to lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and let the air out of the fuel tank. (e) Disconnect the negative (-) terminal cable from the battery. (f) Reinstall the circuit opening relay. 3. FUEL SYSTEM 1GR-FE FUEL: FUEL SYSTEM: PRECAUTION (2007 4Runner) (a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Disconnect the fuel pump tube . (2) Drain the fuel remained inside the fuel pump tube. (3) In order to prevent the disconnected fuel pump tube from damaging and foreign objects from being mixed into, cover them with a vinyl bag. (4) Put a container under the connection. (b) Observe these precautions when removing and installing the injectors. (1) Never reuse the O-ring. (2) When placing a new O-ring on the injector, do not damage it. (3) Coat the new O-rings with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and lower intake manifold as shown in the illustration. NOTICE: Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or cylinder head contacts the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connector (Quick type A): (1) Remove the fuel pipe clamp No. 1. (2) Check that there is no dirt like mud on the pipe and around the connector before disconnecting them. Clean them if necessary. (3) Disconnect them by hand. (4) When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. (5) Inspect that there is no dirt or the like on the seal 1GR-FE FUEL: FUEL SYSTEM: PRECAUTION (2007 4Runner) surface of the disconnected pipe. Clean it away if necessary. (6) In order to prevent the disconnected pipe and connector from damaging and foreign objects from being mixed into, cover them with a vinyl bag. (e) Observe these precautions when connecting the fuel tube connector (Quick Type A): (1) Check that there is no damage or foreign objects in the connected part of the pipe. (2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply a little amount of fresh engine oil on the tip of the pipe. (3) After having finished the connection, check if the pipe and the connector are securely connected by pulling them. (4) Check for any fuel leak. (f) Observe these precautions when disconnecting the fuel tube connector (Quick type B): (1) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary. (2) Disconnect them by your hands. (3) When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. (4) Inspect if there is any dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary. (5) Prevent the disconnected pipe and connector from damaging and foreign objects from being mixed into by covering them with a vinyl bag. (g) Observe these precautions when connecting the fuel tube connector (Quick type B): (1) Match the axis of the connector with the axis of the pipe, and push in the connector until the connector 1GR-FE FUEL: FUEL SYSTEM: PRECAUTION (2007 4Runner) makes a "click" sound. In case that the connection is tight, apply a little amount of new engine oil on the tip of the pipe. (2) After having finished the connection, check if the pipe and the connector are securely connected by pulling them. (3) Check for fuel leakage. (h) Observe these precautions when handling nylon tube. CAUTION: z z z z Be careful not to turn the connection part of the nylon tube and the quick connector when connecting them. Do not kink the nylon tube. Do not remove the EPDM protector on the outside of the nylon tube. Do not close the piping with the nylon tube by bending it. 4. CHECK FOR FUEL LEAK (a) Check that there are no fuel leaks after doing maintenance to the fuel system . 1GR-FE FUEL: FUEL TANK: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Title: 1GR-FE FUEL: FUEL TANK: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM0000028SB001X 1GR-FE FUEL: FUEL TANK: COMPONENTS (2007 4Runner) 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028SA001X Title: 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FUEL TANK TO FILLER PIPE HOSE (a) Hose and pipe connection is as shown in the illustration. NOTICE: The filler hose must be replaced with a new one. 2. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY (a) Push in the tube connector to the pipe until the connector makes a "click" sound and install the retainer. NOTICE: z z Check if there is any damage or foreign objects on the connected part of the pipe. After connecting, check if the pipe and the connector are securely connected by pulling them. 3. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY (a) Install a new gasket onto the fuel tank. 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) (b) Set the fuel suction tube assembly to the fuel tank. NOTICE: Be careful not to bend the arm of the fuel sender gage. (c) Fit a spline of the fuel suction tube assembly into a keyway of the fuel tank. (d) Install a retainer. (1) Using a new retainer, align mark on the retainer with a screw-threads starting point of the fuel tank. (2) While holding the fuel suction tube assembly, tighten the retainer one complete turn by hand. (e) Using a SST, tighten the retainer one more complete turn, and position the mark on the retainer into a range A of the fuel tank. SST: 09808-14020 09808-01410 09808-01420 09808-01430 HINT: z z Turn the retainer two complete turns and position the mark within the range A for the installation of the retainer. A rib on the retainer can be fitted into a tip of the SST. 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) 4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Connect the fuel tank main tube with the tube joint clip. NOTICE: z z z z Check that there is no scratch or foreign objects on the connecting parts. Check that the connector is fully inserted. Check that the tube joint clip is on the collar of the connector. After installing the tube joint clip, check if the tubes are securely connected by puling then. 5. INSTALL FUEL TANK CUSHION (a) Install 3 new fuel tank cushions to the fuel tank. 6. INSTALL FUEL TANK ASSEMBLY (a) Set a mission jack to the fuel tank. (b) Install the fuel tank and 2 fuel tank bands with the 2 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (a) Push in the tube connector to the pipe until the connector makes a "click" sound. NOTICE: 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) z z Check that there is no damage or foreign objects on the connected part of the pipe. After connecting, check if the pipe and the connector are securely connected by pulling them. 8. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Push in the tube connector to the pipe until the connector makes a "click" sound. NOTICE: z z Check that there is no damage or foreign objects on the connected part of the pipe. After connecting, check if the pipe and the connector are securely connected by pulling them. 9. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (a) Set a mission jack to the fuel tank protector. (b) Install the fuel tank protector with the 6 bolts. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 10. CONNECT FUEL TANK TO FILLER PIPE HOSE (a) Hose and pipe connection is as shown in the illustration. 11. CHECK FOR FUEL LEAKAGE 12. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Connect the connector. 1GR-FE FUEL: FUEL TANK: INSTALLATION (2007 4Runner) (b) Install the 3 screws and rear floor service hole cover. (c) Install the rear floor carpet assembly. 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Fuel System Model Year: 2007 Model: 4Runner Doc ID: RM0000028SC001X Title: 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE HINT: 2. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Hold the rear No. 1 seat assembly LH. (b) Hold the rear No. 1 seat assembly RH. (c) Remove a tear-off floor mat. (d) Remove the 3 screws from the rear floor service hole cover. (e) Disconnect the connector. 3. REMOVE FUEL TANK TO FILLER PIPE HOSE (a) Disconnect the fuel-tank-to-filler-pipe hose from the fuel filler pipe. 4. DRAIN FUEL 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) 5. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (a) Set a mission jack to the fuel tank protector. (b) Remove the 6 bolts and the fuel tank protector. 6. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Pinch the tabs of the retainer to remove the lock claws and pull out the 2 fuel tank tubes. NOTICE: z z z z z Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary. Do not use any tool in this work. Do not bend or twist the nylon tube. To protect the tube, cover it with a vinyl bag after checking. When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the fuel tank tube. 7. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (a) Pinch a tab of the retainer to remove the lock claws and pull out the fuel tank tube. NOTICE: z z z z z Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary. Do not use any tool in this work. Do not bend or twist the nylon tube by force. To protect the tube, cover it with a vinyl bag after checking. When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the tube. 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) 8. DISCONNECT FUEL TANK VENT HOSE (a) Disconnect the fuel tank breather tube from the fuel tank. (1) Push the connector deep inside. (2) Pinch portion A, as shown in the illustration. (3) Pull out the connector. 9. REMOVE FUEL TANK ASSEMBLY (a) Set a mission jack to the fuel tank. (b) Remove the 2 bolts, 2 fuel tank bands and fuel tank. 10. REMOVE FUEL TANK CUSHION 11. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE (a) Remove the 2 tubes joint clips, and pull out the 2 fuel tank tubes. NOTICE: z z z z z Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary. Do not use any tool in this work. Do not bend or twist the nylon tube by force. After disconnecting, cover the fuel tube joint with a vinyl bag. When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to free and then disconnect it. Likewise, disconnect the fuel tank return tube. 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) 12. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY NOTICE: Protect a connector and tube joint with a masking tape or something in order to prevent sticking foreign objects onto them, and clean dirt and foreign objects from the fuel suction tube assembly before removing it. (a) Using a SST, loosen the retainer. SST: 09808-14020 09808-01410 09808-01420 09808-01430 HINT: A rib on the retainer can be fitted into a tip of the SST. (b) Remove the retainer. (c) Pull out the fuel suction tube assembly. NOTICE: Be careful not to bend the arm of the sender gage. (d) Remove the gasket from the fuel tank. 13. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY (a) Pinch the tab of the retainer to remove the lock claws and pull out the fuel tank breather tube. NOTICE: z z z z z Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary. Do not use any tool in this work. Do not bend or twist the nylon tube. To protect the tube, cover it with a vinyl bag after checking. When connector and the pipe are stuck, turn the fuel tank breather tube carefully to free and then disconnect 1GR-FE FUEL: FUEL TANK: REMOVAL (2007 4Runner) the tube. 14. REMOVE FUEL TANK TO FILLER PIPE HOSE (a) Remove the fuel tank inlet hose from the fuel tank. 1GR-FE IGNITION: IGNITION SYSTEM: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Control Model Year: 2007 Model: 4Runner Doc ID: RM000002B4N002X Title: 1GR-FE IGNITION: IGNITION SYSTEM: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 to 2,740 Ω Hot 2,065 to 3,225 Ω NOTICE: "Cold" and "Hot" mean the temperature of the coils themselves. "Cold" is from -10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100 °C (212°F). 1GR-FE IGNITION: IGNITION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Engine Control Model Year: 2007 Model: 4Runner Doc ID: RM000000SM6018X Title: 1GR-FE IGNITION: IGNITION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION NOTICE: "Cold" and "Hot" in this section mean the temperature of the coils themselves. "Cold" is from 10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°F). 1. CHECK IGNITION COIL ASSEMBLY AND PERFORM SPARK TEST (a) Check for DTCs. NOTICE: If any DTC is present, perform troubleshooting in accordance with a procedure for that DTC. (b) Check that sparks occur. (1) Remove the ignition coils. (2) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (3) Install the spark plugs to each ignition coil, and connect the ignition coil connectors. (4) Disconnect the 6 injector connectors. (5) Ground the spark plugs. (6) Check if sparks occur at each spark plug while the engine is being cranked. NOTICE: z z z Be sure to ground the spark plug when checking. Replace the ignition coil if it receives an impact. Do not crank the engine for more than 2 seconds. If sparks do not occur, perform the following test: (c) Spark test flow chart. (1) Check that the wire harness side connector of ignition coil assembly is securely connector. Result: RESULT PROCEED TO NG Connect securely. OK Go to next step. (2) Perform spark test on each ignition coil assembly. z z Replace ignition coil assembly with a normal one. Perform spark test again. 1GR-FE IGNITION: IGNITION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Result: RESULT PROCEED TO NG Replace ignition coil assembly. OK Go to next step. (3) Check power supply to ignition coil. z z Turn ignition switch ON. Check that there is battery positive (+) voltage at ignition coil positive (+) terminal. Result: RESULT PROCEED TO NG Check wiring between ignition switch and ignition coil assembly. OK Go to next step. (4) Check resistance in VVT sensor out put voltage (see step 2). Result: RESULT PROCEED TO NG Following test 1. OK Go to next step. z Check that the wiring between VVT sensor and ECM. Result: RESULT PROCEED TO NG Repair wiring between VVT sensor and ECM. OK Repair VVT sensor (5) Check resistance in crankshaft position sensor. Standard resistance: STANDARD CONDITION SPECIFIED CONDITION Cold 1,630 to 2,740 Ω Hot 2,065 to 3,225 Ω Result: RESULT PROCEED TO NG Replace the crankshaft position sensor. OK Go to next step. 1GR-FE IGNITION: IGNITION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) (6) Check IGT signal from ECM. Result: RESULT PROCEED TO NG Check ECM OK Repair wiring between ignition coil and ECM. (d) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 20 N·m (204 kgf·cm, 13 ft·lbf) (e) Install the ignition coils. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 2. CHECK VVT SENSOR OUTPUT VOLTAGE (a) Turn the ignition switch to the ON position. (b) Check that the voltage between terminal VC1 and ground is 5 V. HINT: For the terminal arrangement of the engine ECU . (c) While turning the crankshaft pulley by hand, measure the voltage between each terminal. Check that the voltage changes between the Hi range and Lo range shown in the table below. Standard voltage: SENSOR POSITION TERMINAL NO. VOLTAGE (HI) VOLTAGE (LO) Bank 1 VV1+ ←→ VV1- 3.375 to 4.950 0.450 to 1.375 Bank 2 VV2+ ←→ VV2- 3.375 to 4.950 0.450 to 1.375 HINT: For the terminal arrangement of the engine ECU . 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM0000029RW001X Title: 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT INTAKE AIR SURGE TANK (a) Inspect the diaphragm. (1) Check that the lever moves when vacuum of 26.6 kPa (200 mmHg) is applied with the mighty bag on. (2) Check that the vacuum of 26.6 kPa (200 mmHg) is sustained for 1 minute in the above state. 2. INSPECT VACUUM SWITCHING NO. 1 VALVE ASSEMBLY (a) Inspect the VSV for open circuit. (1) Using an ohmmeter, check that there is continuity between each terminals. Resistance: 33 to 39 Ω at 20°C (68°F) (b) Inspect the VSV for ground. (1) Using an ohmmeter, check that there is no continuity between each terminal and the body. (c) Inspect the VSV operation. 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: INSPECTION (2007 4Runner) (1) Check that air flows from port E to the filter. (2) Apply battery positive voltage across the terminals. (3) Check that air flows from port E to port F. 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runn... Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM0000029RX002X Title: 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT INTAKE AIR CONTROL FUNCTION (a) Remove the V-bank cover. (b) Set intelligent tester to the DLC3. (c) Perform the ACTIVE TEST, then check that the actuator rod operates. (d) Start the engine. (e) Check that the VSV for ACIS is ON under the condition (procedure [A]). z z Depressing the accelerator pedal to 60 % accelerator opening angle. Racing the engine above 4,700 rpm. (f) Check that the VSV for ACIS is OFF under the condition. z z The engine idling. Release the accelerator pedal when the condition of procedure [A]. 2. INSPECT INTAKE AIR CONTROL VALVE 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: ON-VEHICLE INSPECTION (2007 4Runn... (a) Remove V-bank cover. (b) Using a 3-way connector, connect vacuum gauge to the actuator hose. (c) Start the engine. (d) While the engine is idling, check that the vacuum gauge needle momentarily fluctuates up to approximately 39.9 kPa (300 mmHg, 11.8 in.Hg). (The actuator rod is pulled out.) (e) Rapidly depress the accelerator pedal to fully open position and check that the vacuum gauge needle points to 0 kPa (0 mmHg, 0 in.Hg). (The actuator rod is returned.) (f) Remove the vacuum gauge, and connect the vacuum hose to the actuator. (g) Reinstall V-bank cover. 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: PARTS LOCATION (2007 4Runner) Last Modified: 4-26-2007 1.6 R Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM0000029RV002X Title: 1GR-FE INTAKE: INTAKE AIR CONTROL SYSTEM: PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION 1GR-FE LUBRICATION: ENGINE OIL COOLER: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM000002B8L002X Title: 1GR-FE LUBRICATION: ENGINE OIL COOLER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE LUBRICATION: ENGINE OIL COOLER: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: ENGINE OIL COOLER: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM00000172N003X Title: 1GR-FE LUBRICATION: ENGINE OIL COOLER: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT OIL COOLER ASSEMBLY (a) Check the oil cooler for damage and clogging. If necessary, replace the oil cooler. 1GR-FE LUBRICATION: ENGINE OIL COOLER: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM00000172M003X Title: 1GR-FE LUBRICATION: ENGINE OIL COOLER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL OIL COOLER ASSEMBLY (a) Clean the oil cooler contact surface on the cooler mounting. (b) Install a new O-ring onto the oil cooler. (c) Apply a light coat of engine oil to the threads of the union bolt. (d) Install the oil cooler and plate washer with the union bolt. Torque: 68 N·m (693 kgf·cm, 50 ft·lbf) (e) Connect the 2 oil cooler hoses to the oil cooler. 2. INSTALL OIL FILTER SUB-ASSEMBLY 3. ADD ENGINE COOLANT 4. ADD ENGINE OIL 5. INSPECT ENGINE OIL LEVEL 6. INSPECT ENGINE OIL LEAKS 7. CHECK FOR ENGINE COOLANT LEAKAGE 8. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 1GR-FE LUBRICATION: ENGINE OIL COOLER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM00000172O003X Title: 1GR-FE LUBRICATION: ENGINE OIL COOLER: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE OIL FILTER SUB-ASSEMBLY 3. REMOVE V-BANK COVER 4. REMOVE OIL COOLER ASSEMBLY (a) Disconnect the 2 oil cooler hoses from the oil cooler. (b) Remove the union bolt, plate washer and oil cooler. (c) Remove the O-ring from the oil cooler. 1GR-FE LUBRICATION: LUBRICATION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017MF008X Title: 1GR-FE LUBRICATION: LUBRICATION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water contamination, discoloring or thinning. If the quality is visibly poor, replace the oil and filter. 2. CHECK ENGINE OIL LEVEL (a) Warm up the engine, then stop the engine and wait for 5 minutes. (b) Check that the engine oil level is between the low level and full level marks on the level gauge. If low, check for leakage and top oil up to the full level mark. NOTICE: Do not fill with engine oil to above the full level mark. 3. INSPECT OIL PRESSURE (a) Disconnect the oil pressure switch connector. (b) Using a 24 mm deep socket wrench, remove the oil pressure switch. (c) Install the oil pressure gauge. (d) Warm up the engine. (e) Inspect the oil pressure. Oil pressure: WHEN IDLING 29 KPA (0.3 KGF*CM 2, 4.2 PSI) OR MORE At 3,000 rpm 294 to 588 kPa (3.0 to 6.0kgf*cm 2, 43 to 85 psi) (f) Remove the oil pressure gauge. 1GR-FE LUBRICATION: LUBRICATION SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) (g) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent (h) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N·m (153 kgf·cm, 11 ft·lbf) NOTICE: Do not start the engine within 1 hour of installation. (i) Connect the oil pressure switch connector. (j) Start the engine and check for engine oil leakage. 1GR-FE LUBRICATION: OIL FILTER: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Title: 1GR-FE LUBRICATION: OIL FILTER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002B8K002X 1GR-FE LUBRICATION: OIL FILTER: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL FILTER: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017LZ003X Title: 1GR-FE LUBRICATION: OIL FILTER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL OIL FILTER SUB-ASSEMBLY (a) Clean the oil filter contact surface on the oil filter bracket. (b) Lubricate the rubber gasket of a new oil filter with clean engine oil. (c) Tighten the oil filter by hand until the rubber gasket comes into contact with the seat of the filter bracket. (d) Using SST, tighten it an additional 3/4 turn to set the filter. SST: 09228-07501 Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 2. ADD ENGINE OIL (a) Fill with fresh engine oil. Standard engine oil: OIL GRADE ILSAC multigrade engine oil OIL VISCOSITY (SAE) - 5W-30 Standard capacity: ITEM SPECIFIED CONDITION 1GR-FE LUBRICATION: OIL FILTER: INSTALLATION (2007 4Runner) Drain and refill with oil filter change 5.2 liters (5.5 US qts, 4.6 Imp. qts) Drain and refill without oil filter change 4.9 liters (5.2 US qts, 4.3 Imp. qts) Dry fill 6.0 liters (6.3 US qts, 5.3 Imp. qts) (b) Reinstall the oil filler cap. 3. INSPECT ENGINE OIL LEAKS 4. INSPECT ENGINE OIL LEVEL 1GR-FE LUBRICATION: OIL FILTER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017M0003X Title: 1GR-FE LUBRICATION: OIL FILTER: REMOVAL (2007 4Runner) REMOVAL CAUTION: z z z z Prolonged and repeated contact with engine oil will cause the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wash your skin thoroughly with soap and water, or use waterless hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents. For environmental protection, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the engine under cover seal No. 3. (b) Remove the oil pan drain plug and drain the engine oil. (c) Clean the oil pan drain plug and install it with a new gasket. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 2. REMOVE OIL FILTER SUB-ASSEMBLY (a) Remove the drain pipe cap. 1GR-FE LUBRICATION: OIL FILTER: REMOVAL (2007 4Runner) (b) While removing the oil filter with SST, catch the oil from the oil filter with a container. SST: 09228-07501 (c) Install the drain pipe cap. (d) Clean the oil catch plate. HINT: When using a drain hose, perform the following procedures. (e) Remove the drain pipe cap. (f) Connect a drain hose to the oil filter bracket. HINT: z z Drain hose inside diameter: 8 mm (0.31 in.) Drain hose length: 900 mm (35.43 in.) (g) Feed the drain hose down through the engine under cover, and put the drain oil container beneath the drain hose to catch the oil from the oil filter. (h) Using SST, remove the oil filter. SST: 09228-07501 (i) Remove the drain hose and install the drain pipe cap. (j) Clean the oil catch plate. 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Title: 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION Doc ID: RM000002B8J002X 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE LUBRICATION: OIL PUMP: COMPONENTS (2007 4Runner) 1GR-FE LUBRICATION: OIL PUMP: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017M5003X Title: 1GR-FE LUBRICATION: OIL PUMP: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE OIL PUMP COVER (a) Remove the 3 bolts and oil pipe. (b) Remove the 2 O-rings. (c) Remove the 7 bolts, oil pump cover, drive rotor and driven rotor. 2. REMOVE OIL PUMP RELIEF VALVE (a) Remove the plug, spring and relief valve. 1GR-FE LUBRICATION: OIL PUMP: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017M2003X Title: 1GR-FE LUBRICATION: OIL PUMP: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT OIL PUMP RELIEF VALVE (a) Coat the valve with engine oil, then check that it falls smoothly into the valve hole by its own weight. If not, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT OIL PUMP ROTOR SET (a) Place the drive and driven rotors into the timing chain cover with the marks facing upward. (b) Check the rotor tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard clearance: 0.06 to 0.16 mm (0.0024 to 0.0063 in.) Maximum tip clearance: 0.16 mm (0.0063 in.) If the clearance is greater than the maximum, replace the drive and driven rotors together. 1GR-FE LUBRICATION: OIL PUMP: INSPECTION (2007 4Runner) (c) Check the rotor side clearance. (1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard clearance: 0.03 to 0.09 mm (0.0012 to 0.0035 in.) Maximum side clearance: 0.09 mm (0.0035 in.) If the clearance is greater than the maximum, replace the drive and driven rotors. If necessary, replace the timing chain cover assembly. (d) Check the rotor body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and body. Standard clearance: 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum body clearance: 0.325 mm (0.0128 in.) If the clearance is greater than the maximum, replace the drive and driven rotors. If necessary, replace the timing chain cover assembly. 1GR-FE LUBRICATION: OIL PUMP: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017M1003X Title: 1GR-FE LUBRICATION: OIL PUMP: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TIMING CHAIN COVER OIL SEAL (a) Using SST and hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST: 09226-10010 (b) Apply MP grease to the oil seal lip. 2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Install a new O-ring onto the LH cylinder head as shown in the illustration. (c) Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the 4 locations as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent 1GR-FE LUBRICATION: OIL PUMP: INSTALLATION (2007 4Runner) (d) Apply continuous beads of seal packing (diameter 3 to 4 mm (0.12 to 0.16 in.)) to the timing chain cover as shown in the illustration. Seal packing: Water pump part Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other parts Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: z z Install the timing chain cover within 3 minutes of applying the seal packing. Timing chain cover bolts and nuts must be tightened within 15 minutes of installation. Otherwise, the seal packing must be removed and reapplied. Do not apply seal packing to portion A shown in the illustration. (e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place. (f) Install the timing chain cover with the 24 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps. Torque: 23 N·m (235 kgf·cm, 17 ft·lbf) NOTICE: Pay attention not to wrap the chain and slipper over the timing chain cover seal line. Each bolt length is as follows: BOLT LENGTH A 25 mm (0.98 in.) B 55 mm (2.17 in.) 1GR-FE LUBRICATION: OIL PUMP: INSTALLATION (2007 4Runner) 3. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (a) Install a new gasket and the oil filter bracket with the 3 bolts and 2 nuts. Torque: 19 N·m (194 kgf·cm, 14 ft·lbf) 4. INSTALL VVT SENSOR 5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Install the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts. 6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH 7. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH 8. INSTALL IGNITION COIL ASSEMBLY Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 9. INSTALL INTAKE AIR SURGE TANK 10. INSTALL OIL PAN SUB-ASSEMBLY 11. INSTALL OIL STRAINER SUB-ASSEMBLY 12. INSTALL NO.2 OIL PAN SUB-ASSEMBLY 13. INSTALL CRANKSHAFT PULLEY 14. INSTALL NO.1 IDLER PULLEY SUB-ASSEMBLY 15. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY 16. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 17. INSTALL COOLER COMPRESSOR ASSEMBLY 18. REMOVE GENERATOR ASSEMBLY 19. REMOVE VANE PUMP ASSEMBLY 20. INSTALL WATER INLET 21. INSTALL OIL LEVEL GAUGE GUIDE 22. INSTALL AIR CLEANER ASSEMBLY 1GR-FE LUBRICATION: OIL PUMP: INSTALLATION (2007 4Runner) 23. CONNECT VENTILATION HOSE NO.2 24. INSTALL FAN WITH FLUID COUPLING 25. INSTALL FAN AND GENERATOR V BELT 26. FULLY TIGHTEN FAN WITH FLUID COUPLING 27. INSTALL RADIATOR SUPPORT SEAL UPPER 28. INSTALL BATTERY 29. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT 30. INSTALL POWER STEERING LINK ASSEMBLY 31. ADD ENGINE OIL 32. ADD ENGINE COOLANT 33. INSPECT ENGINE OIL LEAKS 34. INSPECT ENGINE COOLANT LEAK 35. INSTALL V-BANK COVER (a) Install the V-bank cover with the 2 nuts. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) 1GR-FE LUBRICATION: OIL PUMP: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Doc ID: RM0000017M6003X Title: 1GR-FE LUBRICATION: OIL PUMP: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL OIL PUMP RELIEF VALVE (a) Coat the relief valve with engine oil and insert the relief valve and spring into the valve hole. (b) Install the relief valve plug. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 2. INSTALL OIL PUMP COVER (a) Apply fresh engine oil to the drive and driven rotors. (b) Place the drive and driven rotors into the timing chain cover with the marks facing the oil pump cover side. (c) Install the oil pump cover with the 7 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) (d) Install a new O-ring onto the oil pump cover. (e) Install a new O-ring onto the oil pipe. 1GR-FE LUBRICATION: OIL PUMP: REASSEMBLY (2007 4Runner) (f) Install the oil pipe with the 3 bolts. Torque: 9.0 N·m (92 kgf·cm, 80 in·lbf) 1GR-FE LUBRICATION: OIL PUMP: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Lubrication Model Year: 2007 Model: 4Runner Title: 1GR-FE LUBRICATION: OIL PUMP: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE POWER STEERING LINK ASSEMBLY 2. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT 3. DRAIN ENGINE COOLANT 4. DRAIN ENGINE OIL 5. REMOVE BATTERY 6. REMOVE V-BANK COVER 7. REMOVE RADIATOR SUPPORT SEAL UPPER (a) Remove the 11 clips and radiator support seal upper. 8. LOOSEN FAN WITH FLUID COUPLING 9. REMOVE FAN AND GENERATOR V BELT 10. REMOVE FAN WITH FLUID COUPLING 11. DISCONNECT VENTILATION HOSE NO.2 12. REMOVE AIR CLEANER ASSEMBLY 13. REMOVE OIL LEVEL GAUGE GUIDE (a) Remove the oil level gauge. (b) Remove the bolt and pull out the oil level gauge guide. (c) Remove the O-ring from the oil level gauge guide. 14. REMOVE WATER INLET 15. SEPARATE VANE PUMP ASSEMBLY 16. REMOVE GENERATOR ASSEMBLY Doc ID: RM0000017M4003X 1GR-FE LUBRICATION: OIL PUMP: REMOVAL (2007 4Runner) 17. SEPARATE COOLER COMPRESSOR ASSEMBLY 18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 19. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY (a) Remove the 2 bolts and 2 idler pulleys. 20. REMOVE NO.1 IDLER PULLEY SUB-ASSEMBLY (a) Remove the bolt and idler pulley. 21. REMOVE CRANKSHAFT PULLEY 22. REMOVE NO.2 OIL PAN SUB-ASSEMBLY 23. REMOVE OIL STRAINER SUB-ASSEMBLY 24. REMOVE OIL PAN SUB-ASSEMBLY 25. REMOVE INTAKE AIR SURGE TANK 26. REMOVE IGNITION COIL ASSEMBLY 27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH 28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 29. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the 2 oil control valve connectors. (b) Remove the 2 bolts and 2 camshaft timing oil control valves. 30. REMOVE VVT SENSOR 31. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (a) Remove the 3 bolts, 2 nuts, oil filter bracket and gasket. 32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (a) Remove the 24 bolts and 2 nuts. 1GR-FE LUBRICATION: OIL PUMP: REMOVAL (2007 4Runner) (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. (c) Remove the O-ring from the LH cylinder head. 33. REMOVE TIMING CHAIN COVER OIL SEAL (a) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the oil pump assembly. Wrap the tip of the screwdriver with tape. 1GR-FE STARTING: ACC CUT RELAY: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DZ6004X Title: 1GR-FE STARTING: ACC CUT RELAY: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT ACC CUT RELAY (a) Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition: BETWEEN TERMINALS SPECIFIED CONDITION 1-2 Continuity 3-5 No continuity (2) Using an ohmmeter, check for continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity 1GR-FE STARTING: IGNITION SWITCH: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DYR003X Title: 1GR-FE STARTING: IGNITION SWITCH: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE STARTING: IGNITION SWITCH: COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: IGNITION SWITCH: COMPONENTS (2007 4Runner) 1GR-FE STARTING: IGNITION SWITCH: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DYQ003X Title: 1GR-FE STARTING: IGNITION SWITCH: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT IGNITION OR STARTER SWITCH ASSEMBLY (a) Inspect the switch continuity. Standard: TERMINAL NO. SWITCH POSITION SPECIFIED CONDITION Between all terminals LOCK No continuity 2-3 ACC Continuity ON Continuity START Continuity 2-3-4 6-7 1-2-4 6-7-8 If the result is not as specified, replace the switch assembly. 1GR-FE STARTING: IGNITION SWITCH: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DYP003X Title: 1GR-FE STARTING: IGNITION SWITCH: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY (a) Install the ignition switch with the 2 screws. (b) Install the clamp. (c) Connect the un-lock warning switch connector and ignition switch connector. 2. INSTALL STEERING COLUMN UPPER COVER (a) Install the steering column upper cover. 3. INSTALL STEERING COLUMN LOWER COVER 1GR-FE STARTING: IGNITION SWITCH: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DYS003X Title: 1GR-FE STARTING: IGNITION SWITCH: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE STEERING COLUMN LOWER COVER 2. REMOVE STEERING COLUMN UPPER COVER (a) Remove the steering column upper cover. 3. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY (a) Disconnect the ignition switch connector and un-lock warning switch connector. (b) Remove the clamp. (c) Remove the 2 screws and ignition switch. 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEM002X Title: 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Cold Area): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Cold Area): DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEO002X Title: 1GR-FE STARTING: STARTER (for Cold Area): DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE STARTER YOKE ASSEMBLY (a) Remove the nut, and disconnect the lead wire from the C terminal. (b) Remove the 2 through bolts. (c) Pull out the starter yoke and the armature together. (d) Remove the O-ring from the starter yoke. 2. REMOVE MAGNET STARTER SWITCH ASSEMBLY (a) Remove the 2 screws and magnet starter switch. (b) Remove the these parts from the starter drive housing. (1) Starter magnet switch return spring (Procedure "A"). (2) Starter idle gear pinion (Procedure "B"). (3) Starter idle gear clutch roller (Procedure "C"). (4) Starter idle gear retainer (Procedure "D"). (5) Starter clutch sub-assembly (Procedure "E"). 1GR-FE STARTING: STARTER (for Cold Area): DISASSEMBLY (2007 4Runner) (c) Using a magnetic finger, remove the steel ball from the clutch shaft hole. 3. REMOVE STARTER BRUSH HOLDER ASSEMBLY (a) Remove the 2 screws and end cover from the starter yoke. (b) Remove the O-ring from the starter yoke. (c) Using a screwdriver, hold the spring back and disconnect the 4 brushes from the brush holder. (d) Remove the brush holder from the armature. 4. REMOVE STARTER ARMATURE ASSEMBLY (a) Remove the starter armature assembly. 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEL002X Title: 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) INSPECTION 1. INSPECT STARTER ASSEMBLY NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. (a) Do pull-in test (Condition A). (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear protrudes. (b) Do holding test. (1) Disconnect the negative (-) lead from the terminal C with the above condition A is being sustained. Check that the pinion gear remains protruded. (c) Inspect clutch pinion gear return. (1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. (d) Perform the operation test without load. (1) Connect the field coil lead wire to terminal C. 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) Torque: 10 N·m (102 kgf·cm, 89 ft·lbf) Torque: 5.9 N·m (60 kgf·cm, 52 in·lbf) (2) Hold the starter with a vise. (3) Connect the battery and ammeter to the starter as shown. (4) Check that the ammeter indicates the specified current. Specified current (for standard area): 90 A or less at 11.5V Specified current (for cold area) 100 A or less at 11.5 V 2. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the commutator for open circuit. (1) Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. (b) Check the commutator for ground. (1) Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. (c) Check the commutator for dirty and burn on surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. (d) Check for the commutator runout. (1) Place the commutator on V-blocks. (2) Using a dial gauge, measure the runout. Maximum runout: 0.05 mm (0.0020 in.) 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) If the runout is greater than maximum, correct it on a lathe. (e) Using vernier calipers, measure the commutator diameter. Standard diameter: 35.0 mm (1.378 in.) Maximum diameter 34.0 mm (1.339 in.) If the diameter is less than minimum, replace the armature. (f) Check that the undercut depth is clean and free of foreign objects. Smooth out the edge. Standard undercut depth: 0.7 mm (0.028 in.) Minimum undercut depth 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. 3. INSPECT STARTER YOKE ASSEMBLY (a) Check the starter yoke for open circuit. (1) Using an ohmmeter, check that there is continuity between the lead wire and brushes. If there is no continuity, replace the starter yoke. (b) Check the shunt coil for open circuit. 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) (1) Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B). Standard resistance: 1.5 to 1.9 Ω at 20°C (68°F) If the resistance is not as specified, replace the starter yoke. 4. INSPECT BRUSH (a) Check the brushes length. (1) Using vernier calipers, measure the brush length. Standard length: 15.0 mm (0.591 in.) Minimum length 9.0 mm (0.354 in.) If the length is less than minimum, replace the brush holder and starter yoke. 5. INSPECT STARTER BRUSH HOLDER ASSEMBLY (a) Check the brush holder insulation. (1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) (b) Check the brush spring load. (1) Take a pull scale reading at the instant the brush spring separates from the brush. Standard spring load: 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf) Minimum spring load 12.7 N (1.3 kgf, 2.9 lbf) If the spring load is less than the minimum, replace the brush holder. 6. INSPECT STARTER CLUTCH SUB-ASSEMBLY (a) Check the clutch pinion gear. (1) Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. (2) Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the starter clutch. 7. INSPECT MAGNET STARTER SWITCH ASSEMBLY (a) Check the pull-in coil for open circuit. (1) Using an ohmmeter, check that there is continuity between terminal 50 and C. If there is no continuity, replace the magnet starter switch. (b) Check the holding coil for open circuit. (1) Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnet starter switch. 1GR-FE STARTING: STARTER (for Cold Area): INSPECTION (2007 4Runner) 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEG005X Title: 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL STARTER ASSEMBLY (for 2WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 2. CONNECT WIRE HARNESS (for 2WD) (a) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) 3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Connect the battery negative terminal. 6. INSTALL STARTER ASSEMBLY (for 4WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) (a) Install the steering sliding yoke to No. 2 steering intermediate shaft. (b) Install the bolt B and tighten the bolt B and A. Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) 8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Install the front fender rear splash shield LH with the 5 clips. 9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) (b) Connect the heated oxygen sensor (bank 2) connector. 10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Connect the battery negative terminal. 1GR-FE STARTING: STARTER (for Cold Area): REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEP002X Title: 1GR-FE STARTING: STARTER (for Cold Area): REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL STARTER ARMATURE ASSEMBLY (a) Apply the grease to the bearings, and install it to the starter yoke. 2. INSTALL STARTER BRUSH HOLDER ASSEMBLY (a) Place the brush holder on the armature. (b) Using a screwdriver, install the 4 brushes. (c) Install a new O-ring to the groove of the field frame. (d) Install the end frame with 2 screws. Torque: 3.8 N·m (39 kgf·cm, 34 in·lbf) 3. INSTALL MAGNET STARTER SWITCH ASSEMBLY (a) Apply grease to the steel ball, and install it to the clutch shaft hole. (b) Apply grease to the these parts "B" to "E", and install them to the starter drive housing. (1) Starter magnet switch return spring (Procedure "A"). (2) Starter idle gear pinion (Procedure "B". (3) Starter idle gear clutch roller (Procedure "C"). 1GR-FE STARTING: STARTER (for Cold Area): REASSEMBLY (2007 4Runner) (4) Starter idle gear retainer (Procedure "D"). (5) Starter clutch sub-assembly (Procedure "E"). (c) Install the magnet starter switch with the 2screws. 4. INSTALL STARTER YOKE ASSEMBLY (a) Install a new O-ring to the groove of the starter yoke. (b) Align the key of the starter yoke with the groove of the magnet starter switch. (c) Install the starter yoke and armature with the 2 through bolts. Torque: 9.3 N·m (95 kgf·cm, 82 in·lbf) (d) Connect the lead wire to the C terminal with the nut. 1GR-FE STARTING: STARTER (for Cold Area): REASSEMBLY (2007 4Runner) Torque: 5.9 N·m (60 kgf·cm, 52 in·lbf) 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM0000026Q1005X Title: 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Disconnect the negative battery terminal. 2. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Remove the 4 bolts and engine rear under cover assembly. 3. REMOVE NO. 2 MANIFOLD STAY (for 2WD) (a) Remove the 3 bolts and No. 2 manifold stay. 4. DISCONNECT WIRE HARNESS (for 2WD) (a) Remove the bolt and disconnect the wire harness from the cylinder block. 5. REMOVE STARTER ASSEMBLY (for 2WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 6. DISCONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Disconnect the negative battery terminal. 7. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Remove the 4 bolts and engine rear under cover assembly. 8. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor (bank 2) connector. (b) Remove the 2 bolts, 2 nuts, No. 2 front exhaust pipe assembly and 2 gaskets. 9. REMOVE FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Remove the 5 clips and front fender rear splash shield LH. 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) 10. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) (a) Loosen the bolt A and remove the bolt B, then separate the No. 2 steering intermediate shaft sub-assembly. 11. REMOVE STARTER ASSEMBLY (for 4WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 1GR-FE STARTING: STARTER RELAY: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DOM001X Title: 1GR-FE STARTING: STARTER RELAY: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT STARTER RELAY ASSEMBLY (a) Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal Specified condition: BETWEEN TERMINALS SPECIFIED CONDITION 1-2 Continuity 3-5 No continuity (2) Using an ohmmeter, check for continuity between terminals 3 and 5 when voltage is applied across terminals 1 and 2. Specified condition: Continuity 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DZS002X Title: 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTER (for Standard): COMPONENTS (2007 4Runner) 1GR-FE STARTING: STARTER (for Standard): DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEI002X Title: 1GR-FE STARTING: STARTER (for Standard): DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE REPAIR SERVICE STARTER KIT (a) Remove the nut, and disconnect the lead wire from the repair service starter kit. (b) Remove the 2 screws which are used to secure the repair service starter drive housing. (c) Remove the repair service starter kit. (d) Remove the return spring and plunger. 2. REMOVE STARTER YOKE ASSEMBLY (a) Remove the 2 through bolts, and pull out the starter yoke assembly together with the commutator end frame assembly. 1GR-FE STARTING: STARTER (for Standard): DISASSEMBLY (2007 4Runner) 3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY (a) Remove the commutator end frame assembly from the starter yoke assembly. 4. REMOVE STARTER ARMATURE PLATE (a) Remove the starter armature plate from the starter yoke assembly. 5. REMOVE STARTER COMMUTATOR END FRAME COVER (a) Using a screwdriver, remove the cover. 6. REMOVE STARTER ARMATURE ASSEMBLY (a) Using snap ring pliers, remove the snap ring and plate washer. (b) Remove the starter armature assembly from commutator end frame assembly. 7. REMOVE PLANETARY GEAR (a) Remove the 3 planetary gears. 8. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Remove the starter center bearing clutch and drive lever set pin together from the starter drive housing. 1GR-FE STARTING: STARTER (for Standard): DISASSEMBLY (2007 4Runner) (b) Remove the drive lever set pin from the starter center bearing clutch. 1GR-FE STARTING: STARTER (for Standard): INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEH002X Title: 1GR-FE STARTING: STARTER (for Standard): INSPECTION (2007 4Runner) INSPECTION 1. INSPECT STARTER ASSEMBLY NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. (a) Do pull-in test (Condition A). (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear protrudes. (b) Do holding test. (1) Disconnect the negative (-) lead from the terminal C with the above condition A is being sustained. Check that the pinion gear remains protruded. (c) Inspect clutch pinion gear return. (1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. (d) Perform the operation test without load. (1) Connect the field coil lead wire to terminal C. 1GR-FE STARTING: STARTER (for Standard): INSPECTION (2007 4Runner) Torque: 10 N·m (102 kgf·cm, 89 ft·lbf) (2) Hold the starter with a vise. (3) Connect the battery and ammeter to the starter as shown. (4) Check that the ammeter indicates the specified current. Specified current: 90 A or less at 11.5V 2. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the commutator for open circuit. (1) Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segments, replace the armature. (b) Check the commutator for ground. (1) Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. (c) Check the commutator for dirty and burn on surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. (d) Using vernier calipers, measure the commutator length. Standard length: 3.1 mm (0.122 in.) Maximum length 3.8 mm (0.150 in.) If the length is greater than maximum, replace the armature. 1GR-FE STARTING: STARTER (for Standard): INSPECTION (2007 4Runner) 3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY (a) Using vernier calipers, measure the brash holder length. Standard length: 9.0 mm (0.354 in.) Minimum length 4.0 mm (0.158 in.) If the length is less than minimum, replace the starter commutator end frame assembly. (b) Check the brush holder. (1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the starter commutator end frame assembly. 4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Inspect the gear teeth of the planetary gear, and the starter center bearing clutch for wear or damage. If any one of the planetary gear is damaged, replace the planetary gear assembly. If any one of the gears of the starter center bearing clutch is damaged, replace the clutch. (b) Check the clutch pinion gear. (1) Rotate the clutch pinion gear clockwise and check that it turns freely. (2) Try to rotate the clutch pinion gear counterclockwise and check that it locks If necessary, replace the center bearing clutch subassembly. 5. INSPECT REPAIR SERVICE STARTER KIT (a) Check the plunger. (1) Plush in the plunger and check that it returns quickly 1GR-FE STARTING: STARTER (for Standard): INSPECTION (2007 4Runner) to its original position. If necessary, replace the repair service starter kit. (b) Check the pull-in coil for open circuit. (1) Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the repair service starter kit. (c) Check whether or not the hold-in coil has an open circuit. (1) Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the repair service starter kit. 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEG004X Title: 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL STARTER ASSEMBLY (for 2WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 2. CONNECT WIRE HARNESS (for 2WD) (a) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) 3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Connect the battery negative terminal. 6. INSTALL STARTER ASSEMBLY (for 4WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) (a) Install the steering sliding yoke to No. 2 steering intermediate shaft. (b) Install the bolt B and tighten the bolt B and A. Torque: 36 N·m (370 kgf·cm, 27 ft·lbf) 8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Install the front fender rear splash shield LH with the 5 clips. 9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) (b) Connect the heated oxygen sensor (bank 2) connector. 10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Connect the battery negative terminal. 1GR-FE STARTING: STARTER (for Standard): REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEJ002X Title: 1GR-FE STARTING: STARTER (for Standard): REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a) Install the drive lever set pin to the starter center bearing clutch. (b) Install the starter center bearing clutch and drive lever set pin together to the starter drive housing. 2. INSTALL PLANETARY GEAR (a) Apply grease to the planetary gears and pin parts of the planetary shaft. (b) Install the 3 planetary gears. 3. INSTALL STARTER ARMATURE ASSEMBLY (a) Apply grease to the plate washer and armature shaft. (b) Install the armature shaft to the starter commutator end frame assembly. (c) Using snap ring pliers, install the plate washer and new 1GR-FE STARTING: STARTER (for Standard): REASSEMBLY (2007 4Runner) snap ring. (d) Using vernier calipers, measure the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than maximum, replace the new snap ring. 4. INSTALL STARTER COMMUTATOR END FRAME COVER (a) Install the starter commutator end frame cover. 5. INSTALL STARTER ARMATURE PLATE (a) Insert the starter armature plate to the starter yoke assembly. (b) Align the keyway of the plate with the key inside the starter yoke, and install the plate. 6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY (a) Align the starter-commutator-rubber -end frame with the convex cutout of starter yoke. 1GR-FE STARTING: STARTER (for Standard): REASSEMBLY (2007 4Runner) (b) Install starter-commutator-end -frame to starter yoke assembly. 7. INSTALL STARTER YOKE ASSEMBLY (a) Align the key of the starter yoke assembly with the keyway of starter drive housing. (b) Install the starter yoke assembly with the 2 through bolts. Torque: 6.0 N·m (61 kgf·cm, 53 in·lbf) 8. INSTALL REPAIR SERVICE STARTER KIT (a) Apply grease to the plunger and hook. (b) Hang the plunger hook of the repair service starter kit to the drive lever. 1GR-FE STARTING: STARTER (for Standard): REASSEMBLY (2007 4Runner) (c) Install the plunger and return spring. (d) Install the repair service starter kit with the 2 screws. Torque: 7.5 N·m (76 kgf·cm, 66 in·lbf) (e) Connect the lead wire to the terminal with the nut. Torque: 10 N·m (102 kgf·cm, 7.4 ft·lbf) 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM0000026Q1004X Title: 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Disconnect the battery negative terminal. 2. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Remove the 4 bolts and engine rear under cover assembly. 3. REMOVE NO. 2 MANIFOLD STAY (for 2WD) (a) Remove the 3 bolts and No. 2 manifold stay. 4. DISCONNECT WIRE HARNESS (for 2WD) (a) Remove the bolt and disconnect the wire harness from the cylinder block. 5. REMOVE STARTER ASSEMBLY (for 2WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 6. DISCONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Disconnect the battery negative terminal. 7. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Remove the 4 bolts and engine rear under cover assembly. 8. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor (bank 2) connector. (b) Remove the 2 bolts, 2 nuts, No. 2 front exhaust pipe assembly and 2 gaskets. 9. REMOVE FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Remove the 5 clips and front fender rear splash shield LH. 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) 10. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) (a) Loosen the bolt A and remove the bolt B, then separate the No. 2 steering intermediate shaft sub-assembly. 11. REMOVE STARTER ASSEMBLY (for 4WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) Last Modified: 4-26-2007 1.6 R Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEQ001X Title: 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) ILLUSTRATION 1GR-FE STARTING: STARTING SYSTEM: PARTS LOCATION (2007 4Runner) 4RUNNER – MAJOR TECHNICAL SPECIFICATIONS 1 MAJOR TECHNICAL SPECIFICATIONS Area Item U.S.A. U.S.A. and Canada Body Type 5-door Wagon Vehicle Grade Model Code Overall Length mm (in.) Width Height*1 mm (in.) mm (in.) Wheel Base 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) mm (in.) mm (in.) Shoulder Room Front Rear mm (in.) mm (in.) Length mm (in.) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) Width Height Front Rear mm (in.) mm (in.) mm (in.) mm (in.) 1051 (41.4) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 1051 (41.4) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 1051 (41.4) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 1051 (41.4) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) Min. Running Ground Clearance mm (in.) 225 (8.9) 30 24*5, 26*6 1015 (2240), 1007 (2220)*7 225 (8.9) 30 24*5, 26*6 1020 (2250), 1012 (2230)*7 230 (9.1) 30 24*5, 26*6 1110 (2445), 1102 (2425)*7 230 (9.1) 30 24*5, 26*6 1115 (2460), 1107 (2440)*7 915 (2015), 936 (2060)*7 1930 (4255), 1943 (4280)*7 1131 (2495) 1375 (3020) 920 (2030), 941 (2075)*7 1940 (4280), 1953 (4305)*7 1131 (2495) 1375 (3020) 935 (2060), 956 (2105)*7 2045 (4505), 2058 (4530)*7 1229 (2710) 1494 (3295) 940 (2070), 961 (2115)*7 2055 (4530), 2068 (4555)*7 1229 (2710) 1494 (3295) 2490 (5490) 87 (23, 19.1)  180 (112) 2490 (5490) 87 (23, 19.1)  180 (112) 2723 (6005) 87 (23, 19.1)  180 (112) 2723 (6005) 87 (23, 19.1)  180 (112)  54 (33) 93 (58) 136 (84)  54 (33) 93 (58) 136 (84)  21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 53 (33)*8, 136 (84)*9  21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 53 (33)*8, 136 (84)*9   12.3 (40.4) 11.7 (38.4)   12.3 (40.4) 11.7 (38.4)   12.3 (40.4) 11.7 (38.4)   12.3 (40.4) 11.7 (38.4) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 10.0 : 1 SFI 87 or higher 194
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5400 (260 @ 5400) 10.0 : 1 SFI 87 or higher 194
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5400 (260 @ 5400) 10.0 : 1 SFI 87 or higher 194
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5400 (260 @ 5400) 10.0 : 1 SFI 87 or higher 194
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5400 (260 @ 5400) 415
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3400 (306 @ 3400) 12 − 55, 12 − 64*10 1560 1.4, 2.0*10 415
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3400 (306 @ 3400) 12 − 55, 12 − 64*10 1560 1.4, 2.0*10 415
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3400 (306 @ 3400) 12 − 55, 12 − 64*10 1560 1.4, 2.0*10 415
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3400 (306 @ 3400) 12 − 55, 12 − 64*10 1560 1.4, 2.0*10  A750E 3.520 2.042  A750E 3.520 2.042  A750F 3.520 2.042  A750F 3.520 2.042 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224  
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3.727 
/
203 (8) Ventilated Disc  
/
3.727 
/
203 (8) Ventilated Disc 1.000
/
2.566 3.727
/
3.727 203 (8)
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203 (8) Ventilated Disc 1.000
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2.566 3.727
/
3.727 203 (8)
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203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum Hydraulic  Ventilated Disc Duo-servo Drum Hydraulic  Ventilated Disc Duo-servo Drum Hydraulic  Ventilated Disc Duo-servo Drum Hydraulic  Double Wishbone 4-link with Lateral Rod Standard Standard Double Wishbone 4-link with Lateral Rod Standard Standard Double Wishbone 4-link with Lateral Rod Standard Standard Double Wishbone 4-link with Lateral Rod Standard Standard Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Cargo Space Overhang Angle of Approach degrees Max. Cruising Speed Performance 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) Front Rear degrees Front kg (lb) Curb Weight Rear kg (lb) Total kg (lb) Front kg (lb) Gross Vehicle Weight Rear kg (lb) Total kg (lb) Fuel Tank Capacity (US.gal, Imp.gal) Luggage Compartment Capacity m3 (cu.ft.) Max. Speed km / h (mph) Max. Permissible Speed Turning Diameter (Outside Front) 1st Gear 2nd Gear 3rd Gear 4th Gear km / h (mph) km / h (mph) km / h (mph) km / h (mph) km / h (mph) 5th Gear km / h (mph) Wall to Wall m (ft.) Curb to Curb m (ft.) Engine Type Valve Mechanism Engine Limited (4WD) UZN215L-GKAZKA 4805 (189.2) Effective Leg Room Angle of Departure Engine Electrical SR5 (4WD) UZN215L-GKAGKA 4805 (189.2) mm (in.) mm (in.) mm (in.) mm (in.) Effective Head Room Bore × Stroke Displacement mm (in.) cm3 (cu.in.) Compression Ratio Fuel System Octane Rating Max. Output (SAE-NET) kW / rpm (HP@rpm) Max. Torque (SAE-NET) N.m / rpm (ft-lb@rpm) Battery Capacity (5HR) Voltage & Amp. hr. Generator Output Starter Output Watts kW Clutch Type Transmission Type Gear Ratio In First In Second In Third In Fourth In Fifth In Reverse Transfer Gear Ratio H4 / L4 Differential Gear Ratio (Front / Rear) Chassis Limited (2WD) UZN210L-GKAZKA 4805 (189.2) Front Rear Front Rear Tread Major Dimensions & Vehicle Weights mm (in.) SR5 (2WD) UZN210L-GKAGKA 4805 (189.2) Differential Gear Size (Front / Rear) Front Brake Type Rear Parking Brake Type Brake Booster Type and Size Proportioning Valve Type Suspension Type Stabilizer Bar Front Rear Front Rear Steering Gear Type Steering Gear Ratio (Overall) Power Steering Type *1: Unladen Vehicle *2: With Roof Rail + 45 mm (1.77 in.) With Rear Spoiler + 40 mm (1.57 in.) mm (in.) in. *3: With Sliding Roof *4: Min
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Max *5: With Hitch Receiver *6: Without Hitch Receiver *7: With 3rd Seat *8: Transfer in Low 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 4RUNNER – MAJOR TECHNICAL SPECIFICATIONS 2 U.S.A. U.S.A. and Canada 5-door Wagon 5 10 15 20 25 30 35 40 SR5 (2WD) GRN210L-GKAGKA 4805 (189.2) 1910 (75.2) Limited (2WD) GRN210L-GKAZKA 4805 (189.2) 1910 (75.2) SR5 (4WD) GRN215L-GKAGKA 4805 (189.2) 1910 (75.2) Limited (4WD) GRN215L-GKAZKA 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) 1051 (41.4) 1473 (58.0) 1454 (57.2) 1105 (43.5) 1051 (41.4) 1473 (58.0) 1454 (57.2) 1105 (43.5) 1051 (41.4) 1473 (58.0) 1454 (57.2) 1105 (43.5) 1051 (41.4) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 225 (8.9) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 225 (8.9) 935 (36.8)
/
969 (38.1)*4 920 (36.2) 1095 (43.1) 230 (9.1) 935 (36.8)
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969 (38.1)*4 920 (36.2) 1095 (43.1) 230 (9.1) 30 24*5, 26*6 952 (2100), 944 (2080)*7 882 (1945), 903 (1990)*7 30 24*5, 26*6 957 (2110), 949 (2090)*7 887 (1955), 908 (2000)*7 30 24*5, 26*6 1047 (2310), 1039 (2290)*7 902 (1990), 923 (2035)*7 30 24*5, 26*6 1052 (2320), 1044 (2300)*7 907 (2000), 928 (2045)*7 1834 (4045), 1847 (4070)*7 1059 (2335) 1365 (3010) 2417 (5330) 1844 (4065), 1857 (4090)*7 1059 (2335) 1365 (3010) 2417 (5330) 1949 (4300), 1962 (4325)*7 1156 (2550) 1388 (3060) 2531 (5580) 1959 (4320), 1972 (4345)*7 1156 (2550) 1388 (3060) 2531 (5580) 87 (23, 19.1)  180 (112)  87 (23, 19.1)  180 (112)  87 (23, 19.1)  180 (112)  87 (23, 19.1)  180 (112)  58 (36) 100 (62) 146 (90)  58 (36) 100 (62) 146 (90)  22 (14)*8, 58 (36)*9 39 (24)*8, 100 (62)*9 57 (35)*8, 146 (90)*9  21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 53 (33)*8, 136 (84)*9   12.3 (40.4) 11.7 (38.4) 1GR-FE  12.3 (40.4) 11.7 (38.4) 1GR-FE  12.3 (40.4) 11.7 (38.4) 1GR-FE  12.3 (40.4) 11.7 (38.4) 1GR-FE 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 10 : 1 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 10 : 1 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 10 : 1 SFI 87 or higher 176
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5200 (236 @ 5200) 361
/
4000 (266 @ 4000) SFI 87 or higher 176
/
5200 (236 @ 5200) 361
/
4000 (266 @ 4000) SFI 87 or higher 176
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5200 (236 @ 5200) 361
/
4000 (266 @ 4000) SFI 87 or higher 176
/
5200 (236 @ 5200) 361
/
4000 (266 @ 4000) 12-55, 12-64*10 1560 1.6, 2.0*10  12-55, 12-64*10 1560 1.6, 2.0*10  12-55, 12-64*10 1560 1.6, 2.0*10  12-55, 12-64*10 1560 1.6, 2.0*10  A750E 3.520 2.042 1.400 A750E 3.520 2.042 1.400 A750F 3.520 2.042 1.400 A750F 3.520 2.042 1.400 1.000 0.716 3.224  
/
3.727 1.000 0.716 3.224  
/
3.727 1.000 0.716 3.224 1.000
/
2.566 3.727
/
3.727 1.000 0.716 3.224 1.000
/
2.566 3.727
/
3.727 
/
203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum 
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203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum 203 (8)
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203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum 203 (8)
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203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum Hydraulic  Double Wishbone 4-link with Lateral Rod Hydraulic  Double Wishbone 4-link with Lateral Rod Hydraulic  Double Wishbone 4-link with Lateral Rod Hydraulic  Double Wishbone 4-link with Lateral Rod Standard Standard Rack and Pinion 15.7 Standard Standard Rack and Pinion 15.7 Standard Standard Rack and Pinion 15.7 Standard Standard Rack and Pinion 15.7 Hydraulic Type Hydraulic Type Hydraulic Type Hydraulic Type 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 45 10 : 1 50 55 60 65 70 75 *9: Transfer in High *10: Option 3 – MEMO – 6 APPENDIX MAJOR TECHNICAL SPECIFICATIONS Area Item U.S.A. 5-door Wagon Body Type Vehicle Grade Model Code Major Dimensions & Vehicle Weights 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) mm (in.) mm (in.) mm (in.) mm (in.) 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 Effective Leg Room Front Rear mm (in.) mm (in.) Shoulder Room Front Rear mm (in.) mm (in.) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) Length mm (in.) Width Height Front Rear mm (in.) mm (in.) mm (in.) mm (in.) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) Min. Running Ground Clearance mm (in.) 1095 (43.1) 225 (8.9) 30 24*5, 26*6 1095 (43.1) 225 (8.9) 30 24*5, 26*6 1095 (43.1) 225 (8.9) 30 24*5, 26*6 1095 (43.1) 225 (8.9) 30 24*5, 26*6 952 (2100), 944 (2080)*7 882 (1945), 903 (1990)*7 1834 (4045), 1847 (4070)*7 1059 (2335) 957 (2110), 949 (2090)*7 887 (1955), 908 (2000)*7 1844 (4065), 1857 (4090)*7 1059 (2335) 1015 (2240), 1007 (2220)*7 915 (2015), 936 (2060)*7 1930 (4255), 1943 (4280)*7 1131 (2495) 1020 (2250), 1012 (2230)*7 920 (2030), 941 (2075)*7 1940 (4280), 1953 (4305)*7 1131 (2495) 1365 (3010) 2417 (5330) 87 (23, 19.1) — 1365 (3010) 2417 (5330) 87 (23, 19.1) — 1375 (3020) 2490 (5490) 87 (23, 19.1) — 1375 (3020) 2490 (5490) 87 (23, 19.1) — 180 (112) — 58 (36) 100 (62) 180 (112) — 58 (36) 100 (62) 180 (112) — 54 (33) 93 (58) 180 (112) — 54 (33) 93 (58) 146 (90) — — 12.3 (40.4) 11.7 (38.4) 146 (90) — — 12.3 (40.4) 11.7 (38.4) 136 (84) — — 12.3 (40.4) 11.7 (38.4) 136 (84) — — 12.3 (40.4) 11.7 (38.4) 1GR-FE 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 1GR-FE 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 10.0 : 1 SFI 87 or higher 176 / 5200 (236 / 5200) 10.0 : 1 SFI 87 or higher 176 / 5200 (236 / 5200) 10.0 : 1 SFI 87 or higher 194 / 5400 (260 / 5400) 10.0 : 1 SFI 87 or higher 194 / 5400 (260 / 5400) 361 / 4000 (266 / 4000) 12 - 55, 12 - 64*10 1560 1.6, 2.0*10 361 / 4000 (266 / 4000) 12 - 55, 12 - 64*10 1560 1.6, 2.0*10 415 / 3400 (306 / 3400) 12 - 55, 12 - 64*10 1560 1.4, 2.0*10 415 / 3400 (306 / 3400) 12 - 55, 12 - 64*10 1560 1.4, 2.0*10 Effective Head Room mm (in.) Width Height mm (in.) mm (in.) Cargo Space Overhang Angle of Approach degrees Angle of Departure degrees Front kg (lb) Curb Weight Rear kg (lb) Total kg (lb) Front kg (lb) Gross Vehicle Weight Rear kg (lb) Total kg (lb) Fuel Tank Capacity (US.gal, Imp.gal) Luggage Compartment Capacity m3 (cu.ft.) Max. Speed km / h (mph) Max. Cruising Speed Performance Limited UZN210L-GKAZKA mm (in.) Tread Max. Permissible Speed Turning Diameter (Outside Front) 1st Gear 2nd Gear 3rd Gear 4th Gear km / h (mph) km / h (mph) km / h (mph) km / h (mph) km / h (mph) 5th Gear km / h (mph) Wall to Wall m (ft.) Curb to Curb m (ft.) Engine Type Valve Mechanism Engine SR5 UZN210L-GKAGKA Front Rear Front Rear Length Wheel Base Engine Electrical Limited GRN210L-GKAZKA 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) Overall Bore × Stroke Displacement mm (in.) cm3 (cu.in.) Compression Ratio Fuel System Octane Rating Max. Output (SAE-NET) kW / rpm (HP / rpm) Max. Torque (SAE-NET) N.m / rpm (ft- lb/ rpm) Battery Capacity (5HR) Voltage & Amp. hr. Generator Output Starter Output Watts kW Clutch Type Transmission Type Gear Ratio In First In Second In Third In Fourth In Fifth In Reverse Transfer Gear Ratio H4 / L4 Differential Gear Ratio (Front / Rear) Chassis SR5 GRN210L-GKAGKA Differential Gear Size (Front / Rear) Front Brake Type Rear Parking Brake Type Brake Booster Type and Size Proportioning Valve Type Suspension Type Stabilizer Bar Front Rear Front Rear Steering Gear Type Steering Gear Ratio (Overall) Power Steering Type *1: Unladen Vehicle *2: With Roof Rail + 45 mm (1.77 in.) With Rear Spoiler + 40 mm (1.57 in.) mm (in.) in. — A750E 3.520 2.042 — A750E 3.520 2.042 — A750E 3.520 2.042 — A750E 3.520 2.042 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 — — / 3.727 — / 203 (8) Ventilated Disc — — / 3.727 — / 203 (8) Ventilated Disc — — / 3.727 — / 203 (8) Ventilated Disc — — / 3.727 — / 203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type *3: With Sliding Roof *4: Min / Max *5: With Hitch Receiver *6: Without Hitch Receiver *7: With 3rd Seat *8: Transfer in Low 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 7 APPENDIX U.S.A. and Canada 5-door Wagon 5 10 15 20 25 30 35 40 SR5 GRN215L-GKAGKA Limited GRN215L-GKAZKA SR5 UZN215L-GKAGKA Limited UZN215L-GKAZKA 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 4805 (189.2) 1910 (75.2) 1760 (69.3)*2 2790 (109.8) 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1575 (62.0) 1575 (62.0) 1009 (39.7), 972 (38.3)*3 992 (39.1), 970 (38.2)*3 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1061 (41.8) 879 (34.6) 1473 (58.0) 1454 (57.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1105 (43.5) 1051 (41.4) 935 (36.8) / 969 (38.1)*4 920 (36.2) 1095 (43.1) 230 (9.1) 30 24*5, 26*6 1095 (43.1) 230 (9.1) 30 24*5, 26*6 1095 (43.1) 230 (9.1) 30 24*5, 26*6 1095 (43.1) 230 (9.1) 30 24*5, 26*6 1047 (2310), 1039 (2290)*7 902 (1990), 923 (2035)*7 1949 (4300), 1962 (4325)*7 1156 (2550) 1052 (2320), 1044 (2300)*7 907 (2000), 928 (2045)*7 1959 (4320), 1972 (4345)*7 1156 (2550) 1110 (2445), 1102 (2425)*7 935 (2060), 956 (2105)*7 2045 (4505), 2058 (4530)*7 1229 (2710) 1115 (2460), 1107 (2440)*7 940 (2070), 961 (2115)*7 2055 (4530), 2068 (4555)*7 1229 (2710) 1388 (3060) 2531 (5580) 87 (23, 19.1) — 1388 (3060) 2531 (5580) 87 (23, 19.1) — 1494 (3295) 2723 (6005) 87 (23, 19,1) — 1494 (3295) 2723 (6005) 87 (23, 19.1) — 180 (112) — 22 (14)*8, 58 (36)*9 39 (24)*8, 100 (62)*9 180 (112) — 21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 180 (112) — 21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 180 (112) — 21 (13)*8, 54 (33)*9 36 (22)*8, 93 (58)*9 57 (35)*8, 146 (90)*9 — — 12.3 (40.4) 11.7 (38.4) 53 (33)*8, 136 (84)*9 — — 12.3 (40.4) 11.7 (38.4) 53 (33)*8, 136 (84)*9 — — 12.3 (40.4) 11.7 (38.4) 53 (33)*8, 136 (84)*9 — — 12.3 (40.4) 11.7 (38.4) 1GR-FE 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 2UZ-FE 32-valve, DOHC with VVT-i 94.0 × 84.0 (3.70 × 3.31) 4664 (284.5) 10.0 : 1 SFI 87 or higher 176 / 5200 (236 / 5200) 10.0 : 1 SFI 87 or higher 194 / 5400 (260 / 5400) 10.0 : 1 SFI 87 or higher 194 / 5400 (260 / 5400) 361 / 4000 (266 / 4000) 12 - 55, 12 - 64*10 1560 1.6, 2.0*10 415 / 3400 (306 / 3400) 12 - 55, 12 - 64*10 1560 1.4, 2.0*10 415 / 3400 (306 / 3400) 12 - 55, 12 - 64*10 1560 1.4, 2.0*10 1GR-FE 24-valve, DOHC with VVT-i 94.0 × 95.0 (3.70 × 3.74) 3956 (241.4) 45 10.0 : 1 SFI 87 or higher 176 / 5200 (236 / 5200) 50 55 60 65 70 75 361 / 4000 (266 / 4000) 12 - 55, 12 - 64*10 1560 1.6, 2.0*10 — A750F 3.520 2.042 — A750F 3.520 2.042 — A750F 3.520 2.042 — A750F 3.520 2.042 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.400 1.000 0.716 3.224 1.000 / 2.566 3.727 / 3.727 203 (8) / 203 (8) Ventilated Disc 1.000 / 2.566 3.727 / 3.727 203 (8) / 203 (8) Ventilated Disc 1.000 / 2.566 3.727 / 3.727 203 (8) / 203 (8) Ventilated Disc 1.000 / 2.566 3.727 / 3.727 203 (8) / 203 (8) Ventilated Disc Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Ventilated Disc Duo-servo Drum Hydraulic — Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Double-wishbone 4-link with Lateral Rod Standard Standard Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type Rack and Pinion 15.7 Hydraulic Type *9: Transfer in High *10: Option AP 8 – MEMO – 4 INTRODUCTION – MODEL CODE & MODEL LINE-UP MODEL CODE GRN210 L – G K A G K A 1 2 BASIC MODEL CODE 1 2 CODE DRIVE TYPE GRN210 GRN215 UZN210 UZN215 2WD 4WD 2WD 4WD ENGINE TYPE 3 4 5 6 7 8 5 GEAR SHIFT TYPE A: 5-speed Automatic, Floor 6 GRADE G: SR5 Z: Limited 7 ENGINE SPECIFICATION K: DOHC and SFI 8 DESTINATION A: U.S.A. and Canada 1GR-FE 2UZ-FE STEERING WHEEL POSITION L: Left-hand Drive 3 MODEL NAME G: Wagon 4 BODY TYPE K: 5-door MODEL LINE-UP TRANSMISSION DESTIDESTI NATION DRIVE TYPE ENGINE 1GR FE 1GR-FE USA U.S.A. 2WD 2UZ FE 2UZ-FE U.S.A. SA and Canada 1GR FE 1GR-FE 4WD 2UZ FE 2UZ-FE GRADE 5-speed Automatic A750E A750F SR5 GRN210L-GKAGKA — Limited GRN210L-GKAZKA — SR5 UZN210L-GKAGKA — Limited UZN210L-GKAZKA — SR5 — GRN215L-GKAGKA Limited — GRN215L-GKAZKA SR5 — UZN215L-GKAGKA Limited — UZN215L-GKAZKA 4RUNNER – OUTLINE OF NEW FEATURES 1 4RUNNER OUTLINE OF NEW FEATURES The following changes are made for the 2008 model year. 1. Exterior The design of the front bumper grille has been changed. A A 07EMO01Y Front Bumper Grille ’08 4Runner ’07 4Runner A - A Cross Section 2. Brake Control System
The VSC OFF switch is used on all models. For details, see page 5.
An Auto LSD function is added to the brake control system for the 1GR-FE engine 4WD models. 3. Tire Pressure Warning System
In the tire pressure warning system, the following items have been changed. Changed Item ’08 4Runner ’07 4Runner Time required for the tire pressure warning ECU to determine a malfunction in the tire pressure warning valve and transmitter 20 minutes 51 minutes Detection of vehicle speed (Judgment of vehicle running) Vehicle speed signal (combination meter) and engine speed signal (ECM) Vehicle speed signal (combination meter) The illumination pattern of the tire pressure warning light when the system fails Turns ON after blinking for 1 minute Blinks The blinking of the tire pressure warning light between the registration of the ID code of the tire pressure warning valve and transmitter and the normal operation of the system Turns ON after blinking for 1 minute — 4RUNNER – OUTLINE OF NEW FEATURES 2
The following DTCs (Diagnostic Trouble Codes) are added. DTC Detection Item C2126
/
26 Transmitter ID not Received in Main Mode C2173
/
73 Vehicle Speed or Engine Speed Signal Malfunction C2194
/
94 Engine Speed Signal Error (Test Mode DTC) 4. Seat Belt Warning System The specifications of the seat belt warning system have been changed. For details, see page 9. 4RUNNER – NEW FEATURES 5 NEW FEATURES BRAKE CONTROL SYSTEM 1. General The VSC OFF switch is used. The operation of the VSC and TRAC functions can be stopped by the VSC OFF switch. While the vehicle is running off the shoulder of the road or running on the dirt road, the engine output control is stopped to maintain drive torque. 2. System Diagram Hydraulic Brake Booster Pump Motor Relay Speed Sensor (4) Park/Neutral Position Switch Pump Motor Switching Solenoid Valve Brake Fluid Level Warning Switch Solenoid Relay Switch*1 Control Solenoid Valve Parking Brake Switch Master Cylinder Pressure Sensor Downhill Assist Control 4WD Control Switch*1 Skid Control ECU Accumulator Pressure Sensor Center Diff. Lock Switch*1 Combination Meter       VSC OFF Switch ABS Warning Light Brake System Warning Light Slip Indicator Light VSC OFF Light Auto LSD Indicator Light*2 Downhill Assist Control Indicator Light*1  Speedometer Stop Light Switch Stop Light Control Relay DLC3 Suspension Control ECU*3 ECM VSC Warning Buzzer Steering Angle Sensor Yaw Rate & Deceleration Sensor CAN (V Bus) 07ECH001Y *1: Only for 4WD Models *2: 1GR-FE Engine Models and 2UZ-FE Engine 2WD Models *3: Only for Models with Rear Air Suspension 4RUNNER – NEW FEATURES 6 3. Layout of Main Components Brake System Warning Light Slip Indicator Light VSC OFF Light ABS Warning Light Auto LSD Indicator Light*2 Downhill Assist Control Indicator Light*1 Steering Angle Sensor Combination Meter ECM VSC Warning Buzzer Stop Light Switch DLC3 VSC OFF Switch Yaw Rate & Deceleration Sensor Downhill Assist Control Switch Speed Sensors Hydraulic Brake Booster (with Actuator and Skid Control ECU) Speed Sensors *1: Only for 4WD Models *2: 1GR-FE Engine Models and 2UZ-FE Engine 2WD Models 07ECH002Y 4RUNNER – NEW FEATURES 7 4. VSC OFF Switch
The VSC OFF switch can select the 3 modes [Normal mode, TRAC-OFF mode (Auto LSD control mode*1), VSC-OFF mode].
On the 2WD models, the Auto LSD function operates when the TRAC-OFF mode is selected.
On the 1GR-FE engine 4WD models, the Auto LSD function operates when the 4WD control switch is at the “H2” position and the TRAC-OFF mode is selected. Normal Mode TRAC-OFF Mode (Auto LSD Control Mode*1) VSC-OFF Mode 04FCH153I : Switch Operation (Press shortly.) : Switch Operation (Keep pressing for 3 seconds with the vehicle at a standstill.)
After the ignition switch is turned OFF in the TRAC-OFF mode (Auto LSD control mode*1) or VSC-OFF mode, turning the ignition switch ON again selects the Normal mode.
The operations of the brake control functions and the illumination state of the respective indicator lights in each mode are as follows: : Controllable ×: Not Controllable Brake Control Function Item TRAC Normal Mode TRAC-OFF Mode (Auto LSD Control Mode*) VSC-OFF Mode Auto LSD*1 Auto LSD Indicator Light Slip Indicator Light 03NCH004Y 03NCH005Y VSC OFF Light VSC 03NCH006Y  ×  — — — ×   Light ON Light ON — × × × — Light ON Light ON *: 1GR-FE Engine Models and 2UZ-FE Engine 2WD Models NOTE The TRAC and VSC functions control brake hydraulic pressure and engine output to ensure vehicle stability. Therefore, operate the VSC OFF switch (stop the operation of the TRAC and VSC functions) only when it is necessary. 4RUNNER – NEW FEATURES 8 5. Warning, Indicator Lights and VSC Warning Buzzer The warning, indicator and VSC OFF lights and VSC warning buzzer operate as follows: : Illuminates (Continuous Sound)
: Blinks (Intermittent Sound) Warning Light Indicator Light Condition 03NCH012Y 03NCH007Y  Initial Check During p Operation Driving Mode 03NCH008Y 
VSC
Downhill Assist Control
Hill-start Assist Control
TRAC-OFF Mode (Auto LSD Control Mode*1)  VSC-OFF Mode  03NCH010Y 07ECH003Y   EBD 
*1
*1   H4L, L4L

*2
 ABS & Brake Assist   TRAC
/
A-TRAC, Auto LSD 
VSC 
Downhill Assist Control  Hill-start Assist Control 

Low Brake Fluid Level   ABS Malfunction Others  TRAC
/
A-TRAC During Actuator Protection Cannot Operate Due to a Malfunction 03NCH009Y Zero Point Calibration of Yaw Rate & Deceleration Sensor not Done Low Accumulator Pressure Warning Buzzer   
*2
*2



*1: Lights up when the Auto LSD and
/
or downhill assist control are operational. *2: Blinks when the downhill assist control switch is pushed.  4RUNNER – NEW FEATURES 9 SEAT BELT WARNING SYSTEM 1. General  If a seat belt is not fastened, this system flashes the seat belt warning light or sounds the buzzer in the combination meter as a reminder.  When the ignition switch is turned ON, this system detects the condition of the seat belts based on the signals from the driver and front passenger seat belt buckle switches and the occupant classification sensor. 2. Warning Method The timing chart of the buzzer and details of the warning method are shown below.
Timing Chart  Ignition Switch ON * OFF 12 mph (20km/h) or more Vehicle Speed 0 mph Not Fasten Driver Seat Belt Buckle Switch Fasten Front Passenger Seat Belt Buckle Switch Not Fasten Shift Position (Reverse) Fasten Hi Lo LVL2 Buzzer LVL1 OFF T4 T5 T4 T7 T8 T4 T7 T1 T2 T6 T3 T5 T3 Flash (0.4 sec.) Driver Seat Belt Warning Light Flash (1.2 sec.) OFF Flash (0.4 sec.) Front Passenger Flash (1.2 sec.) Seat Belt Warning Light OFF 0140BE193C T1: About 1.8 sec. T2: About 1.2 sec. × 5 T3: About 13.8 sec. T4: About 9.6 sec. T5: About 20 sec. T6: About 20 sec. or more T7: About 20 sec. or less T8: About 9.6 sec. or less *: If the vehicle speed drops below the setting level for seat belt warning after a buzzer begins to sound, the buzzer will continue to sound. After the vehicle speed exceeds 20km
/
h (12 mph) again, the buzzer will stop. 2 INTRODUCTION – OUTLINE OF NEW FEATURES INTRODUCTION OUTLINE OF NEW FEATURES 1. Model Line-up The Urban Runner package which has been developed based on the Sport package is newly provided for the GRN210L-GKAGKA and GRN215L-GKAGKA models for U.S.A. 2. Exterior
Exclusive emblems are provided for the Urban Runner package. 4WD model: “URBAN RUNNER 4WD” for the front door, and “X-REAS” for the back door. 2WD Model: “URBAN RUNNER” for the front door, and “X-REAS” for the back door.
A radiator grille which is painted with the same color as an exterior color is provided for the Urban Runner package, as well as for the Limited grade.
A smoke lens type headlight which is the same as for the Sport package is provided for the Urban Runner package.
An exclusive rear spoiler is provided for the Urban Runner package. 07EMO01Y 07EMO02Y Urban Runner Package Other
A silver roof rail is optional equipment for the Urban Runner package.
18-inch aluminum disc wheels which are the same as for the Limited grade are provided for the Urban Runner package.
The following three exterior colors are provided for the Urban Runner package: Color No. Color Name Note 070 White Pearl Crystal Shine Carryover 1D4 Silver Metallic Carryover 202 Black Carryover INTRODUCTION – OUTLINE OF NEW FEATURES 3 3. Interior
An instrument panel center cluster, a front console and a door trim, which are used for the Limited grade, are provided for the Urban Runner package.
A plated inside door handle is provided for the Urban Runner package.
A rear console lid with leather upholstery is provided for the Urban Runner package.
A seat with Alcantala and leather upholstery is provided for the Urban Runner package.
A steering wheel using dimple leather is provided for the Urban Runner package. : Dimple Leather 07EMO03Y IN ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC (BAT) (BAT) (IG) 40A ABS MTR 10A IGN 30A ABS SOL 2 23 1E : 2UZ–FE : 1GR–FE 4WD : w/ Electric Modulated Air Suspension : w/o Electric Modulated Air Suspension 1 J4 Junction Connector G R L P B–O L–O 9 Y FRO Y–B FLO 8 Y–B C 2 A 2 B 31 A 18 A 4 A 3 A 17 A 1 B 38 A +BM1 FL+ +BS +BM2 FL– FR+ FR– IG2 S15 Suspension Control ECU C 2 (∗3) 2 1 2 3 4 L–R 1 ∗ ∗ ∗ ∗ B–O Y–B A10 ABS Speed Sensor Front RH 2 A9 ABS Speed Sensor Front LH 2 (∗3) 2 37 A FLO FRO S28(A), S29(B) Skid Control ECU with Actuator RL– RR– 19 A W PKB GND3 LBL 41 A 4 B 28 A GND1 1 A W–B A B A A A A 6 BC2 3 BC2 4 BE1 3 BE1 2 B W (∗4) W–B (∗4) B W–B A41 ABS Speed Sensor Rear RH A40 ABS Speed Sensor Rear LH W 1 2 P4 Parking Brake SW 1 BE1 W–B LG W–B 1 2 BE1 1 1 W–B EA EB BO -1- (∗1) LG A B 2 J 2(A), J 3(B) Junction Connector B B W–B W B (∗4) (Shielded) V (∗3) G (∗4) P (∗3) (∗4) R (∗4) (Shielded) B A W–B J 2(A), J 3(B) Junction Connector 1 1E W–B 2 BC2 W–B 1 BC2 2 1E B14 Brake Fluid Level Warning SW 5 BC2 (∗1) 8 IB2 W–B V 4 BC2 7 IB2 W 10 IB2 B 9 IB2 P W–B LG 5 A B RR+ 6 A V RL+ 20 A P GND2 32 A ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC (BAT) G–W (IG) Y–R 8 1J 4 2 J1 Junction Connector A 20 1E Y–R E A J18(A) Junction Connector C A B G–B B STP2 LG 7 A 16 A STP Y–R A A P 2 G–B G–B G–Y 45 A 8 IM1 6 13 IC2 J4 Junction Connector H A Y–R G–B J4 Junction Connector G–Y G–Y C A E E H A C 1 B C J25 Junction Connector G–B P1 Park/Neutral Position SW LG G–B E A J20(A) Junction Connector 2 2 S12 Stop Light SW E J35 Junction Connector 2 A G–B G–W G–W 3 E J 8(A) Junction Connector 2 2 1 STOP LP CTRL Relay 5 D J7 Junction Connector D 2 15A IG1 2 Y–R 2 G–B 10A STOP Y–R Y–R 2 IM1 Y–R 14 A STPO P S28(A), S29(B) Skid Control ECU with Actuator CSW R–W W–G (4WD) 43 A R–W W–G (4WD) (4WD) 3 D5 Downhill Assist Control SW 9 V15 VSC Off SW 11 IM2 IND2 B 3F B 3F A B W–B R–L B 3F W–B J28 Junction Connector W–B B A B J14(A), J15(B) Junction Connector W–B W–B R–L (4WD) (4WD) A A B 3F B B 20 A 4 W–B G B (4WD) R–L J31(A), J32(B) Junction Connector G–R (4WD) F A G–R 3 CDL 4 (4WD) J29(A), J30(B) Junction Connector W–L (4WD) L4 6 IC2 W–B 22 B W–B P1 F 9(A), F10(B) 4WD Control ECU A J37 Junction Connector ADD 24 A 17 IC2 J24 Junction Connector 18 B H B W–L J28 Junction Connector C GR F A (4WD) GR C (∗2) GR (∗2) C T3 Transfer Shift Actuator (4WD) GR (∗2) GR (∗2) E A 16 IM2 R–L J20(A), J21(B) Junction Connector G–R (4WD) A B 18 IC3 (∗2) HDCS 44 A 1 IC2 12 IC2 (4WD) W–L 2 IC2 3 6 EC1 R–L G–R (4WD) W–L GR A11 ADD Actuator ADD EXI 27 A (∗2) W–B (∗1) NEO 10 A (4WD) EXI4 21 A (4WD) EXI3 26 A II -2- A A A IK W–B J5 Junction Connector A IG ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC B–R (IG) R–Y R–B 10A ECU–IG R–Y R–B 15 IC2 4 IC2 R–Y R–B B D 28 1J B–R 12 1E R–W B–R J4 Junction Connector B–R V5 VSC Warning Buzzer 2 B R–W F J4 Junction Connector F J1 Junction Connector F 5 IC2 D R–W 46 A BZ R–B B–R 30 A R–Y GR–G 1 13 A 24 A 42 A IG1 D/G TS WFSE S28(A), S29(B) Skid Control ECU with Actuator CANH SP1 BRL WA IND VSCW INFR HDCW 33 A V–W BR–Y 20 IC2 7 IC3 V–W 9 IC2 Y–R 19 IC2 R 18 IC2 LG–R 8 IC2 B–L 7 IC2 GR–R 11 IC2 B 22 IC2 W Y–R 15 A R 36 A LG–R 34 A B–L 29 A GR–R 3 B B 12 A W 11 A (4WD) CANL 25 A BR–Y(4WD) V–W Y–R R LG–R B–L GR–R W–B W–B W–B W–B B W -3- ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC B–R B–R R–Y R–Y R–B R–B R–W R–W ∗ 1 : 2UZ–FE ∗ 8 : 1GR–FE (IG) (BAT) 7. 5A GAUGE 10A DOME 2 4 1G C 8(A), C 9(B), C10(C), C11(D) Combination Meter R R–L 2 15 C Slip 17 C 20 C J7 Junction Connector D 13 C 16 C F B J29(A), J30(B) Junction Connector BR 4 B GR–R LG–R 19 A B–L R Y–R V–W BR–Y(4WD) H A 4 D B A BR–Y(4WD) D B R BR V–W J 8(A), J 9(B) Junction Connector R VSC OFF 18 C D BRAKE AUTO LSD 12 A ABS Downhill Assist Control Speedometer R 10 IC4 Y–R 7 IM1 BR (∗1) BR LG–R (∗8) R B–L GR–R W–B W–B W–B W–B B B W W EE -4- ED ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC B–R R–Y R–Y R–B R–B R–W R–W R W (BAT) 10A ECU–B 2 W–R B–R 2 G A 4 1B J20(A) Junction Connector G A D A B 3E E B D A J12(A), J13(B) Junction Connector W–R B–R 4 1L GND CANL 11 3 1 2 CANL W CANH ESS 2 R B–R IG W–B B–R 5 IG1 B 1 BAT Y W–R 9 W–B S11 Steering Sensor B 3E 3 CANH Y1 Yaw Rate Sensor B Y W–B W–B B B W W -5- ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC R–Y R–B R–W R R–Y W G A J18(A) Junction Connector R–W R–B R–Y G A 15 12 7 D1 Data Link Connector 3 WFSE TS CANH SIL V L LG CANL 34 P CANH 33 R CANL 14 W 6 E7 Engine Control Module 1 B 2 B 1 D 2 D 1 E 2 E 2 C 1 A 2 A Y B W J47(A), J48(B), J49(C), J50(D), J51(E), J52(F) Junction Connector 1 F W–B 1 C B ST–Plug B Y B W IH -6- ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC A9 A 10 A 11 A 40 A 41 Gray Gray Black Black Black 1 1 1 2 1 2 1 2 3 4 5 6 2 B 14 C8 C9 Gray White White 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 1 2 C 10 C 11 D1 White White White 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 2 16 15 14 13 12 11 10 9 8 1 D5 E7 F9 Blue White White 2 3 4 1 7 2 8 3 4 5 6 1 28 29 30 7 7 8 8 J1 J2 Blue 6 2 3 4 5 6 7 8 5 6 3 2 1 21 22 23 24 White 5 4 6 F 10 4 5 4 White 3 6 9 10 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 1 2 5 3 17 18 19 20 21 22 23 24 25 26 27 1 2 9 10 11 12 13 14 15 16 7 9 10 11 1 2 3 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 4 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J3 J4 J5 J7 Blue Black White Blue 1 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 3 12 13 14 15 16 17 18 19 20 21 22 -7- 4 5 2 1 2 3 6 6 7 8 9 10 11 12 13 4 5 ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC 1 2 3 4 5 J8 J9 J 12 Blue Blue Black 6 7 8 9 10 11 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 1 2 3 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 4 5 J 13 J 14 J 15 J 18 Black Gray Gray Blue 1 2 3 6 1 2 3 6 1 2 3 7 8 9 10 11 12 7 8 9 10 11 12 7 8 9 10 11 12 4 5 4 5 4 5 1 6 2 3 2 3 4 5 J 20 J 21 J 24 Blue Blue White 6 7 8 9 10 11 1 12 13 14 15 16 17 18 19 20 21 22 2 3 4 5 6 7 8 9 10 11 2 J 25 J 28 J 29 White Blue 3 4 5 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 J 30 J 31 J 32 Black Black 7 8 5 6 9 10 11 1 2 3 6 1 2 3 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 7 8 9 10 11 12 4 2 3 4 5 8 9 10 11 4 5 6 5 7 8 9 10 11 4 5 6 J 35 J 37 J 47 J 48 J 49 Blue White White White White 1 1 1 2 2 2 1 1 7 12 13 14 15 16 17 18 19 20 21 22 Blue 6 6 12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22 1 5 2 3 Blue 1 2 3 4 5 6 7 8 9 10 11 12 4 12 13 14 15 16 17 18 19 20 21 22 1 1 6 6 7 8 9 10 11 3 2 4 5 6 12 13 14 15 16 17 18 19 20 21 22 J 50 J 51 J 52 P1 P4 White White White Gray Black 1 1 2 2 1 1 1 5 6 -8- 2 7 3 8 4 9 ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC S 11 S 12 S 15 White Blue White 1 1 2 3 4 5 6 7 8 2 3 9 10 11 12 13 14 15 16 1 4 10 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 31 32 27 28 29 30 S 28 S 29 Black Black 1 2 3 4 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33 34 35 36 37 38 39 40 41 42 43 44 45 46 T3 V5 V 15 Y1 Black Black Blue Black 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 2 3 6 1 1E 1G White 4 5 3 4 5 6 1 7 17 18 19 20 21 22 1 5 White 2 3 4 5 6 7 13 14 15 16 17 18 11 12 13 4 1B 6 7 8 9 10 11 12 13 2 3 White 1 2 3 1 2 4 5 8 9 10 11 12 19 20 21 22 23 24 1 1J 1L White White 9 10 11 12 13 14 15 16 1 23 24 25 26 8 27 28 29 30 31 32 13 14 15 16 17 18 3E 3F Dark Gray White 6 7 14 15 16 17 18 19 8 9 10 20 21 22 1 2 3 10 11 12 4 5 2 6 3 7 13 14 15 16 17 18 -9- 4 5 8 6 9 19 20 7 2 3 2 3 4 4 8 9 10 11 12 19 20 21 22 23 24 5 ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC 1 2 3 4 5 6 7 8 BC2 BE1 White White 11 10 9 9 10 11 2 3 4 5 6 7 6 5 4 3 2 1 1 3 22 21 20 19 18 17 16 15 14 13 12 12 13 14 15 16 17 18 19 20 21 22 1 8 EC1 IB2 Gray White 3 2 1 1 2 6 5 4 5 6 2 4 2 4 1 3 3 4 7 8 9 10 11 5 4 4 3 2 1 11 10 9 8 7 6 5 8 7 6 IC2 Gray 1 2 3 4 5 6 7 8 11 10 9 9 10 11 8 7 6 3 2 1 22 21 20 19 18 17 16 15 14 13 12 12 13 14 15 16 17 18 19 20 21 22 IC3 Blue 1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 IC4 White Gray Gray 1 2 3 4 5 6 7 8 9 19 10 11 20 21 12 13 22 23 14 15 24 25 16 17 26 27 29 37 18 30 31 32 33 34 35 4 3 2 1 9 21 20 11 10 23 22 13 12 25 24 15 14 27 26 38 39 40 28 36 5 19 37 29 28 40 39 38 41 42 43 43 42 41 - 10 - 17 16 32 31 30 18 36 35 34 33 ABS , Auto LSD , Downhill Assist Control , Hill-Start Assist Control , TRAC , VSC IM1 White 1 2 3 4 5 6 7 8 9 10 11 12 13 5 4 3 2 1 13 12 11 10 9 8 7 6 IM2 White 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 - 11 - 2003- 4RUNNER TVIP V5 RS3200 PLUS ELECTRICAL WIRING DIAGRAM (EWD) 2003- 4RUNNER TVIP V5 RS3200 PLUS CONNECTORS G F E 1 2 21 5 10 11 12 25 29 1 4 5 6 3 8 (TERMINAL PIN) 31 (FEMALE PIN) (FEMALE PIN) P M 2 1 2 1 4 3 S 1 6 7 T 4 5 9 10 11 12 13 5 4 1 13 12 11 10 9 (MALE PIN) (MALE PIN) (F E MALE P IN) (MALE P IN) 7 6 2005- 4RUNNER TVIP V2 GLASS BREAKAGE SENSOR (GBS) ELECTRICAL WIRING DIAGRAM (EWD) ACC IG1 AM1 ST1 ST2 AM2 DRIVER SIDE J/B IG2 IG-CONTROL 15A CENTER J/B A7 A2 R G6 M1 M2 B GBS ECU G1 W-B BATTERY W MICROPHONE G5 W-R M'1 Y-R M'2 W-B G4 A1 R G8 ALT 140A DOME 10A AM2 36A AM1 50A IGNITION SW G3 R W-B B1 Y-R B7 Y B2 HEATER CONTROL SW 11 SECURITY ECU Splice Splicing to vehicle W/H TVIP W/H VEHICLE W/H TVIP W/H VEHICLE W/H Plug in connector 2005- 4RUNNER TVIP V2 GLASS BREAKAGE SENSOR (GBS) CONNECTORS 4RUNNER V2 (GBS ADD-ON) A 4 B 7 5 3 2 1 14 12 11 10 9 8 1 8 2 3 4 G 5 9 10 11 12 7 14 1 4 5 6 M 3 8 2 1 (F E MALE P IN) (MALE P IN) (F E MALE P IN) (MALE P IN) V E HIC LE S IDE C ONNE C T OR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 (F E MALE P IN) TOYOTA-SIRIUS CUSTOMER TROUBLESH OOTING FLOWCHART Turn ignition on (ACC). Verify AM/FM operates normally INCLUDING NO NOTE The following tests should be accomplished with the vehicle parked outside in clear view of the sky. Volume Balance (left & right aud io) Channel presets Seek/Tune YES Contact Toyota dealer NO Press the SAT button. Verify radio displays SAT1,SAT2 or SAT3 YES YES Verify if SAT radio displays either of the following messages for more than 1 minute. "No Antenna" "No Sig nal" NO Verify if SAT radio displays only Channels 0, 184, 2 55 YES Preview channels or customer's account may have expired. Contact Sirius 1.800.539 .7474 NO All Channels Does the radio display all channels or only preview channels? Preview Channels Verify the following can be viewed on the radio display: Channel number Channel name Song title Artist name Verify if the customer has subscribed to the full Sirius Service NO YES NO YES Verify the following: Volume Balance (left & right aud io) Channel presets Seek/Tune Verify the following can be viewed on the radio display: NO Contact Toyota dealer NO YES Channel number Channel name Song title Artist name YES Verify the following: NO Volume Balance (left and right aud io) Channel presets Seek/Tune YES END OF DIAGNOSTICS DOC-128-7446 Rev A TOYOTA-SIRIUS SATELLITE RADIO DIAGNOSTIC FLOWCHART NOTE The following tests should be accomplished with the vehicle parked outside in clear view of the sky. Verify the installation of the Sirius Receiver Assembly, Antenna and Cable Harness before testing. Turn ignition on (ACC). Verify AM/FM operates normally INCLUDING Turn off ignition. Remove SAT cable harness from back of radio unit. NO Volume Balance (left & right audio) Channel presets Mute YES YES Replacement (Primary) Sirius receiver (Secondary) Cable harness NO Turn ignition on (ACC). Verify AM/FM operates normally INCLUDING Press the SAT button. Verify radio displays SAT1,SAT2 or SAT3 NO Volume Balance (left & right audio) Channel presets Mute YES See Toyota radio diagnostic repair manual. YES Verify if SAT radio displays any of the following for more than 1 minute. Replacement (Primary) Sirius antenna (Secondary) Sirius receiver YES Replacement (Primary) Sirius receiver (Secondary) Cable harness No Signal Antenna Updating Acquiring NO Tune to a preview channel. Verify the following: Volume Balance (left & right audio) Channel presets Mute Verify if only channels 0,184 and 255 are present. NO NO YES Preview channels or customers account may have expired. Contact Sirius 1.800.539.7474. YES Verify the following can be viewed on display: Channel number Channel name Song title Artist name Replacement NO Sirius receiver YES Tune to channel 255 and verify the SID number can be viewed on display. NO YES END OF DIAGNOSTICS DOC-128-7425 Rev A TOYOTA 4RUNNER DVD Rear Seat Entertainment System Diagnostic Manual MDC # 00107-00358 DVD Diagnostics - 1 SYSTEM DESCRIPTION The Rear Seat Entertainment (RSE) System consists of five basic components: (See Figure 1. RSE Main Component Layout) 1. The Flat Panel Display (FPD) Screen 2. The DVD player, located in the Center Console 3. FM Modulator, located beneath the Vehicle Radio 4. Remote Control 5. Wireless IR (Infra-red) Headphones The RSE System can display video from two sources: DVD Video Disc and AUX inputs. Audio can be heard on the Vehicle Speakers, Wireless Headphones and Wired Headphones. AUX Video and Audio Input jacks are located on the front of the DVD Player Console. For disassembly instructions, refer to RSE Installation Instructions: PT900-8903D-03/16 PT900-8903S-03/16 Pre-Check 1. Confirm that the Vehicle Battery voltage is 10.5 volts minimum. If the Battery is below 10.5 volts, the system is designed to shut down to avoid discharging the Battery. 2. Turn the ignition switch to the ACC/ON position, turn system ON by opening the FPD Screen and by pressing the Power button on the DVD Player or on the Remote Control. Check that the TOYOTA Logo appears on the FPD Screen. RSE Status Indicator Light The Status Indicator Light, located between the power and play/pause buttons on the DVD Player, alerts the user to various functions or problems of the RSE. The Status Indicator Light will be Green when the RSE is on standby or is playing. In case of an error, the Status Indicator Light will blink until the error is corrected, up to a maximum-programmed time. The various states of the Status Indicator Light are as follows: Status Indicator Light OFF: The Green Light is OFF when the system is turned OFF. Green Status Indicator Light: A steady Green Light indicates normal operation. Status Indicator Light Blinking: The RSE system is programmed with six different Status Indicator Light blink sequences, which can be used to troubleshoot the RSE system. The blink sequences and indications are as follows: 1. One Blink - Power Failure (ACC abnormal power OFF) (Go to Step A1) 2. Two Blinks - Voltage Over Limit. (Out of range from 9 to 16 volts) (Go to Step A2) 3. Three Blinks - Temperature Over Limit. (Go to Step A3) 4. Four Blinks - Communication Error between CIM and FPD (Go to Step A4) 5. Five Blinks - Rotational Angle of the FPD is less than 20 degrees (Go to Step A5) 6. Six Blinks - Communication Error between CIM and DVD (Go to Step A6) Blinking Status Indicator Light Quick Troubleshooting Guide A1 Blink Sequence The Status Indicator Light is blinking in a steady sequence ON/OFF - ON/OFF 300 mSec On 1 Blink 300 mSec On 1 Second Off Issue: A 01/12/04 Page 1 of 38 pages Indication Solution There is a power failure related to an ACC abnormal power off Proceed with Symptom B1 Supplier Ref #: DIO DVD Diagnostics - 2 The minimum or maximum voltage operating range of the RSE has been exceeded. Prior to the blinking sequence, the FPD screen will display “VOLT LIMIT Shutdown in 5 Sec.”. The minimum or maximum operating temperature range of the RSE has been exceeded. Prior to the blinking sequence, the FPD screen will display “TEMP LIMIT Shutdown in 5 Sec.”. The Status Indicator Light is blinking in a steady sequence ON/ON/OFF - ON/ON/OFF A2 300 mSec On 2 Blinks 300 mSec On 300 mSec On 300 mSec Off 1 Second Off The Status Indicator Light is blinking in a steady sequence ON/ON/ON/OFF - ON/ON/ON/OFF A3 300 mSec On 300 mSec On 3 Blinks 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 1 Second Off The Status Indicator Light is blinking in a steady sequence ON/ON/ON/ON/OFF- ON/ON/ON/ON/OFF 300 mSec On A4 4 Blinks 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On There is a communication error between the CIM and FPD 300 mSec On 300 mSec Off 1 Second Off The Status Indicator Light is blinking in a steady sequence ON/ON/ON/ON/ON/OFF - ON/ON/ON/ON/ON/OFF 300 mSec On A5 5 Blinks 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On 1 Second Off The Status Indicator Light is blinking in a steady sequence ON/ON/ON/ON/ON/ON/OFF - ON/ON/ON/ON/ON/ON/OFF 300 mSec On A6 6 Blinks 300 mSec On 300 mSec Off Issue: A 01/12/04 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off 300 mSec On 300 mSec Off Page 2 of 38 pages 300 mSec On 1 Second Off Verify Battery Voltage to be between 10.5 and 15.8 VDC. Shutdown the RSE system and allow time for the system to either cool down or allow time for the system to warm up. Proceed with Symptom B1 The rotational angle of the FPD is less than 20º Open the FPD Screen greater than the 20º minimum viewing angle. There is a communication error between the CIM and DVD Proceed with Symptom B1 Supplier Ref #: DIO DVD Diagnostics - 3 PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom Suspect Area 1. Low Battery Voltage 2. Fuse 3. Connector/Cable 4. FPD 5. DVD Player See Page 5 B1 No TOYOTA Logo, No Video, Dark Screen B2 No Video Play but the TOYOTA Logo appears on Screen 1. Remote Control 2. Remote Control Batteries 3. DVD Player 9 B3 Poor Video Quality 1. DVD Disc 2. DVD Player 3. FPD Assembly 10 B4 No Video in AUX mode when external source is provided but DVD mode functions properly 1. Remote Control 2. DVD Player 11 1. FM Modulator (FMM) is OFF 2. Vehicle Radio is not tuned to FMM frequency 3. Antenna Cable from FMM is not plugged into Vehicle Radio. 4. FM Modulator 5. Connector/Cable 6. Remote Control 7. DVD Player 1. Wireless Headphones Batteries 2. Wireless IR Headphones 3. FPD Assembly B5 No Audio on Vehicle Speakers, while the Audio on Wireless IR and or Wired Headphones is OK B6 No Audio on Wireless IR Headphones B7 No Audio on Wired Headphones, while the Audio on Wireless IR and or Vehicle Speakers is OK 1. Wired Headphones 2. DVD Player 17 B8 Disc plays, but will not eject 1. DVD Player 18 B9 DVD Player will not accept disc. TOYOTA logo appears on the screen 1. DVD Player 19 B10 DVD System will not respond to any of the remote control functions, but TOYOTA Logo appears on FPD and/or DVD disc auto starts and/or FPD shows Disc menu when the IG/ACC is ON 1. Remote Control 2. Remote Control Batteries 3. FPD Assembly 20 The Dome Light in the FPD does not work 1. 2. 3. 4. 5. 22 B11 Issue: A 01/12/04 The Page 3 of 38 pages Light Bulb Dome light Cable/Connector FPD Assembly Main Harness/Fuse Vehicle Battery 12 15 Supplier Ref #: DIO DVD Diagnostics - 4 B12 DVD disc will not resume last position after the vehicle has been turned OFF and then turned ON again Issue: A 01/12/04 Page 4 of 38 pages 1. Vehicle Radio Fuse #2 (25 Amp) 2. Vehicle Wire Harness 3. RSE Main Wire Harness 25 Supplier Ref #: DIO DVD Diagnostics - 5 B1 SYMPTOM: No TOYOTA Logo, No Video, Dark Screen 1 Check the Vehicle Radio for Power and Sound. NG Go to step 3 OK 2 Check that the DVD Player backlight turns on by pressing the power button. The Power button should glow RED while the Play/Pause and the Stop/Eject buttons glow bright GREEN. Ignition Switch must be in the ACC/ON position with the FPD Screen down. NG Go to step 4 OK Go to step 7 3 Check Vehicle Radio Fuse #1 (7.5 Amp) and Radio Fuse #2 (25 Amp) NG Go to step 12 OK Go to step 10 Issue: A 01/12/04 Page 5 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 6 4 Check the two (5 Amp) Fuses on the B+ and ACC input power lines NG Go to step Replace Fuse(s) and Retest OK 5 Check the B+ and ACC voltages on Pins 1 and 3 and continuity to ground on Pin 2 of connector P13 NG Go to step Replace T-Harness OK 6 Check the B+ and ACC voltages on Pins 1 and 2 and continuity to ground on Pin 3 on connector P21 of the DVD Player. NG OK 7 Thetoharness Go step from the DVD Player to the Input Power connector is defective Replace RSE Main Wire Harness Disconnect P12 and check the +7.5 voltage on Pin 1 and continuity to ground on Pin 2. NG Go to step Replace DVD Player OK Issue: A 01/12/04 Page 6 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 7 8 Reconnect P12 to the DVD Player and disconnect P103 of the FPD. Check the +7.5 voltage on Pin 1 and continuity to ground on Pin 2. NG The harness Go to step from the DVD Player to the FPD is defective. Replace RSE Main Wire Harness. OK 9 Replace FPD. End 10 For 8 Speaker System: Check B+ and ACC voltages on Pins 1 and 11 and continuity to ground on Pin 20 of connector J303 For 6 Speaker System: Check B+ and ACC voltages on Pins 4 and 3 and continuity to ground on Pin 7 of connector J305 NG Go to step Check Vehicle Main Harness OK 11 For 8 Speaker System: Check B+ and ACC voltages on Pins 1 and 11 and continuity to ground on Pin 20 of connector P302 For 6 Speaker System: Check B+ and ACC voltages on Pins 4 and 3 and continuity to ground on Pin 7 of connector P304 NG Go to step Replace T-Harness OK Issue: A 01/12/04 Page 7 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 8 Go to step 1 12 For 8 speaker systems, Disconnect P302, Replace Blown Fuse(s) and Re-check Vehicle Radio Fuse #1 (7.5 Amp) and Radio Fuse #2 (25 Amp) For 6 speaker systems, Disconnect P304, Replace Blown Fuse(s) and Re-check Vehicle Radio Fuse #1 (7.5 Amp) and Radio Fuse #2 (25 Amp) NG Go to step 13 OK Go to step 1 13 Replace T-Harness and Re-test NG Go to step Vehicle Radio not working properly OK Go to step 1 Issue: A 01/12/04 Page 8 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 9 B2 SYMPTOM: No Video Play but the TOYOTA Logo appears on Screen. If the logo appears, this signifies that power is available at the FPD. This condition focuses our attention on the DVD player. 1 Check the DVD System response to the Remote Control commands. Pressing the Source button on the remote will activate either the DVD or AUX mode and display the mode in the center of the screen for approximately two seconds NG Go to B10 step Remote Control Problems OK 2 Insert a DVD disc and verify it is accepted. The video will start playing or the disc menu will appear on the screen NG Go to step Replace DVD Player OK End. System Functions Properly Issue: A 01/12/04 Page 9 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 10 B3 SYMPTOM: Poor Video Quality. 1 Check video performance with various DVD discs. NG Go to step 2 OK End. Go to step First DVD disc is defective. System OK. 2 Check external video performance. Press the Source button on the remote control to activate AUX mode and connect an external video source to the AUX input on the DVD console NG Go to step 3 OK Go to step Replace DVD Player 3 Disconnect P12 and P103. Verify continuity between each pin of the connectors. NG Harness from the DVD Player to the Go to step FPD is defective. Replace RSE Main Wire Harness OK Replace FPD Assembly Go to step Issue: A 01/12/04 Page 10 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 11 B4 SYMPTOM: No Video in AUX mode when external source is connected, but DVD mode functions properly 1 Check the DVD system response to the remote control commands. Pressing the Source button on the remote will activate either the DVD or AUX mode and display the mode in the center of the screen for approximately two seconds NG Go to B10 step Remote Control Problems OK 2 Check the AUX with external source and confirm video appears on screen NG Go to step Replace the DVD Player OK End. System Functions Properly Issue: A 01/12/04 Page 11 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 12 B5 SYMPTOM: No Audio on Vehicle Speakers, but Audio is present on Wireless and/or Wired Headphones 1 Check that the FM Modulator is turned ON. Using the Remote Control, press the FMM ON/OFF Button. The screen will display FMM ON or OFF NG Go to step B10, Remote Control Problems Go to OK 2 Check that the Vehicle Radio is turned ON and tuned to the same FM Modulator Frequency NG Tune the Vehicle Radio to the correct FM Modulator frequency. OK 3 Check if Audio is present on Vehicle Speakers NG Go to step 4 OK End. System Functions Properly Issue: A 01/12/04 Page 12 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 13 4 Check that the Connectors P20 and P307 are properly connected to the DVD Player and FM Modulator. NG Go to step and Re-Test at Step 3 Re-connect OK 5 Disconnect Connector P20 and check the voltage on Pin 1 (+7.5 Volts) and continuity to ground on Pins 6 and 7 NG Go to step Replace DVD Player OK 6 Re-connect Connector P20 and disconnect Connector P307. Check voltage on Pin 1 (+7.5 Volts) and continuity to ground on Pins 6 and 7. NG The harness Go to step from the DVD Player to the FM Modulator is defective. Replace the RSE Main Wire Harness. OK 7 Verify that the Vehicle Antenna is connected into the FM Modulator and that the FM Modulator is connected into the Vehicle Radio NG Connect Vehicle Antenna to the FM Go to step Modulator and/or FM Modulator to the Radio OK Issue: A 01/12/04 Page 13 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 14 8 Disconnect P307 and P20. Verify continuity between each pin of the connectors. NG The harness Go to step from the DVD player to the FM Modulator is defective. Replace the RSE Main Wire Harness. OK Replace FM Modulator Issue: A 01/12/04 Page 14 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 15 B6 SYMPTOM: No Audio on TOYOTA Wireless IR Headphones 1 Check that the Red LED Indicator, on the Wireless Headphones, turns ON when the IR Headphones are turned ON NG Replace batteries and go to step 1 Go to step OK 2 Check that the FPD IR Transmitter is turned ON in the System Menu. Press System Menu button on the Remote Control NG Press the System Menu button on the Remote Control. Press the T button 3 times then the X button 1 time to change the IR Transmitter from OFF to ON OK 3 Check Audio with a second Wireless IR Headphone. NG Go to step 4 OK System functions properly. The first headphone was not working properly. Issue: A 01/12/04 Page 15 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 16 4 Check the Audio using a pair of Wired Headphones. NOTE: Headphone Jacks are located on the front of the DVD Player NG Wired Go to step Replace DVD Player OK Replace FPD (IR Transmitter not working properly). 5 Disconnect P12 and P103, Verify continuity between each pin of the connectors. NG The harness from the DVD player to the FM Modulator is defective. Replace the RSE Main Wire Harness. OK Replace FPD (IR Transmitter not working properly). Issue: A 01/12/04 Page 16 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 17 B7 SYMPTOM: No Audio on Wired Headphones 1 Verify that the System Audio is not muted. Press the Mute button on the Remote Control and the screen will display if the system is muted or not NG Turn Go toOFF stepMute mode OK 2 Check Audio on Wireless IR Headphones. NG Go to step SYMTOM B6 OK 3 Check both Headphone Jacks, on the DVD Console, with an alternate Wired Headphone NG Go to step Replace DVD player OK Original Wired Headphone is not functioning properly. Replace Headphones. End. Issue: A 01/12/04 Page 17 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 18 B8 SYMPTOM: DVD plays disc, but will not Eject 1 With the ignition switch in the ACC/ON position. Power System ONOFF-ON with the Remote Control or by pressing the Power button on the DVD Player and then Stop, to stop the playback of the Disc, then Press Eject. NG Replace DVD Player Go to step OK End. System functions properly Issue: A 01/12/04 Page 18 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 19 B9 SYMPTOM: DVD Player will not accept Disc, but the TOYOTA Logo appears on the screen 1 Verify that the Disc is inserted properly. The label of the disc should be facing the driver upon insertion into the DVD slot. NG Go to step 2 OK End. System functions properly 2 With the ignition switch in the ACC/ON position. Power System ONOFF-ON with the Remote Control or by pressing the Power button on the DVD Player and then Stop, to stop the playback of the Disc, then Press Eject. NG Replace DVD Player Go to step OK End. System functions properly Issue: A 01/12/04 Page 19 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 20 B10 SYMPTOM: DVD System will not respond to the Remote Control. TOYOTA Logo appears on the screen or DVD disc auto starts or displays Disc Menu when the IGN/ACC is ON 1 Check that the remote control can select DVD and AUX modes and all other button functions. After pressing the Source button on the Remote Control, either DVD or AUX will be displayed on the screen. NG Go to step 2 OK System functions properly 2 Install a New Battery in the Remote Control and Re-test NG Go to step 3 OK System functions properly 3 Try control functions of New Remote Control. NG Go to step 4 OK Issue: A 01/12/04 Page 20 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 21 Original Remote Control did not function properly. 4 Disconnect P12 and P103. Verify continuity between each pin of the connectors. NG The harness Go to step from the DVD Player to the FPD is defective. Replace the RSE Main Wire Harness OK Replace the FPD Issue: A 01/12/04 Page 21 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 22 B11 SYMPTOM: The Dome Light in the FPD does not work 1 Switch the Dome Light Rocker Switch to the ON position and the Dome Light turns ON NG Go to step 2 OK Dome Light works properly. End. 2 Remove the Dome Light Cover and verify that the Dome Light Bulb is properly inserted into the Bulb Socket NG Either the bulb was inserted improperly Go to step or the bulb was not inserted at all. Reinsert bulb and Re-test OK 3 Remove and Replace the Dome Light Bulb NG Go to step 4 OK Dome light works, first bulb was defective Issue: A 01/12/04 Page 22 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 23 4 Check the 10 Amp Dome Light Fuse NG Replace Fuse and Retest Go to step OK 5 Disconnect the FPD to expose the Dome Light Wire Harness. Verify that the Dome Light Wire Harness is properly connected to the vehicle Main Wire Harness NG Connect Dome Light Harness to Vehicle Go to step Main Wire Harness and Re-test OK 6 Disconnect the Dome Light connector and verify that +12 VDC exists on Pins 1 and 2 and continuity to ground on Pin 3 NG Go Go to to step step 7 OK Dome Light Circuit is defective. Replace FPD 7 Verify Battery Voltage is approximately 12 VDC. NG Issue: A 01/12/04 Battery Discharged. Re-charge Battery. Go to step Re-test. Page 23 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 24 OK Vehicle Main Wire Harness is defective. Replace Harness Issue: A 01/12/04 Page 24 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 25 B12 SYMPTOM: DVD disc will not resume last position after the vehicle has been turned OFF and then turned ON again This symptom concentrates on the B+ Input Power Line. While in the middle of disc Playback, the vehicle is shut OFF, the DVD Players Memory will mark the last position of the disc and will resume Playback from that point upon power up. 1 Power up the RSE System. Insert a disc into the DVD Player. Skip forward two chapters into the video by pressing the next button twice on the remote control. Shut off the vehicle and wait 5 seconds. Turn the vehicle back ON. The video should resume from the point where the video last left off. NG Go to step 2 OK End. System functions properly 2 Check the Vehicle Radio #2 Fuse (25 Amp) NG Replace Fuse and Re-test OK 3 For 8 Speaker System: Check B+ voltages on Pins 1 of J303 For 6 Speaker System: Check B+ voltages on Pins 4 of J305 NG Check Vehicle Main Wire Harness OK Issue: A 01/12/04 Page 25 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 26 4 Check the B+ voltage on Pin 1 of connector P13 NG Go to step 6 OK 5 Check the B+ voltage on Pin 2 of connector P21 NG Replace RSE Main Wire Harness. Go to step Harness is defective OK End. Replace DVD Player. DVD Player not functioning properly 6 Check the 5 Amp fuses on the T-Harness NG Replace fuse (s) and Re-test OK Replace T-Harness and Re-test Issue: A 01/12/04 Page 26 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 27 RSE Main Component Layout Figure 1. RSE Main Component Layout (Non-Sunroof) Issue: A 01/12/04 Page 27 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 28 Connection Locations on the FM Modulator and DVD Player P307 Figure 2. FM Modulator Connections P21 P12 P20 Figure 3. DVD Player Connections Issue: A 01/12/04 Page 28 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 29 DISC Slot Power Button Status Indicator Light PLAY/ PAUSE STOP/ EJECT Video Input Audio Left Input Audio Right Input Wired Headphone Jacks Figure 4. DVD Player Front Face Plate Issue: A 01/12/04 Page 29 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 30 RSE Wire Harness/Connector Location (Non-Sunroof) Figure 5. RSE Connector/Wire Harness Location Issue: A 01/12/04 Page 30 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 31 RSE Wire Harness/Connector Location (Sunroof) Figure 6. RSE Connector/Wire Harness Location Issue: A 01/12/04 Page 31 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 32 RSE Wire Diagram (6 Speaker) RADIO No.2 25A (B+) MAIN FUSE RADIO No.1 7.5A (Acc)z VEHICLE WIRE HARNESS 1 2 5 6 4 3 J305 7 UP PILLAR "A" BATTERY P103 P12 P304 1 STANDARD RADIO 6 SPEAKER P21 2 5 6 J14 F1 5A 4 1 1 5A 3 F2 7 3 3 2 2 DVD B+ 2 Acc 1 GND 3 6 P13 ANTENNA INPUT 1 2 POWER-7.5V 3 4 5 IR-GND 1 2 GND 3 4 5 IR-IN IR-5V D-GND 6 8 9 10 D-TXD D-RXD D-ACK 7 14 A-GND 11 12 13 AUDIO-R AUDIO-L GND-DOME 3-PIN MALE CONNECTOR P20 RING GND DIVERSITY Tx IR FOR WIRELESS Rx REMOTE EYE 7 14 VIDEO V-GND 11 12 13 DISPLAY (FPD) 6 8 9 10 DOMELIGHT 375N GND-DOME 3 1 2 EXISTING 3-PIN FEMALE CONNECTOR 722N P307 FMM 1 6 7 8 3 2 9 5 10 4 POWER-DOME POWER-7.5V 1 SW-GND-DOME GND GND 2 EXISTING 2-PIN FEMALE CONNECTOR FM-CE FM-DA FM-CK D-GND AUDIO-R 2-PIN MALE CONNECTOR DOOR SWITCH AUDIO-L A-GND CONNECTORS/NOTES 1. J14=(3 PIN) 2. P13= (3 PIN) 3. P12=(14 PIN) 4. P103= (14 PIN) 5. P20= (10 PIN) 6. P21= ( 6 PIN) 7. P307=(10 PIN) 8. J305= (10 PIN) 9. P304= (10 PIN) Figure 7. RSE Wire Diagram (6 Speaker) Issue: A 01/12/04 Page 32 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 33 RSE Wire Diagram (8 Speaker) MAIN FUSE RADIO No.2 25A (B+) VEHICLE WIRE HARNESS RADIO No.1 7.5A (Acc)z 2 4 5 6 12 14 15 9 J303 8 19 18 16 7 17 10 3 13 1 11 20 BATTERY P103 P12 P302 P21 J14 F1 5A 2 4 5 6 12 14 15 STANDARD RADIO 8 SPEAKER UP PILLAR "A" 1 1 B+ 2 F2 5A 3 3 9 8 19 18 16 7 17 10 3 13 Acc 1 DVD 1 2 POWER-7.5V 3 4 5 IR-GND GND 2 2 3 P13 6 1 11 20 IR-5V D-GND 6 8 9 10 D-TXD D-RXD D-ACK VIDEO V-GND A-GND 11 12 13 AUDIO-R AUDIO-L RING GND DISPLAY (FPD) Tx IR FOR WIRELESS Rx REMOTE EYE 7 14 11 12 13 DOMELIGHT 375N GND-DOME DIVERSITY 6 8 9 10 GND-DOME 3-PIN MALE CONNECTOR P20 ANTENNA INPUT 3 4 5 IR-IN 7 14 GND 1 2 3 1 2 EXISTING 3-PIN FEMALE CONNECTOR 722N POWER-DOME P307 1 SW-GND-DOME FMM 1 6 7 8 3 2 9 5 10 4 2 POWER-7.5V EXISTING 2-PIN FEMALE CONNECTOR GND GND FM-CE FM-DA FM-CK D-GND DOOR SWITCH AUDIO-R AUDIO-L A-GND CONNECTORS 1. J14= (3 PIN) 2. P13= (3 PIN) 3. P12= (14 PIN) 4. P103= (14 PIN) 5. P20= (10 PIN) 6. P21= ( 6 PIN) 7. P307= (10 PIN) 8. J303= (20 PIN) 9. P302= (20 PIN) Figure 8. RSE Wire Diagram (8 Speaker) Issue: A 01/12/04 Page 33 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 34 Dome Light Connector FPD FPD / IR Connector Figure 9 FPD Connector Locations Issue: A 01/12/04 Page 34 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 35 Connector Tables PIN # Function 1 FR+ 2 FL+ Green 20# 3 ACC Red 20# 4 B+ White 20# 5 FR- Yellow 20# 6 7 FLGND Blue 20# Black 20# PIN # Function 1 FR+ Connector # J305 6 speaker T-harness (Power End) Connector # P304 6 speaker T-harness (Radio End) Color/Gauge Brown 20# Color/Gauge Brown 20# 2 FL+ Green 20# 3 ACC Red 20# 4 B+ White 20# 5 FR- Yellow 20# 6 7 FLGND Blue 20# Black 20# PIN # Function 1 B+ Connector # J303 8 speaker T-harness (Power End) Color/Gauge 2 - White/Black 20# 3 AMP Violet 20# 4 - White/Red 20# White 20# 5 6 - White/Green 20# 7 MUTE Brown 20# 8 FR Red 20# 9 FL Yellow 20# 10 SGDE Shield 11 ACC Red 20# 12 - White/Yellow 20# 13 ANT Gray 20# 14 - White/Blue 20# 15 - White/Orange 20# 16 SGND Black 20# 17 BEEP Orange 20# 18 RR Green 20# 19 RL Blue 20# 20 GND Black 20# Issue: A 01/12/04 Page 35 of 38 pages Supplier Ref #: DIO DVD Diagnostics - 36 PIN # Function 1 B+ Connector # P302 8 speaker T-harness (Radio End) Color/Gauge 2 - White/Black 20# 3 AMP Violet 20# 4 - White/Red 20# White 20# 5 6 - White/Green 20# 7 MUTE Brown 20# 8 FR Red 20# 9 FL Yellow 20# 10 SGDE Shield 11 ACC Red 20# 12 - White/Yellow 20# 13 ANT Gray 20# 14 - White/Blue 20# 15 - White/Orange 20# 16 SGND Black 20# 17 BEEP Orange 20# 18 RR Green 20# 19 20 RL GND Blue 20# Black 20# PIN # Function 1 B+ 2 GND Black 20# 3 ACC Red 20# PIN # Function 1 B+ 2 GND Black 20# 3 ACC Red 20# Issue: A 01/12/04 Connector P13 T-Harness to 6 & 8 Speaker Power Connector J14 T-Harness Power to DVD Power Page 36 of 38 pages Color/Gauge White 20# Color/Gauge White 20# Supplier Ref #: DIO DVD Diagnostics - 37 PIN # Function 1 ACC Red 20# 2 B+ White 20# 3 GND Black 20# 4 NC 5 NC 6 GND PIN # Function 1 POWER-7.5V 2 GND Connector P21 Power to DVD Color/Gauge Drain Connector P12, P103 DVD to FPD Color/Gauge Red 20# Black 20# 3 IR-GND Black 26# 4 IR-IN Brown 26# 5 IR-5V Red 26# 6 D-GND Black 26# 7 VIDEO Coax, conductor 8 D-TXD Brown 26# 9 D-RXD Red 26# 10 D-ACK Orange 26# 11 A-GND Black 26# 12 AUDIO-R Red 26# 13 14 AUDIO-L V-GND Brown 26# Coax, shield PIN # Function 1 Power-7.5V 2 FM-CK Red 24# 3 FM-DA White 24# 4 A-GND Black 24# 5 AUDIO-R Red 24# 6 GND Black 20# 7 GND White 20# 8 FM-CE Green 24# 9 D-GND Black 24# 10 AUDIO-L White 24# Issue: A 01/12/04 Connector P20, P307 DVD to FM Modulator Page 37 of 38 pages Color/Gauge Red 20# Supplier Ref #: DIO DVD Diagnostics - 38 PIN # Function F1-A Power B+ F2-A Power ACC Issue: A 01/12/04 Connector P20, P307 Power and Memory Fuses Color/Gauge White 20# Red 20# Page 38 of 38 pages Supplier Ref #: DIO TROUBLESHOOTING 20034RUNNER TVIP V5 INFORMATION RS3200 PLUS TROUBLESHOOTING GUIDE RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM CONNECTOR1 CIRCUIT MEASUREMENT 1 - Ground SUB +B Power (Dome) Always Approx. 12V 2 - Ground +B Power (Dome) Always Approx. 12V 3 Trunk Key Input Continuity when key turned to open 4 - Ground Key Unlock Warning Input Continuity when key is in the ignition switch 5 N/C 6 - Ground 7 - Ground G.B.S. Input 8 - Ground N/C 9 - Ground N/C 10 MPX signal 11 Ground ECU Ground Continuity 12 - Ground LED Output Approx. 1.8V when LED on, 0V when LED off 0V during triggering 13 - Ground Starter Cut Input Approx. 12V when ignition switch at ST position, 0V during triggering 14 Ground IG Input 15 0V (Pulsed) when window hit Approx. 12V when ignition switch is in ON position N/C 16 N/C 17 N/C 18 N/C 19 N/C 20 N/C 21 N/C 22 N/C 23 N/C 24 N/C 25 N/C 26 - Ground Starter Cut Output Approx 12V when ignition switch is in ON position TROUBLESHOOTING INFORMATION RS3200PLUS AVALON/ CAMRY/ HIGHLANDER SECURITY SYSTEM Complaint: Remote Control Inoperative Common causes for this complaint: Mis-spliced Key Unlock wire, weak or dead battery in remote, remote programmed improperly (see KNOWN ISSUES page), remote not programmed, connectors not plugged in securely. What to Ask and Verify Does the panic mode operation work? What to Check Yes Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Clear the remote control codes from the ECU, then reprogram both (or all) remotes (they may have accidentally been programmed for second channel output). No control(s) and carefully clean the battery and contacts, then check the battery for a minimum 2.7V during remote operation. Replace the battery if necessary. Clear the remote control codes from the ECU, then reprogram both (or all) remotes (they may have accidentally been programmed for second channel output). Check the automatic door locking/unlocking function. Open the remote Do the vehicle’s door Yes locks work with the door switches or key? No Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the door lock control connectors are plugged in securely. Disconnect the RS3200PLUS harness’ Door Lock Control connectors and reconnect the vehicle’s connectors, then try again, If there is no function, there is probably a problem with one vehicle’s components. RS3200PLUS AVALON/ CAMRY/ HIGHLANDER SECURITY SYSTEM Complaint: System Inoperative (No Remote Arming/Disarming) Common causes for this complaint: Mis-spliced Key Unlock Warning wire, mis-spliced door courtesy wire, connectors not plugged in securely, Fuse or shortpin not installed in vehicle, blown fuse in RS3200PLUS harness (does not apply to all vehicles). What to Ask and Verify Do the vehicle’s door Yes locks work with the door switches or key? No What to Check Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the door lock control connectors are plugged in securely. Disconnect the RS3200PLUS harness’ Door Lock Control connectors and reconnect the vehicle’s connectors, then try again, If there is no function, there is probably a problem with one vehicle’s components. TROUBLESHOOTING INFORMATION RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM Complaint: No Head Light Function Common causes for this complaint: Mis-spliced Head Lamp wire, connectors not plugged in securely, blown Head Lamp fuse. What to Ask and Verify Does the head lamp switch in the vehicle work? Is there continuity between pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the head light wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Check for continuity between the RS3200PLUS ECU connector and the head lamp circuit connection. No Check the vehicle’s head lamp fuse and replace if necessary. Confirm that the combination switch connector for the head lamp circuit is plugged in securely. Yes Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check fix the wire harness. Check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. No If no continuity, there is a wire harness problem. Fix as necessary. RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM Complaint: No Horn Function Common causes for this complaint: Mis-spliced Horn wire, connectors not plugged in securely, blown Horn fuse. What to Ask and Verify Does the horn switch in the vehicle work? Is there continuity on pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the horn wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Check for continuity between the RS3200PLUS ECU connector and the horn circuit connection. No Check the vehicle’s horn fuse and replace if necessary. Confirm that the combination switch connector for the horn circuit is plugged in securely. Yes Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check fix the wire harness or check BODY ECU signal. Check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. If no continuity, there is a wire harness problem. Fix as necessary. No TROUBLESHOOTING INFORMATION RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM Complaint: No Tail Light Or Marker Light Operation Common causes for this complaint: Mis-spliced Tail Light wire, connectors not plugged in securely, blown fuse. What to Ask and Verify Do the vehicle’s tail lights work? Is there continuity on pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the tail light wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Verify the RS3200PLUS harness’ tail light circuit connectors are plugged in securely. Check for continuity between the RS3200PLUS ECU connector and the tail light circuit connection. No Confirm that the vehicle’s connector for the tail light circuit is plugged in securely. Disconnect the RS3200PLUS harness’ tail light circuit connectors and reconnect the vehicle’s connectors, then check the tail light function again. If they work, check the RS3200PLUS harness. If not, the problem is vehicle-related. (applies to some vehicles) Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. Yes No Check and fix the RS3200PLUS harness. RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM Complaint: LED Inoperative (No blinking, No turning on) Common causes for this complaint: Mis-spliced LED wire, mis-spliced door courtesy wire, connectors not plugged in securely. What to Ask and Verify Does the LED blink during arming? Yes No What to Check No problem. Check trunk key switch was installed properly. If not correct, LED may not turn on. Verify the splice connector was applied properly. TROUBLESHOOTING INFORMATION RS3200PLUS AVALON/CAMRY/HIGHLANDER SECURITY SYSTEM Complaint: System Inoperative (Duplicate Panic Alarm) Common causes for this complaint: Mis-connection of Panic signal wire with terminal, mis-spliced panic signal wire, connector not plugged in securely. What to Ask and Verify What to Check Does the duplicate panic Yes mode operation work? Check the panic signal wire’s splice location. (Does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the panic signal wire with terminal location. Check door lock control connector is plugged in securely. No No Problem 2005- 4RUNNER TVIP V2 GLASS BREAKAGE SENSOR (GBS) Troubleshooting Information TROUBLESHOOTING GUIDE G.B.S. Security System CONNECTOR 1 1-GROUND 2-GROUND 3-GROUND 4-GROUND 5-GROUND 6-GROUND 7-GROUND 8-GROUND CIRCUIT +B Power (ECU-B) N/C G.B.S. Output G.B.S. (Microphone) Input G.B.S. (Microphone) Ground GND N/C IG Input 1 4 5 6 MEASUREMENT Always approx 12V 0V (pulsed) when window hit 0V (pulsed) when window hit Continuity Continuity Approx. 12V when ignition switch is in ON position 3 8 CONNECTOR 1 G.B.S. Security System Complaint: G.B.S. Inoperative (no alarm when window is hit) Common causes for this complaint: G.B.S. signal terminal not plugged in securely, sensitivity adjustment not properly set. What to Ask and Verify Does the alarm go off? What to Check Yes No No problem Check the volume of the G.B.S. unit. Confirm microphone location. Verify the connection of the G.B.S. signal wire. Accessory Installation Practices Introduction This document is written and maintained by Toyota Motor Sales, U.S.A., Inc. as an aid to defining accessory installation best practices. Safety 1.1 Eye protection should be worn during any drilling and cutting, and when power tools are used to remove or attach fasteners. Eye protection should also be used when using any special chemicals (as listed on the first page of the Installation Instruction Sheet) to reduce the risk of these chemicals entering the eye. 1.2 Rechecking of fastener tightness. For some accessories it is necessary to recheck the tightness of the fasteners securing the accessory, for example – wheel lug nuts, running board bolts, tow hitch bolts etc. Where a recheck is required it will be noted in the Installation Instruction Sheet (either in the Procedure Section and/or the Checklist Section) 1.3 Supplemental Restraint System SRS Any vehicle equipped with a supplemental restraint system (SRS). Failure to carry out the following procedures listed below could result in possible deployment of airbag, personal injury, or unnecessary repairs to SRS. 1.3.1 Turn the key switch to the LOCK position. 1.3.2 Remove key from ignition switch. 1.3.3 Disconnect the negative battery cable. 1.3.4 Never use a voltmeter to troubleshoot any of the harnesses or connectors to the SRS. Accidentally probing the connectors to the SRS can lead to deployment of the airbag. 1.3.5 SRS wire harness loom/cover is bright yellow in color. 1.3.6 SRS contains a battery backup system; therefore ALWAYS wait for a minimum of 90 seconds after disconnecting the battery negative cable before removal/disassembly of electrical components. (Reference TSB: EL93-001). Vehicle Protection 2.l Vehicle should be clean before performing any accessory installation. 2.2 Prepare grille cover, fender cover, seat cover, and floor mat cover as appropriate to the installation area on the vehicle of the accessory before starting installation. Blankets, seat covers, paper floor coverings are suitable for this purpose. Issue B Page 1 of 4 pages 5/23/2006 2.3 Do not place any tools on unprotected vehicle surfaces, or leave inside vehicle. Use a tool tray to keep tools separate from the vehicle surface. 2.4 It is recommended that no exposed jewelry (rings, watches etc.), zippers, buttons, rivets, belt buckles or other scratch potential objects be worn. Articles of clothing or jewelry that have the potential to come into contact with the vehicle surface (i.e., generally below the chest) and contain any of the above items should be covered with tape and/or other protective material to prevent scratching of the vehicle. 2.5. Clothing and shoes must be free of grease and dirt to maximize vehicle cleanliness. 2.6 Parts and tool trays should be used for interior installations whenever possible. Parts, tools or trays must not be placed onto unprotected, seats, carpets or trim panels. 2.7 Tools, air hoses and power cords should be free of grease and dirt. 2.8 Blanket should be used to cover engine bay while working on accessory that requires hood to be open (e.g. Hood Protector) to prevent fasteners from being dropped into engine bay. Vehicle Disassembly/Re-assembly Panel Removal 3.1 Many panels on the vehicle are held in place with clips. Where the location of this clip is critical it is shown on the figure(s) in the Installation Instruction Sheet. Care must be taken to remove the panel and its clip(s) without damage. Toyota recommends use of plastic (nylon) removal tools, rather than metal and two Toyota Special Service Tools are available:Panel Pry Tool #1 Toyota SST # 00002-06001-01 Panel Pry Tool #2 Toyota SST # 00002-06002-01 Panel Protection 3.2. Place all removed parts on a protected surface. 3.3. All work benches, tables, or platforms used for assembly or temporary storage of parts should be carpeted or suitably covered to provide a soft, non-abrasive surface. Parts Container 3.4 Use a small parts container to keep removed bolts and tapping screws so that they can be reassembled correctly. Electrical Component Disassembly/Reassembly Battery Cable 4.1 Unless otherwise stated battery negative terminal must be disconnected and isolated before performing work on any electrical components (i.e. connecting or disconnecting any Issue B Page 2 of 4 pages 5/23/2006 electrical connectors, etc.). In some installations fuse removal is used instead of battery terminal disconnection, and will be referred to in the Installation Instruction Sheet. 4.2 Ignition key must be removed from the ignition switch when the negative battery terminal or appropriate fuse is disconnected/removed and reconnected/reinstalled. 4.3 Do not touch the positive terminal with any tool when removing the negative battery cable. 4.4 Use a fender cover (blanket) when connecting or disconnecting battery negative terminal and/or when replacing or removing fuses. Ensure battery negative terminal is fully seated when reconnecting. 4.5 Power tools that can exceed 60 pound force-inch of torque should not be used to tighten battery cable. The torque value for battery cable tightening is given in the Installation Instruction Sheet. Connectors 4.4. When disconnecting connectors, do not pull on the wires; pull on the connectors. 4.5. DO NOT pull on vehicle wires and/or wire harnesses. To uncouple electrical connectors, pull only on the connector itself and release the connector securing tab (identified in the Installation Instruction Sheet). 4.6. Disconnected wires must not have any strain on connectors or wires (i.e., do not allow components hanging from a wire harness). 4.7. When reconnecting connectors, ensure connectors are securely snapped together and wires are not twisted or kinked. Wire Harnesses 4.8. When installing the accessories that use wire harnesses (e.g. audio, alarm, trailer wire harness…), make sure the harness is not cut or perforated by any sharp metal objects/edges. Wire Ties 4.9. When using wire ties to secure harness, clip the wire ties after securing them. 4.10. Ensure that wire routing does not interfere with movement of mechanical components before tightening the wire tie. Functional Checks 4.11. Functional checks (from the Checklist Section of the Installation Instruction Sheet) must be performed on all disconnected electrical components. Use of Special Chemicals Cleaners 5.1 All cloths used for preparatory installations must be cleaned and periodically changed. Any cloth that is dropped on the floor should not be used until cleaned. Issue B Page 3 of 4 pages 5/23/2006 5.2. Cleaning solutions/solvents are identified in the Installation Instruction Sheet and are not to be sprayed directly onto vehicle surfaces (interior/exterior). 5.3. Cleaning solutions/solvents are not to be sprayed onto cloth/rag inside of vehicle (this is to prevent over spray on interior). 5.4. When using cleaners such as Prep-Solvent-70, or Household Windex follow manufacturer’s recommendations:5.4.1 Always use a clean (lint free scratch resistant) soft cloth (or wipe), and clean a small area at a time ( ~ 3 ft. x 3 ft. max.). 5.4.2 Shake well. 5.4.3 Apply cleaner to cloth or wipe. Do not spray cleaning solution directly on any vehicle surfaces. 5.4.4 Clean surface thoroughly and wipe dry immediately with a new clean cloth. Do not allow cleaner to air dry. Sealers 5.5 Follow Installation Instruction Sheet recommendations. 5.6 For any cleanup follow sealer manufacturer recommendations. Temperature 6.1. Some accessories require installation in a controlled temperature environment. The installation instructions will provide the temperature range of this temperature and will differentiate between vehicle and accessory temperature (should it not be the same for both.) 6.2. The installation location will be responsible for determining whether the temperature range has been met. 6.3. The method of temperature measurement will NOT be called out in the instructions. 6.4. Recommended tools for measuring vehicle and accessory temperature are:Non-Intrusive IR Temperature Probe/Gun 6.5. Recommended heating/cooling methods are:Heat box (for small components), Car HVAC, Heat Gun…. Torque Recheck 7.1. When rechecking of a fastener torque is called out in the Installation Instruction Sheet it is sufficient to ensure that the fastener does not rotate when the installation torque is reapplied. If the fastener rotates then continue tightening until the specified torque is reached. Do not loosen fastener. Issue B Page 4 of 4 pages 5/23/2006 TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Preparation Part Number: PT278-89063 Kit Contents Item # 1 2 3 Quantity Reqd. 1 2 1 Description Bike Rack Keys (in Bag) DIO Instruction Sheet Additional Items Required For Installation Item # 1 Quantity Reqd. 3 Description Adaptor Kit: P/N PT278-89061 or P/N PT278-35061 or P/N PT278-35064 Conflicts General Applicability Note: Fits on all Toyota Fixed Roof Racks together with an Adaptor Kit: P/N PT278-89061: 4Runner, RAV4, Highlander, Land Cruiser, Matrix, Sequoia, Sienna P/N PT278-35061: Tacoma P/N PT278-35064: FJ Cruiser Recommended Sequence of Application Item # 1 2 Accessory Adaptors Bike Rack None *Mandatory Recommended Tools Personal & Vehicle Protection Vehicle Protection Legend Blankets Special Tools None Installation Tools Screwdriver Screwdriver Flat Blade(~1”) Philips #2 STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Special Chemicals None Issue: A 04/07/05 Page 1 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure 1. STOP Installation Preparation (a) Protect vehicle sides and roof panel with protective blankets. (b) Clean the vehicle Roof Rack from dirt and dry. 2. Fig. 2-1 Installation of Adaptors (a) Open an Adaptor Assembly and slide it on one the vehicle Roof Rack Cross Bars with the opening facing backwards. (Fig. 2-1) NOTE: Place two Adaptor Assemblies on the vehicle Roof Rack Front Cross Bar and one on the Rear Cross Bar. (a) Adjust the position of the Adaptor Assemblies so that they are 5.75" (146 mm) apart center to center on the Front Cross Bar. (Fig. 2-2) Fig. 2-2 (1) The Adaptor Assembly on the Rear Cross Bar should be in line with the Adaptor on the Front Cross Bar that is closest to the outside of the vehicle. (Fig. 2-2) NOTE: When adjusting the position of the Adaptor Assemblies, make sure the rubber gasket remains in place. Fig. 2-3 (b) Fasten each Adaptor Assembly by spinning the plastic lever and folding it down. (Figs. 2-3 & 2-4) (1) Tighten the lever by hand until it is snug and the Adaptor Assembly will not slide by pushing and pulling by hand. Fig. 2-4 Issue: A 04/07/05 Page 2 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure 3. Mounting the Bike Rack on the Adaptor Assemblies (a) Unlock the lever and move the frame holder to the side and rotate the arm forward (Fig. 3-1). Rear Wheel NOTE: Rotating the arm completely forward unlocks the front lever mechanism. Front Wheel Fig. 3-1 Upper Slots (b) Open the three levers on the bike rack and slide the rack into the slot on each adaptor. Note: P/N PT278-89061 has two slots on each of the Adaptor Assemblies: (1) The Bike Rack is mounted to the two upper slots of the front Adaptor Assemblies. (Fig. 3-2) (2) The Bike Rack is mounted to the upper slot of the rear Adaptor Assembly. (Fig. 3-3) Fig. 3-2 (c) Adjust the clamping force by spinning the levers in a vertical position then close the levers. (Fig. 3-4) NOTE: Arm must point forward almost parallel with the wheel track in-order for both of the two front levers to unlock. Upper Slot Fig. 3-3 Front Fig. 3-4 Issue: A 04/07/05 Page 3 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure 4. Fastening the Bike (a) Place the bike in the wheel track. To facilitate, unlatch and fold the straps out of the way. (Fig. 4-1) (b) Rotate the arm towards the bicycle frame. Turn and adjust the frame holder to fit the frame. (Fig. 4-2) Fig. 4-1 STOP 3.15” (c) When the frame holder is adjusted to the frame, tighten by folding the lever up in the unlatched position as shown and spin it to set the correct clamping force. (Fig. 4-3) (1) When the frame is attached firmly, lock the lever Fig. 4-2 NOTE: Light weight frames may be damaged if too much force is used. Do NOT spin in this position 8 Fig. 4-3 Issue: A 04/07/05 Page 4 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure 5. Fastening the Wheels (a) Adjust the position of the rear wheel holder by sliding it, then tighten the strap around the rear wheel. (Fig. 5-1) STOP Fig. 5-1 (b) Tighten the strap on the front wheel, making sure the strap runs round the wheel and through the holder in the profile. Fold the strap into the strap holder underneath to prevent it from hanging down and interfering with the roof. (Fig. 5-2) (c) When driving without a bike, lock the frame holder to the parking post. (Fig. 5-3) Fig. 5-2 Fig. 5-3 Issue: A 04/07/05 Page 5 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure 6. Switching Installation Side (a) To be able to attach more than two bike racks on the roof, the frame holder tube and the attachments have to switch sides. (Fig. 6-1) (b) When more than two bike racks are fitted the bike rack positions alternate. (Fig. 6-2) Fig. 6-1 Fig. 6-2 7. Switching Side of the Frame Holder Tube (a) Open the levers close to the tube and fold the tube up to vertical position. (Fig. 7-1) (b) Unscrew (¼ turn) and pull out the socket cap.(Fig. 7-2) Fig. 7-1 Flat Blade Screwdriver Fig. 7-2 Issue: A 04/07/05 Page 6 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure (c) Make sure the wedge is in the correct position by lining up the “diamond” marks. (Fig. 7-3) (d) Pull up the wedge, press from below and remove. (Fig. 7-4) Fig. 7-3 (e) Pull out the tube and insert it from the other side. (Fig. 7-5) (f) After inserting the tube (1), re assemble the wedge (2) and the socket cap (3). (Fig. 7-6) Fig. 7-4 Fig. 7-5 2 3 2 3 1 1 Fig. 7-6 Issue: A 04/07/05 Page 7 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure (g) The wedge must be assembled correctly. (Fig. 7-7) (h) Unscrew the frame clamp lever and pull it out. (Fig. 7-8) Fig. 7-7 (i) Loosen and remove the washer, the screws and the claw. (Fig. 7-9) (j) Re-assemble the claw on the other side and reinstall washer, screws and lever. (Fig. 710) Fig. 7-8 Phillips # 2 Screwdriver Fig. 7-9 Phillips #2 Screwdriver Fig. 7-10 Issue: A 04/07/05 Page 8 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure (k) Check to make sure that everything is tightened properly. (l) Remove Phillips screw and turn the front wheel holder (strap) 180 degrees. (Fig. 711) Phillips # 2 Screwdriver Fig. 7-11 (m) Remove the rear attachment plate by sliding it forward over the pins on the wheel track (this will be stiff) and turn it 180 degrees. (Fig. 7-12) (n) Re position the attachment plate by sliding it back over the plastic pins in the profile. (Fig. 7-13) Fig.7-12 (o) Slide the rear wheel holder strap and clamp backward off the wheel track and switch the sides. (Fig. 7-14) Fig. 7-13 Fig. 7-14 Issue: A 04/07/05 Page 9 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Procedure (p) Slide the rear wheel holder strap and clamp back on the wheel track. (Fig. 7-15) Fig. 7-15 8. Completing the Installation (a) Place keys, and DIO installation instructions in the glove compartment. Issue: A 04/07/05 Page 10 of 11 pages DIO TOYOTA 4Runner/Highlander/Land Cruiser 2000Rav4/Matrix/Sequoia/Sienna/Tacoma/FJ Cruiser BIKE RACK Checklist – these points MUST be checked to ensure a quality installation. Check: Look For: Rubber Gaskets are properly in place The Rubber Gaskets should be aligned within the Adaptors. within the metal Adaptors. Adaptors are securely attached to the Pushing and pulling on the mounted Bike vehicle Roof Rack. Rack can not move adaptors. Front levers are closed properly Inner lever is locked by locking mechanism. Both levers aligned against profile. The wheel track does not interfere with the Look between the roof and Bike Rack. vehicle. Front wheel holder strap is not hanging down and interfering with the roof The bicycle is firmly attached Issue: A 04/07/05 Make sure that the wheel holders and the frame holder are firmly attached to the bike. Page 11 of 11 pages DIO TOYOTA / SCION ALL 2007 - FORGED OIL CAP Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Vehicle Service Parts (may be required for reassembly) Part Number: PTR35-00070 Kit Contents Item # 1 2 3 Quantity Reqd. 1 1 1 Description Oil Filler Cap w/gasket TRD Appliqué Instructions Item # 1 2 3 Additional Items Required For Installation Item # 1 2 3 Quantity Reqd. Legend STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. None Notes Blankets or covers Special Tools Notes Installation Tools Notes Special Chemicals Notes Liquid Dish Soap/Water Solution Distilled Water Joy brand or similar General Applicability All Toyota and Scion models with screw-in style oil cap Recommended Sequence of Application Item # 1 2 3 Accessory *Mandatory Issue: A 09/14/07 Description Description Conflicts Recommended Tools Personal & Vehicle Protection Quantity Reqd. Page 1 of 5 pages TOYOTA / SCION ALL 2007 - FORGED OIL CAP Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Check Box Contents 12 mm Wrench (a) Check box for contents and/or damage. 2. Vehicle Protection (a) Open vehicle hood. (b) Use blankets to protect the front grille area. 3. Removal Procedure: Factory Oil Filler Cap (a) Remove factory oil filler cap by turning cap counter-clockwise (Fig. 3-1). Note: Yaris oil filler cap shown. Other vehicle models may have oil cap in a different area on the engine. (b) Discard factory oil filler cap. Fig. 3-1 4. Installation Procedure: TRD Oil Filler Cap (a) Remove TRD appliqué from the top of the oil filler cap by lifting the piece of tape that secures the appliqué (Fig. 4-1). (b) Do not touch top of oil filler cap. Fig. 4-1 Issue: A 09/14/07 Page 2 of 5 pages TOYOTA / SCION ALL 2007 - FORGED OIL CAP Procedure (c) Install TRD oil filler cap by turning clockwise until cap is snug on the engine (Fig. 4-2). Fig. 4-2 (d) If necessary, the top of the oil filler cap may be cleaned by using a lint-free cloth and a solution of 4 drops Joy liquid dish soap per cup of water (Fig. 4-3). (e) Use another lint-free cloth and distilled water to wipe top of oil filler cap (Fig. 4-3). (f) Dry top of oil filler cap with a lint-free cloth. Fig. 4-3 (g) Remove liner paper from back of TRD appliqué to expose adhesive (Fig. 4-4). Fig. 4-4 Issue: A 09/14/07 Page 3 of 5 pages TOYOTA / SCION ALL 2007 - FORGED OIL CAP Procedure (h) Install TRD appliqué on oil filler cap with TRD logo facing forward (Fig. 4-5). (1) The TRD logo is correct if it can be read while standing in front of the vehicle. (2) Press logo firmly over entire surface to fully seat adhesive. Fig. 4-5 (i) Carefully remove the plastic laminate from the top of the TRD appliqué (Fig. 4-6). (j) Remove vehicle protection from front of vehicle. Fig. 4-6 Issue: A 09/14/07 Page 4 of 5 pages TOYOTA / SCION ALL 2007 - FORGED OIL CAP Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Correct TRD logo clocking TRD logo can be read from front of vehicle TRD appliqué finish No plastic laminate covering TRD appliqué Vehicle Function Checks Issue: A 09/14/07 Page 5 of 5 pages TOYOTA ALL VEHICLES ALL YEARS EMERG. ASSIST. KIT Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Vehicle Service Parts (may be required for reassembly) Part Number: PT420-00045 Kit Contents Item # 1 Quantity Reqd. 1 2 1 Description Emergency Assistance Kit (EAK) Tether Strap, Heavy Duty P/N: PT420-08040 3 Quantity Reqd. Description Additional Items Required For Installation Item # 1 2 3 Quantity Reqd. Description Legend Hardware Bag Contents Item # 1 2 Item # 1 2 3 Quantity Reqd. Description STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. Conflicts Note: None Recommended Tools Personal & Vehicle Protection Notes None Special Tools Notes None Installation Tools Notes None Special Chemicals Notes None General Applicability Note: All Toyota Vehicles Recommended Sequence of Application Item # 1 2 3 Accessory *Mandatory Issue: C 01/12/07 Page 1 of 3 pages DIO TOYOTA ALL VEHICLES ALL YEARS EMERG. ASSIST. KIT Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. NOTES: “EAK” denotes Emergency Assistance Kit 1. Install Emergency Assistance Kit. (A) Cars / SUVs / VAN: (1) Remove EAK from package. (2) Place the EAK in the trunk / cargo area of the vehicle. (Fig. 1-1) (3) Use included strap to secure EAK to vehicle trunk / cargo area, as applicable. Fig. 1-1 (B) Trucks: (1) Remove EAK from package. (2) Place EAK on the right front floor of vehicle. (Fig. 1-2) (3) The customer may use included strap to secure to any area of the vehicle, as applicable. Fig. 1-2 Issue: C 01/12/07 Page 2 of 3 pages DIO TOYOTA ALL VEHICLES ALL YEARS EMERG. ASSIST. KIT Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Confirm secure placement of Emergency Whenever possible, “Toyota” name is Assistance Kit. visible and upright. Confirm tether strap is tightened and kit is Loose strap and secure placement. securely in place. Vehicle Function Checks Issue: C 01/12/07 Page 3 of 3 pages DIO 2005- 4RUNNER TVIP V2 GLASS BREAKAGE SENSOR (GBS) OWNER’S GUIDE G.B.S. TVIP (GLASS SENSOR) ENHANCEMENT 2004-2005 PRIUS V2BREAKAGE GLASS BREAKAGE SENSOR (GBS) DESIGNED FOR USE WITH YOUR VEHICLE’S OWNER'S GUIDE THEFT DETERRENT SYSTEM OWNERS GUIDE The G.B.S. (GLASS BREAKAGE SENSOR) provides protection for your vehicle above and beyond the entry point monitoring performed by the TDS (Theft Deterrent System)—it “listens” for the noise made by tapping on, or breaking of glass, and triggers alarms upon detection of these types of noise. Using a microphone designed VSHFL¿FDOO\IRUWKLVWDVNWKH*%6LVFDSDEOHRILJQRULQJRWKHUQRLVHVZKLFKKHOSVSUHYHQW³IDOVHDODUPV´IURP occurring. (See reverse for descriptions of alarms.) GLASS BREAKAGE SENSOR CHECK PROCEDURE :KHQWKH*%6ZDVLQVWDOOHGLQ\RXUYHKLFOHFDUHZDVWDNHQWRDGMXVWWKHVHQVLWLYLW\OHYHOSURSHUO\\RXPD\ REVHUYHKRZLWZRUNVIROORZLQJWKHSURFHGXUHOLVWHGEHORZ 1.  Arm the theft deterrent system. Press the lock button on the remote control or ORFNWKHGRRUVZLWKWKHNH\ 5HPHPEHUWKHV\VWHPZLOO not arm if any door, or the trunk, is open.)   :DLWXQWLOWKH6HFXULW\/('VWDUWVÀDVKLQJ 7KH/('ZLOOEHJLQWRÀDVKVHFRQGVDIWHUWKHODVW door or the trunk is closed. Please note, your vehicle’s Security LED may look different than the one pictured here.    :LWKWKHWLSRIDNH\WDSWKHFHQWHURIWKHGULYHU¶V GRRUZLQGRZ 7DSWKHJODVVZLWKOLJKWWRPRGHUDWHIRUFH   :$51,1* 'RQRWKLWWKHJODVVZLWKH[FHVVLYHIRUFH  HVSHFLDOO\LQFROGZHDWKHURU\RXPD\ crack or break it.  4. A WARN AWAY ALARM should be triggered. (See re verse for details.) If the ALARM IS not triggered, make sure you performed the procedure correctly and try DJDLQ,IWKHV\VWHPGLGQRWSHUIRUPDV\RXH[SHFWHG contact your Toyota dealer for more information. Disarm the theft deterrent system to stop the WARN AWAY ALARM. Press the unlock button on the remote control, or use the key to unlock a door, to disarm the system. Please note, your remote controls may look different than the one pictured here.  5HY$ GBS ADD-ON OWNERS GUIDE Please note, your remote controls may look different than the one pictured here. ALARM INFORMATION ALARM DESCRIPTIONS WARN-AWAY ALARM Upon initial detection of noise from tapping on, or breaking glass, the GLASS BREAKAGE SENSOR triggers a WARN AWAY ALARM:  7KHKRUQVRXQGVUHSHDWHGO\IRUVHFRQGV  7KHKHDGOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHWDLODQGPDUNHUOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHLQWHULRUOLJKWVWXUQRQIRUVHFRQGV If the GLASS BREAKAGE SENSOR detects noise again, or if a door or the trunk is forcibly opened, the regular DODUP GHVFULEHGEHORZ LVDFWLYDWHG REGULAR ALARM :KHQDQDODUPLVWULJJHUHGLQDQ\ZD\RWKHUWKDQLQLWLDOGHWHFWLRQE\WKH*/$66%5($.$*(6(1625WKHIRO ORZLQJRFFXUV  7KHKRUQVRXQGVUHSHDWHGO\IRUVHFRQGV  7KHKHDGOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHWDLODQGPDUNHUOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHLQWHULRUOLJKWVWXUQRQIRUVHFRQGV  $Q\GRRUORFNZLOOEHUHORFNHGLIVRPHRQHUHDFKHVLQDQGXQORFNVDQLQVLGHORFNEXWWRQ$IWHUVHF RQGVWKHWKHIWGHWHUUHQWV\VWHPZLOOUHDUPDQGFRQWLQXHWRSURWHFWWKHYHKLFOH STOPPING AN ALARM 6LPSO\GLVDUPWKHWKHIWGHWHUUHQWV\VWHPXVLQJWKHUHPRWHFRQWURORUNH\DVGHVFULEHGLQWKH2ZQHU¶V*XLGHIRU your vehicle. TOYOTA 4RUNNER 2006 - HOOD PROTECTOR Preparation Part Number: PT427-89060 PT427-8906B NOTE: Part number of this accessory may not be the same as the part number shown. Kit Contents General Applicability Item # 1 2 Quantity Reqd. 1 1 Description Hood protector Hardware bag Note- Recommended Sequence of Application Item # 1 2 3 Hardware Bag Contents Item # 1 2 3 4 5 6 7 8 9 10 Quantity Reqd. 4 2 2 4 4 4 6 4 2 2 Description Outside hood bracket Grill hood bracket Grill Hook bracket 6-32 well nut 6-32 x 0.5 MS #6 SS flat washer 10-24 MS Mylar pad - small Double-sided tape Mylar pad – large *Mandatory Vehicle Service Parts (may be required for reassembly) Item # 1 2 3 Quantity Reqd. Description Conflicts Recommended Tools Personal & Vehicle Protection Notes Vehicle Protection Blanket Special Tools Notes Quantity Reqd. Description Legend Additional Items Required For Installation Item # Accessory STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. None Installation Tools Notes Screwdriver Ratchet Phillips, #2 Phillips #2 Bit Special Chemicals Notes Cleaner Soap and Water Issue: A 8/14/06 Page 1 of 5 pages Supplier Ref. #I-1136 TOYOTA 4RUNNER 2006 - HOOD PROTECTOR Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Pre-installation Preparation. (a) Inspect and verify the kit contents. (b) Open the hood. STOP (c) Make sure front edge of hood and grill, where the deflector is to be installed, is clean and free from dirt and/or debris using soap and water. STOP (d) Cover engine bay completely with a protective blanket to catch any dropped hardware. 2. Mylar Pad Installation. (a) Install the two (2) large mylar pads to underside of grill. Install the pads third slot from center on either side. (Fig. 2-1). (b) Install four (4) mylar pads to the outer bracket sections. Align with holes in hood. (Fig. 2-2). Fig. 2-1 Fig. 2-2 Issue: A 8/14/06 Page 2 of 5 pages Supplier Ref. #I-1136 TOYOTA 4RUNNER 2006 - HOOD PROTECTOR Procedure 3. Outer Bracket Installation. (a) Install four (4) well nuts into the outer holes. (Fig. 3-1). (b) Install the outside hood brackets in the locations shown (Fig. 3-2). (c) Attach the bracket to the hood using the 6-32 x ½" screw and washer. The washer goes between the screw head and bracket. (Fig. 3-2) Fig. 3-1 Fig. 3-2 4. Grill Bracket Installation (a) Insert Grill Hook Brackets into the third slot from center on either side. Make sure brackets are centered in the slot. (Fig. 4-1) Fig. 4-1 (b) Apply the double-sided tape to the Grill Hood Bracket. Remove paper backing from one side only. Apply this side towards the bracket, and align pad along top edge and sides of bracket extension. (Fig. 4-2). Fig. 4-2 Issue: A 8/14/06 Page 3 of 5 pages Supplier Ref. #I-1136 TOYOTA 4RUNNER 2006 - HOOD PROTECTOR Procedure (c) Attach Grill Hood Brackets to the Grill Hook brackets. Remove paper backing from double-sided tape and adhere to grill, make sure the holes in both brackets (grill and extension) line up. (Fig. 4-3). Fig. 4-3 5. Install the Shield Assembly to the Vehicle (a) Attach shield to grill brackets using two (2) – ½” (10-24) screws. Hand start the screws. (Fig. 5-1). (b) Peel back protective film from shield in location where screws attach to brackets. (c) Line up shield with the grill brackets making sure the shield is centered. The center "V" nib on the inner edge of the shield should align with the center rib on the grill (Fig. 5-2). Fig. 5-1 (d) Line up shield with the outer hood brackets once again making sure the shield is centered. Fig. 5-2 (e) Screw shield to outer brackets using four (4) 10-24 x ½” screws. Hand start screws (Fig 5-3). Fig. 5-3 (f) Make sure the shield is centered and all six (6) screws are tight. (g) Close the hood. (h) Remove entire protective film from shield and discard film. Issue: A 8/14/06 Page 4 of 5 pages Supplier Ref. #I-1136 TOYOTA 4RUNNER 2006 - HOOD PROTECTOR Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Inspect brackets Six brackets installed on hood. Inspect screws Six screws installed on hood protector Screw tightness Six screws holding hood protector to brackets are firmly tightened. Hood closure. Outside Hood brackets should not contact the headlights. Clearance of hood protector to hood. The hood protector (shield) should not contact the grill. Issue: A 8/14/06 Page 5 of 5 pages Supplier Ref. #I-1136 TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: PTS31-33051 Kit Contents Item # 1 2 3 4 5 6 Quantity Reqd. 1 1 1 1 2 1 Description Antenna, Interior Antenna Tape Pad Wire Harness Bracket, Floor Hardware Bags SIRIUS Satellite Radio Brochure Quantity Reqd. 6 7 4 Quantity Reqd. 8 3 Special Chemicals Notes Cleaner VDC approved cleaner and cleaning method Note: Description Foam Pads Lock Ties Double-Sided Tape Recommended Sequence of Application Hardware Bag Contents - 2 Item # 1 2 Matt Knife Metric 6 ¼” Plastic Bondo Spreader General Applicability Hardware Bag Contents - 1 Item # 1 2 3 Scissors Carpet Cutting Knife Tape Measure Plastic Spreader Description Screw (6-32x5/16) Nut (Hex 6-32) DO NOT USE Item # 1 2 3 Accessory *Mandatory Vehicle Service Parts (may be required for reassembly) Hardware Bag Contents Item # Quantity Reqd. Item # 1 2 3 Description Description Legend Conflicts Recommended Tools Personal & Vehicle Protection STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Notes Safety Goggles Seat Covers Floor Protector When cutting carpet Special Tools Notes None Installation Tools Ratchet Extension Sockets Screwdriver Nylon Panel Removal Tool Low Adhesive Tape Torque Wrench Side Cutter Issue: B Quantity Reqd. 2/27/06 Notes 10 mm, 14 mm, 8 mm Phillips, #2 e.g. Panel Pry Tool #1 Toyota SST # 00002-06001-01 50 mm width Page 1 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. Socket (10 mm), Ratchet Negative Battery Cable 1. Vehicle Disassembly. (a) Set parking brake. (b) Remove the negative battery cable. (Fig. 1-1) (1) Protect the fender before starting. (2) Do not touch the positive terminal with any tool when removing cable. Fig. 1-1 (c) Disengage the clips and claws and remove the passenger side door scuff plate. (Fig. 1-2) Fig. 1-2 Round Knob (d) Remove the passenger side cowl side trim as follows: (Fig. 1-4) (1) Remove the round knob fastener. (2) Disengage the 2 claws and then remove. Fig. 1-3 Issue: B 2/27/06 Page 2 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure Screw (e) Remove the glove box under cover subassembly: (Fig. 1-4) (1) Remove the screw. (2) Disengage the 3 clips and remove the panel. Fig. 1-4 (f) Remove the glove box. (Fig. 1-5) (1) Remove the screw from the damper. (2) Deform the upper part of the glove box to release the stoppers. (3) Pull the glove box upward to release 2 claws & remove. Screw Fig. 1-5 (g) Remove the glove box finish panel.(Fig. 1-6) (1) Remove the 4 screws. (2) Disengage the 2 claws and remove the panel. Fig. 1-6 (h) Remove Center Console Upper Rear Panel Sub-Assembly. (1) Disengage the 5 clips and 2 claws, and remove the console upper rear panel, and then disconnect the connectors. (Fig. 1-7) Fig. 1-7 Issue: B 2/27/06 Page 3 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (i) Remove Center Console Panel SubAssembly Upper. (Fig. 1-8) (1) Disengage the 6 clips and 2 claws, and then remove the console panel subassembly upper. NOTE: Be careful not to snap the claws during the operation. Fig. 1-8 (j) Remove Console Upper Panel Garnish (both sides). (Fig. 1-9) (1) Disengage the clip. Pull the console upper panel garnish rearward to be removed. Fig. 1-9 (k) Remove Air Conditioning Control Assembly. (Fig. 1-10) (1) Remove the screw. Screw Fig. 1-10 (2) Disengage the 4 clips on the control assembly. (Fig. 1-11) (3) Disconnect the connectors and then remove. Fig. 1-11 Issue: B 2/27/06 Page 4 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (l) Remove driver’s side under dash trim panel. (Fig. 1-12) (1) Remove the 2 bolts as shown. (2) Disengage the 4 claws and remove the panel. Fig. 1-12 (m) Remove Instrument Cluster Finish Panel Sub-Assembly Center. (Fig. 1-13) (1) Remove the 3 bolts. (2) Disengage the 8 clips and remove the instrument cluster finish panel subassembly center. Fig. 1-13 (n) Prepare Radio Assembly for Removal. (Fig. 1-14) (1) Remove the 2 bolts. 2. Remove the “A” Pillar Garnish. Fig. 1-14 Place mark here 390mm Metric Tape Measure Fig. 2-1 Issue: B NOTE: Before removing the garnish you must clean the antenna mounting area with an approved cleaner and then mark the mounting location of the tape pad. 2/27/06 (a) Measure from the right side of the tape pad over to the right side “A” pillar 390mm and place a mark on the window as shown. (Fig. 2-1) Page 5 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (b) Remove “A” Pillar Garnish. (1) Using a nylon removal tool, remove the small covers to access the 2 screws. (Fig. 2-2) (2) Remove the 2 screws. (3) Disengage the 3 clips and remove the garnish. (Fig. 2-2) Fig, 3-4 Fig. 2-2 10mm Socket 3. Install the Antenna. NOTE: Mounting location must be completely dry & installation temperature must be between 60° - 100° F before mounting the tape pad. (a) Place the pad in the correct mounting location. (1) At this point only remove the white release paper from the mounting pad. (Fig. 3-1) Fig. 3-1 Align here 5mm Gap (2) When placing the pad on the window, align the red release paper pull-tab with approximately 5mm gap from the front of the headliner and then align with the mark on the window as shown. (Fig 3-2) (3) Initially only stick the very top edge of the tape pad onto the window. Fig. 3-2 (b) Complete the installation of the tape pad. (Fig 3-3) (1) Using a 6 ¼” Plastic Spreader start from the top of the tape pad and evenly squeegee down the pad to assure complete wet-out of the tape. 6 ¼” Plastic Spreader Fig. 3-3 Issue: B 2/27/06 NOTE: Spreader must completely cover the width of the tape pad in one downward stroke in order to assure complete wet-out of the tape. Page 6 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (c) Remove the red release paper from the front of the antenna tape pad. (Fig. 3-4) (d) Remove the release tabs from the back of the antenna, and place the antenna in the proper position over the mounting pad. (Fig. 3-5) (1) By hand firmly apply pressure upward on all 3 corners of the antenna to assure complete wet-out of the tape pads. Fig, 3-4 (e) Route the antenna cable up underneath the front of the headliner as shown. (Fig. 3-5) Apply pressure upward on all 3 corners Fig. 3-5 Note: Must run antenna cable on top part of “A” pillar 3 Foam Tape Pads Cable routing behind dash (f) Route the cable down the upper part of the “A” pillar as shown. (Fig. 3-6) (1) Cut the foam tape pads supplied in kit in half and place 3 strips along the cable to hold in position as shown. (Fig. 3-6) Cable passes through at bottom Fig. 3-6 (1) By hand pull down the front of the headliner and position the antenna cable up underneath the headliner as shown. (2) Make sure the cable does not interfere with the airbag system. (3) Make sure the cable passes over at the bottom part of the “A” pillar so it does not interfere with the airbag system. (Fig. 3-6) (g) Continue routing the cable down the “A” pillar behind the dash as shown. (Fig. 3-7) Fig. 3-7 Issue: B 2/27/06 Page 7 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (h) Apply 2 1/3 pieces of foam tape behind the dash as shown. (Fig. 3-8) 1/3 Foam Tape Antenna Cable Fig. 3-8 (i) Continue routing the cable down the “A” pillar behind the existing wire harness as shown. (Fig. 3-9) NOTE: Lock tie will be added when receiver harness is installed in step 4. (Fig. 3-9) Lock Tie Fig. 3-9 (1) Route the cable inside the factory harness wire clamps along the doorsill. (After the seat is moved in step 5 the cable will continue under the carpet to where the receiver module will be installed.) (Fig. 3-10) Antenna Cable Fig. 3-10 Factory Clips General routing behind dash 4. Install and Route the Receiver Harness. (a) Install and route the receiver harness from the center cluster and along the front support bar. (Fig. 4-1) Fig. 4-1 Issue: B 2/27/06 Page 8 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure Harness Routing (1) Route the receiver harness through the opening in the glove box behind the cross member up to the back of the radio. (Fig. 4-2) (2) Gently pull out the radio cluster in order to access the plug-in location and rest on a support platform to prevent scratching of dash panels. (Fig. 4-3) Fig. 4-2 Radio NOTE: Be careful not to put too much tension on the radio wire harness when pulling out the radio. Support Platform Fig. 4-3 Lock Tie (3) Continue pulling the receiver harness toward the back of the radio. Make sure you provide sufficient cable slack to connect to the audio head unit as shown. Adjust the slack of the cable to match slack of other cables. (Fig. 4-4) (4) Install lock tie as shown. (Fig. 4-4) (5) Connect the receiver harness to the audio unit. (Fig. 4-5) NOTE: There already may be a factory connector in this location. The factory connector should be removed and plugged into the other end of the “Y” on the receiver harness. If the other end of the “Y” is not used lock tie it to the receiver harness so that it does not rattle. Fig. 4-4 (6) Place the radio cluster back into position. 12P Receiver Harness Fig. 4-5 Issue: B 2/27/06 (7) Be careful not to crimp any of the factory harnesses or the receiver harness when replacing the radio. Page 9 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure Harness (b) Routing behind the glove box. (1) Continue routing the receiver harness behind the main cross member as shown. (Fig. 4-6) (2) Place lock tie on metal bracket to secure receiver harness as shown. (Fig. 4-6) Lock Tie Fig. 4-6 Harness Main Vehicle Harness Lock Tie (3) Continue routing the harness toward the “A” pillar bringing it forward crossing the Main Vehicle Harness as shown. (Fig. 4-7) (4) Lock tie to main vehicle harness as shown. (Fig. 4-7) Fig. 4-7 (c) Continue routing the harness down the “A” pillar following where the antenna cable passes behind the vehicle harnesses. (Fig. 4-8) Harness Lock Tie (1) Lock Tie to vehicle harness as shown. (Fig. 4-8) Fig. 4-8 (d) Cowl Side Wiring Lock Tie (2) Cut off excess lock ties with a side cutter. Fig. 4-9 Issue: B (1) Continue routing behind the side cowl trim and secure both the antenna cable along with the receiver harness to the vehicle harness with lock tie as shown. (Fig. 4-9) 2/27/06 Page 10 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure (3) Continue routing the harness through the door seal through the center of the factory clips. (After the seat is moved the harness will continue under the carpet to where the receiver module will be installed.) (Fig. 4-10) Factory Clips Fig. 4-10 Receiver Harness 5. Access the Receiver Mounting Location. (a) Protect the center console area before accessing seat. (b) Slide the passenger seat forward and remove the two (2) plastic covers on the seat rails. Remove the three (2) bolts under the plastic covers. (Fig. 5-1) 14 mm Socket Fig. 5-1 14 mm Socket (c) Slide the seat backwards and remove the two (2) bolts that hold the front end of the seat rails. (Fig. 5-2) (d) Tilt the seat up being careful not to put too much tension on the wire harness connected under the seat. (Fig. 5-3) Bolts x 2 Fig. 5-2 (e) Position the seat so it remains tilted back to access the receiver mounting area. NOTE: Be careful not to damage the seat or put too much tension on the seat wire harness when tilting the seat in the vehicle. Fig. 5-3 Issue: B 2/27/06 Page 11 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure 6. Cut Carpet. (a) Position the metal bracket over the plastic air vent on the floor under the passenger seat as shown. (Fig. 6-1) (Seat not shown in picture) Fig. 6-1 Bracket Front (1) Slide the metal bracket over the air vent under the carpet. (Fig. 6-2) NOTE: The bracket will be used as a cutting template when cutting the carpet. Air Vent under Seat Fig. 6-2 (b) Using a carpet cutting knife follow the outside edges of the bracket and cut both sides of the carpet all the way through to the end of the bracket as shown. (Fig 6-3 & 6-4) (1) Make sure there are no wires under the carpet where the cuts will be made. Bracket used as template Fig. 6-3 Leave flap. Do not cut back edge (2) Cut the full length of the bracket. (3) Do not cut along the back edge. Carpet will be inserted under the bracket at final installation. (Fig. 6-4) Fig. 6-4 Issue: B 2/27/06 Page 12 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure 7. Install the Receiver. (a) Remove the bracket from over the air vent and clean the bracket tape-mounting surface with an approved cleaner. (b) Apply 4 pieces of double sided tape onto the bracket as shown. (Fig. 7-1) Fig. 7-1 Phillips Screwdriver NOTE: All tape mounting surfaces must be completely dry and installation temp must be between 60° - 100° F. (c) Install the receiver onto the bracket using the 8 screws supplied in the kit. (Fig. 7-2) (d) Slide the bracket/receiver assembly over the air vent and tuck the carpet under the bracket as shown (Fig. 7-3) Fig. 7-2 (1) Make sure the bottom of the bracket is not touching the carpet so it can be mounted to the floor pan. (Fig. 7-4) (e) Continue running both the receiver harness and antenna cable under the carpet to the receiver unit as shown. (Fig. 7-4 & 7-5) Fig. 7-3 Connector Front of Vehicle Antenna Fig. 7-4 Issue: B 2/27/06 Foam Tape (1) Make sure the receiver harness goes over the air vent. (f) Plug the harness connector and antenna into the receiver module as shown. (Fig. 7-4) (1) Tape the antenna cable down to the bracket with a piece of foam tape as shown. (Fig. 7-4) Page 13 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure Coil up & foam tape antenna cable Fig. 7-5 Bundle & lock tie receiver harness (2) Bundle up any excess harness and antenna cable with lock tie and foam tape and place under the carpet as shown. (Fig. 7-5) (g) Clean the floor pan mounting area with an approved cleaner then remove the 4 release tabs from the double-sided tape on the bottom of the bracket and mount the bracket to the floor pan. (Fig. 7-6) (1) Make sure the bracket is firmly attached to the floor pan by firmly applying pressure down on the receiver/bracket assembly. 8. Secure Seat Harness. (a) Seat harness must be slightly moved toward the center of the vehicle to prevent rubbing on receiver module. Fig. 7-6 Metal Bracket (b) Route as shown & apply lock tie to metal bracket. (Fig. 8-1) NOTE: Clip all lock ties before reassembly. 9. Retighten the Radio/Player Head Unit. (a) Re-install the two (2) screws. Lock Tie 10. In Process Functional Test. Move (a) Temporarily reconnect battery cable. (b) Turn ignition key to ACC position. (c) Press the power button on the receiver/player head unit. Verify the backlighting illuminates. Fig. 8-1 (d) Press and release the “SAT” button on the head unit. (1) Verify that a satellite channel is received, or a "NO SIGNAL" message appears on the display. Issue: B 2/27/06 Page 14 of 16 pages TOYOTA 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Procedure NOTE: If "ANTENNA" appears (flashing) on the display - then one or both of the antenna cables are disconnected from the satellite tuner. NOTE: If the head unit will not tune or go into satellite mode - then the tuner cable is disconnected from the satellite tuner. (e) Disconnect battery negative cable. (f) Complete the Reassembly of Vehicle. 11. Complete the Reassembly of the Vehicle: (a) Re-install the front seat (1) Reinstall the bolts loosely, and then tighten them. (2) Tighten bolts to 37 N-m (27 lbf-ft) (3) Reconnect any disconnected connectors. (b) Reinstall glove box. Socket (10 mm), Ratchet Negative Battery Cable (c) Reinstall upper console panel. (1) Reconnect any disconnected connectors. (d) Reinstall lower console panel. (1) Reconnect the lighter connector and clip. (e) Reinstall doorsill. (f) Reconnect the vehicle’s negative battery cable. (Fig. 10-1) Fig. 10-1 (1) Reconnect the negative terminal to factory original position. (2) Tighten the nut with 4.1 N-m (36 lbf-in) of torque. (3) Be careful not to touch the positive battery terminal. (g) Clean up and remove any trash. (h) Place the owner "SIRIUS Satellite Radio" brochure in the glove box. Issue: B 2/27/06 Page 15 of 16 pages LEXUS 4RUNNER 2006 - SIRIUS SATELLITE RADIO TUNER Checklist - these points MUST be checked to ensure a quality installation. Check: Accessory Function Checks Look For: Satellite Radio Tuner *Verify the proper operation of the Satellite Radio Tuner. Receiver/player Assembly *Verify the proper operation of the Receiver/player Assembly *Verify both AM & FM have good reception. *(Refer to the receiver assembly and radio owner’s manuals.) Vehicle Function Checks Hazard switch Proper operation of the hazard switch Navigation System (if equipped) Functioning NAV System HVAC Proper operation of the air conditioning system Multi-information displays.(Clock, Temp., Verify the proper operation of the multi- and MPG meter) information displays. Operation of the L&R seat heater switch Verify the proper operation of the L&R seat heater switch. Operation of the 12V outlet switch Verify the proper operation of the 12V outlet switch. Issue: B Refer to your Auto Repair Manual, and return the electric Moon Roof to its initial position. Electric Moon Roof Auto-open and Autoclose functions operate correctly. 4wd Switch if applicable) Functioning Suspension Control Switch Functioning 2/27/06 Page 16 of 16 pages 2003 4 RUNNER TVIP V5 RS3200 PLUS OWNER’S GUIDE RS3200 PLUS SECURITY SYSTEM DESIGNED FOR USE WITH YOUR VEHICLE’S REMOTE KEYLESS ENTRY SYSTEM OWNER’S GUIDE Rev. A 09/24/02 TOYOTA RS3200 PLUS Security system Page 1 To better understand the features and functions of this security system, please read this Owner’s Guide completely prior to use. For N m d ock r on w TABLE OF CONTENTS DESCRIPTION INTRODUCTION BRIEF DESCRIPTION–RS3200 PLUS FEATURES OPERATION ARMING THE RS3200 PLUS (except PASSIVE ARMING) DISARMING THE RS3200 PLUS (except PASSIVE DISARMING) PASSIVE (AUTOMATIC) ARMING & DISARMING AUTOMATIC REARMING ARMING SUSPENSION ALARM INFORMATION ALARM TRIGGERS ALARM DESCRIPTIONS STOPPING AN ALARM PAGE 2 3, 4 5 6 7 8 8 9 9 10 10 GLASS BREAKAGE SENSOR INFORMATION GLASS BREAKAGE SENSOR CHECK PROCEDURE 11 PROGRAMMING PASSIVE (AUTOMATIC) ARMING AND ENTRY DELAY (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information.) WARNING and CAUTION INFORMATION 12 13 Page 2 TOYOTA RS3200 PLUS Security system INTRODUCTION GLASS BREAKA Congratulations on your choice of the RS3200 PLUS add-on security system to protect your vehicle! To get the most from the system, we strongly recommend that you read this Owner’s Guide completely to learn all of its features and functions. The RS3200 PLUS provides security through point-of-entry monitoring, glass breakage detection and ignition switch monitoring. While ARMED, the system will be TRIGGERED and sound an ALARM when a door, trunk or hatch is forcibly unlocked or opened*, or when a window is tapped on or broken. During the ALARM, the vehicle’s horn sounds and the headlights, tail lights and front marker or turn signal lights flash. A l s o , the vehicle’s starter is disabled, preventing engine start. In addition to the comprehensive protection, the RS3200 PLUS works in conjunction with your vehicle’s remote keyless entry system, enabling you to ARM and DISARM the security system at the same time the doors are remotely locked and unlocked. In vehicles equipped with a buzzer, it will chirp when the system is REMOTE ARMED and DISARMED. The RS3200 PLUS provides pro “listens” for the noise made by specifically for this task, the GL helps to prevent “false alarms” GLASS BREAKAGE SE When the RS3200 PLUS was in of the GLASS BREAKAGE SENSO below. 1. An important note about your system ➀➁ Throughout this guide, there are references to the STATUS MONITOR for this system. Illustrated below, this panel holds the LED indicator (for the system’s operating status) and the GLASS BREAKAGE SENSOR’S microphone. In vehicles equipped with an engine immobilizer system, there is a LED already installed, so the RS3200 PLUS utilizes the vehicle’s engine immobilizer system LED➂ instead and a microphone mounted in a separate location. If your vehicle falls into this category, remember to look at that LED when the information refers to the STATUS MONITOR. If you do not know where the LED is located, refer to your vehicle’s owner’s guide for specific information. ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ 2. ➂ YOUR ENGINE IMMOBILIZER SYSTEM LED MAY LOOK DIFFERENT THAN THE ONE ILLUSTRATED HERE 3. * When the system is PASSIVELY (AUTOMATICALLY) ARMED, there is an ENTRY DELAY that will elapse when a door is opened before an ALARM is TRIGGERED. 4. OR, H S tem GH S TOYOTA RS3200 PLUS Security system Page 3 BRIEF DESCRIPTION–RS3200 PLUS FEATURES FEATURES FUNCTIONS The RS3200 PLUS will ARM 30 seconds after the lock button on the remote REMOTE keyless entry system’s remote control is pressed, and DISARM when the ARMING/DISARMING unlock button is pressed. If your vehicle is equipped with a buzzer that chirps when the lock and unlock buttons on the remote controls are pressed, the buzzer will also chirp when the system is REMOTE ARMED and DISARMED. The RS3200 PLUS will automatically REARM at the same time the AUTOMATIC vehicle’s remote keyless entry system relocks the vehicle’s REARMING doors, if no door is opened within 30 seconds after REMOTE DISARMING. The RS3200 PLUS will ARM 30 seconds after you close the trunk (if KEY open) and lock the vehicle’s doors with the key, and will DISARM when ARMING/DISARMING you unlock a door with the key. While ARMED, the trunk may be opened with the key (or trunk release button ARMED MODE SUSPENSION** on your remote control, if so equipped) without TRIGGERING an ALARM. Once the open trunk is closed, the system ARMS again. The RS3200 PLUS may be programmed to automatically ARM 30 PASSIVE (AUTOMATIC) seconds after the ignition key is removed, the vehicle exited and the ARMING last door and the trunk closed, without the necessity of locking doors. The RS3200 PLUS may be DISARMED with the vehicle’s ignition key PASSIVE DISARMING after it was PASSIVELY ARMED. ADJUSTABLE ENTRY When the RS3200 PLUS has been PASSIVELY ARMED, an ENTRY DELAY DELAY (user-selectable at 0, 15, or 30 seconds) will start when a door is opened before an ALARM is TRIGGERED. When you lock the vehicle with the central lock switch (while a door MANUAL ARMING is open), the RS3200 PLUS will ARM 30 seconds after you close all the doors and the trunk (if open). The RS3200 PLUS may be DISARMED by inserting the key into the IGNITION KEY ignition switch and turning it to “ON.” DISARMING Forcibly unlocking or opening a door or trunk while the RS3200 PLUS POINT-OF-ENTRY is ARMED will TRIGGER an ALARM immediately. (If the system was PASSIVELY PROTECTION ARMED, the ENTRY DELAY must pass after opening a door before the ALARM is TRIGGERED.) The RS3200 PLUS utilizes a microphone (usually mounted in the GLASS BREAKAGE STATUS MONITOR) to sense the noise from tapping on window glass, or SENSOR glass breaking, and TRIGGER the system to sound an ALARM. It is fine tuned to “listen” for this type of noise, and ignore other sounds. WARN AWAY ALARM When the GLASS BREAKAGE SENSOR’S microphone picks up tapping or breaking of window glass, it TRIGGERS a WARN AWAY ALARM; the headlights and tail and marker or turn signal lights flash, and the horn sounds for 20 seconds, but the starter is not disabled. If there is another detection of glass tapping or breaking, or if a door is opened or unlocked without a key, the regular ALARM is TRIGGERED. While ARMED, the RS3200 PLUS monitors the ignition switch. If an attempt is IGNITION SWITCH made to start the vehicle without a key, an ALARM is TRIGGERED. MONITORING **Starting from 2002 M.Y., Arming Suspension Mode by using the key to unlock the trunk is not applicable to Camry, Solara, and Corolla. Page 4 TOYOTA RS3200 PLUS Security system BRIEF DESCRIPTION–RS3200 PLUS FEATURES FEATURES FUNCTIONS When an ALARM is TRIGGERED, the system disables the vehicle’s starter and prevents engine start until the system is reset (DISARMED). During an ALARM, the system will lock the doors if one is unlocked, FORCED LOCK and will continue to do so for the duration of the ALARM. DURING ALARM The user is notified that an ALARM occurred. Upon DISARMING the TRIGGER MEMORY * system after an ALARM was TRIGGERED, the vehicle’s tail and marker lights will be turned on for 2 seconds. The RS3200 PLUS flashes the vehicle’s tail and marker or turn signal lights EXTERIOR LIGHT during REMOTE ARMING and REMOTE DISARMING, and during an ALARM. ACTIVATION Also, during an ALARM the headlights flash. If your vehicle is equipped with a buzzer that chirps when the lock BUZZER ACTIVATION and unlock buttons on the remote keyless entry system’s remote controls are pressed, the buzzer will also chirp when the system is REMOTE ARMED and DISARMED. HORN ACTIVATION During an ALARM, the RS3200 PLUS activates the vehicle’s horn. If power to the RS3200 PLUS is disrupted while it is ARMED, an ALARM is POWER LOSS MEMORY TRIGGERED once power is restored. This panel houses the GLASS BREAKAGE SENSOR microphone and the STATUS MONITOR flashing LED that indicates the operating status of the security system. (Some vehicle applications utilize the vehicle’s engine immobilizer system LED and a separate microphone, instead.) STARTER DISABLE ALARM INFORMA ALARM TRIGGERS While the system is ARMED, an ➤ F P a ➤ M M N ➤ “ T t * TRIGGER MEMORY is not available for Corolla / Matrix. ➤ T T A h ➤ P I A e em LL R 30 S HEN THE RMED TOYOTA RS3000 PLUS Security system Page 5 OPERATION ARMING THE RS3200 PLUS (except PASSIVE ARMING) The system may be ARMED in several ways. Do one of the following: Lock the doors with your key: Remove the key from the ignition switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Insert the key into the door key switch and turn it toward the front of the vehicle: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. TURN TOWARD THE FRONT OF THE VEHICLE Lock the doors from inside the vehicle: Remove the key from the ignition switch. Open the driver’s or front passenger’s door. Push the central lock switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Then: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. PUSH THE LOCK SWITCH WHILE THE and sing R’S Lock the doors with the remote control: Remove the key from the ignition switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Press the lock button on the remote control. Simultaneously: The doors lock.➁ The vehicle’s tail and marker or turn signal lights flash once.③ The vehicle’s buzzer chirps once.∆ The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. PRESS AND RELEASE THE LOCK BUTTON ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN FLASHES (SYSTEM IS ARMED) ➁ ALL DOORS LOCK WHEN THE SYSTEM IS REMOTE ARMED ③ THE TAIL AND MARKER OR TURN SIGNAL LIGHTS FLASH ONCE WHEN THE SYSTEM IS REMOTE ARMED * The system will not ARM while any of the doors, trunk or hatch is open. ∆ If your vehicle is equipped with a buzzer. Page 6 TOYOTA RS3200 PLUS Security system OPERATION OPERATION DISARMING THE RS3200 PLUS (except PASSIVE DISARMING) PASSIVE (AUTOMATIC) The system may be DISARMED in several ways. Do one of the following: When the RS3200 PLUS is prog is removed and all doors and th come back to your vehicle and it to “ON” during the ENTRY DEL the doors, regular ARMING will o PROGRAMMING information o the ENTRY DELAY time. (Not a Deale Unlock the doors with your key: Insert the key into the door key switch and turn it toward the rear of the vehicle: The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* TURN TOWARD THE REAR OF THE VEHICLE In the case of Highlander, Sienna, and 4Runner, you may also disarm the system using the key in the back door; all doors will unlock at the same time. Unlock the doors with the remote control: Press the unlock button on the remote control. Simultaneously: The driver’s door unlocks.➁ The vehicle’s tail and marker or turn signal lights flash twice.➂ The vehicle’s buzzer chirps twice.∆ The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* Press the unlock button again within 3 seconds after unlocking the driver’s door to unlock the remaining doors. PUSH THE UNLOCK BUTTON Use the ignition switch: Insert the key into the ignition switch, then turn it to ON. The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* TURN THE KEY TO “ON” TO DISARM THE SYSTEM This method of disarming is rarely used. You must be inside the vehicle while the system is armed in order to do it. NOTE: If your vehicle’s tail and marker or turn signal lights turn on for 2 seconds when the system is DISARMED,* the TRIGGER MEMORY was activated; something TRIGGERED an ALARM while you were away from the vehicle. This feature is not available for Corolla / Matrix. ➀ ➁ STOPS FLASHING WHEN THE SYSTEM IS DISARMED THE DRIVER’S DOOR UNLOCKS WHEN THE SYSTEM IS REMOTE DISARMED ➂ THE TAIL AND MARKER OR TURN SIGNAL LIGHTS FLASH TWICE WHEN THE SYSTEM IS REMOTE DISARMED * Please note, if the system utilizes your vehicle’s engine immobilizer system LED instead of the STATUS MONITOR, the LED will continue to flash. ∆ If your vehicle is equipped with a buzzer. T R E A C w A THE SYSTEM ARMS 30 SECONDS AFTER THE LAST ENTRY POINT (DOOR, TRUNK OR HATCH) IS CLOSED T E T I b THE SYSTEM DISARMS WHEN YOU INSERT THE KEY AND TURN IT TO “ON” Y d NOTE: If your vehicle’s tail an is turned to “ON”, the while you were away f ➀ LIGHTS FOR 30 SECONDS (PRE-ARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ * If the ENTRY DELAY time elap TRIGGERED. To DISARM the sy press and release the remote of m is sarm the m is e m is em e AL EM e TOYOTA RS3200 PLUS Security system Page 7 OPERATION PASSIVE (AUTOMATIC) ARMING & DISARMING When the RS3200 PLUS is programmed to PASSIVELY ARM, the system will ARM after the ignition key is removed and all doors and the trunk are closed; you do not need to lock the doors. When you come back to your vehicle and open a door, you must insert the key into the ignition switch and turn it to “ON” during the ENTRY DELAY (0, 15 or 30 seconds), or an ALARM will be TRIGGERED. If you lock the doors, regular ARMING will override PASSIVE ARMING; there will be no ENTRY DELAY. See the PROGRAMMING information on page 13 to activate the PASSIVE ARMING mode, as well as to select the ENTRY DELAY time. (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information .) THE SYSTEM ARMS 30 SECONDS AFTER THE LAST ENTRY POINT (DOOR, TRUNK OR HATCH) IS CLOSED THE SYSTEM DISARMS WHEN YOU INSERT THE KEY AND TURN IT TO “ON” To PASSIVELY ARM the system: Remove the key from the ignition switch. Exit the vehicle, and close all the doors. (The system will not ARM while any of the doors are open.) Close the trunk or hatch, if necessary. (The system will not ARM while the trunk or hatch is open.) After the last door, trunk or hatch is closed: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀The system is now ARMED. To DISARM the PASSIVELY ARMED system: Enter the vehicle through a front door. The ENTRY DELAY begins: The STATUS MONITOR’S LED turns on (no flashing.)➁ Insert the key into the ignition switch and turn it to “ON” before the ENTRY DELAY ends.* The LED turns off. The system is now DISARMED. You may also DISARM the system following any of the methods described on page 6. NOTE: If your vehicle’s tail and marker lights turn on for 2 seconds when the ignition key is turned to “ON”, the TRIGGER MEMORY was activated; something TRIGGERED an ALARM while you were away from the vehicle. This feature is not available for Corolla/Matrix. ➀ LIGHTS FOR 30 SECONDS (PRE-ARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ TURNS ON (NO FLASHING) DURING THE ENTRY DELAY * If the ENTRY DELAY time elapses before the ignition switch is turned to “ON”, an ALARM will be TRIGGERED. To DISARM the system during an ALARM, insert the ignition key and turn it to “ON”, or press and release the remote control’s unlock button. Page 8 TOYOTA RS3200 PLUS Security system OPERATION OPERATION AUTOMATIC REARMING ARMING THE RS3200 P When you unlock the doors using the remote control, the RS3200 PLUS is DISARMED at the same time. However, if you do not open a door or the trunk within 30 seconds, the keyless entry system will relock the doors and the RS3200 PLUS will REARM 30 seconds later. The system may be ARMED in s L R E C I f How the RS3200 PLUS automatically REARMS: 0 45 TURN TOWARD THE FRONT OF THE VEHICLE 15 30 THE DOORS ARE UNLOCKED BY PRESSING THE UNLOCK BUTTON ON THE REMOTE CONTROL... WHEN NO DOOR, TRUNK OR HATCH IS OPENED... FOR MORE THAN 30 SECONDS... ARMING SUSPENSION** THE LED WILL THE KEYLESS ENTRY LIGHT UP FOR 30 SYSTEM AUTOMATSECONDS (PRE-ARM), THEN ICALLY RELOCKS THE DOORS, THEN FLASH WHEN THE THE RS3200 PLUS SYSTEM IS ARMED AUTOMATICALLY REARMS. L R O P E C PUSH THE LOCK SWITCH WHILE THE The ARMED state of the RS3200 PLUS can be suspended temporarily by using the key to unlock and open the trunk. If your remote control is so equipped, you may also suspend the ARMED state using the trunk release button➀to open the trunk. When the ARMING is suspended, the STATUS MONITOR’S LED will turn off ➁until the trunk is closed again. ➀ OPENING THE TRUNK SUSPENDS THE ARMED STATE OF THE SECURITY SYSTEM L R E C P ➁ TURNS OFF WHEN THE ARMED STATE IS SUSPENDED **Starting from 2002 M.Y., Arming Suspension Mode by using the key to unlock the trunk is not applicable to Camry, Solara, and Corolla. PRESS AND RELEASE THE LOCK BUTTON ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN FLASHES (SYSTEM IS ARMED) ➁ ALL THE * The system will not ARM whil ∆ If your vehicle is equipped w TOYOTA RS3200 PLUS Security system Page 9 ALARM INFORMATION ALARM TRIGGERS While the system is ARMED, an ALARM will be TRIGGERED when any of the following occurs: ➤ Forcibly opening a door, or the trunk or hatch without a key Pulling the trunk release lever inside the vehicle will also TRIGGER an ALARM. s ts m ➤ Manually unlocking a door Manually operating an inside lock button will TRIGGER an ALARM. Note: Because this action will TRIGGER an ALARM, it is important that you do not ARM the system while someone is in the vehicle. ➤ “Hot wiring” the vehicle The RS3200 PLUS can detect the absence of the ignition key if the ignition circuit is shorted in attempt to start the vehicle. ➤ Tapping on or breaking the glass The noise from tapping on, or breaking of glass TRIGGERS a WARN AWAY ALARM first, then a regular ALARM. See the description of how the GLASS BREAKAGE SENSOR TRIGGERS ALARMS on page 12. ➤ Power restoration If power to the system is interrupted while it is ARMED, an ALARM will be TRIGGERED immediately when power is restored. TOYOTA RS3000 PLUS Security system Page 10 BRIEF DESCRIP ALARM INFORMATION ALARM DESCRIPTIONS FEATURES Regular ALARM ➀ When an ALARM is triggered in any way other than initial detection by the GLASS BREAKAGE SENSOR, the following occur: The horn sounds repeatedly for 60 seconds. The headlights flash repeatedly for 60 seconds. The tail and marker or turn signal lights flash repeatedly for 60 seconds. The starter is disabled (no engine start) until the system is DISARMED. The door lock will be relocked if someone reaches in and unlocks the inside lock button. After 60 seconds of ALARM, the system will REARM and continue to protect the vehicle. ➀ THE HORN SOUNDS FOR 60 SECONDS THE STARTER IS DISABLED UNTIL THE SYSTEM IS DISARMED TAIL OR TURN SIGNAL LIGHTS FLASH FOR 60 SECONDS MARKER OR TURN SIGNAL LIGHTS FLASH FOR 60 SECONDS HEAD LIGHTS FLASH FOR 60 SECONDS WARN-AWAY ALARM ➁ Upon initial detection of noise from tapping on, or breaking glass, the GLASS BREAKAGE SENSOR TRIGGERS a WARN AWAY ALARM: The horn sounds repeatedly for 20 seconds. The headlights flash repeatedly for 20 seconds. The tail and marker or turn signal lights flash repeatedly for 20 seconds. If the GLASS BREAKAGE SENSOR detects noise again, or if a door or trunk is opened while the system is still ARMED, the regular ALARM (described above) is activated. ➁ THE HORN SOUNDS FOR 20 SECONDS TAIL OR TURN SIGNAL LIGHTS FLASH FOR 20 SECONDS HEADLIGHTS FLASH FOR 20 SECONDS MARKER OR TURN SIGNAL LIGHTS FLASH FOR 20 SECONDS STOPPING AN ALARM Simply DISARM the system using the remote control or key as described on page 6. Th ke un wh bu Th AUTOMATIC ve REARMING do Th KEY op ARMING/DISARMING yo W ARMED MODE SUSPENSION** on th Th PASSIVE (AUTOMATIC) se ARMING la Th PASSIVE DISARMING af ADJUSTABLE ENTRY W DELAY (u op W MANUAL ARMING is th Th IGNITION KEY ig DISARMING Fo POINT-OF-ENTRY is PROTECTION AR TR Th GLASS BREAKAGE ST SENSOR gl tu WARN AWAY ALARM W br an se ta re W IGNITION SWITCH m MONITORING REMOTE ARMING/DISARMING **Starting from 2002 M.Y., Armin to Camry, Solara, and Corolla cle! - and na n he ors em TOYOTA RS3200 PLUS Security system Page 11 GLASS BREAKAGE SENSOR INFORMATION The RS3200 PLUS provides protection for your vehicle above and beyond entry point monitoring–it “listens” for the noise made by tapping on, or breaking of glass. Using a microphone designed specifically for this task, the GLASS BREAKAGE SENSOR is capable of ignoring other noises, which helps to prevent “false alarms” from occurring. GLASS BREAKAGE SENSOR CHECK PROCEDURE When the RS3200 PLUS was installed in your vehicle, care was taken to adjust the sensitivity level of the GLASS BREAKAGE SENSOR. You may observe how it works following the procedure listed below. 1. ARM the system. Press the lock button on the remote control or lock the doors with the key. (Remember, the system will not ARM if any door, the trunk or hatch is open.) is D➂ 2. Wait until the STATUS MONITOR’S LED starts flashing. The LED will flash 30 seconds after the last door, the trunk or hatch is closed. 3. With the tip of a key, tap the center of the driver’s door window. Tap the glass with light to moderate force. WARNING: Do not hit the glass with excessive force, especially in cold weather, or you may crack or break it. A WARN AWAY ALARM should be TRIGGERED. If the ALARM is not TRIGGERED, make sure you performed the procedure correctly and try again. If you find that the system did not perform as expected, contact your Toyota dealer for more information. se 4. DISARM the system to stop the WARN AWAY ALARM. Press the unlock button on the remote control or use the key to DISARM the system. Page 12 TOYOTA RS3200 PLUS Security system PROGRAMMING The RS3200 PLUS is factory-set to not PASSIVELY ARM. To change the system’s operation for PASSIVE ARMING operation, as well as adjust the ENTRY DELAY time, follow the procedure below. For more information on this feature, please refer to page 7. (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information.) PASSIVE ARMING ON/OFF SELECTION, ENTRY DELAY TIME SELECTION 1. Before you begin: Open the driver’s door. Close the remaining doors and the trunk or hatch. Unlock all doors with the inside lock switch. Remove the key from the ignition switch. 2. Insert and remove the key from the ignition key cylinder 3 times; this must be completed within 5 seconds. Start the Programming Procedure. (Complete these steps within 40 seconds.) To better understand the featu Guide completely prior to use. TABLE OF CONT INTRODUCTION BRIEF DESCRIPTIO OPERATION ARMING THE RS DISARMING THE PASSIVE (AUTOM AUTOMATIC REA ARMING SUSPEN ALARM INFORMATIO a. Close the driver’s door. b. Lock and unlock all doors 3 times by key or remote control. c. Open and close the driver’s door. d. Lock, then unlock the driver’s door inside lock button 3 times. ALARM TRIGGER ALARM DESCRIP STOPPING AN AL GLASS BREAKAGE GLASS BREAKAG PROGRAMMING PASSIVE (AUTOM (Not applicable to Toyota Dealer for e. Open the driver’s door. 3. f. The system locks the door in 2 seconds; if this does not happen, start over. g. Unlock the driver’s door knob. Select the Operating Mode and Complete the Programming Procedure. a. Close, then Open the driver’s door: b. Lock then unlock the 2 times = PASSIVE ARMING OFF driver’s door inside lock 3 times = PASSIVE ARMING ON, button 1 time. 0 Sec. ENTRY DELAY 4 times = PASSIVE ARMING ON, 15 Sec. ENTRY DELAY 5 times = PASSIVE ARMING ON, 30 Sec. ENTRY DELAY c. The system locks the door in 2 seconds; if this does not happen, start over. Programming is now complete. WARNING and CAUT TOYOTA RS3200 PLUS Security system Page 13 Warning • This product is applicable only to vehicles with 12V DC, negative grounding specifications. Do not use in vehicles with 24V specifications. Otherwise, damage to the unit or a fire may result. • Never attempt to disassemble or modify the product. Otherwise, an accident, fire or electric shock may result. • When replacing fuses, be sure to use fuses with the same specified capacity (amperage.) Otherwise, damage to the unit or vehicle, fire or electric shock may result. • If an abnormal condition occurs, such as liquids spilling onto the product, or the product emitting smoke or strange odors, stop using it immediately and consult the dealer from whom you purchased the product. Continued use of the product before corrective actions are taken may result in an accident, injury or fire. • Never pull the plastic bag over your head. Otherwise, a serious injury or death from suffocation may occur. Caution • Do not use this product for applications other than in-vehicle use. Otherwise, an electric shock or injury may result. • Do not allow children to play with the remote controls. Otherwise, the doors may be locked or unlocked, the security system armed or disarmed, or an alarm triggered unintentionally. • If this product is dropped or its case is damaged, disconnect the power supply lead and contact the dealer from whom you purchased it to obtain service. Otherwise, a fire or electric shock may result. RS3 SECURI DESIGN REMOT OWN 090002-25520700 TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200 PLUS) Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: 08586-3D871 Kit Contents Item # 1 2 3 4 5 6 Quantity Reqd. 1 1 1 1 1 1 Description Wire Harness V5 Security ECU ECU Mounting Bracket GBS ECU GBS ECU Mounting Bracket Microphone Torque Wrench Pliers Pliers Pneumatic/Electric Wrench 4.1 N·m (36 lbf·in) Slip-joint Needle Nose Special Chemicals Notes Cleaner Glass Cleaner 3MTM Prep Solvent-70 Household Windex Hardware Bag Contents Item # 1 2 3 4 5 6 7 8 9 10 11 12 Quantity Reqd. 15 5 2 2 2 1 1 1 1 2 1 1 General Applicability Description Medium Wire Ties Large Wire Ties Small Foam Tape Strip Large Foam Tape Strip Splicing Connector Bolt Nut Butyl Tape Key Tag Warning Label Owner’s Guide Warranty Card Note: 4Runner with factory keyless entry, only. Recommended Sequence of Application Item # 1 2 *Mandatory Vehicle Service Parts (may be required for reassembly) Item # Quantity Reqd. Description Conflicts Note: Must not be installed in vehicles with factory TDS. Recommended Tools Personal & Vehicle Protection Notes Safety Glasses Safety Gloves Vehicle Protection (Optional) Blankets, Part Boxes Special Tools Notes Striker Tool CAD-E IADE P/N ALL 02-016-01 Installation Tools Notes Phillips Head Screwdriver Flat Blade Screwdriver Socket Socket Extension Nylon Panel Removal Tool #2, screwdriver or tip Small, Flat Blade 10mm 3" e.g. Panel Pry Tool #1 Issue: B 04/22/05 Description STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. Toyota SST # 00002-06001-01 Wrench Side Cutters Quantity Reqd. Legend Additional Items Required For Installation Item # Accessory V5 Audio 10mm Page 1 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:x Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). x Safety (eye protection, rechecking torque procedure, etc.). x Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). x Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Disassembly. (a) Remove the negative battery cable. (Fig. 1-1) 10mm Wrench Negative Battery Cable (1) Protect the fender before starting. (2) For automatic equipped vehicles, place the shifter in low gear and set the parking brake prior to disconnecting the battery. (3) Do not touch the positive terminal with any tool when removing cable. Fig. 1-1 (b) Remove the passenger side step cover. (Fig. 1-2) Nylon Panel Removal Tool (1) Cover the floor and seats before starting. (c) Remove the passenger side cowl cover. (Fig. 1-3) (1) Remove the nut securing the cover. Step Cover Fig. 1-2 Nylon Panel Removal Tool Nut Cowl Cover Fig. 1-3 Issue: B 04/22/05 Page 2 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure (d) Remove the glove box assembly. (Fig. 1-4) (1) Remove the screw securing the glove box assembly. (2) Remove the glove box damper. Damper Screw (1) Remove the four screws securing the cover. Glove Box Fig. 1-4 (e) Remove the cover from the upper glove box area. (Fig. 1-5) (2) Remove the air bag connector holder from the cover. 10mm Wrench Cover Screws (x2) Screws (x2) (f) Remove the under-dash cover below the glove box area. (Fig. 1-6) (1) Remove the one screw. (2) Disconnect the two connectors on the 4WD control ECU (if equipped), and remove the one vehicle wire harness clip. Air Bag Connector Fig. 1-5 2. V5 Wire Harness Installation. (a) Prepare a protective sheet (blanket), and cover the blower assembly in the glove box area with the sheet as shown. (Fig. 2-1) Under-Dash Cover Screw Fig. 1-6 Protective Sheet Fig. 2-1 Issue: B Clip 04/22/05 Page 3 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure 4P (White) (b) Locate the vehicle harness’ white 4P connector from the glove box area. (Fig. 2-2) 4P (White) V5 Harness (c) Plug in the V5 harness’ white 4P connector to the vehicle harness’ white 4P connector. (Fig. 2-2) (1) Verify the connectors are plugged in securely. (d) Locate and disconnect the white 13P connector from the connector block in the glove box area. Plug in the V5 harness’ white 13P connectors between the vehicle harness’ white 13P connector and the connector block. (Fig. 2-3) Fig. 2-2 13P (White) V5 Harness Fig. 2-3 (1) Verify the connectors are plugged in securely. (e) Wrap the white 4P connectors with one large strip of foam tape. (Fig. 2-4) 13P (White) (f) Wrap the white 13P connectors, V5 harness and vehicle harness with one large strip of foam tape. (Fig. 2-4) Side Cutter Medium Wire Ties (x2) Relay 13P Large Wire Ties (x2) Fig. 2-4 Large Foam Tapes (x3) (h) Secure the V5 harness relay to the vehicle harness with one large wire tie. (Fig. 2-4) 4P (i) Secure the 4P connectors to the vehicle harness with one large wire tie. (Fig.2-4) 10mm Socket V5 Harness Existing Bolt (g) Wrap the V5 harness relay with one large strip of foam tape. (Fig. 2-4) (j) Secure the V5 harness to the vehicle harness with two medium wire ties. (Fig.2-4) (k) Locate and remove the existing bolt from the ground point in the passenger-side cowl area. (Fig. 2-5) Fig. 2-5 Issue: B 04/22/05 Page 4 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure Side Cutter V5 Harness (l) Secure the V5 harness ground wire terminal, along with the vehicle harness ground wire terminal, using the existing bolt. (Fig. 2-6) (1) Use the vehicle’s ground bolt to secure the V5 harness ground wire. Existing Bolt Medium Wire Ties (x2) (2) Verify the bolt is tight. (m)Secure the V5 harness with two medium wire ties. (Fig. 2-6) Fig. 2-6 (n) Route the V5 harness toward the upper glove box area, and secure it to the vehicle harness with two medium wire ties. (Fig. 2-7) Side Cutter (o) Route the V5 harness toward the left side of the glove box area, and secure it to the vehicle harness with one medium wire tie and the existing vehicle wire clip. (Fig. 2-8) Medium Wire Ties (x2) V5 Harness Fig. 2-7 Side Cutter, Pliers (1) Remove the vehicle wire clip on the center brace and open the vehicle wire clip. (2) Route the V5 wire harness though the open vehicle wire clip. Medium Wire Tie Wire Clip (3) Close and reinstall the vehicle wire clip to the brace. (p) Locate the vehicle harness’ white 40P connector in the upper left side of the glove box area. (Fig. 2-9) V5 Harness Fig. 2-8 (1) Remove the adjacent vehicle wire clip and tape to loosen the 40P connector. Pliers (2) Reinstall the vehicle wire clip without the 40P connector. Tape Wire Clip 40P (White) Fig. 2-9 Issue: B 04/22/05 Page 5 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure V5 Harness’ GREEN/RED and GRAY/GREEN Wires (r) Locate the wire on the white 40P connector (top row, sixteenth space from the left) and attach the V5 harness’ GREEN/RED wire with a splicing connector. Then locate the wire on the bottom row (sixteenth space from the left) and attach the V5 harness’ GRAY/GREEN wire with a splicing connector. (Fig. 2-11) Fig. 2-10 Side Cutter, Slip-joint Pliers 30mm GREEN/RED 40P (White) GRAY/GREEN Fig. 2-11 (q) Route the V5 harness’ GREEN/RED and GRAY/GREEN wires inside the vehicle wire clip. (Fig. 2-10) WIRE SIDE VIEW (1) Using a side cutter, cut 30 mm of tape from the 40P connector wire harness to expose the wires for splicing. (2) Verify the correct wire and connector openings are chosen for splicing. (s) Wrap the V5 harness’ white 40P connector with one large piece of foam tape. (Fig. 2-12) (t) Secure the V5 harness’ GREEN/RED and GRAY/GREEN wires to the vehicle harness with two medium wire ties. (Fig. 2-12) Side Cutter V5 Harness Medium Wire Ties (x2) (u) Secure the V5 harness’ microphone wire to the vehicle harness with three medium wire ties. (Fig. 2-13) 40P (White) Fig. 2-12 Large Foam Tape Side Cutter Medium Wire Ties (x3) V5 Harness To Microphone Fig. 2-13 Issue: B 04/22/05 Page 6 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure ECU Mounting Bracket V5 ECU 3. V5 ECU Preparation and Installation. (a) Insert the ECU mounting bracket into the indicated bracket slot on the V5 ECU. (Fig. 3-1) (1) Before beginning this section, verify the protective sheet covering the blower assembly is still fully in place. Fig. 3-1 (b) Plug the V5 harness’ white 40P connector into the V5 ECU. (Fig. 3-2) 10mm Wrench, Needle Nose Pliers (1) Verify the connectors are plugged in securely. Nut V5 Harness (c) Install the V5 ECU on the metal substructure of the reinforcement tube with the nut supplied in the kit. (Fig. 3-2) Protective Sheet 40P (White) (1) Locate the existing stud bolt on top of the metal substructure. V5 ECU Fig. 3-2 Side Cutter Vehicle Harness V5 Harness Medium Wire Tie (2) Use needle nose pliers to place the nut over the stud bolt. Start the nut by hand, and finish tightening with a 10mm wrench. (3) Be careful not to drop and lose the nut. Large Wire Tie Reinforcement V5 ECU Fig. 3-3 (d) Secure the V5 harness to the vehicle harness with one medium wire tie and secure the V5 harness to the reinforcement tube with one large wire tie. (Fig. 3-3) 4. GBS ECU Preparation and Installation. Flat Blade Screwdriver (a) Turn the adjustment screw on the GBS ECU to the “9” position. (Fig. 4-1) GBS ECU Fig. 4-1 Issue: B 04/22/05 Page 7 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure Butyl Tape (b) Insert the GBS ECU mounting bracket into the indicated bracket slot on the GBS ECU. (Fig. 4-2) (1) Attach the bracket as shown. GBS ECU (2) Make sure the bracket is firmly attached to the ECU. Mounting Bracket Fig. 4-2 (c) Apply the butyl tape to the GBS ECU as shown. (Fig. 4-2) (d) Locate and remove the existing bolt from the connector block in the passenger side cowl area. (Fig. 4-3) 10mm Socket (1) Discard the existing bolt. Existing Bolt (e) Mount the GBS ECU on the right side of the connector block with the bolt supplied in the kit. (Fig. 4-4) (f) Plug the V5 harness’ white 8P connector into the GBS ECU. (Fig. 4-4) Fig. 4-3 10mm Socket Fig. 4-4 Issue: B GBS ECU 8P (White) 04/22/05 (1) Verify the connectors are plugged in securely. Bolt Page 8 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure Under-Dash Cover 10mm Socket 5. Microphone Installation. (a) Using 3MTM Prep Solvent-70, clean the area indicated on the back side of the under-dash cover. (Fig. 5-1) Large Hole (b) When cleaning with 3MTM Prep Solvent-70: Microphone 45˚ Insulator Fig. 5-1 10mm Socket Small Foam Tape Microphone Fig. 5-2 (1) Always use a clean (lint free scratch resistant) soft cloth (or wipe), and clean a small area at a time (3x3-ft. max.). (2) Shake well. (3) Apply 3MTM Prep Solvent-70 to cloth or wipe. Do not spray cleaning solution directly on any vehicle surfaces. (4) Clean the surface thoroughly and wipe dry immediately with a new clean cloth. Do not allow cleaner to air dry. (c) Remove the backing sheet and secure the microphone to the back side of the underdash cover. (Fig. 5-1) (1) Secure the microphone under the insulator at a 45˚ angle with the back of the microphone lined up with the front edge of the large hole as shown. (Fig. 5-1) (2) Do not touch the adhesive surface of the microphone. (3) Press the microphone to the under-dash cover firmly. (d) Secure the microphone with a small strip of foam tape. (Fig. 5-2) (1) Do not cover the opening of the microphone with the foam tape. Issue: B 04/22/05 Page 9 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure (e) Plug the microphone’s 2P connector into the V5 harness’ 2P connector. (Fig. 5-3) Small Foam Tape V5 Harness (1) Verify the connectors are plugged in securely. 2P (White) Microphone (f) Wrap the 2P connectors with a small strip of foam tape. (Fig. 5-3) (g) Reinstall the under-dash cover. (Fig. 5-3) Fig. 5-3 Under-Dash Cover 6. Warning Label and Key Tag Installation. (a) Clean the inside surface of the front door’s windows using 3MTM Prep Solvent-70 and the method in Step 5(b). (Fig. 6-1) 10mm Warning Label (b) Place the warning label on the inside surface of the front door’s window as shown. (Fig. 6-1) (1) Use a piece of clear adhesive tape to lift the labels off the protective backing sheet. Fig. 6-1 Remote Control Key Ring Fig. 6-2 Issue: B (2) Do not touch the adhesive surface of the warning labels. (c) Attach the key tag to the remote control key’s ring. (Fig. 6-2) Key Tag 04/22/05 Page 10 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Procedure 7. Completing the Installation Torque Wrench, 10mm Socket 45 deg. Negative Battery Cable (a) Complete the reassembly of the vehicle. (1) Reconnect any disconnected connectors. (2) Verify the panels fit together properly with no uneven gaps between them. Battery (b) Clean up and remove any trash. (c) Reconnect the vehicle’s negative battery cable. (Fig. 7-1) Fig. 7-1 (1) Position the negative terminal at an angle of 30º to the battery as shown. (2) Tighten the nut to 4.1 N•m (36 lbf•in). (3) Do not touch the positive terminal with any tool when replacing the cable. (d) Place the owner’s manual and warranty card, left in their protective bags, in the glove box. Issue: B 04/22/05 Page 11 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Press and release the remote control’s lock button to start the system’s arming process. 1. The turn signal lights flash once. All doors lock. The Security LED lights up. Wait 30 seconds. 2.After 30 seconds, the LED starts flashing; the system is now armed. Press and release the remote control’s unlock button to disarm the system. 3. The turn signal lights flash twice. The driver’s door unlocks. The LED stops flashing. Open the driver’s door, insert the key into the ignition switch and turn it to “ON.” Roll down all the windows, remove the key and exit the vehicle. Arm and disarm the system with the remote again, then wait 30 seconds. 4. The doors automatically relock. The system automatically starts the arming process. Press and release the remote control’s 5. Refer to Step 3. unlock button again to stop the arming process. Insert the key into the driver’s door key cylinder and turn it toward the front of the 6. All doors lock. The LED lights up. vehicle to start the arming process. Wait 30 seconds. 7. After 30 seconds, the LED starts flashing; the system is now armed. Issue: B 04/22/05 Page 12 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Reach inside and manually unlock the 8. The driver’s door automatically relocks. driver’s door to trigger an alarm. The horn sounds repeatedly. The headlights flash repeatedly. The turn signal lights flash repeatedly. The LED lights up. Manually unlock the driver’s door again 9. The driver’s door lock attempts to lock and hold it unlocked, open the door, then sit repeatedly. in the driver’s seat. The horn continues to sound repeatedly. The headlights and turn signal lights continue flashing. The LED remains on. Insert the key into the ignition switch and turn it to “START’ to stop the alarm. 10. The horn stops sounding. All the lights stop flashing and/ or turn off. The LED turns off. The starter cranks and the engine starts. Turn the key back to “LOCK,” remove it, then exit the vehicle. With the door open, press the lock switch on the door to lock the doors, then close the 11. All doors lock. The LED lights up. door to start the system’s arming process. Wait 30 seconds. 12. After 30 seconds, the LED starts flashing; the system is now armed. Reach inside and manually unlock the front passenger’s door to trigger an alarm. 13. The front passenger’s door automatically relocks. The horn sounds repeatedly. The headlights flash repeatedly. The turn signal lights flash repeatedly. The LED lights up. Issue: B 04/22/05 Page 13 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Press and release the remote control’s 14. The horn stops sounding. unlock button to stop the alarm. All the lights stop flashing. The LED turns off. Press and release the remote control’s lock 15. Refer to Steps 1 and 2. button to start the system’s arming process, then wait 30 seconds until the system is armed. Unlock and open one of the rear passenger 16. Refer to Step 13. doors to trigger an alarm. Repeat the above steps with the other rear 17. Refer to Steps 15 and 16. passenger door and back door (if equipped). Roll up all windows, remove the key and exit the vehicle. Press and release the remote control’s lock 18. Refer to Step 1. button to start the arming process. 19. After 30 seconds, the LED starts Wait 30 seconds. flashing; the system is now armed. Perform the following check in a temperature-controlled environment (50º-90º F) Pull the striker tool all the way out to tap 20. The horn sounds repeatedly. the center of the drivers door window to The headlights flash repeatedly. trigger an alarm. The turn signal lights flash repeatedly. The LED lights up. NOTE: Adjust as necessary by increasing the GBS setting to the next level if the alarm does not trigger during the functional verifications. NOTE: If you do not disarm the system, The alarm will last 20 seconds. It is not necessary to check the alarm duration. Issue: B 04/22/05 Page 14 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Insert the key into the driver’s door key 21. The horn stops sounding. cylinder and turn it toward the back of the All the lights stop flashing and/ or turn vehicle to stop the alarm. off. The Security LED turns off. Vehicle Function Checks Head Lights Functioning Head Lights High Beams Functioning High Beams Turn Signal Lights Functioning Turn Signal Lights Tail Lights Functioning Tail Lights Stop Lights Functioning Stop Lights Backup Lights Functioning Backup Lights Hazard Lights Functioning Hazard Lights Marker Lights Functioning Marker Lights Dome/Courtesy Lights Functioning Dome/Courtesy Lights Panel/Switch Illumination Functioning Switch/Illumination Accessory Controls/Illumination (if Functioning Accessory Controls/Illumination equipped) Issue: B Key Sensor Buzzer Functioning Key Sensor Fog Lights (if equipped) Functioning Fog Lights Daytime Running Lights (if equipped) Functioning DR Lights 04/22/05 Page 15 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Trunk/Tailgate/Bed Lights (if equipped) Functioning Lights Glove Box Light (if equipped) Functioning Glove Box Light Cruise Control Light (if equipped) Functioning Cruise Control Light Seat Belt Warning Light Functioning Seat Belt Warning Light. If the warning light remains on, it may indicate a system malfunction. Air Bag Warning Light Functioning Air Bag Warning Light. If the warning light remains on, it may indicate a system malfunction. ABS Light (if equipped) Functioning ABS Light. If the warning light remains on, it may indicate a system malfunction. Lamp Failure Sensor (if equipped) Functioning Lamp Failure Light. If the warning light remains on, it may indicate a system malfunction. Track/Skid Control Light (if equipped) Functioning Track/VSC Light. If the warning light remains on, it may indicate a system malfunction. Issue: B HVAC Functioning HVAC Controls Power Locks (if equipped) Functioning Power Locks Power Windows (if equipped) Functioning Power Windows Power Seats (if equipped) Functioning Power Seats Power Sunroof (if equipped) Functioning Sunroof Horn Functioning Horn Gauges Functioning Gauges Front Wiper/Washer Functioning Front Wiper/Washer 04/22/05 Page 16 of 17 pages TOYOTA 4RUNNER 2006 - TVIP V5 (RS3200PLUS) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Rear Wiper/Washer (if equipped) Functioning Rear Wiper/Washer Clock (if equipped) Functioning Clock Accessory Power Socket (if equipped) Functioning Power Socket Starter Functioning Starter Audio/Video (if equipped) Functioning Audio/Video Power Sliding Door (if equipped) Functioning Power Sliding Door Convenience Memory Settings (if Functioning Memory Settings equipped) Heated Seats (if equipped) Functioning Heated Seats Massage Seats (if equipped) Functioning Massage Seats Rear Window Defogger (if equipped) Functioning Rear Window Defogger Power Side Mirrors (if equipped) Functioning Power Side Mirrors Side Mirror Defogger (if equipped) Functioning Side Mirror Defogger Front Windshield Defogger (if equipped) Functioning Front Windshield Defogger Navigation System (if equipped) Functioning Navigation System Power Back Door (if equipped) Functioning Power Back Door Remove the appropriate fuse after checks are completed. Issue: B 04/22/05 Page 17 of 17 pages 2003- 4RUNNER TVIP V5 TROUBLESHOOTING INFORMATION RS3200 PLUS TROUBLESHOOTING GUIDE RS3200PLUS SECURITY SYSTEM CONNECTOR1 CIRCUIT MEASUREMENT 1 - Ground SUB +B Power (Dome) Always Approx. 12V 2 - Ground +B Power (Dome) Always Approx. 12V 3 Trunk Key Input Continuity when key turned to open 4 - Ground Key Unlock Warning Input Continuity when key is in the ignition switch 5 N/C 6 - Ground 7 - Ground G.B.S. Input 8 - Ground N/C 9 - Ground N/C 10 MPX signal 11 Ground ECU Ground Continuity 12 - Ground LED Output Approx. 1.8V when LED on, 0V when LED off 0V during triggering 13 - Ground Starter Cut Input Approx. 12V when ignition switch at ST position, 0V during triggering 14 Ground IG Input 15 0V (Pulsed) when window hit Approx. 12V when ignition switch is in ON position N/C 16 N/C 17 N/C 18 N/C 19 N/C 20 N/C 21 N/C 22 N/C 23 N/C 24 N/C 25 N/C 26 - Ground Starter Cut Output Approx 12V when ignition switch is in ON position TROUBLESHOOTING INFORMATION RS3200PLUS SECURITY SYSTEM Complaint: Remote Control Inoperative Common causes for this complaint: Mis-spliced Key Unlock wire, weak or dead battery in remote, remote programmed improperly (see KNOWN ISSUES page), remote not programmed, connectors not plugged in securely. What to Ask and Verify Does the panic mode operation work? What to Check Yes Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Clear the remote control codes from the ECU, then reprogram both (or all) remotes (they may have accidentally been programmed for second channel output). No control(s) and carefully clean the battery and contacts, then check the battery for a minimum 2.7V during remote operation. Replace the battery if necessary. Clear the remote control codes from the ECU, then reprogram both (or all) remotes (they may have accidentally been programmed for second channel output). Check the automatic door locking/unlocking function. Open the remote Do the vehicle’s door Yes locks work with the door switches or key? No Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the door lock control connectors are plugged in securely. Disconnect the RS3200PLUS harness’ Door Lock Control connectors and reconnect the vehicle’s connectors, then try again, If there is no function, there is probably a problem with one vehicle’s components. RS3200PLUS SECURITY SYSTEM Complaint: System Inoperative (No Remote Arming/Disarming) Common causes for this complaint: Mis-spliced Key Unlock Warning wire, mis-spliced door courtesy wire, connectors not plugged in securely, Fuse or shortpin not installed in vehicle, blown fuse in RS3200PLUS harness (does not apply to all vehicles). What to Ask and Verify Do the vehicle’s door Yes locks work with the door switches or key? No What to Check Check and correct the key unlock warning wire’s splice location (does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the door lock control connectors are plugged in securely. Disconnect the RS3200PLUS harness’ Door Lock Control connectors and reconnect the vehicle’s connectors, then try again, If there is no function, there is probably a problem with one vehicle’s components. TROUBLESHOOTING INFORMATION RS3200PLUS SECURITY SYSTEM Complaint: No Head Light Function Common causes for this complaint: Mis-spliced Head Lamp wire, connectors not plugged in securely, blown Head Lamp fuse. What to Ask and Verify Does the head lamp switch in the vehicle work? Is there continuity between pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the head light wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Check for continuity between the RS3200PLUS ECU connector and the head lamp circuit connection. No Check the vehicle’s head lamp fuse and replace if necessary. Confirm that the combination switch connector for the head lamp circuit is plugged in securely. Yes Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check fix the wire harness. Check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. No If no continuity, there is a wire harness problem. Fix as necessary. RS3200PLUS SECURITY SYSTEM Complaint: No Horn Function Common causes for this complaint: Mis-spliced Horn wire, connectors not plugged in securely, blown Horn fuse. What to Ask and Verify Does the horn switch in the vehicle work? Is there continuity on pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the horn wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Check for continuity between the RS3200PLUS ECU connector and the horn circuit connection. No Check the vehicle’s horn fuse and replace if necessary. Confirm that the combination switch connector for the horn circuit is plugged in securely. Yes Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check fix the wire harness or check BODY ECU signal. Check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. If no continuity, there is a wire harness problem. Fix as necessary. No TROUBLESHOOTING INFORMATION RS3200PLUS SECURITY SYSTEM Complaint: No Tail Light Or Marker Light Operation Common causes for this complaint: Mis-spliced Tail Light wire, connectors not plugged in securely, blown fuse. What to Ask and Verify Do the vehicle’s tail lights work? Is there continuity on pin 10 of the RS3200PLUS harness’ ECU connector? What to Check Yes Check and correct the tail light wire’s splice location (applies to most vehicles). Verify the splice connector was applied properly. Verify the RS3200PLUS harness’ tail light circuit connectors are plugged in securely. Check for continuity between the RS3200PLUS ECU connector and the tail light circuit connection. No Confirm that the vehicle’s connector for the tail light circuit is plugged in securely. Disconnect the RS3200PLUS harness’ tail light circuit connectors and reconnect the vehicle’s connectors, then check the tail light function again. If they work, check the RS3200PLUS harness. If not, the problem is vehicle-related. (applies to some vehicles) Activate the panic mode and check pin 10 for pulsed continuity to ground. If there is continuity, check the RS3200PLUS ECU for signs of liquid damage; it may be necessary to open the ECU case. LIQUID DAMAGE ITEMS ARE NOT COVERED UNDER WARRANTY. Yes No Check and fix the RS3200PLUS harness. RS3200PLUS SECURITY SYSTEM Complaint: LED Inoperative (No blinking, No turning on) Common causes for this complaint: Mis-spliced LED wire, mis-spliced door courtesy wire, connectors not plugged in securely. What to Ask and Verify Does the LED blink during arming? Yes No What to Check No problem. Check trunk key switch was installed properly. If not correct, LED may not turn on. Verify the splice connector was applied properly. TROUBLESHOOTING INFORMATION RS3200PLUS SECURITY SYSTEM Complaint: System Inoperative (Duplicate Panic Alarm) Common causes for this complaint: Mis-connection of Panic signal wire with terminal, mis-spliced panic signal wire, connector not plugged in securely. What to Ask and Verify What to Check Does the duplicate panic Yes mode operation work? Check the panic signal wire’s splice location. (Does not apply to all vehicles). Verify the splice connector was applied properly. Confirm the panic signal wire with terminal location. Check door lock control connector is plugged in securely. No No Problem TOYOTA Section I 4RUNNER 2003 − CARGO NET Installation Preparation Part Number: PT347−89030 Section I Installation Preparation Kit Contents Item # 1 Quantity Reqd. 1 General Applicability Description Spider Floor Net Recommended Sequence of Application Item # 1 2 3 Hardware Bag Contents Item # Quantity Reqd. Description Accessory *Mandatory Additional Items Required For Installation Item # Quantity Reqd. Legend Description STOP STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury Conflicts Note: CRITICAL PROCESS: Proceed with caution to ensure a quality installation. Recommended Tools Safety Tools GENERAL PROCESS: This highlights specific processes to ensure a quality installation. None TOOLS & EQUIPMENT: This calls out the specific tools and equipment required for this process Special Tools None Installation Tools None Special Chemicals None Rev: A 05/15/02 Page 1 of 2 pages Supplier Ref #: 5INS023030TA DIO TOYOTA 4RUNNER Section II Installation Procedure Section II Installation Procedure 2003 − CARGO NET A. Attach Cargo Net 1. Locate anchor points, two D−rings, and four buttons. (Fig. A−1) 2. Attach the hooks at the top of the net to the D− rings. (Fig. A−2) Fig. A−1 3. Attach loops at the bottom of the net to the four buttons on the underside of the cargo platform. (Fig A−3) 4. Confirm completed assembly. (Fig. A−4) Fig. A−2 Fig. A−3 Fig. A−4 TOYOTA Section III 4RUNNER 2003 − CARGO NET Functional Verifications Section III Functional Verifications Check: Look For: Confirm that net is attached properly to Make sure hooks are attached to D−rings anchor points in the vehicle. and loops are attached to four buttons on the underside of the cargo platform. Rev: A 05/15/02 Page 2 of 2 pages Supplier Ref #: 5INS023030TA DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section I – Installation Preparation Part Number: 08380-35802 Section I – Installation Preparation Kit Contents Item # 1 2 3 4 5 6 7 8 9 10 11 Quantity Reqd. 1 1 1 1 1 1 2 1 1 1 1 General Applicability Description Right Side Rail Left Side Rail End Cushion (Front RH) End Cushion (Rear RH) End Cushion (Front LH) End Cushion (Rear LH) Cross Bar End Support Cover (Front RH) End Support Cover (Rear RH) End Support Cover (Front LH) End Support Cover (Rear LH) Recommended Sequence of Application Item # 1 2 3 *Mandatory Legend STOP Hardware Bag Contents Item # 1 2 Quantity Reqd. 8 1 Accessory Description M8 bolt (corner clamping part) DIO Installation Manual STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Additional Items Required for Installation Item # 1 2 3 Quantity Reqd. Description Conflicts Note: Recommended Tools Safety Tools Safety glasses Vehicle protection Masking tape ( ½" to 1") Special Tools None Installation Tools Socket Torx socket Torque wrench Screwdriver Cloth Special Chemicals Cleaner Issue: A 09/06/02 12 mm (M8) TX-25 Thin blade Lint-free 3MTM Prep Solvent-70 Page 1 of 6 pages DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section II – Installation Procedure Section II – Installation Procedure Protective Tape Molding Joint Cover A. Installation Preparations 1. For ease of installation, the temperature of the work location and the surface of the body must be at least 60º F (15.5º C). Protective Tape Do NOT remove Middle Molding Joint Covers Molding Joint Cover B. Preparing the Body 1. Clear dust and dirt from the roof of the vehicle with 3MTM Prep Solvent-70. i. TM When cleaning with 3M Prep Solvent-70 follow the manufacturer’s directions. Do not allow cleaner to air dry. Fig. C-1 Molding Joint Cover Clip Clip 1 3 C. Removal of Molding Joint Cover and Bracket 1. To install the side rails the front and rear molding joint covers on both sides must be removed. (Fig. C-1) STOP 2 Fig. C-2 Interlocking Back Clip 2. When removing the molding joint covers, to prevent vehicle body damage, apply protective tape (masking tape) to both ends of the grooved moldings and to both sides of the factory molding joint groove. (Fig. C-1) 3. Remove the molding joint cover by pushing the molding joint cover in the direction of the arrow molded into the cover with your finger Fig. C-2 . Bracket Bracket M8 Bolt Fig. C-3 4. Disengage the cover from the interlocking back clip by lightly pulling up (Fig, C-2) , push the molding joint cover in the opposite direction and remove the cover. Thin Blade Screwdriver 5. Using a 12mm socket, remove and discard the eight M8 bolts. (Fig. C-3) 6. Remove the bracket. In the event that the bracket will not come off, use a thin slotted screwdriver to assist with removal. (Fig. C-4) Issue: A 09/06/02 Page 2 of 6 pages Bracket Fig. C-4 DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section II – Installation Procedure 7. Once you have removed the bracket, peel off the protective tape (masking tape). After Bracket Removal Collar Nut 8. Do not remove the molding. In the event that it does come off, reattach it in the same position. 9. Completely remove any dry screw seals, paint chips, or dirt, to retain the integrity of the seal. (Fig. C-5) Clean surface Fig C-5 D. Checking Cushion Fitting 1. Make sure that the holes of the front end support of the side rails match the protruding part of the front end cushion. (Fig. D-1) Enlarged View of Front End Cushion Installation 2. Make sure that the holes of the rear end supports of the side rails match the protruding part of the rear end cushion. (Fig. D-2) 3. Match the three (3) front end and two (2) rear end locations of the boss of the cushions to the holes of the end supports. Install the cushions as shown in Fig. D-3. Side Rail Cushion Fig D-1 Enlarged View of Rear End Cushion Installation Side Rail Fig D-2 Cushion Cushion Boss Section (Before Installation) (After Installation) Fig D-3 Issue: A 09/06/02 Page 3 of 6 pages Push in DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section II – Installation Procedure E. Assemble the Roof Rack STOP 1. Carefully place each side rail onto the roof, ensuring that the support parts at the ends coincide with the holes in both ends of the molding. (Fig. E-1) Side Rails 2. To prevent any damage to the body, have an assistant help you when placing the side rails. 3. Make sure that the M8 bolt holes of the end supports match the collar nut position of the vehicle body. (Fig. E-2) Fig E-1 Right and Left Side Front M8 Bolt - Tighten to 275lbf•In (31 N•M) - i. When aligning the positions, adjust by lifting up the end supports. Do not slide the rails for alignment. NOTE: When adjusting the side rail positions be careful not to get the cushion caught in the track. 4. Attach the end supports to the front end using M8 bolts (each side has four locations). Right and Left Side Rear M8 Bolt - Tighten to 275lb•In (31 N•M) 5. Tighten the end support bolts (M8 bolts) to a torque of 275 lbf•in (31 N•m). 6. Insert the front and rear cross bars from the rear of the vehicle into the left and right side rails. STOP i. Check the orientation of the cross bar. If the arrow stamped at the end of the cross bar is facing the front of the vehicle, the orientation is correct. (Fig. E-3) Fig E-2 Rear of RH Side Rail Knob Side Rail Fig E-3 Issue: A 09/06/02 Page 4 of 6 pages Knob Cross Bar DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section II – Installation Procedure 7. In the event that the cross bar will not fit, loosen the bottom left (driver's side) screws (TX-25) on the crossbar side and adjust to appropriate width. After it has been adjusted and tightened to at 22 lbf•in (2.5 N•m ), reinsert the side rail. (Fig. E-4) Screw 8. Tighten the knob by hand at any position. Fig E-4 9. Insert the clip c at the end of the support cover, into the hole in the side rail, and leaving the clip inserted, gently push in the cover d until it is firmly in position. (Fig. E-5) Enlarged View of Mounting Part of End Support Cover (Front) End Support Cover (Front) i. Ensure that clip is firmly located into side rail. Fig E-6. 10. Make sure the entire support cover has been fastened completely. Enlarged View of Mounting Part of End Support Cover (Rear) End Support Cover (Rear) Fig E-5 Detail Drawing Clip Side Rail Fig E-6 Issue: A 09/06/02 Page 5 of 6 pages End Support Cover DIO TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section II – Installation Procedure STOP 11. Once installation is complete, confirm that there is no dirt, dry screw seals or paper washers remaining on the roof. (Fig E-7) Detail Showing the Roof Rack Completely Installed Fig E-7 TOYOTA 4RUNNER 2003 - FIXED ROOF RACK Section III – Functional Verifications Section III – Functional Verifications Check: Look For: Support covers Confirm that all four support covers are completely fitted into the corner support parts at the specified positions and are facing the correct direction. Issue: A 09/06/02 Page 6 of 6 pages DIO TOYOTA Section I 4RUNNER 2003 − FRONT END MASK Installation Preparation Part Number: PT218−89030 Section I Installation Preparation Kit Contents Item # 1 2 3 4 Quantity Reqd. 1 1 1 1 Description Hood Piece Fender Bumper piece Installation Instructions Hardware Bag Hardware Bag Contents Item # 1 2 Quantity Reqd. 2 2 Description Snap/screw Washer General Applicability This Mask can be fitted to all 4Runner models from 2003 onwards. Recommended Sequence of Application Item # 1 2 3 *Mandatory Additional Items Required For Installation Quantity Reqd. (if applicable) Legend STOP Item # Accessory Sport Bumper Trim* Front End Mask STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury CRITICAL PROCESS: Proceed with caution to ensure a quality installation. Description Conflicts GENERAL PROCESS: This highlights specific processes to ensure a quality installation. Note: TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Recommended Tools Safety Tools None For technical assistance regarding this Toyota product, please call: 1−800−347−1200. Special Tools None Installation Tools Screwdriver Screwdriver Scissors Phillips Head, #2 Flat Head Engineered by Toyota to meet cooling requirements. Please follow these installations instructions in the order they are written. It will make installing your custom made mask much easier. Your mask was designed to have a tight fit, and when fully installed it will be snug. Don t be afraid to tug Special Chemicals None Issue: A 01/03/03 Page 1 of 5 pages Supplier Ref# DIO TOYOTA 4RUNNER Section II Installation Procedure Section II Installation Procedure 2003 − FRONT END MASK A. Protect the Vehicle STOP 1. Customer Care Information: NOTE: Important, please observe the following precautions, the manufacturer cannot be responsible for damage to paint. i. Area to be covered by mask must be free of dirt. The mask, especially the flannel surface, must be clean. ii. Both car and mask must be completely dry. If moisture is present under mask, and is allowed to dry on the vehicle, it may cause the paint to cloud. If mask gets wet, remove and allow to dry completely before reinstalling. iii. To clean vinyl and flannel backing use a mild soap and water solution. (Approx. one tablespoon of soap per half gallon of water.) Using a cloth or sponge, gently rub soiled area until clean. Take care to rinse with clear water when finished. Repeat if necessary. Hang out to dry, but not in direct sunlight. iv. It is recommended that the mask be removed before washing the vehicle. v. If mask should flap due to high speed or wind conditions, stop car and adjust or remove the mask. 2. Pre−installation Tip: i. Remove mask from package and familiarize yourself with its shape in relation to the contours of the vehicle. NOTE: Mask will be easier to install if it is warmed (to room temperature) before installation. Issue: A 01/03/03 Page 2 of 5 pages Supplier Ref# DIO TOYOTA Section II 4RUNNER 2003 − FRONT END MASK Installation Procedure B. Hardware Installation NOTE: Turning the wheels eases the next operation. Flathead Screwdriver Phillips Screwdriver 1. Remove the plastic fastener already installed in vehicle wheel well area with a flathead screwdriver (Fig. B−1.) 2. Replace with the snap/screw and washer (Fig. B−2.) Repeat on opposite side of vehicle. Fig. B−1 Fig. B−2 C. Hood Piece Installation 1. Open hood. 2. Attach five (5) plastic clips to the upper rear edge of the grill. Place two (2) pockets over the edge of the hood to the left and right of the grill (Fig. C−1.) Fig. C−1 3. Attach two (2) elastics with S hooks to the holes at the bottom of the hood. Attach two (2) elastics with S hooks to the holes at the top of the hood underneath the grill (Fig. C−2.) IMPORTANT: Pull elastic straps towards you NEVER away from you. D. Bumper Piece Installation NOTES BEFORE INSTALLATION: If your vehicle is equipped with a Toyota Sport Bumper Trim accessory, use scissors to cut just the stitching that attaches the vinyl flaps to the back of the mask and remove the flaps. (Fig. D−1.) Fig. C−2 Scissors 1. Place fender pocket of mask over fender point above headlight (Fig. D−2.) Attach one (1) plastic clip to edge of the fender flange. Repeat on other side of the vehicle. Fig. D−1 Fig. D−2 Issue: A 01/03/03 Page 3 of 5 pages Supplier Ref# DIO TOYOTA Section II 4RUNNER 2003 − FRONT END MASK Installation Procedure 2. Attach snap at top of wheel well to previously installed hardware (Fig. D−3.) Repeat on other side of the vehicle. 3. Insert one (1) plastic flap above the bumper fascia and below the headlight. Repeat on other side of the vehicle. (Fig. D−4.) Fig. D−3 4. Attach three (3) plastic clips to the top edge of the bumper (Fig. D−4.) NOTE: Fig D−4 shows only the driver s side clip and the center clip. Plastic Clip 5. Attach two (2) plastic clips to the side edge of the fender well, and two (2) plastic clips to the bottom edge of the fender well. Repeat on other side of the vehicle (Fig. D−5.) Plastic Clip Plastic Flap Fig. D−4 6. Attach two (2) elastics with S hooks to the top of the intake opening. (Fig. D−6.) 7. Attach four (4) elastics with S hooks to the bottom of the intake opening. (Fig. D−6.) 8. Attach three (3) plastic clips to the bottom edge of the bumper. (Fig. D−6.) Fig. D−5 9. Hook one (1) elastic with S hook to the other elastic with S hook underneath the bumper bracket (Fig. D−7.) Repeat on other side of vehicle. Elastics S−Hooks (x2) Elastics S−Hooks (x4) Vehicle shown with Front Sport Bumper Trim Plastic Clips (x3) Fig. D−6 Vehicle shown with Front Sport Bumper Trim Fig. D−7 Issue: A 01/03/03 Page 4 of 5 pages Supplier Ref# DIO TOYOTA Section II 4RUNNER 2003 − FRONT END MASK Installation Procedure 10. Attach the elastics with S hooks to the rear edge of the bumper guard bracket (Fig. D−8.) E. Installation Instructions 1. Place installation instructions in glove box for customer future reference. Fig. D−8 TOYOTA Section III 4RUNNER 2003 − FRONT END MASK Functional Verifications Section III Functional Verifications Check: Look For: Vehicle and mask are free of dirt. Verify that there are no smudges or dirt particles. Verify that any area that may have been wet Vehicle and mask are dry. is completely dry. Verify that headlights, markers, turn signals, Mask is properly adjusted. cooling intakes and ducts are unobstructed. Verify that there is no flapping and the mask Mask has proper fit. fits tightly. Issue: A 01/03/03 Page 5 of 5 pages Supplier Ref# DIO TOYOTA Section I 4RUNNER 2003 − HOOD PROTECTOR Installation Preparation Part Number: PT427−89030 Section I Installation Preparation Kit Contents Item # 1 2 Quantity Req. 1 1 Description Hood Protector Hardware Bag Hardware Bag Contents Item # 1 2 4 5 6 7 8 Quantity Req. 6 2 4 2 2 2 6 pieces 9 1 Description 10−24 x 3/8" Screw Flat Washer Grill Bracket End Bracket Well Nut 6−32 x ½" Screw Urethane Pad (2 pieces per strip) DIO Instruction Sheet General Applicability Recommended Sequence of Application Item # 1 2 3 *Mandatory Legend STOP Quantity Req. STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Additional Items Required For Installation Item # Accessory Description Conflicts Note: Front End Mask Recommended Tools Safety Tools None Special Tools None Installation Tools Screwdriver Right Angle Screwdriver Socket Ratchet Wrench Cloth Phillips #2 Phillips #2 10 mm, ¼" Drive ¼" Drive Lint−free Special Chemicals 3MTM Prep Solvent−70 Cleaner Issue: C 11/05/02 Page 1 of 3 pages Supplier Ref #: I−954 DIO TOYOTA 4RUNNER Section II Installation Procedure Section II Installation Procedure 2003 − HOOD PROTECTOR (Side) Grill Retaining Nuts A. Pre−Installation Preparation 1. Inspect and verify the kit contents. (Upper) Grill Retaining Nuts 2. Open the hood. Fig. B1 STOP 3. Make sure front edge of hood and grill, where the deflector is to be installed, is clean and free from dirt and/or debris. Use 3MTM Prep Solvent−70 and a clean lint free cloth. Section A i. When cleaning with 3MTM Prep Solvent−70 follow the manufacturer s directions. Do not allow cleaner to air dry. Section B Urethane Pad B. Prepare the Deflector for Installation 1. Cover engine bay completely with a protective blanket to catch any dropped hardware. Section A Section B Urethane Pad Fig. B2 2. Remove the grill from the hood. i. Using a 10 mm socket, remove eight (8) nuts holding grill to the hood. (Fig. B1) ii. Unhook hood latch to separate grill. Fig. B3 3. Apply the six (6) urethane pads to the hood in the locations shown. (Fig. B2) Hood i. The urethane pads wrap around the front edge of the hood. (Fig. B2) Urethane Pad 4. Place center grill brackets in locations shown. (Fig. B3) i. The brackets go between the grill and the hood and are secured by the grill studs. (Fig. B4) Bracket Grill Grill Stud Fig. B4 ii. Re−attach the grill to the hood. Re−install eight (8) nuts. Re attach hood latch. 5. Install the outer hood brackets in the locations shown. (Fig. B5) Issue: C 11/05/02 Fig. B5 Page 2 of 3 pages Supplier Ref #: I−954 DIO TOYOTA Section II 4RUNNER 2003 − HOOD PROTECTOR Installation Procedure i. Insert a well nut into each of the holes. (Fig. B6) ii. Attach the bracket to the hood using the 6−32 x ½" screw and washer. The washer goes between the screw head and bracket. Fig. B6 C. Install the Shield Assembly to the Vehicle 1. Peel back protective film from shield in location where screws attach to brackets. Shield 2. Line up shield with the center grill brackets making sure the shield is centered. Bracket 3. Screw shield to grill brackets using four (4) 10−24 x 3/8" screws. Hand start screws. (Fig. C1) 4. Line up shield with the outer hood brackets once again making sure the shield is centered. Phillips Screwdriver Urethane Pad Screw Fig. C1 Grill 5. Screw shield to outer brackets using two (2) 10−24 x 3/8" screws. Hand start screws. (Fig C2) Phillips Screwdriver Shield 6. Make sure the shield is centered and all six (6) screws are tight. Urethane Pad 7. Close the hood. 8. Remove entire protective film from shield and discard film. Fig. C2 TOYOTA Section III 4RUNNER Screw 2003 − Bracket HOOD PROTECTOR Functional Verifications Section III Functional Verifications Check: Look For: Hood closure. Hood brackets or hardware should not contact the headlights. Clearance of hood protector to hood. The hood protector (shield) or hardware should not contact the grill. Issue: C 11/05/02 Page 3 of 3 pages Supplier Ref #: I−954 DIO TOYOTA 4RUNNER 2003 − RUNNING BOARD Section I − Installation Preparation Part Number: 08474−35801 Section I Installation Preparation Kit Contents Item # 1 2 3 4 5 6 Quantity Reqd. 1 1 2 2 2 1 General Applicability Description Left Hand Running Board Right Hand Running Board Front Bracket Middle Bracket Rear Bracket Hardware Bag (Bolt Package) Quantity Reqd. 12 12 1 Recommended Sequence of Application Item # 1 2 3 *Mandatory Description M6 Bolt M8 Bolt DIO Instruction Sheet STOP Quantity Reqd. STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. Additional Items Required For Installation Item # Accessory Legend Hardware Bag Contents Item # 1 2 3 Note: SR5 model only. Description TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Conflicts Note: Recommended Tools Safety Tools Safety Glasses Special Tools None Installation Tools Ratchet Sockets Extension Torque Wrench 1/4" or 3/8" drive 10mm, 12mm 6" 1/4" or 3/8" drive (25 lbf−ft) Special Chemicals 3MTM Prep Solvent−70 Cleaner Issue: A 08/30/02 Page 1 of 4 pages DIOSR52003 DIO TOYOTA 4RUNNER 2003 − RUNNING BOARD Section II − Installation Procedure Section II Installation Procedure A. Remove Running Board from Packaging 1. Remove running board assembly from package, and place on a clean protected surface. 2. Verify kit contents and inspect the running board for damage. B. Running Board Preparation for Installation (LH Side) 1. Identify Left Hand Side Platform from Right Hand Side Platform as shown in Fig. B−1. Fig. B−1 2. Starting with the left−hand side platform, identify the front and the rear portions of the board, as shown in Fig. B−1. 3. Install the front bracket (stamped with the number 1) by inserting the locating tab (front of bracket) into the slot in the front part of the running board, and using two (2) M6 bolts to attach it. Tighten bolts. See Fig. B−2. Fig. B−2 4. Torque bolts to 70 lbf−in (8 N−m). 5. Install the middle bracket (stamped with the number 2) by inserting the locating tab (front of bracket) into the slot in the front part of the running board, and using two (2) M6 bolts to attach it. Tighten bolts. See Fig. B−3. 6. Torque bolts to 70 lbf−in (8 N−m). Fig. B−3 7. Install the rear bracket (stamped with the number 3) by inserting the locating tab (front of bracket) into the slot in the front part of the running board, and using two (2) M6 bolts to attach it. Tighten bolts. See Fig. B−4. 8. Torque bolts to 70 lbf−in (8 N−m). Issue: A 08/30/02 Fig. B−4 Page 2 of 4 pages DIOSR52003 DIO TOYOTA 4RUNNER 2003 − RUNNING BOARD Section II − Installation Procedure C. Running Board Installation (LH Side) 1. Ensure the area on the vehicle where running board will be installed is clean before proceeding. If necessary clean area with 3MTM Prep Solvent−70. i. When cleaning with 3MTM Prep Solvent−70 follow the manufacturer s directions. Do not allow cleaner to air dry. Fig. C−1 2. Raise board up to vehicle rocker panel. (See Fig. C−1). 3. Attach front bracket onto the rocker panel hole by using a M8 bolt as shown in Fig. C−2. Secure bracket by tightening bolt. 4. Attach rear bracket onto the rocker panel hole by using an M8 bolt as shown in Fig. C−3. Secure bracket by tightening bolt. Fig. C−2 5. Install a second M8 bolt in the front bracket as shown in Fig. C−4. Secure bracket by tightening bolts. Fig. C−3 Fig. C−4 Issue: A 08/30/02 Page 3 of 4 pages DIOSR52003 DIO TOYOTA Section II 4RUNNER 2003 − RUNNING BOARD Installation Procedure 6. Install two (2) M8 bolts to attach the middle bracket as shown in Fig. C−5. Secure bracket by tightening bolts. 7. Install a second M8 bolt in the rear bracket as shown in Fig. C−6. Secure bracket by tightening bolts. 8. Torque all M8 bolts to 275 lbf−in (31N−m) Fig. C−5 D. Running Board Installation (RH Side) 1. Repeat steps B.1. through C.8. for right hand side. Fig. C−6 TOYOTA 4RUNNER 2003 − RUNNING BOARD Section III − Functional Verifications Section III − Functional Verifications Check: Look For: Visual check of Running Board. Proper fit. Re−check all bolts for proper torque. M6 bolts − 70 lbf−in (8 N−m). M8 bolts − 275 lbf−in (31N−m) Issue: A 08/30/02 Page 4 of 4 pages DIOSR52003 DIO TOYOTA 4RUNNER 2003 − SPORT BUMPER TRIM Section I − Installation Preparation Part Number: PT212−89032 Section I − Installation Preparation Kit Contents Item # 1 2 3 Quantity Reqd. 1 1 1 General Applicability Description Sport Bumper Trim Upper Mounting Bracket (LH) Upper Mounting Bracket (RH) Hardware Bag Contents Item # 1 2 3 4 5 6 Quantity Reqd. 4 2 2 2 2 1 Description M6 Nylon Insert Nut (Nyloc) M5 Extruded Panel Nut M5 x 20 mm Hex Head Bolt Drill Templates M5 Compression Li miter DIO Instruction Sheet Note: All Trim Levels Recommended Sequence of Application Item # 1 2 3 *Mandatory Legend STOP Quantity Reqd. STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Additional Items Required For Installation Item # 1 Accessory Description Conflicts Note: None Recommended Tools Safety Tools Safety Glasses Special Tools None Installation Tools Variable Speed D rill Motor Drill Bit Drill Stop (x2) Deburring Tool Socket Torque Wrench 1/8" & 3/8" set to 25 mm 10 mm 30 200 lbf−in (~25N−m) (e.g. Snap−on P/N QJR217C) Ratchet Wiping Cloth Small Hammer Screwdriver Extension Lint−free, non−scratch Flat Head 3" Special Chemicals None Issue: D 10/14/03 Page 1 of 4 pages Supplier Ref #: AI0259−000 DIO TOYOTA 4RUNNER 2003 − SPORT BUMPER TRIM Section II − Installation Procedure Section II − Installation Procedure A. Preparation. Up 1. Verify hardware bag content by referring to the instruction sheet. 2. Four holes are to be drilled in the bumper fascia. Fig A−1. Right Mounting Holes (to be drilled) Fig. A−1 Left 3. Set drill stop to 25 mm for each of the two drill sizes. Fig. A−2. 1 /8", & 3/8" B. Mounting Hole Drilling. 1. Wear safety glasses before drilling of the vehicle. 25 mm 2. Remove drill templates from hardware bag and assemble so the "RH/Pass Side" marking is in the same quadrant as shown in Fig. B−1. 3. Firmly place the assembled drill templates on the right bumper fascia as shown in Fig. B−1. Lightly tap center of the templates with a small hammer to mark the drill center. STOP Fig. A−2 Up Right 4. Drill 1/8" pilot hole at the markings. Enlarge pilot holes to 3/8". Do not drill more than 25 mm into the bumper fascia. RH Fixture Configuration 5. Disassemble the drill templates. 6. Reassemble the drill templates so the "LH/Driver Side" marking is in the same quadrant as shown in Fig. B−2. 8. Drill 1/8" pilot hole at the markings. Enlarge pilot holes to 3/8". Do not drill more than 25 mm into the bumper fascia. LH/Pass Side Up Left Bumper Fascia Fig. B−2 Issue: D 10/14/03 Bumper Fascia Fig. B−1 7. Firmly place the assembled drill templates on the left bumper fascia as shown in Fig. B−2. Lightly tap center of the template with a small hammer to mark the drill center. STOP RH/Pass Side Page 2 of 4 pages LH Fixture Configuration Supplier Ref #: AI0259−000 DIO TOYOTA 4RUNNER 2003 − SPORT BUMPER TRIM Section II − Installation Procedure 9. Deburr plastic shavings around each hole if necessary. STOP i. Wipe chips from sport bumper trim mounting area with a clean, lint free, non− scratch cloth. Previously Dri lled 3 /8" Holes C. Mounting of the Sport Bumper Trim. 1. Remove and save the existing M8 bolt as shown in Fig. C−1 from both sides of the vehicle. Bolts will be required in Step C. 3.. 2. Install Sport Bumper Trim by carefully placing the mounting studs (on the Sport Bumper Trim) through the previously drilled holes in the bumper fascia. Remove and discard rubber bolt covers. Fig C−2 3. Position the Sport Bumper Trim and align the lower mounting bracket holes with holes on the vehicle and attach loosely using the M8 bolts from Step C. 1.. Socket, 10 mm Fig. C−1 Right Side Bumper Fascia Existing M8 Bolt M6 Rubber Bolt Covers Right Rear Fig. C−2 4. Apply pressure on the Sport Bumper Trim until the seal makes full contact with the surrounding bumper fascia surfaces as shown in Fig. C−3. Seal Socket, 10 mm Torque Wrench 5. Tighten the two (2) M8 Bolts to 16 N−m (144 lbf−in.) on both sides of the vehicle. D. Installation of (RH) Upper Mounting Bracket. 1. Open hood and locate right air dam between radiator support bracket and top of bumper fascia as shown in Fig. D−1. STOP Seal Fig. C−3 Radiator Support Bracket 2. Protect bumper fascia with blanket. 3. Remove and discard front pushpin on the side of the rubber air dam as shown in Fig. D−1. Pushpin Air Dam Fig. D−1 Issue: D 10/14/03 Page 3 of 4 pages Supplier Ref #: AI0259−000 DIO TOYOTA 4RUNNER 2003 − SPORT BUMPER TRIM Section II − Installation Procedure 4. Peel back rubber air dam to expose mounting hole. Install M5 extruded panel nut over the mounting hole in the radiator support bracket exposed after removal of pushpin.. Fig. D−2. 5. Place right hand upper mounting bracket over the two (2) M6 studs as shown in Fig. D−3. Radiator Support Bracket M5 Extruded Panel Nut ÂÂÂÂ ÂÂÂÂ Fig. D−2 6. Hand tighten two (2) M6 nylon insert nuts provided onto the Sport Bumper Trim studs. 7. Align top hole in upper mounting bracket to the hole in radiator support bracket as shown with M5 extruded panel nut. (Fig. D−4) Bumper Fascia Upper Mounting Bracket M6 Nylon Insert Nut x2 M6 Stud x2 Sport Bumper Trim 8. Place M5 compression limiter in rubber air dam as shown in Fig. D−4. 9. Hand tighten M5 x 20 bolt into M5 extruded panel nut. Fig. D−3 Compression Limite r M5 Bolt E. Installation of (LH) Upper Mounting Bracket. 1. Repeat Steps D. 1. to D. 9. for left hand upper mounting bracket. Radiator Support Bracket Rubber Air Dam Upper Mounting Bracket Panel Nut F. Final Assembly. 1. Tighten all M6 nuts to 3.4 N−m (30 lbf−in.). 2. Tighten both M5 bolts to 6.8 N−m (60 lbf−in.). Fig. D−4 Front (Right Hand Side) 3. Remove blanket from bumper fascia. TOYOTA 4RUNNER 2003 − SPORT BUMPER TRIM Section III − Functional Verifications Section III − Functional Verifications Check: Look For: Visual check of Sport Bumper Trim. Visually centered left to right. Top edge stanchion visually taller to the top edge of bumper fascia. Verify Sport Bumper Trim is fully seated No visible gap − seal and bumper fascia. and seal is properly seated. Seal is evenly pressed against fascia. Issue: D 10/14/03 Page 4 of 4 pages Supplier Ref #: AI0259−000 DIO TOYOTA 4RUNNER 2004 − DVD VES Section I − Installation Preparation Part Number: PT900− 8903D03 (NSR) (Charcoal/Stone) PT900− 8903D16 (NSR) (Taupe) PT900− 8903S03 (SR) (Charcoal/Stone) PT900− 8903S16 (SR) (Taupe) Section I − Installation Preparation Kit Contents Item # 1 2 Quantity Reqd. 1 1 3 4 5 6A 6B 7 8 1 1 1 1 1 2 9 1 10 11 1 1 Description DVD Player Flat Panel Display (with screw caps) Main Harness FM Modulator Trim Ring FPD Bracket (NSR only) FPD Bracket (SR only) DVD Bracket Wireless Headphones (with batteries, owner’s manual and headphone sticker) Remote Control with (1) CR2025 battery Owner’s Manual Console Warning Label Quantity Reqd. 4 2 2 4 1 1 2 2 2 6 20 2 Note: Vehicle with Rear Seat Audio (RSA) CD Changer (P9) Recommended Tools Safety Tools Safety Goggles Vehicle Protection Blankets, Clean Cloths, Seat Covers, Part Boxes Special Tools Templates & Fixtures In DIO Install Kit Installation Tools Drive Ratchet Screw Gun Socket Torque Wrenches (2) Nylon Panel Removal Tool 3 /8" 8 mm, 10 mm, 14 mm 0−50 lbf−in, 0−50 lbf−ft e.g. Panel Pry Tool #1 Toyota SST # 00002−06001−01 Hardware Bag Contents Item # 1 2 3A 3B 4 5 6 7 8 9 10 11 Conflicts Description Screw, M5 x 12 Rivnut (M5 thread) (NSR only) Screw, M5 x 10 (NSR only) Screw, M6 x 10 (SR only) Braided Sleeving (SR only) Spacer, Foam U−Clip, #8 Screw, Long Self Tapping, #8 Screw, 6−32 x 5/8" Wire Tie (Large) , 17.5" Wire Tie (Small), 8" Foam Pad Sheet, (6 pads per sheet) Additional Items Required For Installation Item # 1A Quantity Reqd. 1 Description DIO Install Kit (NSR only) 1B 1 DIO Install Kit (SR only) Screwdriver Bit Screwdriver Shop Vacuum Rivet Nut Tool Utility Knife Side Cutters Marker Pen Drill Motor Drill Bits Phillips, #2 Phillips # 2, Stubby Pneumatic, 5 mm Mandrel Letter "N" (7.7 mm), Number "32" (2.95 mm) Drill Stops Hole Cutter Saber Saw & Blade Deburring Tool Headphones (PT900−00030) Headphones DVD Disc Remote Control Electrical Tape 1 1/8 " Blade for cutting plastic Wireless (for Test) Wired (for Test) (for Test) (for Test) P/N PT900−89030 P/N PT900−8903S 2A 1 2B 1 W/H Adapter, Premium JBL Audio, P/N PT900−00038 W/H Adapter, Standard Audio, P/N PT900−00036 Issue: B 10/08/03 Special Chemicals Cleaner 3MTM Prep Solvent−70 General Applicability Note:− All MY2004 4 Runner WITHOUT Rear Seat Audio (RSA). Page 1 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section I − Installation Preparation Recommended Sequence of Application Item # 1 2 3 Accessory DVD VES EC Mirror TVIP *Mandatory Legend STOP STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Issue: B 10/08/03 Page 2 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure Section II − Installation Procedure NOTES: STOP Removed Parts:− Place all removed parts on a protected surface. STOP Connectors:− When disconnecting connectors, do not pull on the wires; pull on the connectors. STOP Wire Ties:− When using wire ties to secure harness, clip the wire ties after securing them. A. Vehicle Preparation and Protection. 1. Set the emergency brake, and unlock all vehicle doors. STOP 10 mm Socket 2. Open the hood and apply protective covers to the fender/grill area by the battery. 3. Remove the negative battery cable. (Fig. A−1) i. Do not touch the positive terminal with any tool when removing cable. Fig. A−1 4. Wait a minimum of 90 seconds after the vehicle battery is disconnected before beginning Step B. (for Air Bag safety). STOP 5. Cover the front and middle seats and the interior of vehicle using seat covers and blankets. B. Headliner Preparation. Claws (x4) 1. Remove the center dome light assembly. (Fig. B−1) i. Remove the lens cover. ii. Remove and retain the factory bulb. iii. Disengage the four (4) claws. iv. Disconnect the center dome light wiring harness 3−pin connector. Fig. B−1 Flat Blade Screwdriver Panel Removal Tool v. Discard center dome light assembly. Issue: B 10/08/03 Page 3 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure NOTE: Eye protection must be worn during the drilling/cutting process. Dome Light Opening Cutting Template (1) FOR VEHICLES WITHOUT SUNROOF (NSR) ONLY. (Steps B. 2. through B. 17.) Roof Bow 2. Attach headliner cutting template (1) to the factory dome light opening. (Fig. B−2) Template Locator Tab i. Cut headliner material away. Template Hook ii. Position the template hook securely in the dome light opening on the forward side (driver) side of the roof bow. Fig. B−2 Template Captive Screw iii. Position the template locator tab on the rear side of the roof bow. Dashed Lines Headliner Slots iv. Use a screw gun (with Philips #2 bit) to secure the template to the roof bow by tightening the (1) # 8, 1 1/4" captive screw in the template. 3. Mark the dashed lines in the template onto the headliner using a marker pen. (Fig. B−3) STOP Front of Vehicle Phillips Screwdriver #2, Screw Gun, Marker Pen Fig. B−3 NOTE: Use caution to ensure damage does not occur to the dome light wiring harness. Hold the knife perpendicular to the headliner surface. Do not cut on an angle. Cutting Template (1) 4. Carefully cut the headliner along the slots in the template. (Fig. B−4) STOP i. Do not cut the dome light wiring harness. Utility Knife Fig. B−4 5. Use a screw gun (with Philips #2 bit) to remove the template. 6. Finish cutting the headliner by cutting along the marked dashed lines. (Fig. B−5) STOP Dome Light Cutout Cut Dashed Lines i. Do not cut the dome light wiring harness. Fig. B−5 Issue: B 10/08/03 Page 4 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 7. Attach the headliner cutting template (2) to the factory dome light opening. (Fig. B−6) Dome Light Opening Cutting Template (2) Roof Bow i. Position the template hook securely in the dome light opening on the forward side (driver) side of the roof bow. ii. Position the template locator tab on the rear side of the roof bow. iii Use a screw gun (with Philips #2 bit) to secure the template to the roof bow by tightening the (1) # 8, 1 1/4" captive screw in the template. Template Locator Tab Template Hook Template Fig. B−6 Dashed Lines #32 Drill Hole N Drill Bushing #32 Drill Hole 8. Mark the dashed lines in the template onto the headliner using a marker pen.. (Fig. B−7) 9. Carefully cut the headliner along the slots in the template. (Fig. B−7) STOP Front of Vehicle Captive Screw Headliner Slots N Drill Bushing Phillips Screwdriver #2, Screw Gun, Marker Pen, Deburring Tool Fig. B−7 i. Do not cut the dome light wiring harness. 10. Set the drill stops on both letter "N" and #32 drill bits to 27 mm. (Fig. B−8) 11. Drill two (2) "N" sized holes using the two (2) drill bushings (located on the template) as guides. (Fig. B−7) 27 mm Drill Stop 2.95 & 7.7 mm Drill Bits, Drill Gun, Drill Stop Fig. B−8 Cut Dashed Lines i. Deburr holes. Utility Knife 12. Drill two (2) #32 sized holes into the headliner in the locations indicated on the template. (Fig. B−7) STOP 13. Vacuum all debris from floor and seats. Fig. B−9 14. Use a screw gun (with Philips #2 bit) to remove the template. 15. Finish cutting the headliner by cutting along the dashed lines. (Fig. B−9) 16. Install two (2) M5 threaded rivnuts in the holes drilled in the roof bow. (Fig. B−10) M5 Rivnuts (x2) Rivet Nut Gun Fig. B−10 Issue: B 10/08/03 Page 5 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 17. Install the two (2) mounting U−clips. Position the clips over previously drilled (#32) holes. (Fig. B−11) FOR VEHICLES WITH SUNROOF (SR) ONLY. (Steps B. 18. through B. 28.) U−Clips STOP NOTE: Make sure that the Sunroof and Sunshade are closed fully. (Forward position) STOP NOTE: Use caution to ensure damage does not occur to the dome light wiring harness. Drop rear edge of sunroof open and position dome light harness away from cutting template. Hold the knife perpendicular to the headliner surface. Do not cut on an angle. Fig. B−11 Dome Light Harness Slots (x5) 18. Attach the sunroof headliner cutting template to the factory dome light opening. i. Cut headliner material to allow template plus access to roof bow holes. Rear Edge ii Position the template locator pins on the roof bow. iii Secure the template to the roof bow by tightening the (1) # 8, 1 1/4" captive screw in the template. Fig. B−12 Marker Pen Utility Knife 19. Use a screw gun (with Philips #2 bit) to tighten the template screw. SR Cutting Template Slots (x5) 20. Mark the dashed lines in the template using a marker pen. (Fig. B−12) 21. Carefully cut the headliner along the slots in the template. (Fig. B−13) Fig. B−13 22. Set the drill stop on the #32 drill bit to 27 mm (Fig. B−14) 27 mm Drill Stop 2.95 mm Drill Bit, Drill Gun, Drill Stop Fig. B−14 Issue: B 10/08/03 Page 6 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 23. Drill two (2) #32 holes into the headliner in the locations indicated on the template. 24. Remove the template by loosening the one (1) captive screw on the template. U− clips 25. Once the template is removed, cut the remaining portion of the headliner between the five (5) slots. (Fig. B−13) 26. Finish cutting the headliner across the dashed lines. (Fig. B−13) 27. Install two (2) U−clips. (Fig. B−15) STOP 28. Protect the vehicle center dome light wiring harness with the braided sleeving (provided in kit) i Compress the braided sleeving so that the 3−pin connector and center dome light wiring harness can pass through it. ii Decompress the protective wiring harness webbing to expand to its full length. iii Tape the protective wiring harness webbing to the center dome light wiring harness just below the 3−pin connector with electrical tape. Fig. B−15 Clips (x4) Hood and Fuel Door Release Levers Bolts (x2) Fig. C−1 8 mm Socket, Panel Removal Tool C. Remove Lower Instrument Panel Finish Plate. 1. Remove the instrument panel and finish panel lower subassembly. (Fig. C−1) i. Remove and retain the six (6) bolts. ii. Pull the radio receiver and integration control panel forward. iii. Disconnect the electrical connectors. iv. Disconnect the hood and fuel door release levers. Issue: B 10/08/03 Page 7 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure v. Remove finish panel lower subassembly and temporarily store in the clear plastic wire harness bag for protection. D. Remove Shift Cover, Side Covers and Coin Box. 1. Cover the shift knob with a protective cloth. Panel Removal Tool 2. Remove the shift cover in order from (1) to (6) using panel removal tool. (Fig. D−1) 3. Use panel removal tool to disengage clips under left (L) and right (R) side covers. 4. Unplug connectors and remove covers and coin box. Fig. D−1 E. Remove Console Cover and Console Box. 1. Remove the console cover. (Fig. E−1) i. Disengage the console cover clips in order from (1) to (6) using panel removal tool. 2. Remove the console box (Fig. E−l) from the vehicle. i. Remove the six (6) bolts on console box with 10 mm socket. Panel Removal Tool, 10 mm Socket Fig. E−1 ii. Disconnect the two electrical connectors from the console box. F. Remove the Center Console Rear Cover. 1. Use panel removal tool to disengage six (6) clips on rear cover as shown in the (Fig. F−1) Fig. F−1 Issue: B 10/08/03 Page 8 of 25 pages Panel Removal Tool Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure G. Remove Air Conditioner Cluster, Center Cluster and Audio. 1. Remove the air conditioner cluster (unit). i. Cover the face of the air conditioner cluster assembly with a protective blanket during the removal procedure. STOP ii. Remove the screw on air conditioner cluster with Phillips screwdriver. (Fig. G−1) iii. Remove plug from cluster. STOP iv. When removed, wrap the air conditioner cluster assembly in a protective blanket and store outside the vehicle. Phillips Screwdriver, 10 mm Socket, Panel Removal Tool 2. Remove the center cluster. Fig. G−1 i. Remove the three (3) bolts on center cluster with 10 mm socket. (Fig. G−1) ii. Remove the center cluster in order from (1) to (6) using panel removal tool. (Fig. G−1) iii. Disconnect the two (2) electrical connectors from center cluster. (Fig. G−1) 3. Remove the radio. i. Remove two (2) bolts on radio with 10 mm socket. (Fig. G−1) ii. Disconnect the connectors from rear of radio. (Fig. G−1) H. Glove Compartment Removal. 1. Release glove compartment stoppers, by pressing inwards on side panels of glove compartment. (Fig. H−l) 2. Disconnect damper from glove box opening, leave connected to glove box assembly. Issue: B 10/08/03 Phillips #2 Stubby Screwdriver, Fig. H−1 Page 9 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 3. Remove four (4) screws and remove the I/P finish panel #2. (Fig. H−2) Air Bag Connector 4. Remove the hook on glove compartment. STOP STOP i Unclip the air bag connector from the storage box. (Fig. H−2) NOTE: DO NOT DISCONNECT THE AIR BAG ELECTRICAL CONNECTORS. I. Vehicle Disassembly − Headliner Components. STOP Phillips #2 Stubby Screwdriver, Screws (x 4) Fig. H−2 1. Remove the roof console box assembly. (Fig.s I−1. & I−2) i. Use the panel removal tool to pry the two (2) retainer clips free. (Fig. I−1) ii. Verify the clips are not damaged. Claws (x 3) iii. Lower the overhead console assembly. iv. Disconnect the electrical connector. (Fig. I−2) Clips (x 2) Panel Removal Tool Fig. I−1 2. Remove the LH and RH visor assembly. (Fig. I−3) i. Remove the two (2) screws from the Visor assembly. Connector ii. Remove the two (2) screws from the visor subassembly. iii. Remove the screw and the visor holder. 3. Remove the upper portion of the front door opening trim weather strips. Panel Removal Tool Fig. I−2 Visor Holder Phillips Screwdriver 4. Remove the upper portion of the rear door opening trim weather strips. Screws (x 4) Fig. I−3 Issue: B 10/08/03 Page 10 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 5. Loosen the top of the B−pillar lower garnishes by disengaging the eight (8) claws and two (2) clips. (Fig. I−4) 6. Protect the lower garnish panels with blanket. 7. Remove the B−pillar upper garnishes. (Fig. I−5) Fig. I−4 Panel Removal Tool i. Remove two (2) bolts. ii. Disengage six (6) claws and clip. iii. Slide the center pillar garnishes down over the seat belt. CAUTION DO NOT REMOVE CLIP! 8. Remove the LH and RH A−pillar garnish. (Fig. I−6) i. Remove the two (2) grab handle plugs. ii. Remove the two (2) grab handle bolts. iii. Disengage the two (2) claws and clip. Bolt (x 2) Fig. I−5 9. Remove the LH and RH front, center and rear (if applicable) grab handles. (Fig. I−7) 10 mm Socket Panel Removal Tool Clip i. Remove the two (2) grab handle plugs. ii. Remove the two (2) screws and grab handles. Bolt (x2) iii. Remove coat hanger hook if applicable. Claw 10 mm Socket Panel Removal Tool Fig. I−6 10 mm Socket Panel Removal Tool Screw (x 2) Fig. I−7 Issue: B 10/08/03 Page 11 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure FOR VEHICLES WITH SUNROOF (SR) ONLY. (Steps I. 10. through I. 16.) 10. Carefully open the C−pillar upper bolt cover to expose the 10 mm hex head bolt. (Fig. I−8) STOP 11. Loosen the upper portion of the LH and RH rear inner roof side garnish panels, by disengaging the upper four (4) clips. If clips are damaged, replace with TOYOTA P/N 90467−12086 during reassembly. (Fig. I−9) i. Avoid losing clips into body panel. STOP Fig. I−8 ii. Remove the tonneau cover (if applicable). iii. Remove the two (2) bolts. Clip (xClips 9) (x 4) 12. For vehicles with SR and third row seats, remove upper seat anchor at passenger side and driver side "D" pillar. i. Remove passenger side and driver side grab handles. Bolt (x 2) CAUTION DO NOT REMOVE CLIPS! 13. Remove the upper portion of the backdoor weather strip. 10 mm Socket, Panel Removal Tool Fig. I−9 14. Remove the LH and RH coat hooks by removing the screw. Panel Removal Tool 15. Lower the headliner assembly. (Fig. I−9) Pushpins i. Remove the four (4) pushpins and domelight assembly. ii. Detach the headliner from the VelcroTM retainers. STOP STOP iii. Place clean cloths between headliner and the LH and RH rear inner roof side garnish panels. Headliner must not rest directly on the panels. Dome Light Assembly Fig. I−10 iv. Avoid creasing headliner by putting too much pressure on it. Issue: B 10/08/03 Page 12 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 16. Lower the headliner so that it rests on the headrest(s). J. Center Console Assembly Preparation. Center Console Box Bottom 1. Place console box onto drilling fixture. (Fig. J−1) Heater Duct i. Use care to avoid damaging the console. ii. Ensure drilling fixture is secured to workbench. 2. Remove the heater duct assembly. i Remove the two (2) screws securing the heater duct with Phillips screwdriver. (Fig. J−2) Drilling Fixture (Secured to Workbench) Center Console Holding Fixture Fig. J−1 Phillips Screwdriver Center Console Holding Fixture 3. Place center console drilling template on bottom of the center console and use guide pins of the storage box bottom to position the template in the correct location. (Fig J−3) 4. Drill six (6) holes using #32 drill (for pilot hole) and then 11/8" hole cutter. (Fig. J−3). Fig. J−2 5. Remove the center console drilling template. Drill Six (6) 11/8" Holes Center Console Drilling Template Fig. J−3 Issue: B 10/08/03 Page 13 of 25 pages Drill Gun, # 32 Drill, 11/8" Hole Cutter Center Console Drilling Template Center Console Holding Fixture Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 6. Use saber saw to cut material out between the four (4) holes (Fig. J−4). 7. Remove all plastic shavings from console after drilling and cutting is complete. 8. Reinstall the heater duct. i. Reinstall heater duct using the two (2) screws securing the heater duct with Phillips screwdriver. (Fig. J−5) 9. Remove console box from holding fixture. Remove the Material between the Four (4) Drilled Holes to Make One (1) Large Hole. Saber Saw, Center Console Holding Fixture Fig. J−4 K. Install Video Display Unit Mounting Bracket. FOR VEHICLES WITHOUT SUNROOF (SR) ONLY. (Steps K. 1. through K. 3.) 1. Using 3MTM Prep Solvent−70 clean the surface of the front roof bow. i. When cleaning with 3MTM Prep Solvent−70 follow the manufacturer s directions. Do not allow cleaner to air dry. Fig. J−5 2. Install the NSR mounting bracket. (Fig. K−1) Phillips Screwdriver Rivnut (x 2) 3. Peel the paper backing from the adhesive strip. i. Install the bracket and secure with the two (2) M5 screws. ii. Tighten screws to bracket to 4 N−m (35 lbf−in) Adhesive Tape Fig. K−1 NSR Mounting Bracket Phillips Screwdriver iii. Press the adhesive strip against the roof bow. Issue: B 10/08/03 Page 14 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure FOR VEHICLES WITH SUNROOF ONLY (Step K. 4..) 4. Install the four (4) M6 mounting screws to the cross vehicle mounting bracket i SR Mounting Bracket MUST be installed with the Direction Arrow Facing Toward the Front of the Vehicle. Install the SR mounting bracket to the roof bow. (Fig. K−2 & K−3). ii. Tighten screws to bracket to 4 N−m (35 lbf−in). Fig. K−2 NOTE: The SR mounting bracket MUST be installed with direction arrow facing toward the front of vehicle. Front of Vehicle 10 mm Socket Torque Wrench L. Route the Main Wiring Harness. STOP NOTE: It is important to first set the length before anchoring the wiring harness. All excess should be positioned behind the radio and secured with foam tape & wire ties. STOP NOTE: Do not allow the flat wire wiring harness to twist during installation. A twist in the wiring harness can cause a bulge in the headliner. Fig. K−3 1. Route the main wiring harness to headliner. i. Start routing of main wire wiring harness 10−pin connector from the center IP opening area. ii. Route the DVD main wiring harness end (with the three (3) connectors) along the RH side of the gear selector assembly and through the round cutout in the rear center console bracket. (Fig. L−1) Existing Weldnut SR Mounting Bracket M6 Screws (x 4) Wire Ties (x 4) Service Loop 18" Length Fig. L−1 Red Tape Foam Tape (x 3) iii. Align the red tape on the wiring harness with the bracket opening and secure using three (3) foam tapes and four (4) wire ties in the locations indicated. (Fig. L−1) Issue: B 10/08/03 Page 15 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure iv. Route the long portion of the main wiring harness (with the single 14−pin connector) through the glove box opening along the IP reinforcement bar and up the A−pillar. (Fig.s L−2. & L−3) v. Route harness forward of IP reinforcement bar to allow harness to be routed up A−pillar. Loosely secure with four (4) wire ties. vi. Use the three (3) existing vehicle plastic harness brackets to secure the DVD main wiring harness along the A−pillar. (Fig. L−3) FOR VEHICLES WITHOUT SUNROOF ONLY. (Step L. 2.) Wire Ties (x 4) Side Cutter Fig. L−2 Plastic Harness Brackets DVD Main Wiring Harness 2. Route the main wiring harness from the A− pillar across the headliner near the windshield to the center of the headliner and back to the hole cut in the headliner. STOP I/P Reinforcement Bar Fig. L−3 i. Ensure that the wiring harness is routed under the padding in headliner to prevent rattles. Foam Tape Red Tape to Opening in Headliner ii. Align the red tape on the wiring harness with RH corner of the headliner opening (Fig. L−4) iii. Secure the wiring harness to the headliner using foam tape. Padding Fig. L−4 (1) Use care when applying the foam tape to prevent creasing the headliner. STOP FOR VEHICLES WITH SUNROOF ONLY. (Step L. 3.) 3. Position and secure the main wiring harness above the headliner. Issue: B 10/08/03 Page 16 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure i. Pull the wiring harness over the sunroof frame brackets to the roof bow where the FPD bracket was installed. ii. Route the wiring harness along the center of the roof bow (inside of the channel) and position the red tape on the wiring harness so it aligns with the passenger side of the FPD bracket (Fig. L−5) Foam Tape (x3) Foam Block Main Harness iii. Secure wiring harness to bracket with two (2) small wire ties. (Fig. L−6) iv. Secure wiring harness to brackets with two (2) small wire ties. (Fig. L−7) v. Secure the wiring harness using foam tape at three (3) locations indicated. (Fig. L−5) vi. Install the 7" foam block by pressing the adhesive side of the foam block down on the forward edge of the sunroof bow. (Fig. L−5) (1) Make sure that the foam block is positioned in the center of the roof bow and in the channel. Fig. L−5 Red Tape Aligned to Passenger Side Hole in Headliner Side Cutter Fig. L−6 Side Cutter 4. If any excess, gather and secure the excess wire wiring harness slack in the radio opening (Fig. L−8) Fig. L−7 Wire Ties (x 2) Wire Ties (x 2) Main Harness Main Harness Wire Tie Side Cutter Fig. L−8 Issue: B 10/08/03 Page 17 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 5. Secure the wiring harness in the glove box using four (4) large wire ties in the areas indicated. (Fig. L−9) Main Harness I/P Reinforcement Bar M. Install the Modulator Assembly. 1. If the vehicle is not equipped with diversity antennas, loop the modulator small antenna connector back into the modulator. (Fig. M−1) Wire Ties (x 4) Side Cutter Fig. L−9 2. Connect the DVD main wiring harness 10−pin connector to the modulator assembly. (Fig. M−2) Modulator 3. Position the modulator assembly below the radio opening on top of the main IP wiring harness. 4. Secure the modulator to the main IP wiring harness with two (2) large wire ties. One wire around middle of modulator and one wire tie on driver side tab of modulator. (Fig. M−2) Vehicle Antenna(s) Fig. M−1 Modulator Side Cutter 5. Bundle excess and secure the DVD main harness to the vehicle harness with one (1) wire tie as indicated. (Fig. M−2) Large Wire Ties (x 2) DVD Main Harness Wire Tie Fig. M−2 Issue: B 10/08/03 Page 18 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure N. Connect the Wiring Harnesses in the Radio Opening. 1. Connect the T−wiring harness 3−pin connector to the DVD main wiring harness 3−pin connector. (Fig. N−1) 2. Connect the radio T−wiring harness male connector to the vehicle radio wiring harness female connector. (Fig. N−1) 3. Position the fuses in the glove box opening. (Fig. N−2) DVD Main Harness 3−pin Connector Tee Harness Female Connector Vehicle Radio Harness Tee Harness 3−pin Connector Fig. N−1 Wire Ties (x 3) i. Ensure fuse location does not interfere with opening and closing of the glove box. Side Cutter ii. Secure wire harness with three (3) wire ties. 4. Connect the modulator antenna wires to the radio. Fuses Main Harness Fig. N−2 5. Connect the radio T−wiring harness female connector to the radio and reinstall the radio A/C cluster and panels. O. Install the DVD Player into the Console Box. 1. Reinstall the center console box, and route the DVD main wiring harness through the cut hole in the bottom of center console box. (Fig. O−1) Fig. O−1 2. Install the main center console bolt inside the console box on the driver’s side. (Fig. O−2) 3. Install the DVD player mounting bracket into the factory holes in the center console box using the remaining factory bolts. (Fig. O−2) DVD Player Mounting Bracket 8 mm Socket Factory Bolts i. Be careful not to scratch the interior of the center console box when installing the DVD player mounting bracket. Fig. O−2 Issue: B 10/08/03 Main Harness Page 19 of 25 pages NOTE: Install Main Center Console Bolt First. Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure ii. If the vehicle is equipped with an AC inverter, the bracket will need to be rotated around the AC power outlet 4. Connect the three (3) DVD main wiring harness electrical connectors to the DVD player. (Fig. O−3) 5. Install the DVD player into the center console box using the two (2) DVD player mounting screws. (Fig. O−4) STOP Fig. O−3 i. Use caution when installing the screws in so that the main wiring harness is not trapped between the DVD player and the bottom of the center console box. ii. Use the storage box opening at the back of the center console box to remove slack in the DVD main wiring harness when installing the DVD player. Screws (x 2) Phillips Screwdriver Fig. O−4 P. Install DVD Video Display Unit. Pushpins FOR VEHICLES WITH SUNROOF ONLY. (Step P. 1.) 1. Install the roof headliner with the four (4) pushpins. (Fig. P−1) 2. Connect the DVD video display unit. (Fig. P−2) Fig. P−1 i. Connect the factory dome light wiring harness connector to the DVD video display unit. ii. Connect the DVD main wiring harness connector to the DVD video display unit. DVD Main Harness Dome Light Harness 3. Mount the DVD video display unit. i. Place the DVD main harness and dome light harness in channel of roof bow, above mounting bracket. Issue: B 10/08/03 Fig. P−2 Page 20 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure ii. Make sure wire harnesses do not interfere with sunshade movement. (Fig. P−3) iii. Secure with foam tape. iv. Remove the dome light lens cover. (Fig. P−4) v. Lower the video screen to access the mounting holes. Fig. P−3 vi. Mount the DVD video display unit to the bracket with four (4) M5 screws. (Fig. P−4) Phillips Screwdriver, Torque Wrench (1) Tighten screws to bracket to 1.2 N−m (10 lbf−in). Factory Bulb Dome Light Lens Cover vii. Install the previously removed factory dome light bulb. (Fig. P−4) viii. Install two (2) #8 screws into the U−clips and tighten. M5 Screws (x4) Screw Caps (x4) Fig. P−4 ix. Install the dome light lens cover. x. Install the four (4) screw cap covers under the video screen. (Fig. P−4) Place CAUTION Label Here Center Console Lid Q. Center Console Lid CAUTION Label. 1. Place the CAUTION label (supplied in kit) on the inside of the center console lid as shown in Fig. Q−1. Facial Tissue Holder Fig. Q−1 i. Remove the facial tissue holder to provide additional clearance. R. In Process Functional Test. 1. Temporarily reconnect battery negative (−) cable. i. Do not touch the positive terminal with any tool when replacing the cable. 2. Turn ignition key to ACC position. Issue: B 10/08/03 Page 21 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 3. Press the power button on the DVD Player. Verify the backlighting illuminates and the power switch illuminates bright red. 4. Insert a DVD into the DVD player. Verify that DVD accepts disc. 5. Press the play button on the DVD player. Verify that DVD video is displayed on the LCD monitor. 6. Test the Remote Control functions using the test remote. i. Press and release the FM TRANSMITTER ON/OFF button on the remote control. ii. Press the SELECT button on the remote control until 88.3 MHz is displayed on the LCD monitor. iii. Tune radio to 88.3 MHz on FM band. 7. Press and release the FM TRANSMITTER ON/OFF button on the remote control. Verify that audio from the DVD can be heard through the vehicle speakers. 8. Using the test wireless headphones verify that audio from the DVD can be heard through the headphones. 9. Press the STOP button on the DVD player. 10. Check the FPD display unit dome light functions. 11. Disconnect battery negative cable. S. Reassemble the Vehicle. 1. Reinstall all removed panels and parts as per the following procedure. Be sure that all panel clips are engaged. i. Retighten seat belt anchor bolts to 32 lbf−ft. Issue: B 10/08/03 Page 22 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section II − Installation Procedure 2. Reconnect the vehicle’s negative battery cable. (Fig. S−1) 30 10 mm Socket Torque Wrench i. Position the negative terminal at an angle of ~30º to the battery as shown. ii. Tighten the nut to 4.1 N−m (36 lbf−in). Negative Battery Cable Battery iii. Do not touch the positive terminal with any tool when replacing the cable. T. Final Preparation. 1. Place the Owner’s Manual in the glove box. Fig. S−1 2. Place remote control in center console. 3. Refer to PPO wireless headphone instructions for placement of headphone stickers. 4. Place headphones in rear side pockets. 5. Vacuum debris from floor and seats. Issue: B 10/08/03 Page 23 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section III − Functional Verifications Section III − Functional Verifications Check: Look For: Accessory Function Checks Turn the Ignition Key to the ACC or Run Position and Turn the Vehicle Radio ON. Press the power button on the DVD Verify the backlighting illuminates and the Player. power switch illuminates bright red. Insert a DVD into the DVD Player. Verify that the DVD accepts disc. Press the play button on the DVD Player. Verify that DVD video is displayed on the LCD monitor. Press and release the FM TRANSMITTER Verify that audio from the DVD can be ON/OFF button on the remote control. heard through the vehicle speakers. Press the SELECT button on the remote control until 88.3 MHz is displayed on the LCD monitor. Tune radio to 88.3 MHz on FM band. Press and release the FM TRANSMITTER ON/OFF button on the remote control. Press and release the power button on the Verify that audio from the DVD can be test wireless headphones to turn them on. heard through the headphones. Press the STOP button on the DVD Verify that DVD Player switches off. Player. Verify that all three dome light switch Check the FPD display unit Dome Light positions function correctly. functions. Turn the Ignition Key to the OFF Position and Turn the Vehicle Radio OFF. Issue: B 10/08/03 Page 24 of 25 pages Supplier Ref #: DIO TOYOTA 4RUNNER 2004 − DVD VES Section III − Functional Verifications Section III − Functional Verifications Check: Look For: Vehicle Function Checks Console Map Light Functioning Map Light Sunroof (if applicable) Functioning Sunroof Vanity Lights (if equipped) Functioning Vanity Lights Air Conditioner Functioning Air Conditioner Fan Functioning Fan Radio Back Light Functioning Radio Back Light Cigarette Lighter Functioning Cigarette Lighter Cigarette Lighter Illumination Functioning Cigarette Lighter Illumination ECT Snow Function (if equipped) Functioning ECT Indicator Lights Emergency Flashers Functioning Emergency Flashers Seat Heaters (if equipped) Seat Heater Lights turn on Glove Box Light Glove Box Light turns on Issue: B 10/08/03 Page 25 of 25 pages Supplier Ref #: DIO TOYOTA Preparation 4RUNNER 2006 - NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: PT212-89060 Kit Contents Item # 1 Quantity Reqd. 1 Description Skid Plate Installation Tools Torque Wrench Socket Hardware Bag Contents Item # 1 2 3 Quantity Reqd. 1 1 4 4 5 6 7 1 2 2 1 8 1 9 2 Description LH Bracket RH Bracket M12 x 1.75 x 20 Course thread SEMS Head Bolts DIO Instruction Sheet M8 Rivnuts M8 x 25mm Flange Head Bolts M10 Nut (Discard after Rivn ut install) M8 x 45mm SEMS Head Bolt (Discard after Rivn ut install) M12 x 1.25 x 25 Fine Thread Bolts - Serrated Flange Head Additional Items Required For Installation Item # 1 Quantity Reqd. Description Conflicts Note: Recommended Tools Personal & Vehicle Protection None Extension Measuring Rule Combina tion Wrench Ratchet Special Chemicals None Notes ½" & 3/8" Drive 17 mm, 12 mm, 13 mm (M8 bolt) 3" Metric (mm) 15 mm Notes General Applicability Recommended Sequence of Application Item # 1 Accessory *Mandatory Vehicle Service Parts (may be requi red for reassembly) Item # 1 2 Quantity Reqd. Description Legend Notes Safety Glasses Special Tools SKID PLATE STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. Notes CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Issue: A 07/25/05 Page 1 of 4 pages TOYOTA 4 RUNNER Procedure 2006 - SKID PLATE Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follo w approved guideli nes to ensure a quality inst allation. These guideli nes can be found in the "Accessory Installation Practices" document. This document covers such items as:-- Vehicle Protection (use of covers and blankets, cleaning chemicals , etc.). -- Safety (eye protection, recheckin g torque procedure, etc.). -- Vehicle Dis assembl y/Reassembl y (panel removal, part storage, etc.). -- Electrical Component Disassembl y/Reassembl y (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Install Riv Nut Fig. 1-1 (a) Working under a vehicle requires installer to wear safety glasses. M8 Bolt M10 Nut M8 Riv nut 15 mm W rench, 12 mm Socket, Ratchet (b) Remove hardware bag from carton, and verify content by referring to the instruction sheet. (c) Assemble Rivnut, oversize nut (M10), and M8 x 45 mm bolt together as shown in Fig. 1-1. Hand tighten the M8 bolt into the Rivnut and the M10 nut against the Rivnut. (d) Place the assembly into the non-threaded upper hole located on the connection brace between the lower radiator support crossmember and the vehicle's frame above the tow loop. Ensure that the flange of the Rivnut is flush against the surface of the hole as shown in Fig. 1-2. Fig. 1-2 (e) Hold the assembly in place using a 15 mm combination wrench on oversize nut as shown in inset detail (Fig. 1-2). (f) Use a hand or air ratchet to drive the M8 Flange Head Bolt into the Rivnut. (Fig. 1-2 inset) This will cause the cylinder of the Rivnut to mushroom against the inner wall of the frame. You will feel a change in resistance when the Rivnut is compressed at which time you can stop. Final torquing after bracket installation will ensure proper compression of Rivnut. Issue: A 07/25/05 Page 2 of 4 pages TOYOTA Procedure 4 RUNNER 13 mm, 17 mm Socket 2006 - SKID PLATE (g) Remove M8 bolt and oversize nut. (h) Repeat on other side. (i) Discard oversize nut and M8 x 45 mm bolt. 2. Installation of Brackets. Fig. 2-1 (a) Install (hand tight) LH bracket using supplied M8 and M12 x 1.25 x 25 mm fine thread bolt as shown in Fig. 2-1. (b) Repeat for RH bracket. NOTE: Be sure to use M12 fine thread bolts in these positions only. 17 mm Socket 3. Installation of Skid Plate. (a) Remove skid plate from packaging and place on a protected worktable to avoid damage. Fig. 3-1 (b) Hold the skid plate up to the brackets and place M12 course thread SEMS head flange bolts through skid plate. Thread (hand tight) the bolts into the weld nuts on the brackets as shown in Fig. 3-1. (c) Move skid plate to create a 16 mm min. and 20 mm max. gap between the middle of the front edge of the skid plate and the bumper. Fig. 3-2. (d) Tighten vehicle mounting bolts, torque M8 hardware to 20 lbf-ft (27 N-m) and M12 fine thread hardware to 60 lbf-ft (81 N-m). Fig. 3-2 (e) Tighten skid plate mounting M12 flange bolts to 20 lbf-ft (27 N-m). Issue: A 07/25/05 Page 3 of 4 pages TOYOTA 4 RUNNER 2006 - Checklist - these points MUST be checked to ensure a quality installation. Check: SKID PLATE Look For: Accessory Function Checks Visual check of skid plate Gap to vehicle bumper (16 mm min./20 mm max.). Symmetric gap between bumper fascia and skid plate on right and left sides. Check all bracket bolts for proper torque with torque wrench. (Note: Do not perform check of M12 flange bolts on Skid Plate). Issue: A 07/25/05 Page 4 of 4 pages Tightening torques have a range of ±25%. TOYOTA 4RUNNER 2006 - TVIP V2 (GBS ADD-ON) Preparation NOTE: Part number of this accessory may not be the same as the part number shown. General Applicability Part Number: 08586-3D892 Kit Contents Item # 1 2 3 4 Quantity Reqd. 1 1 1 1 Description Wire Harness V2 Security ECU Microphone Owner’s Guide Note: 4Runner with factory TDS system, only. Recommended Sequence of Application Item # 1 *Mandatory Hardware Bag Contents Item # 1 2 3 4 5 6 Quantity Reqd. 1 1 1 2 5 5 Vehicle Service Parts (may be required for reassembly) Description ECU Mounting Bracket Butyl Tape Bolt Small Foam Tape Strips Medium Wire Ties Large Wire Ties Item # 1 Quantity Reqd. Description Conflicts Recommended Tools Personal & Vehicle Protection Safety Glasses Safety Gloves Vehicle Protection Optional Blankets, Part Boxes Notes Striker Tool (PPO only) CAD-E IADE P/N ALL 02-016-01 Installation Tools Notes Screwdriver Screwdriver Screwdriver Wrench Socket Ratchet Nylon Panel Removal Tool Phillips Head, #2 Small, Flat Blade Flat Blade, Jeweler’s Pneumatic/Electric 10 mm e.g. Panel Pry Tool #1 Toyota SST # 00002-06001-1 Torque Wrench Pliers Cloth Side Cutter Tool 36 lbf-in Needle Nose Lint-free Special Chemicals Notes Cleaner Issue: C 10/05/05 Description Center Cluster Panel Clips STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Notes Special Tools Quantity Reqd. 4 Legend Additional Items Required For Installation Item # Accessory V2 3MTM Prep Solvent-70 Page 1 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:-- Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). -- Safety (eye protection, rechecking torque procedure, etc.). -- Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). -- Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Disassembly. 10mm Wrench Battery Negative Battery Cable (a) For vehicles equipped with automatic transmission, place the shifter in low gear and set the parking brake prior to disconnecting the battery. (b) Remove the negative battery cable. (Fig. 1-1) Fig. 1-1 (1) Protect the fender before starting. (2) Do not touch the positive terminal with any tool when removing cable. Nylon Panel Removal Tool (c) Remove the passenger side step cover. (Fig. 1-2) (1) Cover the floor and seats before starting. Step Cover Fig. 1-2 (d) Remove the passenger side cowl cover. (Fig. 1-3) (1) Remove the nut securing the cover. Nylon Panel Removal Tool Nut Fig. 1-3 Issue: C Cowl Cover 10/05/05 Page 2 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure (e) Remove the glove box assembly. (Fig. 1-4) Phillips Screwdriver Damper Screw (1) Remove the screw securing the glove box assembly. (2) Remove the glove box damper. (f) Remove the cover from the upper glove box area. (Fig. 1-5) Fig. 1-4 (1) Remove the four screws securing the cover. Glove Box Phillips Screwdriver Screws (x2) Air Bag Connector Holder Screws (x2) (2) Remove the air bag connector holder from the cover. (g) Remove the under-dash cover below the glove box area. (Fig. 1-6) (1) Remove the one screw securing the cover. (2) Disconnect the two connectors of the 4WD control ECU (if equipped) and one connector of the tire pressure monitor ECU. Then remove the one vehicle wire harness clip. Cover Fig. 1-5 Phillips Screwdriver (h) Remove the center cluster panel. (Fig. 1-7) (1) Remove the one screw securing the panel. (2) Disconnect all connectors from the panel. Under-Dash Cover Clip Fig. 1-6 Screw Phillips Screwdriver Nylon Panel Removal Tool Center Cluster Panel Fig. 1-7 Issue: C Screw 10/05/05 Page 3 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure 2. V2 ECU Preparation and Installation. (a) Prepare a protective sheet (blanket), and cover the blower assembly in the glove box area with the sheet as shown. (Fig. 2-1) (b) Turn the adjustment screw on the V2 ECU to the “9” position. (Fig. 2-2) Fig. 2-1 (c) Insert the V2 ECU mounting bracket into the indicated bracket slot on the V2 ECU. (Fig. 2-3) Protective Sheet Small Flat Blade Screwdriver (1) Insert the mounting bracket into the correct slot; you have only one chance to install it properly. V2 ECU (2) Make sure the bracket is firmly attached to the ECU. (d) Apply the butyl tape to the V2 ECU as shown. (Fig. 2-3) Fig. 2-2 Butyl Tape (e) Locate and remove the existing bolt from the connector block in the passenger side cowl area. (Fig. 2-4) (1) Discard the existing bolt. V2 ECU Mounting Bracket Fig. 2-3 10 mm Socket V2 ECU Existing Bolt Connector Block Fig. 2-4 Issue: C 10/05/05 Page 4 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure 10 mm Socket V2 ECU Bolt (Supplied) (f) Mount the V2 ECU on the right side of the connector block with the bolt supplied in the kit. (Fig. 2-5) 3. V2 Wire Harness Installation. (a) Plug the V2 harness' white 8P connector into the V2 ECU. (Fig. 3-1) Fig. 2-5 (1) Verify the connector is plugged in securely. V2 ECU V2 Harness 8P (White) Fig. 3-1 (b) Secure the V2 harness to the vehicle harness with one medium wire tie and one small foam tape strip. (Fig. 3-2) (c) Route the V2 harness toward the upper glove box area, and secure it to the vehicle harness with one large wire tie and one medium wire tie. (Fig. 3-3) Side Cutter V2 Harness Medium Wire Tie Fig. 3-2 Side Cutter Medium Wire Tie Large Wire Tie Fig. 3-3 Issue: C 10/05/05 Page 5 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure Pliers, Needle Nose Wire Clip (1) Remove the vehicle wire clip on the center brace and open the vehicle wire clip. V2 Harness Fig. 3-4 (2) Route the V2 wire harness though the open vehicle wire clip. 40P (White) V2 Harness (3) Close and reinstall the vehicle wire clip to the center brace. Vehicle Security ECU Fig. 3-5 Jeweler's Screwdriver 40P (White) V2 Harness’ YELLOW Wire (e) Locate the vehicle security ECU's white 40P connector in the upper left side of the glove box area, and disconnect it. (Fig. 3-5) (f) Using a small jeweler's screwdriver, lift up the terminal retainer on the back of the white 40P connector. (Fig. 3-6) (1) Do not pull out the retainer. (g) Insert the terminal at the end of the V2 harness' YELLOW wire into the top row, tenth space from the left of the white 40P connector, then close the retainer. (Fig. 3-6) Retainer Fig. 3-6 (d) Route the V2 harness toward the left side of the glove box area, and secure it to the vehicle harness with the existing vehicle wire clip. (Fig. 3-4) (1) Turn the connector so the wires face you and the tab is on top. WIRE SIDE VIEW (2) Verify the correct opening is chosen. Side Cutter 40P (White) Medium Wire Ties (x3) V2 Harness Microphone Wire Fig. 3-7 Issue: C Vehicle Security ECU 10/05/05 (3) Verify the terminal is inserted and seated properly. The terminal should not come out when pulled lightly from the back. If the terminal comes off, push it in again. (h) Reconnect the white 40P connector to the vehicle security ECU. (Fig. 3-7) (i) Secure the V2 harness’ microphone wire to the vehicle harness with three medium wire ties. (Fig. 3-7) Page 6 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure (1) Bundle and secure the excess V2 harness’ YELLOW wire in the top wire tie. Side Cutter Large Wire Ties (x3) (j) Secure the V2 harness to the vehicle harness with three large wire ties. (Fig. 3-8) V2 Harness (k) Route the V2 harness toward the center cluster panel area. (Fig. 3-9) (l) Plug the V2 harness' white 14P male connector into the vehicle harness white 14P female connector. (Fig. 3-10) Fig. 3-8 (1) Verify the connectors are plugged in securely. (m) Secure the V2 harness to the vehicle harness with one large wire tie. (Fig. 3-11) 14P (White) V2 Harness Fig. 3-9 (1) Connect the V2 harness’ white 14P female connector to the center cluster panel during reassembly of the vehicle. Vehicle ‘s 14P (White) 14P (White) V2 Harness Fig. 3-10 Side Cutter Large Wire Tie 14P (White) V2 Harness Fig. 3-11 Issue: C 10/05/05 Page 7 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure 4. Microphone Installation. (a) Using 3MTM Prep Solvent-70, clean the area indicated on the back side of the under-dash cover. (Fig. 4-1) Large Hole Under-dash Cover 45˚ Microphone Fig. 4-1 Insulator (1) Always use a clean (lint free scratch resistant) soft cloth (or wipe), and clean a small area at a time (~ 3 ft. x 3 ft. max.). (2) Shake well. (3) Apply 3MTM Prep Solvent-70 to cloth or wipe. Do not spray cleaning solution directly on any vehicle surfaces. (4) Clean surface thoroughly and wipe dry immediately with a new clean cloth. Do not allow cleaner to air dry. (c) Remove the backing sheet and secure the microphone to the back side of the underdash cover. (Fig. 4-1) 2P (White) V2 Harness Small Foam Tape Microphone Fig. 4-2 Under-Dash Cover (1) Secure the microphone under the insulator at a 45˚ angle with the back of the microphone lined up with the front edge of the large hole as shown. (Fig. 4-1) (2) Do not touch the adhesive surface of the microphone. (3) Press the microphone to the under-dash cover firmly. (d) Plug in the microphone's 2P connector to the V2 harness’ 2P connector. (Fig. 4-2) (1) Verify the connectors are plugged in securely. (e) Wrap the 2P connectors with a small foam tape strip. (Fig. 4-2) (f) Reinstall the under-dash cover. (Fig. 4-2) Issue: C 10/05/05 Page 8 of 13 pages TOYOTA 4RUNNER 2006- TVIP V2 (GBS ADD-ON) Procedure 5. Completing the Installation. (a) Complete the reassembly of the vehicle. Torque Wrench, 10 mm Socket (1) Reconnect any disconnected connectors. 30˚ Negative Battery Cable (2) Verify the panels fit together properly with no uneven gaps between them. (b) Clean up and remove any trash. (c) Reconnect the vehicle’s negative battery cable. (Fig. 5-1) Battery Fig. 5-1 (1) Position the negative terminal at an angle of 30˚ to the battery as shown, or to the original factory installed angle. (2) Tighten the nut to 4.1 N-m (36 lbf-in). (3) Do not touch the positive terminal with any tool when replacing the cable. (4) Reattach the negative battery cable clip. (d) Place the owner’s manual, left in the protective bag, in the glove box. Issue: C 10/05/05 Page 9 of 13 pages TOYOTA 4RUNNER 2006 - TVIP V2 (GBS ADD-ON) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Fit appropriate fuse before beginning. Close the hood before beginning. Press and release the remote control’s lock button to start the system’s arming process. 1. The turn signal lights flash once. The buzzer chirps once. All doors lock. The Immobilizer System's LED lights up. Wait 30 seconds. 2. After 30 seconds, the LED starts flashing; the system is now armed. Perform the following check in a temperature controlled environment (500-900). With the tip of key (or Striker Tool pulled all the way out (PPO only)), tap the center of the driver's door window to trigger the "warn away" alarm. 3. The horn sounds repeatedly. The interior lights turn on. The headlights flash repeatedly. The turn signal lights flash repeatedly. The Security LED lights up. NOTE: Adjust as necessary by increasing the GBS setting to the next level if the alarm does not trigger during the functional verifications. NOTE: If you do not disarm the system, the alarm will last 20 seconds. It is not necessary to check the alarm duration. Insert the key into the driver’s door key cylinder and turn it toward the back of the vehicle to stop the alarm. Issue: C 10/05/05 4. The horn stops sounding. All the lights stop flashing. The status monitor’s LED lights up. The driver’s door unlocks. Page 10 of 13 pages TOYOTA 4RUNNER 2006 - TVIP V2 (GBS ADD-ON) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Vehicle Function Checks Head Lights Functioning Head Lights High Beams Functioning High Beams Turn Signal Lights Functioning Turn Signal Lights Tail Lights Functioning Tail Lights Stop Lights Functioning Stop Lights Backup Lights Functioning Backup Lights Hazard Lights Functioning Hazard Lights Marker Lights Functioning Marker Lights Dome/Courtesy Lights Functioning Dome/Courtesy Lights Panel/Switch Illumination Functioning Controls/Illumination Accessory Controls/Illumination (if Functioning Accessory Controls equipped) Key Sensor Buzzer Functioning Key Sensor Fog Lights (if equipped) Functioning Fog Lights Daytime Running Lights (if equipped) Functioning DR Lights Trunk/Tailgate/Bed Lights (if equipped) Functioning Lights Glove Box Light (if equipped) Functioning Glove Box Light Cruise Control Light (if equipped) Functioning Cruise Control Light Seat Belt Warning Light Functioning Seat Belt Warning Light. If the warning light remains “ON”, it may indicate a system malfunction. Issue: C 10/05/05 Page 11 of 13 pages TOYOTA 4RUNNER 2006 - TVIP V2 (GBS ADD-ON) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Air Bag Functioning Air Bag Warning Light. If the warning light remains “ON”, it may indicate a system malfunction. ABS Light (if equipped) Functioning ABS Light. If warning light remains “ON”, it may indicate a system malfunction. Lamp Failure Sensor (if equipped) Functioning Lamp Failure Sensor. If the warning light remains “ON”, it may indicate a system malfunction. Track/ Skid Control Light (if equipped) Functioning Track/ VSC Light. If the warning light remains “ON”, it may indicate a system malfunction. HVAC Functioning HVAC Controls Power Locks (if equipped) Functioning Power Locks Power Windows (if equipped) Functioning Power Windows Power Seats (if equipped) Functioning Power Seats Power Sunroof (if equipped) Functioning Sunroof Horn Functioning Horn Gauges Functioning Gauges Front Wiper/Washer (if equipped) Functioning Front Wiper/Washer Rear Wiper/Washer (if equipped) Functioning Rear Wiper/Washer Clock (if equipped) Functioning Clock Accessory Power Socket (if equipped) Functioning Accessory Power Socket Starter Functioning Starter Issue: C 10/05/05 Page 12 of 13 pages TOYOTA 4RUNNER 2006 - TVIP V2 (GBS ADD-ON) Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Audio/Video (if equipped) Functioning Audio/Video Power Sliding Door (if equipped) Functioning Sliding Door Convenience Memory Setting (if equipped) Functioning Convenience Memory Setting Heated Seats (if equipped) Functioning Seats Massage Seats (if equipped) Functioning Massage Seats Rear Window Defogger (if equipped) Functioning Rear Window Defogger Side Mirror Defogger (if equipped) Functioning Side Mirror Defogger Front Windshield Defogger (if equipped) Functioning Front Windshield Defogger Navigation System (if equipped) Functioning Navigation System Tire Pressure Monitor Functioning Tire Pressure Monitor Passenger Occupant Air Bag Light Functioning Passenger Occupant Air Bag Light Remove the appropriate fuse after checks completed. Issue: C 10/05/05 Page 13 of 13 pages TOYOTA 4RUNNER 2006 - EXHAUST Installation Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Vehicle Service Parts (may be required for reassembly) Part Number: PTR31-89060 Kit Contents Item # 1 2 3 Quantity Reqd. 1 1 1 Item # 1 Description Front Muffler Assembly Rear Tailpipe Assembly Hardware Bag Quantity Reqd. 1 Description Front Flange Gasket PN: 17451-74051 – DIO ONLY 2 3 Hardware Bag Contents Item # 1 2 Quantity Reqd. 1 2 3 2 4 4 5 1 Legend Description Gasket 23000-00035 M10x1.5x35 mm long Hex Head Bolts M10x1.5 Hex Nuts M10 Flat Washers Installation Instructions Additional Items Required For Installation Item # 1 Quantity Reqd. STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Description Conflicts Recommended Tools Personal & Vehicle Protection Notes None Special Tools Notes Exhaust Hanger Removal Tool e.g. Snap On P/N YA3202 Installation Tools Notes Socket Wrenches Torque Wrench 14 mm, 16 mm, 17 mm 14 mm, 16 mm, 17 mm 50 lbf.ft Special Chemicals Notes Lubricant Soap and Water General Applicability 2006MY V6 4Runner: PTR31-89060 Recommended Sequence of Application Item # 1 Accessory *Mandatory Issue: A 03/01/06 Page 1 of 6 pages TOYOTA 4RUNNER 2006 - EXHAUST Installation Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:-- Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). -- Safety (eye protection, rechecking torque procedure, etc.). -- Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). -- Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Check the Kit content. Converter Assembly (a) Make sure that the kit contains all the parts listed in the Kit Contents. Spring 14 mm Socket Muffler Assembly (a) Using the 14mm socket, remove two bolts with springs from front flange located between catalytic converter and rear muffler. (Fig. 2-1) Gasket Location Bolt Fig. 2-1 Rear tailpipe assembly 2. Remove Existing Exhaust System. Bolt (b) Keep all original equipment (OE) bolts and springs. (Fig. 2-1) (1) Ensure that the original gasket remains on converter assembly flange 14 mm Socket Bolt NOTE: For DIO, installation gasket must be replaced – P/N 17451-74051. Front Muffler Assembly Fig. 2-2 Rubber hanger Exhaust Hanger Removal Tool (c) Using the 14mm socket, remove and discard two bolts from rear flange located between muffler assembly and rear tailpipe assembly. (Fig 2-2) Tailpipe (d) Pry the rear tailpipe exhaust bracket loose from the rubber hanger located near the rear bumper. (Fig. 2-3) Bracket (e) Remove the OE rear tailpipe assembly from the vehicle. Fig. 2-3 Issue: A 03/01/06 Page 2 of 6 pages TOYOTA 4RUNNER 2006 - EXHAUST Installation Procedure (f) Pry the two front muffler exhaust brackets loose from the rubber hangers. (Fig. 2-4) Rubber Hanger Exhaust Hanger Removal Tool Bracket Bracket Rubber Hanger Fig. 2-4 (g) Pry the two rear muffler exhaust brackets loose from the rubber hangers. (Fig 2-5) Exhaust Hanger Removal Tool NOTE: Use of lubrication (such as “soap and water”) on the rubber exhaust hangers can facilitate removal and installation of rubber hangers. Rubber Hanger Bracket Bracket Rubber Hanger Fig. 2-5 (h) Do not remove the five (5) original (OE) rubber hangers from the vehicle. (i) Remove the OE front muffler assembly from the vehicle. Rubber Hanger 3. Installation of TRD Exhaust System. (a) Connect the two front muffler hangers of the TRD muffler assembly to OE rubber hangers. (Fig. 3-1) Bracket Bracket Fig. 3-1 Issue: A Rubber Hanger 03/01/06 Page 3 of 6 pages TOYOTA 4RUNNER 2006 - EXHAUST Installation Procedure (b) Connect the two rear muffler hangers to OE rubber hangers. (Fig. 3-2) Rubber Hanger Bracket Bracket Rubber Hanger Fig. 3-2 Rubber hanger Tailpipe (c) Connect TRD tailpipe hanger to OE rubber hanger. (Fig. 3-3) (d) Make sure TRD muffler front flange is lined up to converter assembly flange. (e) Make sure rear flange between front muffler assembly and rear tailpipe assembly is lined up. Bracket Fig. 3-3 Converter Assembly Spring Torque Wrench 14 mm Socket Muffler Assembly (g) Tighten bolts to 32 lbf-ft (43N-m) (Fig. 3-4). Gasket Location Bolt Fig. 3-4 Issue: A (f) Install muffler front flange to connect to OE front converter assembly. Reinstall two (2) OE springs and bolts evenly for proper flange alignment. (Fig. 3-4) 03/01/06 Page 4 of 6 pages TOYOTA 4RUNNER 2006 - EXHAUST Installation Procedure (h) Install supplied gasket P/N 23000-00035 on the rear flange of the muffler. (Fig. 3.5) Torque Wrench, 16 & 17 mm Socket & Wrench Rear Tailpipe Assembly Washer (x2) Nut Gasket Location Bolt Washer (x2) (i) Connect the rear tailpipe assembly to the muffler rear flange and securely fasten the flange connection, using bolts and nuts supplied in the kit. (Fig. 3-5) Nut Front Muffler Assembly Fig. 3-5 (1) Using the 16 & 17mm socket & wrench, install two supplied washers between the bolts and the upper flange, and two washers between the nuts and the lower flange. (j) Tighten bolts to 25 lbf-ft (34N-m) (Fig. 3-4). Issue: A 03/01/06 Page 5 of 6 pages TOYOTA 4RUNNER 2007 - EXHAUST Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Correct part has been installed. Verify part number on package. All joints have been securely fastened. Verify joints are tightened. Hooks/hangers have been securely Verify hooks/hangers are securely attached. reattached. Start the vehicle. Verify the flange joints do not have abnormal leak sound or water leak. Vehicle Function Checks Inspection torque - muffler to converter assembly. 32+/- 5 lbf-ft (43 +/- 6 N-m). Inspection torque – tailpipe assembly to outlet flange. Issue: A 03/01/06 25+/- 5 lbf-ft (34 +/- 6 N-m). Page 6 of 6 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: PT228-89460 Kit Contents Item # 1 2 3 4 5 6 7 Quantity Reqd. 1 1 1 1 2 2 1 Description High Assembly Wiring Harness Bracket Hardware Bag Hitch Cover Frame Spacer Center Spacer Close-out Panel Quantity Reqd. 4 2 4 3 4 4 2 5 2 6 1 Description M12 x 1.25 x 45 Hex Flange Bolt (Black) M12 x 1.25 x 35 Hex Flange Bolt (Black) M8 x 1.25 x 25 Bolt w/Trapped Washer (Black) M8 x 1.25 x 20 Bolt w/Trapped Washer (Black) M6 x 1.00 x 20 hex Flange Bolt (Black) Harness Clamp/Cable tie Description Note: Notes Safety Glasses Vehicle Protection Cloth (Shop Towel) Special Tools Notes Recommended Sequence of Application Item # 1 2 3 *Mandatory Vehicle Service Parts (may be required for reassembly) Item # 1 2 3 Notes Nylon Panel Removal Tool e.g. Panel Pry Tool #1 Toyota SST # 00002-06001-01 Ratchets Sockets (Deep Well) Socket Wrench Extensions Issue: C 07/06/05 Quantity Reqd. Description Legend None Installation Tools Accessory STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Conflicts Recommended Tools Personal & Vehicle Protection Notes Note: All V-8 4-Runner vehicles Additional Items Required For Installation Quantity Reqd. Special Chemicals General Applicability (P/N 82711-16830) Item # 1 2 0-100 lbf-ft, 0-100 lbf-in e.g. Snap On P/N YA3202 None Hardware Bag Contents Item # 1 Torque Wrench (x2) Exhaust Hanger Removal Tool ½" and ⅜" 10 mm, 12 mm, 13 mm, 17 mm 6" min. Page 1 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Inspection. (a) Inspect parts for damage. 2. Prepare Vehicle for Hitch Installation. (a) Cover exhaust pipe with clean shop towel. (Fig. 2-1). (b) Caution muffler may be sharp and or hot. Fig. 2-1 Vehicle Frame (c) Remove and save tie-down. Discard the two (2) bolts removed from the vehicle. (Fig. 2-2) Fig. 2-2 Exhaust Hanger Removal Tool (d) Lower exhaust by disconnecting the rubber exhaust hanger from one of the connection points. (Fig. 2-3) Fig. 2-3 Issue: C 07/06/05 Page 2 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Procedure Nylon Panel Removal Tool (e) For vehicles equipped with air suspension, loosen the air suspension cover by removing the plastic fastener. Save fastener for reinstallation. (Fig. 2-4) Fig. 2-4 Panel Pry Tool (f) Using panel pry tool, unclip harness from the frame. Install harness clamp close to harness connector (around black wrap). Secure harness to frame and trim excess on cable tie. (Fig. 2-5) Fig. 2-5 Socket, 12 mm (g) Remove the two (2) M8 bolts securing the factory wiring bracket to the frame. Discard the two (2) bolts. (Fig. 2-6) Fig. 2-6 (h) Remove the two (2) M6 bolts connecting the 7-pin plug to the bracket, slide the plug from the bracket. Discard the bolts and factory wiring bracket. (Fig. 2-7) Fig. 2-7 Issue: C 07/06/05 Page 3 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Procedure 3. Attach Hitch Center to Vehicle. Socket, 17 mm, Extension 6” Spacer Plates Closeout Panel (a) Install closeout panel and (2) spacer plates to center attachment bracket by hand starting (2) M12-1.25x45 black bolts through closeout panel and spacer plates into forward most set of holes. (Fig. 3-1) (b) Slide hitch onto pre-installed bolts using open ended slots to support the hitch. (Fig. 3-1) Fig. 3-1 (c) Hand start two (2) M12-1.25x45 black bolts to rear most position to secure the hitch and spacer plates using a socket extension and a 17mm socket. Bolts can be fed through chain holes. Do not tighten. (Fig. 3-1) 4. Install 7-Pin Wire Harness to Hitch. Socket, 10 mm, 12mm; Torque Wrench (a) Install 7-pin wiring harness (removed in Step B. 8.) to the provided wiring bracket using two (2) M6-1.00x20mm bolts. (Fig. 4-1) (b) Install wiring bracket to inside surface of the driver side hitch bracket using two (2) M8x1.25x20 black bolts with trapped washers. (Fig. 4-1) Fig. 4-1 (c) Be sure to feed wiring between the hitch tube and the vehicle cross member. (d) Tighten the M8 bolts to 19 ± 4 lbf•ft (25 ± 5 N•m). (Fig. 4-1) (e) Tighten M6 bolts to 94 ± 19 lbf•in (10.4 ± 2 N•m). (Fig. 4-1) 5. Place Frame Spacers. (a) Place frame spacers between hitch brackets and vehicle frame. (Fig. E-1) Fig. 3-1 Issue: C 07/06/05 Page 4 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Procedure 6. Install Hitch to Frame Rail. (a) Reinstall tie-down bracket to hitch using two (2) M12 x 1.25x35 black bolts in driver side rear most frame locations. (Fig. 6-1, Step 1) (b) Secure hitch to frame using two (2) M12 x 1.25x35 black bolts in passenger side rear most frame locations. (Fig. 6-1, Step 2) (c) Hand start four (4) M8 x 1.25 x 25 black bolts in forward most frame locations. (Fig. 6-1, Step 3) Fig. 6-1 (d) Ensure all bolts engage frame spacers and the spacers do not impede on frame welds. 7. Visually Center Hitch (a) Visually center hitch so that closeout panel is centered in fascia cut out. (Fig. 7-1) Fig. 7-1 8. Tighten Remaining Hitch Hardware. Socket, 13 mm, 17 mm; Torque Wrench (a) Tighten four (4) M12 bolts in the center to 60 ± 12 lbf-ft (80 ± 15 N-m). (Fig. H-1, Steps 1 - 4) (b) Tighten four (4) M12 bolts on the frame rail to 60 ± 12 lbf-ft (80 ± 15 N-m). (Fig. H-1, Steps 5 - 8). (c) Tighten four (4) M8 bolts to 19 ± 4 lbf-ft (25 ± 5 N-m). (Fig. H-1, Steps 9 - 12) Fig. 8-1 Issue: C 07/06/05 Page 5 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Procedure 9. Reinstall Vehicle Components. Exhaust Hanger Removal Tool (a) Reconnect exhaust to the exhaust hanger ensuring to fully engage the hanger. (Fig. 9-1) Fig. 9-1 (b) Reinstall the air suspension cover by replacing the one fastener. (Fig. 9-2) (1) If fastener is damaged fit a new fastener, (P/N 90467-09185). (c) Place the hitch plug in the glove box. Fig. 9-2 Issue: C 07/06/05 Page 6 of 7 pages TOYOTA 4-RUNNER 2006 - TOWING HITCH Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Inspection torque (M12 bolts) 60 ± 12 lbf-ft (80 ± 15 N-m) Inspection torque (M8 bolts) 19 ± 4 lbf-ft (25 ± 5 N-m) Inspection torque (M6 bolts, 7-pin to 94 ± 19 lbf-in (10.4 ± 2 N-m) bracket) Frame Spacers Installed and off of welds Wiring Bracket Installed and fed between hitch and cross member. Hitch Plug Issue: C 07/06/05 Placed in glove box Page 7 of 7 pages 2005- 4RUNNER TVIP V2 GLASS BREAKAGE SENSOR (GBS) OWNER’S GUIDE G.B.S. TVIP (GLASS SENSOR) ENHANCEMENT 2004-2005 PRIUS V2BREAKAGE GLASS BREAKAGE SENSOR (GBS) DESIGNED FOR USE WITH YOUR VEHICLE’S OWNER'S GUIDE THEFT DETERRENT SYSTEM OWNERS GUIDE The G.B.S. (GLASS BREAKAGE SENSOR) provides protection for your vehicle above and beyond the entry point monitoring performed by the TDS (Theft Deterrent System)—it “listens” for the noise made by tapping on, or breaking of glass, and triggers alarms upon detection of these types of noise. Using a microphone designed VSHFL¿FDOO\IRUWKLVWDVNWKH*%6LVFDSDEOHRILJQRULQJRWKHUQRLVHVZKLFKKHOSVSUHYHQW³IDOVHDODUPV´IURP occurring. (See reverse for descriptions of alarms.) GLASS BREAKAGE SENSOR CHECK PROCEDURE :KHQWKH*%6ZDVLQVWDOOHGLQ\RXUYHKLFOHFDUHZDVWDNHQWRDGMXVWWKHVHQVLWLYLW\OHYHOSURSHUO\\RXPD\ REVHUYHKRZLWZRUNVIROORZLQJWKHSURFHGXUHOLVWHGEHORZ 1.  Arm the theft deterrent system. Press the lock button on the remote control or ORFNWKHGRRUVZLWKWKHNH\ 5HPHPEHUWKHV\VWHPZLOO not arm if any door, or the trunk, is open.)   :DLWXQWLOWKH6HFXULW\/('VWDUWVÀDVKLQJ 7KH/('ZLOOEHJLQWRÀDVKVHFRQGVDIWHUWKHODVW door or the trunk is closed. Please note, your vehicle’s Security LED may look different than the one pictured here.    :LWKWKHWLSRIDNH\WDSWKHFHQWHURIWKHGULYHU¶V GRRUZLQGRZ 7DSWKHJODVVZLWKOLJKWWRPRGHUDWHIRUFH   :$51,1* 'RQRWKLWWKHJODVVZLWKH[FHVVLYHIRUFH  HVSHFLDOO\LQFROGZHDWKHURU\RXPD\ crack or break it.  4. A WARN AWAY ALARM should be triggered. (See re verse for details.) If the ALARM IS not triggered, make sure you performed the procedure correctly and try DJDLQ,IWKHV\VWHPGLGQRWSHUIRUPDV\RXH[SHFWHG contact your Toyota dealer for more information. Disarm the theft deterrent system to stop the WARN AWAY ALARM. Press the unlock button on the remote control, or use the key to unlock a door, to disarm the system. Please note, your remote controls may look different than the one pictured here.  5HY$ GBS ADD-ON OWNERS GUIDE Please note, your remote controls may look different than the one pictured here. ALARM INFORMATION ALARM DESCRIPTIONS WARN-AWAY ALARM Upon initial detection of noise from tapping on, or breaking glass, the GLASS BREAKAGE SENSOR triggers a WARN AWAY ALARM:  7KHKRUQVRXQGVUHSHDWHGO\IRUVHFRQGV  7KHKHDGOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHWDLODQGPDUNHUOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHLQWHULRUOLJKWVWXUQRQIRUVHFRQGV If the GLASS BREAKAGE SENSOR detects noise again, or if a door or the trunk is forcibly opened, the regular DODUP GHVFULEHGEHORZ LVDFWLYDWHG REGULAR ALARM :KHQDQDODUPLVWULJJHUHGLQDQ\ZD\RWKHUWKDQLQLWLDOGHWHFWLRQE\WKH*/$66%5($.$*(6(1625WKHIRO ORZLQJRFFXUV  7KHKRUQVRXQGVUHSHDWHGO\IRUVHFRQGV  7KHKHDGOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHWDLODQGPDUNHUOLJKWVÀDVKUHSHDWHGO\IRUVHFRQGV  7KHLQWHULRUOLJKWVWXUQRQIRUVHFRQGV  $Q\GRRUORFNZLOOEHUHORFNHGLIVRPHRQHUHDFKHVLQDQGXQORFNVDQLQVLGHORFNEXWWRQ$IWHUVHF RQGVWKHWKHIWGHWHUUHQWV\VWHPZLOOUHDUPDQGFRQWLQXHWRSURWHFWWKHYHKLFOH STOPPING AN ALARM 6LPSO\GLVDUPWKHWKHIWGHWHUUHQWV\VWHPXVLQJWKHUHPRWHFRQWURORUNH\DVGHVFULEHGLQWKH2ZQHU¶V*XLGHIRU your vehicle. 2003 4 RUNNER TVIP V5 RS3200 PLUS OWNER’S GUIDE RS3200 PLUS SECURITY SYSTEM DESIGNED FOR USE WITH YOUR VEHICLE’S REMOTE KEYLESS ENTRY SYSTEM OWNER’S GUIDE Rev. A 09/24/02 TOYOTA RS3200 PLUS Security system Page 1 To better understand the features and functions of this security system, please read this Owner’s Guide completely prior to use. For N m d ock r on w TABLE OF CONTENTS DESCRIPTION INTRODUCTION BRIEF DESCRIPTION–RS3200 PLUS FEATURES OPERATION ARMING THE RS3200 PLUS (except PASSIVE ARMING) DISARMING THE RS3200 PLUS (except PASSIVE DISARMING) PASSIVE (AUTOMATIC) ARMING & DISARMING AUTOMATIC REARMING ARMING SUSPENSION ALARM INFORMATION ALARM TRIGGERS ALARM DESCRIPTIONS STOPPING AN ALARM PAGE 2 3, 4 5 6 7 8 8 9 9 10 10 GLASS BREAKAGE SENSOR INFORMATION GLASS BREAKAGE SENSOR CHECK PROCEDURE 11 PROGRAMMING PASSIVE (AUTOMATIC) ARMING AND ENTRY DELAY (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information.) WARNING and CAUTION INFORMATION 12 13 Page 2 TOYOTA RS3200 PLUS Security system INTRODUCTION GLASS BREAKA Congratulations on your choice of the RS3200 PLUS add-on security system to protect your vehicle! To get the most from the system, we strongly recommend that you read this Owner’s Guide completely to learn all of its features and functions. The RS3200 PLUS provides security through point-of-entry monitoring, glass breakage detection and ignition switch monitoring. While ARMED, the system will be TRIGGERED and sound an ALARM when a door, trunk or hatch is forcibly unlocked or opened*, or when a window is tapped on or broken. During the ALARM, the vehicle’s horn sounds and the headlights, tail lights and front marker or turn signal lights flash. A l s o , the vehicle’s starter is disabled, preventing engine start. In addition to the comprehensive protection, the RS3200 PLUS works in conjunction with your vehicle’s remote keyless entry system, enabling you to ARM and DISARM the security system at the same time the doors are remotely locked and unlocked. In vehicles equipped with a buzzer, it will chirp when the system is REMOTE ARMED and DISARMED. The RS3200 PLUS provides pro “listens” for the noise made by specifically for this task, the GL helps to prevent “false alarms” GLASS BREAKAGE SE When the RS3200 PLUS was in of the GLASS BREAKAGE SENSO below. 1. An important note about your system ➀➁ Throughout this guide, there are references to the STATUS MONITOR for this system. Illustrated below, this panel holds the LED indicator (for the system’s operating status) and the GLASS BREAKAGE SENSOR’S microphone. In vehicles equipped with an engine immobilizer system, there is a LED already installed, so the RS3200 PLUS utilizes the vehicle’s engine immobilizer system LED➂ instead and a microphone mounted in a separate location. If your vehicle falls into this category, remember to look at that LED when the information refers to the STATUS MONITOR. If you do not know where the LED is located, refer to your vehicle’s owner’s guide for specific information. ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ 2. ➂ YOUR ENGINE IMMOBILIZER SYSTEM LED MAY LOOK DIFFERENT THAN THE ONE ILLUSTRATED HERE 3. * When the system is PASSIVELY (AUTOMATICALLY) ARMED, there is an ENTRY DELAY that will elapse when a door is opened before an ALARM is TRIGGERED. 4. OR, H S tem GH S TOYOTA RS3200 PLUS Security system Page 3 BRIEF DESCRIPTION–RS3200 PLUS FEATURES FEATURES FUNCTIONS The RS3200 PLUS will ARM 30 seconds after the lock button on the remote REMOTE keyless entry system’s remote control is pressed, and DISARM when the ARMING/DISARMING unlock button is pressed. If your vehicle is equipped with a buzzer that chirps when the lock and unlock buttons on the remote controls are pressed, the buzzer will also chirp when the system is REMOTE ARMED and DISARMED. The RS3200 PLUS will automatically REARM at the same time the AUTOMATIC vehicle’s remote keyless entry system relocks the vehicle’s REARMING doors, if no door is opened within 30 seconds after REMOTE DISARMING. The RS3200 PLUS will ARM 30 seconds after you close the trunk (if KEY open) and lock the vehicle’s doors with the key, and will DISARM when ARMING/DISARMING you unlock a door with the key. While ARMED, the trunk may be opened with the key (or trunk release button ARMED MODE SUSPENSION** on your remote control, if so equipped) without TRIGGERING an ALARM. Once the open trunk is closed, the system ARMS again. The RS3200 PLUS may be programmed to automatically ARM 30 PASSIVE (AUTOMATIC) seconds after the ignition key is removed, the vehicle exited and the ARMING last door and the trunk closed, without the necessity of locking doors. The RS3200 PLUS may be DISARMED with the vehicle’s ignition key PASSIVE DISARMING after it was PASSIVELY ARMED. ADJUSTABLE ENTRY When the RS3200 PLUS has been PASSIVELY ARMED, an ENTRY DELAY DELAY (user-selectable at 0, 15, or 30 seconds) will start when a door is opened before an ALARM is TRIGGERED. When you lock the vehicle with the central lock switch (while a door MANUAL ARMING is open), the RS3200 PLUS will ARM 30 seconds after you close all the doors and the trunk (if open). The RS3200 PLUS may be DISARMED by inserting the key into the IGNITION KEY ignition switch and turning it to “ON.” DISARMING Forcibly unlocking or opening a door or trunk while the RS3200 PLUS POINT-OF-ENTRY is ARMED will TRIGGER an ALARM immediately. (If the system was PASSIVELY PROTECTION ARMED, the ENTRY DELAY must pass after opening a door before the ALARM is TRIGGERED.) The RS3200 PLUS utilizes a microphone (usually mounted in the GLASS BREAKAGE STATUS MONITOR) to sense the noise from tapping on window glass, or SENSOR glass breaking, and TRIGGER the system to sound an ALARM. It is fine tuned to “listen” for this type of noise, and ignore other sounds. WARN AWAY ALARM When the GLASS BREAKAGE SENSOR’S microphone picks up tapping or breaking of window glass, it TRIGGERS a WARN AWAY ALARM; the headlights and tail and marker or turn signal lights flash, and the horn sounds for 20 seconds, but the starter is not disabled. If there is another detection of glass tapping or breaking, or if a door is opened or unlocked without a key, the regular ALARM is TRIGGERED. While ARMED, the RS3200 PLUS monitors the ignition switch. If an attempt is IGNITION SWITCH made to start the vehicle without a key, an ALARM is TRIGGERED. MONITORING **Starting from 2002 M.Y., Arming Suspension Mode by using the key to unlock the trunk is not applicable to Camry, Solara, and Corolla. Page 4 TOYOTA RS3200 PLUS Security system BRIEF DESCRIPTION–RS3200 PLUS FEATURES FEATURES FUNCTIONS When an ALARM is TRIGGERED, the system disables the vehicle’s starter and prevents engine start until the system is reset (DISARMED). During an ALARM, the system will lock the doors if one is unlocked, FORCED LOCK and will continue to do so for the duration of the ALARM. DURING ALARM The user is notified that an ALARM occurred. Upon DISARMING the TRIGGER MEMORY * system after an ALARM was TRIGGERED, the vehicle’s tail and marker lights will be turned on for 2 seconds. The RS3200 PLUS flashes the vehicle’s tail and marker or turn signal lights EXTERIOR LIGHT during REMOTE ARMING and REMOTE DISARMING, and during an ALARM. ACTIVATION Also, during an ALARM the headlights flash. If your vehicle is equipped with a buzzer that chirps when the lock BUZZER ACTIVATION and unlock buttons on the remote keyless entry system’s remote controls are pressed, the buzzer will also chirp when the system is REMOTE ARMED and DISARMED. HORN ACTIVATION During an ALARM, the RS3200 PLUS activates the vehicle’s horn. If power to the RS3200 PLUS is disrupted while it is ARMED, an ALARM is POWER LOSS MEMORY TRIGGERED once power is restored. This panel houses the GLASS BREAKAGE SENSOR microphone and the STATUS MONITOR flashing LED that indicates the operating status of the security system. (Some vehicle applications utilize the vehicle’s engine immobilizer system LED and a separate microphone, instead.) STARTER DISABLE ALARM INFORMA ALARM TRIGGERS While the system is ARMED, an ➤ F P a ➤ M M N ➤ “ T t * TRIGGER MEMORY is not available for Corolla / Matrix. ➤ T T A h ➤ P I A e em LL R 30 S HEN THE RMED TOYOTA RS3000 PLUS Security system Page 5 OPERATION ARMING THE RS3200 PLUS (except PASSIVE ARMING) The system may be ARMED in several ways. Do one of the following: Lock the doors with your key: Remove the key from the ignition switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Insert the key into the door key switch and turn it toward the front of the vehicle: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. TURN TOWARD THE FRONT OF THE VEHICLE Lock the doors from inside the vehicle: Remove the key from the ignition switch. Open the driver’s or front passenger’s door. Push the central lock switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Then: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. PUSH THE LOCK SWITCH WHILE THE and sing R’S Lock the doors with the remote control: Remove the key from the ignition switch. Exit the vehicle, and close all the doors.* Close the trunk or hatch, if necessary.* Press the lock button on the remote control. Simultaneously: The doors lock.➁ The vehicle’s tail and marker or turn signal lights flash once.③ The vehicle’s buzzer chirps once.∆ The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀ The system is now ARMED. PRESS AND RELEASE THE LOCK BUTTON ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN FLASHES (SYSTEM IS ARMED) ➁ ALL DOORS LOCK WHEN THE SYSTEM IS REMOTE ARMED ③ THE TAIL AND MARKER OR TURN SIGNAL LIGHTS FLASH ONCE WHEN THE SYSTEM IS REMOTE ARMED * The system will not ARM while any of the doors, trunk or hatch is open. ∆ If your vehicle is equipped with a buzzer. Page 6 TOYOTA RS3200 PLUS Security system OPERATION OPERATION DISARMING THE RS3200 PLUS (except PASSIVE DISARMING) PASSIVE (AUTOMATIC) The system may be DISARMED in several ways. Do one of the following: When the RS3200 PLUS is prog is removed and all doors and th come back to your vehicle and it to “ON” during the ENTRY DEL the doors, regular ARMING will o PROGRAMMING information o the ENTRY DELAY time. (Not a Deale Unlock the doors with your key: Insert the key into the door key switch and turn it toward the rear of the vehicle: The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* TURN TOWARD THE REAR OF THE VEHICLE In the case of Highlander, Sienna, and 4Runner, you may also disarm the system using the key in the back door; all doors will unlock at the same time. Unlock the doors with the remote control: Press the unlock button on the remote control. Simultaneously: The driver’s door unlocks.➁ The vehicle’s tail and marker or turn signal lights flash twice.➂ The vehicle’s buzzer chirps twice.∆ The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* Press the unlock button again within 3 seconds after unlocking the driver’s door to unlock the remaining doors. PUSH THE UNLOCK BUTTON Use the ignition switch: Insert the key into the ignition switch, then turn it to ON. The STATUS MONITOR’S LED stops flashing.➀The system is now DISARMED.* TURN THE KEY TO “ON” TO DISARM THE SYSTEM This method of disarming is rarely used. You must be inside the vehicle while the system is armed in order to do it. NOTE: If your vehicle’s tail and marker or turn signal lights turn on for 2 seconds when the system is DISARMED,* the TRIGGER MEMORY was activated; something TRIGGERED an ALARM while you were away from the vehicle. This feature is not available for Corolla / Matrix. ➀ ➁ STOPS FLASHING WHEN THE SYSTEM IS DISARMED THE DRIVER’S DOOR UNLOCKS WHEN THE SYSTEM IS REMOTE DISARMED ➂ THE TAIL AND MARKER OR TURN SIGNAL LIGHTS FLASH TWICE WHEN THE SYSTEM IS REMOTE DISARMED * Please note, if the system utilizes your vehicle’s engine immobilizer system LED instead of the STATUS MONITOR, the LED will continue to flash. ∆ If your vehicle is equipped with a buzzer. T R E A C w A THE SYSTEM ARMS 30 SECONDS AFTER THE LAST ENTRY POINT (DOOR, TRUNK OR HATCH) IS CLOSED T E T I b THE SYSTEM DISARMS WHEN YOU INSERT THE KEY AND TURN IT TO “ON” Y d NOTE: If your vehicle’s tail an is turned to “ON”, the while you were away f ➀ LIGHTS FOR 30 SECONDS (PRE-ARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ * If the ENTRY DELAY time elap TRIGGERED. To DISARM the sy press and release the remote of m is sarm the m is e m is em e AL EM e TOYOTA RS3200 PLUS Security system Page 7 OPERATION PASSIVE (AUTOMATIC) ARMING & DISARMING When the RS3200 PLUS is programmed to PASSIVELY ARM, the system will ARM after the ignition key is removed and all doors and the trunk are closed; you do not need to lock the doors. When you come back to your vehicle and open a door, you must insert the key into the ignition switch and turn it to “ON” during the ENTRY DELAY (0, 15 or 30 seconds), or an ALARM will be TRIGGERED. If you lock the doors, regular ARMING will override PASSIVE ARMING; there will be no ENTRY DELAY. See the PROGRAMMING information on page 13 to activate the PASSIVE ARMING mode, as well as to select the ENTRY DELAY time. (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information .) THE SYSTEM ARMS 30 SECONDS AFTER THE LAST ENTRY POINT (DOOR, TRUNK OR HATCH) IS CLOSED THE SYSTEM DISARMS WHEN YOU INSERT THE KEY AND TURN IT TO “ON” To PASSIVELY ARM the system: Remove the key from the ignition switch. Exit the vehicle, and close all the doors. (The system will not ARM while any of the doors are open.) Close the trunk or hatch, if necessary. (The system will not ARM while the trunk or hatch is open.) After the last door, trunk or hatch is closed: The STATUS MONITOR’S LED turns on for 30 seconds, then starts flashing.➀The system is now ARMED. To DISARM the PASSIVELY ARMED system: Enter the vehicle through a front door. The ENTRY DELAY begins: The STATUS MONITOR’S LED turns on (no flashing.)➁ Insert the key into the ignition switch and turn it to “ON” before the ENTRY DELAY ends.* The LED turns off. The system is now DISARMED. You may also DISARM the system following any of the methods described on page 6. NOTE: If your vehicle’s tail and marker lights turn on for 2 seconds when the ignition key is turned to “ON”, the TRIGGER MEMORY was activated; something TRIGGERED an ALARM while you were away from the vehicle. This feature is not available for Corolla/Matrix. ➀ LIGHTS FOR 30 SECONDS (PRE-ARMING) THEN STARTS FLASHING (SYSTEM IS ARMED) ➁ TURNS ON (NO FLASHING) DURING THE ENTRY DELAY * If the ENTRY DELAY time elapses before the ignition switch is turned to “ON”, an ALARM will be TRIGGERED. To DISARM the system during an ALARM, insert the ignition key and turn it to “ON”, or press and release the remote control’s unlock button. Page 8 TOYOTA RS3200 PLUS Security system OPERATION OPERATION AUTOMATIC REARMING ARMING THE RS3200 P When you unlock the doors using the remote control, the RS3200 PLUS is DISARMED at the same time. However, if you do not open a door or the trunk within 30 seconds, the keyless entry system will relock the doors and the RS3200 PLUS will REARM 30 seconds later. The system may be ARMED in s L R E C I f How the RS3200 PLUS automatically REARMS: 0 45 TURN TOWARD THE FRONT OF THE VEHICLE 15 30 THE DOORS ARE UNLOCKED BY PRESSING THE UNLOCK BUTTON ON THE REMOTE CONTROL... WHEN NO DOOR, TRUNK OR HATCH IS OPENED... FOR MORE THAN 30 SECONDS... ARMING SUSPENSION** THE LED WILL THE KEYLESS ENTRY LIGHT UP FOR 30 SYSTEM AUTOMATSECONDS (PRE-ARM), THEN ICALLY RELOCKS THE DOORS, THEN FLASH WHEN THE THE RS3200 PLUS SYSTEM IS ARMED AUTOMATICALLY REARMS. L R O P E C PUSH THE LOCK SWITCH WHILE THE The ARMED state of the RS3200 PLUS can be suspended temporarily by using the key to unlock and open the trunk. If your remote control is so equipped, you may also suspend the ARMED state using the trunk release button➀to open the trunk. When the ARMING is suspended, the STATUS MONITOR’S LED will turn off ➁until the trunk is closed again. ➀ OPENING THE TRUNK SUSPENDS THE ARMED STATE OF THE SECURITY SYSTEM L R E C P ➁ TURNS OFF WHEN THE ARMED STATE IS SUSPENDED **Starting from 2002 M.Y., Arming Suspension Mode by using the key to unlock the trunk is not applicable to Camry, Solara, and Corolla. PRESS AND RELEASE THE LOCK BUTTON ➀ LIGHTS FOR 30 SECONDS (PREARMING) THEN FLASHES (SYSTEM IS ARMED) ➁ ALL THE * The system will not ARM whil ∆ If your vehicle is equipped w TOYOTA RS3200 PLUS Security system Page 9 ALARM INFORMATION ALARM TRIGGERS While the system is ARMED, an ALARM will be TRIGGERED when any of the following occurs: ➤ Forcibly opening a door, or the trunk or hatch without a key Pulling the trunk release lever inside the vehicle will also TRIGGER an ALARM. s ts m ➤ Manually unlocking a door Manually operating an inside lock button will TRIGGER an ALARM. Note: Because this action will TRIGGER an ALARM, it is important that you do not ARM the system while someone is in the vehicle. ➤ “Hot wiring” the vehicle The RS3200 PLUS can detect the absence of the ignition key if the ignition circuit is shorted in attempt to start the vehicle. ➤ Tapping on or breaking the glass The noise from tapping on, or breaking of glass TRIGGERS a WARN AWAY ALARM first, then a regular ALARM. See the description of how the GLASS BREAKAGE SENSOR TRIGGERS ALARMS on page 12. ➤ Power restoration If power to the system is interrupted while it is ARMED, an ALARM will be TRIGGERED immediately when power is restored. TOYOTA RS3000 PLUS Security system Page 10 BRIEF DESCRIP ALARM INFORMATION ALARM DESCRIPTIONS FEATURES Regular ALARM ➀ When an ALARM is triggered in any way other than initial detection by the GLASS BREAKAGE SENSOR, the following occur: The horn sounds repeatedly for 60 seconds. The headlights flash repeatedly for 60 seconds. The tail and marker or turn signal lights flash repeatedly for 60 seconds. The starter is disabled (no engine start) until the system is DISARMED. The door lock will be relocked if someone reaches in and unlocks the inside lock button. After 60 seconds of ALARM, the system will REARM and continue to protect the vehicle. ➀ THE HORN SOUNDS FOR 60 SECONDS THE STARTER IS DISABLED UNTIL THE SYSTEM IS DISARMED TAIL OR TURN SIGNAL LIGHTS FLASH FOR 60 SECONDS MARKER OR TURN SIGNAL LIGHTS FLASH FOR 60 SECONDS HEAD LIGHTS FLASH FOR 60 SECONDS WARN-AWAY ALARM ➁ Upon initial detection of noise from tapping on, or breaking glass, the GLASS BREAKAGE SENSOR TRIGGERS a WARN AWAY ALARM: The horn sounds repeatedly for 20 seconds. The headlights flash repeatedly for 20 seconds. The tail and marker or turn signal lights flash repeatedly for 20 seconds. If the GLASS BREAKAGE SENSOR detects noise again, or if a door or trunk is opened while the system is still ARMED, the regular ALARM (described above) is activated. ➁ THE HORN SOUNDS FOR 20 SECONDS TAIL OR TURN SIGNAL LIGHTS FLASH FOR 20 SECONDS HEADLIGHTS FLASH FOR 20 SECONDS MARKER OR TURN SIGNAL LIGHTS FLASH FOR 20 SECONDS STOPPING AN ALARM Simply DISARM the system using the remote control or key as described on page 6. Th ke un wh bu Th AUTOMATIC ve REARMING do Th KEY op ARMING/DISARMING yo W ARMED MODE SUSPENSION** on th Th PASSIVE (AUTOMATIC) se ARMING la Th PASSIVE DISARMING af ADJUSTABLE ENTRY W DELAY (u op W MANUAL ARMING is th Th IGNITION KEY ig DISARMING Fo POINT-OF-ENTRY is PROTECTION AR TR Th GLASS BREAKAGE ST SENSOR gl tu WARN AWAY ALARM W br an se ta re W IGNITION SWITCH m MONITORING REMOTE ARMING/DISARMING **Starting from 2002 M.Y., Armin to Camry, Solara, and Corolla cle! - and na n he ors em TOYOTA RS3200 PLUS Security system Page 11 GLASS BREAKAGE SENSOR INFORMATION The RS3200 PLUS provides protection for your vehicle above and beyond entry point monitoring–it “listens” for the noise made by tapping on, or breaking of glass. Using a microphone designed specifically for this task, the GLASS BREAKAGE SENSOR is capable of ignoring other noises, which helps to prevent “false alarms” from occurring. GLASS BREAKAGE SENSOR CHECK PROCEDURE When the RS3200 PLUS was installed in your vehicle, care was taken to adjust the sensitivity level of the GLASS BREAKAGE SENSOR. You may observe how it works following the procedure listed below. 1. ARM the system. Press the lock button on the remote control or lock the doors with the key. (Remember, the system will not ARM if any door, the trunk or hatch is open.) is D➂ 2. Wait until the STATUS MONITOR’S LED starts flashing. The LED will flash 30 seconds after the last door, the trunk or hatch is closed. 3. With the tip of a key, tap the center of the driver’s door window. Tap the glass with light to moderate force. WARNING: Do not hit the glass with excessive force, especially in cold weather, or you may crack or break it. A WARN AWAY ALARM should be TRIGGERED. If the ALARM is not TRIGGERED, make sure you performed the procedure correctly and try again. If you find that the system did not perform as expected, contact your Toyota dealer for more information. se 4. DISARM the system to stop the WARN AWAY ALARM. Press the unlock button on the remote control or use the key to DISARM the system. Page 12 TOYOTA RS3200 PLUS Security system PROGRAMMING The RS3200 PLUS is factory-set to not PASSIVELY ARM. To change the system’s operation for PASSIVE ARMING operation, as well as adjust the ENTRY DELAY time, follow the procedure below. For more information on this feature, please refer to page 7. (Not applicable to Highlander and Sienna. Please consult your Toyota Dealer for programming information.) PASSIVE ARMING ON/OFF SELECTION, ENTRY DELAY TIME SELECTION 1. Before you begin: Open the driver’s door. Close the remaining doors and the trunk or hatch. Unlock all doors with the inside lock switch. Remove the key from the ignition switch. 2. Insert and remove the key from the ignition key cylinder 3 times; this must be completed within 5 seconds. Start the Programming Procedure. (Complete these steps within 40 seconds.) To better understand the featu Guide completely prior to use. TABLE OF CONT INTRODUCTION BRIEF DESCRIPTIO OPERATION ARMING THE RS DISARMING THE PASSIVE (AUTOM AUTOMATIC REA ARMING SUSPEN ALARM INFORMATIO a. Close the driver’s door. b. Lock and unlock all doors 3 times by key or remote control. c. Open and close the driver’s door. d. Lock, then unlock the driver’s door inside lock button 3 times. ALARM TRIGGER ALARM DESCRIP STOPPING AN AL GLASS BREAKAGE GLASS BREAKAG PROGRAMMING PASSIVE (AUTOM (Not applicable to Toyota Dealer for e. Open the driver’s door. 3. f. The system locks the door in 2 seconds; if this does not happen, start over. g. Unlock the driver’s door knob. Select the Operating Mode and Complete the Programming Procedure. a. Close, then Open the driver’s door: b. Lock then unlock the 2 times = PASSIVE ARMING OFF driver’s door inside lock 3 times = PASSIVE ARMING ON, button 1 time. 0 Sec. ENTRY DELAY 4 times = PASSIVE ARMING ON, 15 Sec. ENTRY DELAY 5 times = PASSIVE ARMING ON, 30 Sec. ENTRY DELAY c. The system locks the door in 2 seconds; if this does not happen, start over. Programming is now complete. WARNING and CAUT TOYOTA RS3200 PLUS Security system Page 13 Warning • This product is applicable only to vehicles with 12V DC, negative grounding specifications. Do not use in vehicles with 24V specifications. Otherwise, damage to the unit or a fire may result. • Never attempt to disassemble or modify the product. Otherwise, an accident, fire or electric shock may result. • When replacing fuses, be sure to use fuses with the same specified capacity (amperage.) Otherwise, damage to the unit or vehicle, fire or electric shock may result. • If an abnormal condition occurs, such as liquids spilling onto the product, or the product emitting smoke or strange odors, stop using it immediately and consult the dealer from whom you purchased the product. Continued use of the product before corrective actions are taken may result in an accident, injury or fire. • Never pull the plastic bag over your head. Otherwise, a serious injury or death from suffocation may occur. Caution • Do not use this product for applications other than in-vehicle use. Otherwise, an electric shock or injury may result. • Do not allow children to play with the remote controls. Otherwise, the doors may be locked or unlocked, the security system armed or disarmed, or an alarm triggered unintentionally. • If this product is dropped or its case is damaged, disconnect the power supply lead and contact the dealer from whom you purchased it to obtain service. Otherwise, a fire or electric shock may result. RS3 SECURI DESIGN REMOT OWN 090002-25520700 TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Part Number: Mounting Kit PT546-89060 Tuner Assy 86180-0W030 Tuner Assy Kit Contents (86180-0W030) Item # Quantity Reqd. 1 1 Description TUNER ASSY, STEREO COMPONENT Quantity Reqd. 1 2 3 4 1 2 5 1 Description Antenna Bracket Ass’y SDARS Receiver Wire, To Radio Installation Base Bracket Ass’y SDARS Receiver Ground Cord Hardware Bag Contents 1 (PT546-89060) Item # 1 2 3 4 Quantity Reqd. 2 6 1 1 Description Cushion Tape (100mm×50mm) Lock Tie A Template Butyl cushions Quantity Reqd. 4 4 Quantity Reqd. 1 1 7 1 4 1 1 1 Quantity Reqd. Description Housing Template Nylon Tape (30mm×30mm) Lock Tie B Cable Rail (150mm) Cable Rail (20mm) Cable Rail (10mm) Cushion Tape (40mm ×80mm) Description Conflicts Vehicles with third row seat Recommended Tools Personal & Vehicle Protection Notes Wrench Socket Phillips Screwdriver Nylon Removal Tool Torque Wrench Open End, 10mm 10mm, 12mm, 14mm Utility Knife Masking Tape Special Chemicals Cleaner 03/02/06 Notes 3MTM Prepsolvent-70 General Applicability Accessory Vehicle Service Parts (may be required for reassembly) Item # 1 2 Quantity Reqd. Description Legend STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. Notes Safety Goggles Issue: A 4.1 N-m (3 lbf·ft), 42 N-m (31 lbf·ft), 37 N-m (27 lbf·ft) *Mandatory Additional Items Required For Installation Item # Installation Tools Item # 1 2 Description Screw (M5×L8 ) Nut (M6) Hardware Bag Contents 3 (PT546-89060) Item # 1 2 3 4 5 6 7 8 Notes Recommended Sequence of Application Hardware Bag Contents 2 (PT546-89060) Item # 1 2 Special Tools None Mounting Kit Contents (PT546-89060) Item # 1 2 Seat Covers Floor Protectors Page 1 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Preparation Parts Description of Tuner Assy (86180-0W030) Item # Parts Name Tuner 1 Parts No. Qty 86180-0W030 1 Parts Description of Mounting Kit (PT546-89060) Item # 1 2 3 4 5 6 7 8 9 10 A B C D E 11 F G H I Issue: A Parts Name Wire, To Radio Installation Cushion Tape (100mm x 50mm) Lock Tie A Ground cord Template Bracket Ass’y SDARS Receiver Base Bracket Ass’y SDARS Receiver Screw (M5 x L8) Nut (M6) Butyl Cushions Antenna Housing Template Nylon Tape (30mm x30mm) Lock Tie B Cable Rail (L=150mm) Cable Rail (L=20mm) Cable Rail (L=10mm) Cushion Tape (80mm x 40mm) 03/02/06 Parts No. Qty 1 2 6 1 1 2 2 4 4 1 1 1 1 7 1 4 1 1 1 Page 2 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Remove the Negative (–) Battery Cable. (Fig. 1-1): Negative battery cable (a) Protect the fender before removing the battery cable. (b) Be careful not to touch the positive terminal. 10 mm Socket Fig. 1-1 2. Disassembly of Rear Cargo Area. (a) Remove the trunk mat. (Fig. 2-1) (b) Remove the rear scuff trim. (Fig. 2-2) (c) Remove the rear deck board (Fig 2-2) Fig. 2-1 Rear deck board Rear scuff trim Fig. 2-2 Issue: A 03/02/06 Bolts x 2 Screw x5 Phillips screwdriver 12mm socket Page 3 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (d) Rear right seat (Fig. 2-3) (1) Remove rear right seat back headrests. (2) Fold seat bench forward by lifting rear of seat forward. (3) Pull the rear seatback release button and tilt the rear right seat back forward. Fig. 2-3 (e) Remove RR Seat Belt Anchor and Trim Cover. (Fig 2-4) 14mm socket Nylon Pry Tool NOTE: Use protective cloth and tape to cover seat belt anchor after removal. Bolt x 1 Trim Cover Fig. 2-4 (f) Remove rear right door scuff plate. (Fig 2-5) (g) Remove the right rear trim panel. (Fig. 2-6) Clips x 7 (1) Remove 2 bolts as shown. Fold back right rear cargo area carpet and remove 3 screws securing quarter panel trim. (2) Using Nylon Pry Tool remove the plastic plugs as shown. Nylon Pry Tool Fig. 2-5 (3) Disconnect the auxiliary power jack. 10mm Socket Phillips Screwdriver Nylon Pry Tool Bolts x 2 Plastic Plug Fig. 2-6 Issue: A Screws x 3 03/02/06 Auxiliary power jack Page 4 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (h) Remove the taillight 10mm Open ended wrench (1) From the inside corner, remove the tail lamp nuts, disconnect the harness connector, then remove the tail lamp assembly. (Fig. 2-7) Nut x2 (i) Remove front seat belt anchor and B-pillar trim panel. Fig. (2-8) Fig. 2-7 3. Disassemble Vehicle Interior (a) Remove the front right scuff plate and cowl side trim. Clips x 6 (1) Remove the right scuff plate, and then remove the cowl side trim (R). (Fig 3-1) Fig. 2-8 Bolt x 1 (2) Remove the scuff plate in order from front (c) to rear (d) using a nylon pry tool. 14 mm Socket Nylon Pry Tool Molded Pins (x6) Nylon Pry Tool Molded Pins (x2) (3) Remove the cowl side trim, secured by one (1) clip and two (2) molded pins. (b) Remove front seat belt anchor and B-pillar trim panel. Fig. (3-2) Fig. 3-1 Clips x 6 Fig. 3-2 Issue: A Bolt x 1 03/02/06 14 mm Socket Nylon Pry Tool Page 5 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (c) Remove the glove compartment door. (1) Release the glove compartment stoppers by pressing both glove box side panels inward. (Fig. 3-3) Phillips #2 Stubby Screwdriver (2) Remove the damper, using a Phillips #2 stubby screwdriver. (3) Remove the glove box from the hinge hooks on the rear. Fig. 3-3 (d) Remove the upper glove box. (1) Remove the screws, then pull the upper glove box trim outward to access the SRS harness connector. (Fig. 3-4 Screws x4 (2) Push the SRS harness bracket clips inward to release the bracket from the glove box trim. (Fig. 3-5) (3) Disengage the SRS harness connector bracket, and then remove the upper glove box. Fig. 3-4 SRS Harness Bracket Clips (e) Remove Shift Cover, Side Covers and Coin Box. (Fig. 3-6) (1) Protect center cluster with the tape to avoid the damage to center cluster when removing console box. Fig. 3-5 (2) Remove the shift cover in order from c to h using a nylon pry tool. (3) Use the nylon pry tool to disengage the clip under the left side cover (L). (4) Use the nylon pry tool to disengage clip under the right side cover (R). Nylon Pry Tool Fig. 3-6 Issue: A 03/02/06 (5) Unplug the connector. Page 6 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (f) Remove the Center Console Cover. (1) Use nylon pry tool to disengage six clips on rear cover as shown. (Fig. 3-7) (g) Remove driver’s side underdash trim panel. (Fig. 3-8). Fig. 3-7 (1) The dash panel must be removed to access the center console bolt. Nylon Pry Tool (2) Remove 2 bolts as shown. (3) Disengage 4 claws using Nylon Pry Tool. (h) Remove the air conditioner unit. (Fig. 3-9) Bolts x 2 Claws x 4 (1) Remove the screw on air conditioner unit with a Phillips screwdriver. (2) Remove plug from cluster. Nylon Pry Tool 10 mm Socket Fig. 3-8 (3) Remove two (2) plugs from the center cluster. (i) Remove the Audio Unit (Fig. 3-9) (1) Using a 10 mm socket, remove two bolts on the audio unit. (2) Remove the connectors from the rear of the unit. Phillips Screwdriver 10 mm Socket Fig. 3-9 14 mm Socket (j) Remove the Front Passenger Seat. (1) Remove the covers and bolts (x4) from the front passenger seat mounting bracket, then tilt the seat backwards. (Fig.s 3-10 and 3-11) NOTE: Do not disconnect the harness from the seat or remove the seat from the vehicle. Seat bolts and covers x4 Fig. 3-10 Issue: A 03/02/06 Page 7 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure Rear side seat bolt and cover Front side seat bolt and cover Fig. 3-11 4. Antenna Installation Template Tailgate Fig. 4-1 Center of Roof (a) Using 3MTM Prepsolvent-70, carefully clean the mounting surface for the template, antenna, tape, and cable rails. (b) Tape the antenna mounting template onto the rear roof section. (Fig. 4-1) TAPE (1) Remove the backing from the antenna, and then install the antenna onto the roof along the template guide lines. Remove and discard the template. 10mm Cable Rail Rear door Antenna wire (c) Route the antenna wire as follows. Tape Cable rails x2 - 150mm (1) Route the antenna wire into and along the rear door channel toward the RR tail lamp to route the antenna wire as shown. (Fig. 4-2, Fig. 4-3) Fig. 4-2 20mm Cable rail Cable rails x2 150mm Fig. 4-3 Issue: A 03/02/06 Page 8 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (d) Insert the antenna wire through the access hole in the tail lamp mounting base and into the vehicle interior. (Fig. 4-4) RR tail lamp mounting base Access hole between body walls NOTE: Do not take off Anti-Static Bag until antenna terminal is plugged into Satellite Receiver. Anti-Static Bag Fig. 4-4 (1) Slide grommet to remove any slack. (2) Plug the access hole with the rubber grommet supplied with the antenna wire. (3) Tape the antenna wire in the tail lamp area as shown. (Fig. 4-5) Tape x5 NOTE: Using 3MTM Prepsolvent-70, carefully clean any tape mounting surface. Fig.4-5 (e) Cut the supplied foam cushion tape in half. Cushion tape (g) Route the antenna wire along the right rear body panel with the windshield washer hose and using existing wire clips. Apply ½ foam cushion tape to the body panel at location shown. (Fig 4-7) Antenna Wire Fig. 4-6 ½ foam cushion tape Fig. 4-7 Issue: A (f) Remove excess antenna slack, then secure to the body panel with ½ cushion tape as shown. (Fig. 4-6) 03/02/06 Page 9 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure If equipped with optional subwoofer. NOTE: Apply ½ foam cushion tape to the existing wire harness if equipped with subwoofer assy. (Fig 4-8) (h) Route the antenna wire with the rear window washer hose along the RR door sill. Stop at the B-pillar. (Fig.s 4-9, 4-10) ½ foam cushion tape Fig. 4-8 (i) Route antenna wire along existing wire harness along wheel well. Lock tie to existing harness. (Fig 4-9) Washer hose RH rear door opening Lock tie Antenna wire Fig. 4-9 Existing harness clamps (j) Secure antenna wire under the existing harness clamps on the RR rear door sill. (Fig. 4-10) 5. Install the Tuner Harness and Ground Wire. Secure antenna cable here (a) Install the Tuner Harness Fig. 4-10 Radio harness Tuner harness Lock tie x2 (1) Starting from the cowl side area, route the tuner harness upwards into the glove box area above the reinforcement bar, then into the center opening. (Fig 5-1, 5-2, and 5-3) Ground wire Fig. 5-1 Issue: A 03/02/06 Page 10 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (b) Install the Ground Wire. 10 mm Socket (1) Route the ground wire into the cowl side trim area, then attach the ground terminal onto the existing ground screw as shown (Fig 5-2) Lock tie (c) Install lock ties. Ground connection Fig. 5-2 (1) Install 1 Lock Tie to secure the tuner harness to the existing harness. (Fig. 5-2) (2) Install 2 Lock Ties to secure the tuner harness to the existing harness. (Fig. 5-3) Lock tie x2 (3) Install 1 Lock Tie to secure the tuner harness to the existing harness. (Fig. 5-4) Fig. 5-3 6. Install the Tuner and Harness (a) Cut the carpet opening at the location shown to allow the seat harness to be moved without damaging connectors to the seat. (Fig. 6-1) Lock tie NOTE: Be careful not to cut seat harness Fig. 5-4 120 mm Cut Floor Carpet Utility Knife Fig. 6-1 Issue: A 03/02/06 Page 11 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure (b) Align the template on the carpet. Using the existing cut along the side of the heater duct place the left mounting bracket at this location. Using the bracket as a template, transfer the hole locations to the carpet then cut two 7 mm holes onto the carpet. (Fig. 6-2) Cut Two 7 mm Holes Utility Knife Fig. 6-2 Tuner base bracket, LH (c) Add butyl cushions spacers (adhesive pads) to the tuner base brackets. (Fig. 6-3) Add corner pad Adhesive pad x4 Tuner base bracket, RH FWD Fig. 6-3 Tuner unit Phillips Screwdriver (d) Assemble the side brackets onto the tuner. (Fig. 6-4) Side bracket x2 Hex screws x4 Fig. 6-4 Cushion tape (100 x 50mm) (e) Route the antenna wire from the B-Pillar area toward the tuner mounting area, then tape the antenna wire in place as shown. (Fig. 6-5) (f) Route the tuner harness and ground wire along the rear right door scuff plate channel then toward the tuner mounting area. B-pillar Antenna wire Fig. 6-5 Issue: A 03/02/06 Page 12 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure Antenna Wire Existing seat harness Ground Wire (g) Route harness and wires to the tuner mount area. (Fig. 6-6) (1) Relocate the existing seat harness into the new opening shown. NOTE: Route the tuner harness, antenna wire and ground wire through carpet openings. Fig. 6-6 1 - Remove to insert terminal. (h) Take off Anti-Static bag and insert the antenna terminal into the connector housing. (Fig. 6-7) Connector housing 2 - Replace to lock. 3 - Insert antenna terminal into connector Antenna wire Fig. 6-7 (i) Install the tuner unit. (Fig. 6-8) NOTE: Trial fit the tuner before mounting in place. Cushion Tape Nuts x 4 (1) Using 3MTM Prepsolvent-70, carefully clean the mounting surface. (2) Remove the adhesive backing from each tuner base bracket, then install onto the floor of the vehicle with the studs sticking up through the carpet openings. Fig. 6-8 (3) Install the tuner onto the base brackets as shown using the M6 nuts. (Fig. 6-8) (4) Install the ground wire terminal under one of the side bracket screws. (5) Plug the tuner cable and antenna cable into the tuner unit. (6) Tape the existing seat harness to the top of the tuner. (Fig. 6-8) Issue: A 03/02/06 Page 13 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Procedure 7. Re-install the Radio Unit Tuner harness (a) Plug the tuner connector into the radio unit, and then reinstall the radio. (Fig. 7-1) (b) If the vehicle is equipped with other options, such as any radio controlled unit, use and connect the other harness connectors from the additional modules to the radio unit. Radio unit Fig. 7-1 8. Reconnect the Negative Battery Cable. Negative battery cable (a) Reconnected the vehicle’s negative battery cable at original factory position. (Fig. 8-1) (1) Tighten the nut to 36 lbf in. (4.1 N-m) (2) Do not touch the positive terminal with any tool when replacing the cable. 9. Proceed to Checklist (page 15) 10 mm Socket, Torque Wrench Fig. 8-1 (a) Complete checklist before reassembly of vehicle. 10. Reassembly (1) Reassemble the removed panels and connectors. (2) Reinstall the front seat bolts. Specified tightening torque: 37 N-m (375 kgf-cm) (27 lbf-ft) (3) Reinstall seat belt anchor bolts: Specified tightening torque: 42 N-m (430 kgf-cm) (31 lbf-ft) Issue: A 03/02/06 Page 14 of 15 pages TOYOTA 4RUNNER 2006 - xM SATELLITE RADIO Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Verify the proper operation of the satellite radio tuner. Refer to the tuner assembly and radio owner’s manuals. Verify the proper operation of the tuner assembly and radio. Refer to the tuner assembly and radio owner’s manuals. Vehicle Function Checks Verify the proper operation of the hazard switch. Verify the removed seat is securely fastened. Verify the proper operation of the removed seat lock mechanism. Verify the proper operation of the air conditioning system. Verify the proper operation of the multiinformation displays. Verify the proper operation of the R/R taillight assembly. Verify the proper operation of the rear 12V auxiliary power jack. Verify the proper operation of the 4WD switch. Verify the proper operation of the Rear window switch. Verify the proper operation of the differential lock switch. Verify the proper operation of the seat heaters. Issue: A 03/02/06 Page 15 of 15 pages TOYOTA ALL VEHICLES ALL YEARS FIRST AID KIT Preparation NOTE: Part number of this accessory may not be the same as the part number shown. Vehicle Service Parts (may be required for reassembly) Part Number: PT420-03023 Kit Contents Item # 1 2 3 Quantity Reqd. 1 Item # 1 2 3 Description First Aid Kit Hardware Bag Contents Item # 1 2 3 Quantity Reqd. Quantity Reqd. Description Legend Description Additional Items Required For Installation Item # 1 2 3 Quantity Reqd. Description Conflicts STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. Note: None Recommended Tools Personal & Vehicle Protection Notes None Special Tools Notes None Installation Tools Notes None Special Chemicals Notes None General Applicability Note: All Toyota Vehicles Recommended Sequence of Application Item # 1 2 3 Accessory *Mandatory Issue: G 09/26/06 Page 1 of 3 pages PPO TOYOTA ALL VEHICLES ALL YEARS FIRST AID KIT Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. NOTES: “FAK” denotes First Aid Kit 1. Install First Aid Kit. (A) Cars / SUVs / VAN: Place the FAK in the right rear corner of the trunk / cargo area of the vehicle. (Do not remove FAK from package). (Fig 1-1) Fig. 1-1 (B) Trucks: Place the FAK on the right / front floor of the vehicle. (Do not remove FAK from package). (Fig 1-2) Fig. 1-2 Issue: G 09/26/06 Page 2 of 3 pages PPO TOYOTA ALL VEHICLES ALL YEARS FIRST AID KIT Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Confirm proper placement of First Aid Kit. Whenever possible, “Toyota” name is visible and upright. Vehicle Function Checks Issue: G 09/26/06 Page 3 of 3 pages PPO XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 1 TOYOTA and SCION XM Satellite Radio Tuner 86180-0W030 TROUBLESHOOTING GUIDE Rev. A 12/12/2006 PAGE - 2 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE TABLE OF CONTENTS DESCRIPTION PAGE Failure Analysis by the DTC (DIAGNOSTIC TROUBLE CODE) for the Navigation system 3 - 8, 17, 18 Failure Analysis by the DTC for the Audio system 9 – 18 Satellite Radio Tuner Power Source Circuit 19 Satellite Radio Broadcast cannot be Received 20 - 23 Cannot Change from FM / AM to Satellite Radio 24 -25 Satellite Radio Broadcast cannot be selected or After Selecting Broadcast, Broadcast cannot be added into Memory 26 - 28 Satellite Radio cannot Receive Pay Type Broadcasts 29 - 30 Warning This troubleshooting guide is in addition to the Audio or Navigation System Troubleshooting Guide for the XM Satellite Radio Tuner (86180-0W030) of each vehicle. Therefore, if you analyze the XM satellite radio tuner failure mode, you have to refer not only this guide but also the vehicle audio or navigation system troubleshooting guide and the XM radio tuner installation manual at the same time. *In some multimedia and navigation systems, if you disconnect the negative (-) battery terminal, you may have to initialize the multi media systems after the cable is reconnected. You may also have to refer the vehicle audio or navigation system troubleshooting guide about these procedures. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 3 Failure Analysis by the DTC (DIAGNOSTIC TROUBLE CODE) for the Navigation system DTC CHECK / CLEAR HINT: • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. • If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication components and repair or replace problem parts (see VEHICLE AUDIO AND VISUAL SYSTEM TROUBLESHOOTING GUIDE). • After the engine switch is turned on (IG), check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. 1. START DIAGNOSTIC MODE (a) Turn the engine switch on (ACC). (b) Press the "DISP" switch. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 4 (b) From the display quality adjustment screen, touch the corners of the screen in the following order: upper left →lower left →upper left →lower left →upper left →lower left. (c) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. 2. FINISH DIAGNOSTIC MODE (a) Turn the engine switch off. 3. DIAGNOSIS MENU (a) Press the menu button on the “System Check Mode” screen to enter the "Diagnosis MENU“. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 5 4. CHECK DTC (a) Read the system check result. (1) If the check result is "EXCH", "CHEK“ or "Old", touch the displayed check result to view the results on the "Unit Check Mode" screen and record them. HINT: If all check results are "OK", go to the communication DTC check. If a device name is not known, its physical address is displayed. HINT: When proceeding to view the results of another device, press the service switch to return to the "System Check Mode" screen. Repeat this step. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 6 (b) Read the communication diagnostic check result. (1) Return to the "System Check Mode“ screen, and press the "LAN Mon“ switch to enter the "LAN Monitor“ screen. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 7 (2) If the check result is "CHEK" or "OLd", touch the displayed check result to view the results on the individual communication diagnostic screen and record them. HINT: If all check results are "No Err", the system judges that no DTC exists. The sub-code (relevant device) will be indicated by its physical address. When proceeding to view the results of another device, press the "Service" switch to return to the original "LAN Monitor" screen. Repeat this step. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 8 5. DTC CLEAR/RECHECK (a) Clear DTC (1) Press the "Code CLR" switch for 3 seconds. (2) The check results are cleared. (b) Recheck (1) Press the "Recheck" switch. (2) Confirm that all diagnostic codes are "OK" when the check results are displayed. If a code other than "OK" is displayed, troubleshoot again. (3) Press the "LAN Mon" switch to change to the "LAN Monitor“ screen. (4) Confirm that all diagnostic codes are "No Err". If a code other than "No Err" is displayed, troubleshoot again. NEXT GO TO DESCRIPTION TABLE (See Page 17) XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 9 Failure Analysis by the DTC (DIAGNOSTIC TROUBLE CODE) for the Audio system DTC CHECK / CLEAR HINT: • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. • If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication components and repair or replace problem parts (see VEHICLE AUDIO AND VISUAL SYSTEM TROUBLESHOOTING GUIDE). 1. START DIAGNOSTIC MODE (a) Turn the engine switch on (ACC). (b) Turn off the audio system. (c) While pressing the preset switches "1" and "6" at the same time, press the "DISC" switch 3 times. HINT: A beep is emitted 3 times and the diagnostic function is activated. The system enters the all element illumination mode and the switch check mode. 2. SERVICE CHECK MODE (a) Press the "SEEK TRACK UP" switch. HINT: For details of the service check mode, refer to “4.CHECK DTC" and “5. DTC CLEAR/RECHECK". 3. FINISHING DIAGNOSTIC MODE • Press the "DISC" switch for 2 seconds or more, or turn the engine switch off. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 10 4. CHECK DTC HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. (a) Reference: In the system check mode, the system check and the diagnostic memory check are performed, and the check results are displayed in ascending order of the component codes (physical address). (b) Service check result display (c) Device name and physical address Physical Address # Equipment 190 Audio (Radio receiver) 440 Stereo component Amplifier 19D(*1) 1F1 "Bluetooth" Hands Free Module XM Satellite Radio Tuner *1: for Radio Receiver with Built-in "Bluetooth" Hands free Function XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 11 (d) Service check mode (1) Press the "SEEK TRACK" switch to see the check result of each component. (2) The component code (physical address) is displayed first, and then the check result follows. HINT: • If all check results are “good”, the system judges that no DTC exists. • If the preset switch "1" is pressed in the service check mode, service check is performed again. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 12 (e) Detailed information mode 1 HINT: • “Detailed information mode 1” is displayed when there is no response to “System Check Result Request" and DTC is detected only in "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch “2” to go to the “Detailed Information Mode 1". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch “3” to go to the “Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request“ and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode" and "Diagnostic Memory code" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 1", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request" contains the information received from each ECU or stored in each ECU in the past. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 13 • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)“ is displayed first, and then the logical address and DTC appear in order. • "Diagnostic Memory Request (COdE)" is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 14 (f) Detailed information mode 2 HINT: • "Detailed information mode 2" is displayed when DTCs are detected in the responses to both "System Check Result Request" and "Diagnostic Memory Request". • The component device code (physical address) is displayed first, and then the check result follows. • This illustration is only an example and may differ in cases such as for each option part and output DTCs. (1) Press the preset switch "2" to go to the "Detailed Information Mode 2". (2) Press the "SEEK TRACK" switch to display the physical address and DTC of the component. (3) Press the preset switch "3" to go to the "Service Check Mode". (4) Distinguish between the displays of the responses to "System Check Result Request“ and "Diagnostic Memory Request". In order to distinguish the information detected in "System Check Mode“ and "Diagnostic Memory Mode" in "ECHn", "CHEC", and "OLd" in "Detailed Information Mode 2", refer to the following: • "SyS" is displayed before the detailed codes detected as a result of "System Check Result Request" are displayed. • "COdE" is displayed before the detailed codes detected as a result of "Diagnostic Memory Request" are displayed. HINT: • The response to "System Check Result Request" is the current information given from each ECU as a result of the system check. • The response to "Diagnostic Memory Request“ contains the information received from each ECU or stored in each ECU in the past. • The response to "Diagnostic Memory Request" is the output DTCs as a result of the diagnostic memory check or the DTCs received from each ECU. • "System Check Result Request (SyS)“ is displayed first, and then the logical address and DTC appear in order. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 15 • "Diagnostic Memory Request (COdE)“ is displayed first, and then the logical address, DTC, sub-code, connection check number, and the number of occurrence appear in order. XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 16 5. DTC CLEAR/RECHECK (a) Clearing All DTC Memory (when clearing all the memory of the DTCs previously detected). (1) When the preset switch "5" is pressed for 2 seconds or more during "Service Check Mode", the DTCs for all components are cleared. ("CLr“ is displayed at this time.) HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory for all the components is cleared, only the component codes (physical address) are displayed. • After the DTC memory is cleared, the "Service Check Mode" is restored. (b) Clearing Individual DTC Memory (when clearing the memory of the DTC previously detected individually). (1) When the preset switch "5" is pressed for 2 seconds or more during "Detailed Information Mode 1" or "Detailed Information Mode 2", the DTCs for the target component are cleared. HINT: • A beep sound is emitted once when the DTC memory is completely cleared. • When the DTC memory is cleared, only the component code (physical address) is displayed for the target component. • After the DTC memory is cleared, the "Service Check Mode" is restored. • To check DTCs, press the preset switch "1“ and perform the system check again. (c) Press the preset switch "1" to perform the service check again, and check that no DTCs are displayed for all the component codes (physical address). NEXT GO TO DESCRIPTION TABLE (See Page 17) XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE DTC C0-11 Satellite Radio Tuner Internal Circuit Error 1 DTC C0-12 Satellite Radio Tuner Internal Circuit Error 2 DTC C0-13 Satellite Radio Tuner Internal Circuit Error 3 DTC C0-14 Satellite Radio Tuner Internal Circuit Error 4 DTC C0-15 Satellite Radio Tuner Internal Circuit Error 5 DTC C0-16 Satellite Radio Tuner Internal Circuit Error 6 PAGE - 17 CAUTION: Audio system will display “ _ ” instead of “ - ” on the DTC #. DESCRIPTION DTC No. DTC Detection Condition Trouble Area C0-11 Satellite radio tuner malfunction Satellite radio tuner C0-12 C0-13 C0-14 C0-15 C0-16 INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK SURROUNDINGS • Check if the vehicle is in an environment where reception is difficult due to something blocking the area above the vehicle. HINT: If the area above the vehicle is blocked, such as when in a building or tunnel, reception may not be possible. OK: Area above vehicle is not blocked XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE NG PAGE - 18 END (MOVE THE VEHICLE TO LOCATION OK PROCEED TO NEXT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PAGE - 19 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE Satellite Radio Tuner Power Source Circuit INSPECTION PROCEDURE 1 INSPECT FUSE • Remove the ACC and +B FUSE from the junction block. (b) Measure the resistance of the FUSE. Standard resistance Tester Connection Condition Specified Condition ACC Always Below 1 Ohm +B Always Below 1 Ohm NG REPLACE FUSE OK 2 CHECK HARNESS AND CONNECTOR (SATELLITE RADIO TUNER - BATTERY AND BODY GROUND) (a) Disconnect the left picture’s tuner connector. •Measure the resistance according to the value(s) in the below table. Standard resistance Tester Connection Condition Terminal #7 - Body GND Always Specified Condition Below 1 Ohm (c) Measure the voltage according to the value(s) in the below table. Standard voltage Tester Connection OK Condition Specified Condition Terminal #12(+B) - Terminal #7(GND) Always 11 to 14V Terminal #11(ACC) - Terminal #7(GND) Always 11 to 14V NG REPAIR OR REPLACE, HARNESS OR CONNECTOR PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 20 Satellite Radio Broadcast cannot be Received INSPECTION PROCEDURE NOTICE: Some satellite radio broadcast require payment. A contract must be made between a satellite radio company and the user. If the contract expires, the broadcast will not be able to be listened to or viewed. 1 CHECK AUDIO SYSTEM • Check if noise occurs when using other sources (CD,DVD, AM, FM, etc.). OK: Other sources are normal NG GO TO VEHICLE AUDIO AND VISUAL SYSTEM TROUBLESHOOTING GUIDE OK 2 CHECK SURROUNDINGS • Check if the vehicle is in an environment where reception is difficult due to something blocking the area above the vehicle. HINT: If the area above the vehicle is blocked, such as when in a building or tunnel, reception may not be possible. OK: Area above vehicle is not blocked NG OK 3 CHECK DISPLAY END (MOVE THE VEHICLE TO LOCATION PAGE - 21 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 3 CHECK DISPLAY (a) Check the display's screen. Result: Result Proceed to "OFF AIR" is displayed A "ANTENNA" is displayed B "LOADING" is displayed C "NO SIGNAL" is displayed D None of the displays above are shown E A CHANNEL IS CURRENTLY NOT BEING BROADCAST. IF BROADCAST RESUMES, MEMORY FUNCTION CAN BE PERFORMED B Go to step 5 C Go to step 7 D REPLACE SATELLITE RADIO TUNER ASSEMBLY (See Installation Manual) E 4 CONFIRM CURRENTLY SELECTED CHANNEL (a) Confirm if CH000 is currently selected. OK: CH000 is selected OK END (CH000 HAS NO SOUND. SELECT ANOTHER CHANNEL.) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PAGE - 22 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 5 CHECK DTC (a) Check for DTCs. Result: Result Proceed to "C0-40" is output A "C0-41" is output B CAUTION: Audio system will display “ _ ” instead of “ - ” as the DTC #. B REPLACE ANTENNA OR ANTENNA CABLE (See Installation Manual) A 6 CHECK CONNECTION OF ANTENNA CABLE (a) Check if the antenna cable is securely connected to the satellite radio tuner and antenna. OK: Antenna cable is securely connected. NG SECURELY CONNECT ANTENNA CABLE OK REPLACE ANTENNA OR ANTENNA CABLE (See Installation Manual) PAGE - 23 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 7 CHECK DTC (a) Check for DTCs. Result: Result Proceed to One of "C0-11", "C0-12", "C0-13", "C014", "C0-15" or "C0-16" is output "C0-41" is output A B CAUTION: Audio system will display “ _ ” instead of “ - ” as the DTC #. B MOVE VEHICLE TO LOCATION WHERE RECEPTION IS BETTER A REPLACE SATELLITE RADIO TUNER ASSEMBLY (See Installation Manual) PAGE - 24 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE Cannot Change from FM / AM to Satellite Radio INSPECTION PROCEDURE 1 CHECK DTC and DIAGNOSIS MENU (SYSTEM CHECK MODE) (a) Start the diagnostic mode Navigation system: See from page 3 Audio system: See from page 9 (b) Check the connection condition of the satellite radio tuner. Result: Result Proceed to NCON or NRES is displayed, or there is no display EXCH or CHECK is displayed B OK C B REPLACE SATELLITE RADIO TUNER ASSEMBLY (See Installation Manual) C REPLACE RADIO RECEIVER (See Installation Manual) A 2 A CHECK CONNECTION OF SATELLITE RADIO TUNER (a) Check if the wire harness is securely connected to the satellite radio tuner. OK: Wire harness is securely connected. NG SECURELY CONNECT WIRE HARNESS OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 25 Noise Occurs Only with Satellite Radio INSPECTION PROCEDURE 1 CHECK AUDIO SYSTEM (a) Check if noise occurs when using other sources (CD,DVD, AM, FM, etc.). OK: Other sources are normal NG GO TO VEHICLE AUDIO AND VISUAL SYSTEM TROUBLESHOOTING GUIDE OK CHECK WIRE HARNESS (SATELLITE RADIO TUNER - ANTENNA AND RADIO RECEIVER) PAGE - 26 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE Satellite Radio Broadcast cannot be Selected or After Selecting Broadcast, Broadcast cannot be Added into Memory INSPECTION PROCEDURE 1 CHECK SATELLITE RADIO (a) Check radio condition. Result Result Proceed to Broadcast cannot be selected Broadcast can be selected, but selection can be memorized B A 2 A B Go to step 6 CHECK CONTRACT CONDITIONS (a) Check if the pay-type contract has been extended, or if the contract period has ended. OK: Pay-type contract is valid NG TO RECEIVE PAY-TYPE BROADCASTS, CONTRACT MUST BE MADE WITH THE XM SATELLITE RADIO COMPANY OK 3 PERFORM ACTIVATION REFRESH BY REFERRING TO XM SATELLITE RADIO COMPANY WEB SITE (http://www/xmradio.com/refresh) (a) Perform activation refresh by referring to XM satellite radio company web site (http:www.xmradio.com/refresh/). OK: Malfunction disappears OK NG 4 CHECK DISPLAY END PAGE - 27 XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 4 CHECK DISPLAY (a) Check the display's screen. Result: Result Proceed to "OFF AIR" is displayed A After "---" is displayed, display B automatically switches to CH001 Other C A CHANNEL IS CURRENTLY NOT BEING BROADCAST. IF BROADCAST RESUMES, SELECTION CAN BE PERFORMED (CONFIRM WITH RADIO STATION) B CHANNEL BROADCAST HAS ENDED (CONFIRM WITH RADIO STATION) C 5 CHECK DTC • Start the diagnostic mode Navigation system: See from page 3 Audio system: See from page 9 • Check DTCs Result: Result Proceed to "C0-16" is not output A "C0-16" is output B CAUTION: Audio system will display “ _ ” instead of “ - ” as the DTC #. B REPLACE SATELLITE RADIO TUNER ASSEMBLY (See Installation Manual) A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 6 PAGE - 28 CHECK SATELLITE RADIO MODE ON AV SYSTEM (a) Check if all preset channels have been erased. OK: Preset channels are all erased OK Go to step 8 NG 7 ADD PRESET CHANNEL INTO MEMORY AGAIN (a) Check if the preset channels that have been erased can be added into memory again. OK: Preset channels can be added into memory NG Go to step 5 OK 8 CHECK BATTERY (a) Check if the battery was replaced. OK: Battery was not replaced. OK Go to step 5 NG ADD PRESET CHANNEL INTO MEMORY AGAIN XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE PAGE - 29 Satellite Radio cannot Receive Pay Type Broadcasts INSPECTION PROCEDURE NOTICE: Some satellite radio broadcast require payment. A contract must be made between a satellite radio company and the user. If the contract expires, the broadcast will not be able to be listened to or viewed. 1 CHECK SATELLITE RADIO (a) Check if CH001 (free broadcast) can be received. OK: Can be received NG OK 2 GO TO "SATELLITE RADIO BROADCAST CANNOT BE RECEIVED“ FLOWCHART (See page 20) CHECK CONTRACT CONDITIONS (a) Check if the pay-type contract has been extended, or if the contract period has ended. OK: Pay-type contract is valid NG OK Go to step 3 TO RECEIVE PAY-TYPE BROADCASTS, CONTRACT MUST BE MADE WITH XM SATELLITE RADIO COMPANY XM SATELLITE RADIO TUNER TROUBLESHOOTING GUIDE 3 PAGE - 30 PERFORM ACTIVATION REFRESH (a) Perform activation refresh. HINT: Refer to the satellite radio tuner company's homepage. http:www.xmradio.com/refresh/ OK: Malfunction disappears NG OK END REPLACE SATELLITE RADIO TUNER ASSEMBLY (See Installation Manual ) BODY DIMENSIONS BODY DIMENSION DRAWINGS ENGINE COMPARTMENT DI-3 BODY DIMENSIONS BODY OPENING AREAS (Side View: Rear) DI-5 DI-6 BODY DIMENSIONS BODY OPENING AREAS (Rear View) DI-4 BODY DIMENSIONS BODY OPENING AREAS (Side View: Front) BODY DIMENSIONS DI-9 FRAME DIMENSION-Upper Face (Three-Dimensional Distance) 755 (29.72) 1,286 (50.63) 778 (30.63) 926 (36.46) 1,986 (78.19) 774 (30.47) 994 (39.13) 1,556 (61.26) 1,030 (40.55) 1,263 (49.72) 1,259 (49.57) 1,360 (53.54) 1,041 (40.98) 952 (37.48) Front 383 (15.08) 300 (11.81) 300 (11.81) 419 (16.50) 402 (15.83) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Wire harness installation hole Hole dia. A, a Power steering tube installation nut 8 (0.31) nut D, d B, b Side rail inner channel standard hole 16
16 (0.63
0.63) E Side rail inner channel working nut 8 (0.31) nut 10 (0.39) C, c Side rail inner channel standard hole 20 (0.79) e Air suspension unit installation nut 8 (0.31) nut BODY DIMENSIONS DI-10 FRAME DIMENSION-Upper Face (Cont’d) (Two-Dimensional Distance) 2,033 (80.04) 767 (30.20) 515 (20.28) 387 (15.24) 497 (19.57) 476 (18.74) 515 (20.28) 521 (20.51) 755 (29.72) 1,692 (66.61) Front Wheel base 383 (15.08) 300 (11.81) 2,790 (109.84) 300 (11.81) 419 (16.50) 402 (15.83) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Wire harness installation hole Hole dia. A, a Power steering tube installation nut 8 (0.31) nut D, d B, b Side rail inner channel standard hole 16
16 (0.63
0.63) E Side rail ilnner channel working nut 8 (0.31) nut 10 (0.39) C, c Side rail inner channel standard hole 20 (0.79) e Air suspension unit installation nut 8 (0.31) nut BODY DIMENSIONS DI-11 FRAME DIMENSION-Lower Face (Three-Dimensional Distance) 995 (39.17) 1,095 (43.11) 795 (31.30) 1,411 (55.55) 1,030 (40.55) 994 (39.13) 1,062 (41.81) 908 (35.75) 1,339 (52.72) 941 (37.05) 1,419 (55.87) 1,456 (57.32) 1,055 (41.54) Front 284 (11.18) 140 (5.51) 140 (5.51) 320 (12.60) 305 (12.01) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Stabilizer bracket installation nut 10 (0.39) nut D, d Height control sensor bracket installation nut 8 (0.31) nut B, b Side rail inner channel standard hole 16
16 (0.63
0.63) E, e Transport hook installation nut 12 (0.47) nut C, c Side rail inner channel standard hole 20 (0.79) — — — BODY DIMENSIONS DI-12 FRAME DIMENSION-Lower Face (Cont’d) (Two-Dimensional Distance) 2,076 (81.73) 889 (35.00) 515 (20.28) 398 (15.67) 497 (19.57) 470 (18.50) 515 (20.28) 528 (20.79) 995 (39.17) 1,949 (76.73) Front Wheel base 284 (11.18) 140 (5.51) 2,790 (109.84) 140 (5.51) 320 (12.60) 305 (12.01) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Stabilizer bracket installation nut 10 (0.39) nut D, d Height control sensor bracket installation nut 8 (0.31) nut B, b Side rail inner channel standard hole 16
16 (0.63
0.63) E, e Transport hook installation nut 12 (0.47) nut C, c Side rail inner channel standard hole 20 (0.79) — — — BODY DIMENSIONS DI-7 FRAME DIMENSION (Three-Dimensional Distance) 1,687 (66.42) 1,082 (42.60) 473 (18.62) 271 (10.67) 1,548 (60.94) 959 (37.76) 1,335 (52.56) 1,325 (52.17) 1,012 680 (39.84) (26.77) 732 (28.82) 680 (26.77) 1,277 (50.28) 1,054 (41.50) 610 (24.02) 959 (37.76) 934 (36.77) 2,119 (83.43) 1,856 (73.07) 1,290 (50.79) 1,287 (50.67) 479 (18.86) 680 (26.77) Front 371 (14.61) 96 608 105 (3.78) (23.94) (4.13) 232 (9.13) 105 (4.13) 259 (10.20) 300 (11.81) 210 (8.27) 371 (14.61) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Body mounting hole 26 (1.02) F, f Lower control link installation hole B, b Suspension lower arm installation hole 38
20 (1.50
0.79) G, g Body mounting hole 14.2 (0.56) C, c Shock absorber installation hole 12.15 (0.478) H, h Upper control link installation hole 12.15 (0.478) D, d Suspension lower arm installation hole 32.5
14.5 (1.280
0.571) I Lateral control rod installation hole 15 (0.59) E, e Body mounting hole 43 (1.69) J, j Body mounting hole 43 (1.69) 43 (1.69) BODY DIMENSIONS DI-8 FRAME DIMENSION (Cont’d) (Two-Dimensional Distance) 2,748 (108.19) 2,237 (88.07) 480 (18.90) 506 (19.92) 340 (13.39) 2,324 (91.50) 1,687 (66.42) 294 (11,57) 638 (25.12) 644 (25.35) 340 (13.39) 305 (12.01) 676 (26.61) 570 (22.44) 644 (25.35) 2.053 (80.83) 527 (20.75) 645 (25.39) 83 (3.27) 1,331 (52.40) Front Wheel base 371 (14.61) 96 608 105 (3.78) (23.94) (4.13) 2,790 (109.84) 232 (9.13) 105 (4.13) 259 (10.20) 300 (11.81) 210 (8.27) 371 (14.61) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Body mounting hole 26 (1.02) F, f Lower control link installation hole B, b Suspension lower arm installation hole 38
20 (1.50
0.79) G, g Body mounting hole 14.2 (0.56) C, c Shock absorber installation hole 12.15 (0.478) H, h Upper control lilnk installation hole 12.15 (0.478) D, d Suspension lower arm installation hole 32.5
14.5 (1.280
0.571) I Lateral control rod installation hole 15 (0.59) E, e Body mounting hole 43 (1.69) J, j Body mounting hole 43 (1.69) 43 (1.69) BODY DIMENSIONS Three-dimensional distance Center-to-center straight-line distance DI-1 GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance)
Straight-line distance between the centers of two measuring points. Two-dimensional distance Vertical distance in center Center-to-center Horizontal distance in forward / rearward Vertical distance in lower surface Imaginary Standard Line Under Surface of The Rocker Panel (2) (Two-dimensional distance)
Horizontal distance in forward/rearward between the centers of two measuring points.
The height from an imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.) SYMBOL Name 1 The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. 2 The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point. Imaginary Standard Line BODY DIMENSIONS DI-2 Plate Looseness Body Looseness Pointer Looseness 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. Pointer Master Gauge Wrong HINT: 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3) Take care not to drop the tracking gauge or otherwise shock it. 4) Confirm that the pointers are securely in the holes. Correct Pointer Front Spring Support Inner Hole Tape Measure Along Body Surface Front Suspension Member Rear Side Upper Installation Hole (c) When using a tape measure, avoid twists and bends in the tape. (d) When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface. BODY PANEL REPLACEMENT BP-39 BACK DOOR OPENING TROUGH (ASSY) REMOVAL With the quarter panel removed. F14063-A F14063 BP-40 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14064 POINT 1 Inspect the fitting of the quarter panel, bark door and rear combination light, etc., before welding, since this affects the appearance of the finish. BODY PANEL REPLACEMENT BP-49 BODY LOWER BACK PANEL (CUT) REMOVAL With the back door opening trough removed. F14073-A F14073 330mm (12.99in.) BP-50 BODY PANEL REPLACEMENT F14074 BODY PANEL REPLACEMENT BP-51 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14075 POINT 1 Inspect the fitting of the quarter panel, bark door and rear combination light, etc., before welding, since this affects the appearance of the finish. BP-52 BODY PANEL REPLACEMENT F14076 BODY PANEL REPLACEMENT BP-53 F14058 POINT 1 Check if the body mounting hole is in the correct position. 2 Vertically tighten the bolt. HINT: 1) Specified torque for the cab mounts No.1, No.2, No.3 and rear end cab mounts. NOTICE: Do not reuse the lock nut. PART NAME A Lock Nut (Non-reusable part) B Body Mounting Hole BODY PANEL REPLACEMENT BP-47 BODY LOWER BACK PANEL (CUT-H) REMOVAL F14071-A F14071 330mm (12.99in.) BP-48 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14072 BODY PANEL REPLACEMENT BP-20 CENTER BODY PILLAR (CUT) REMOVAL F14036-A F14036 20mm (0.79in.) 45mm (1.77in.) 50mm (1.97in.) 120mm (4.72in.) 270mm (10.63in.) BODY PANEL REPLACEMENT BP-21 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14037 POINT 1 After welding the reinforcement to the vehicle side, install the outer pillar. PART NAME A Rocker Inner Front Panel 605mm (23.82in.) B Center Body Inner Pillar C Pillar Reinforcement BP-22 BODY PANEL REPLACEMENT F14038 15mm (0.59in.) BP-72 BODY PANEL REPLACEMENT FRAME REAR CROSSMEMBER (ASSY) REMOVAL F14055-A F14055 POINT 1 Remove the A at the same time. PART NAME A Frame Rear Crossmember Gusset BODY PANEL REPLACEMENT BP-73 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14056 PART NAME A Frame Rear Crossmember Gusset 60mm (2.36in.) 103mm (4.06in.) 119 mm (4.69in.) 141mm (5.55in.) 249mm (9.80in.) BODY PANEL REPLACEMENT BP-74 F14057 POINT 1 *1: Air Suspension Compressor Installation Nut

*2: Rear Hook Installation Nut *3: Rear Bumper Installation Nut

*4: Frame Rear Crossmember Standard Hole 152mm (5.98in.) 153mm (6.02in.) 157mm (6.18in.) 414mm (16.30in.) 427mm (16.81in.) BODY PANEL REPLACEMENT BP-11 FRONT FENDER APRON FRONT EXTENSION (ASSY) REMOVAL With the radiator side support, front crossmember removed. F14013-A F14013 BP-12 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14014 BODY PANEL REPLACEMENT BP-13 F12192-C PART NAME Radiator Support To Front Fender Bracket B BP-14 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REMOVAL With the radiator side support, front crossmember removed. F14009-A F14009 BODY PANEL REPLACEMENT BP-15 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14010 BP-16 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REMOVAL F14015-A F14015 30mm (1.18in.) 40mm (1.57in.) 120mm (4.72in.) BODY PANEL REPLACEMENT BP-17 F14016 POINT 1 Remove the remaining foamed from the vehicles side. BODY PANEL REPLACEMENT BP-18 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14017 POINT 1 Before temporarily installing the new parts, weld the A , B and C with standard points. PART NAME A Side Inner Panel 50mm (1.97in.) B Front Body Pillar Lower Reinforce C Outer Pillar BODY PANEL REPLACEMENT BP-19 F14018 BODY PANEL REPLACEMENT BP-5 FRONT CROSSMEMBER (ASSY) REMOVAL F14005-A F14005 BP-6 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14006 POINT 1 First install the hood lock support. BODY PANEL REPLACEMENT BP-23 FRONT DOOR OUTER PANEL (ASSY) REMOVAL F14039-A F14039 POINT 1 Before removing the outer panel, make the installation position with a tape. 2 After grinding off the hemming location, remove the outer panel. BP-24 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT: 1) Apply sealer evenly about 10mm (0.39in.) from the flange and 3mm (0.12in.) in diameter to the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly. BODY PANEL REPLACEMENT BP-9 FRONT FENDER FRONT APRON (ASSY) REMOVAL With the radiator side support, front crossmember removed. F14011-A F14011 BP-10 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14012 BP-54 BODY PANEL REPLACEMENT LOWER BACK UPPER GUSSET (ASSY) REMOVAL F14077-A F14077 BODY PANEL REPLACEMENT BP-55 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14078 BODY PANEL REPLACEMENT BP-41 QUARTER PANEL REAR EXTENSION (CUT) REMOVAL With the back door opening trough removed. F14065-A F14065 40mm (1.57in.) BP-42 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14066 POINT 1 Inspect the fitting of the quarter panel, bark door and rear combination light, etc., before welding, since this affects the appearance of the finish. BODY PANEL REPLACEMENT BP-31 QUARTER PANEL (CUT) REMOVAL F14047-A F14047 50mm (1.97in.) 90mm (3.54in.) BP-32 BODY PANEL REPLACEMENT F14048 BODY PANEL REPLACEMENT BP-33 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14049 POINT 1 Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: 1) Apply body sealer about 5mm (0.20in.) from the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. 2 Use waterproof rivets for the A installation. HINT: 1) Apply the body sealer before installing the A . PART NAME A Fuel Filler Opening Lid B Waterproof Rivets BP-34 BODY PANEL REPLACEMENT F14050 BODY PANEL REPLACEMENT BP-35 QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REMOVAL With the quarter panel removed. F14051-A F14051 POINT 1 After removing the A , remove quarter wheel housing outer panel. 2 *1 : Reuse PART NAME A Roof Side Outer Panel BP-36 BODY PANEL REPLACEMENT F14052 BODY PANEL REPLACEMENT BP-37 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14053 POINT 1 Determine the position of the new parts by assembly marks of the inner and outer panels. BP-38 BODY PANEL REPLACEMENT F14054 BODY PANEL REPLACEMENT BP-3 RADIATOR SIDE SUPPORT (ASSY) REMOVAL With the radiator upper support removed. F14003-A F14003 POINT 1 Replace the A at the same time. PART NAME A Radiator Mounting Reinforcement BP-4 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14004 POINT 1 *1: The valve is reference valve. PART NAME A B Radiator Mounting Reinforcement Radiator Support To Front Fender Bracket C Front Body Mounting Reinforcement No.2 40mm (1.57in.) 180mm (7.09in.) BODY PANEL REPLACEMENT BP-7 RADIATOR SUPPORT (ASSY) REMOVAL F14007-A F14007 BP-8 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14008 BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY) REMOVAL F14001-A F14001 BP-2 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14002 POINT 1 First install the hood lock support. BODY PANEL REPLACEMENT BP-25 REAR DOOR OUTER PANEL (ASSY) REMOVAL F14041-A F14041 POINT 1 Before removing the outer panel, make the installation position with a tape. 2 After grinding off the hemming location, remove the outer panel. BP-26 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14042 POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT: 1) Apply sealer evenly about 10mm (0.39in.) from the flange and 3mm (0.12in.) in diameter to the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly. BP-60 BODY PANEL REPLACEMENT REAR FLOOR PAN (ASSY) REMOVAL With the body lower back panel, lower back upper gusset, rear floor side panel removed. F14083-A F14083 BODY PANEL REPLACEMENT BP-61 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F12195 POINT 1 Attach the A to the center of the bearing surface. 2 *1 USA Only PART NAME A Weld Bolt B Flexible Hose Mounting Bracket BP-62 BODY PANEL REPLACEMENT REAR FLOOR SIDE PANEL REAR EXTENSION (ASSY) REMOVAL With the quarter panel removed. F14085-A F14085 PART NAME A Rear Bumper Arm Bracket BODY PANEL REPLACEMENT BP-63 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14086 POINT 1 *1: The value is reference value. PART NAME A Rear Bumper Arm Bracket 45mm (1.77in.) 110mm (4.33in.) 140mm (5.51in.) BP-64 BODY PANEL REPLACEMENT REAR FLOOR SIDE MEMBER (CUT) REMOVAL With the body lower back panel, rear floor pan removed. F14087-A F14087 110mm (4.33in.) BODY PANEL REPLACEMENT BP-65 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14088 BP-66 BODY PANEL REPLACEMENT REAR FLOOR SIDE CENTER MEMBER (ASSY) REMOVAL With the body lower back panel, rear floor pan removed. F14089-A F14089 POINT 1 Leave the A to the vehicle, remove the B . PART NAME A Rear Floor Side Member Center Reinforcement B Rear Floor Side Center Member BODY PANEL REPLACEMENT BP-67 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14090 POINT 1 Remove the A from the B . PART NAME A Rear Floor Side Member Center Reinforcement B Rear Floor Side Rear Center Member (New Parts) BP-56 BODY PANEL REPLACEMENT REAR FLOOR SIDE PANEL (ASSY) REMOVAL With the lower back upper gusset removed. F14079-A F14079 PART NAME A Deck Board Set Support (w / Double Deck) BODY PANEL REPLACEMENT BP-57 F14080 PART NAME A Deck Board Set Support (w / Double Deck) BP-58 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14081 POINT 1 *1: w/ Double Deck PART NAME A Deck Board Set Support (w / Double Deck) BODY PANEL REPLACEMENT BP-59 F14082 POINT 1 *1: w/ Double Deck PART NAME A Deck Board Set Support (w / Double Deck) BODY PANEL REPLACEMENT BP-29 ROCKER OUTER PANEL (CUT) REMOVAL F14045-A F14045 70mm (2.76in.) BP-30 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14046 BODY PANEL REPLACEMENT BP-27 ROCKER OUTER PANEL (CUT-H) REMOVAL F14043-A F14043 200mm (7.87in.) BP-28 BODY PANEL REPLACEMENT INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14044 BP-70 BODY PANEL REPLACEMENT ROOF PANEL (ASSY): w/sun roof REMOVAL F14021-A F14021 BODY PANEL REPLACEMENT BP-71 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14022 POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT: 1) Apply just enough sealer for the new parts to make contact. 2 Bend the flange hem with a wooden hammer and dolly. HINT 1) Perform hemming three steps, being careful not to warp the panel. BP-68 BODY PANEL REPLACEMENT ROOF PANEL (ASSY): w/o sun roof REMOVAL F14019-A F14019 BODY PANEL REPLACEMENT BP-69 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14020 POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT: 1) Apply just enough sealer for the new parts to make contact. BODY PANEL REPLACEMENT BP-43 ROOF SIDE INNER REAR PANEL (ASSY) REMOVAL With the quarter panel rear extension removed. F14067-A F14067 POINT 1 Remove the A at the same time. PART NAME A Roof Side To Wheel House Brace (LH Only) BP-44 BODY PANEL REPLACEMENT F14068 POINT 2 *1 : LH Only PART NAME B Back Door Opening Lower Reinforcement BODY PANEL REPLACEMENT BP-45 INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F14069 POINT 1 Inspect the fitting of the quarter panel, bark door and rear combination light, etc., before welding, since this affects the appearance of the finish. PART NAME C Back Door Opening Upper Patch BP-46 BODY PANEL REPLACEMENT F14070 POINT 2 *1 : LH Only PART NAME A Roof Side To Wheel House Brace (LH Only) B Back Door Opening Lower Reinforcement IN-18 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA 4 RUNNER. Applicable models: UZN210, 215 series KZN215 series GRN210, 215 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA 4 RUNNER refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice. INTRODUCTION IN-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. Glass Cover Seat Cover F10001A (b) SAFETY (1) Never stand in direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable. WRONG F10002A (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. WRONG F10003A (c) F10004 SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves INTRODUCTION IN-2 2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the property of the plastic. Code Material name Heat* resistant temperature limit C (F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acrylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless. Avoid alkali. EVA Ethylene Acetate 70 (158) Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless. PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali. PA *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION Code Material name Heat* resistant temperature limit C (F) Resistance to alcohol or gasoline IN-3 Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for quick wiping to remove grease. Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents etc. TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali. POM PS TSOP UP *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION IN-4 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Headlight PC/PP Radiator Grille ABS/ASA Front Bumper Cover TSOP Front Turn Signal Light PP/PMMA Fog Light PC/PET Hood Bulge FRP Front Fender Side View Device ABS/PA Side Turn Signal Light ABS Front Wheel Opening Extension TSOP Front Body Mudguard PP/EPDM Cowl Top Ventilator Louver TSOP Outer Rear View Mirror ABS/PBT/AAS Roof Rack Leg Cover PC Door Outside Moulding TSOP Quarter Outside Moulding TSOP Rocker Panel Moulding TSOP Door Window Frame Moulding ASA Quarter Panel Rear Mudguard PP/EPDM Rear Spoiler ABS Center Stop Light PC/PA Back Door Outside Garnish ABS License Plate Light PC/PA Rear Fog Light PMMA/PET Rear Combination Light PMMA/ASA Rear Under Mirror PC/PBT/AAS Rear Bumper Cover TSOP
Resin material differs with model. / Made up of 2 or more kinds of materials. INTRODUCTION IN-15 HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in section BR of the repair manual for the relevant model when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section. 3. Component to be aligned Section of repair manual for relevant model Front Wheels Front Suspension (26) section Rear Wheels Rear Suspension (27) section Propeller Shaft Propeller Shaft (30) section COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery. When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them. INTRODUCTION IN-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL BP-34 A BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REMOVAL C B I K A D I J POINT 1 E Remove the A at the same time. PART NAME A Fuel Filler Opening Lid A : REPLACEMENT PART AND METHOD QUARTER PANEL (CUT) Replacement method (ASSY) ... Assembly replacement (CUT) ... Major cutting (less than 1 / 2 of part used) (CUT-H) ... Half cutting (about 1 / 2 of part used) (CUT-P) ... Partial cutting (most of part used) Replacement part B : REMOVAL CONDTIONS C : PART LOCATION D : REMOVAL DIAGRAM Describes in detail removal of the damaged part involving repair by cutting. E : REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal. F13890A INTRODUCTION IN-6 BODY PANEL REPLACEMENT BP-35 INSTALLATION
Temporaily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Inspect the fiting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F I J G I 5mm POINT 1 Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: 1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. 3) For other sealing points, refer to section PC. H PART NAME A Fuel Filler Opening Lid B Waterproof Rivet F : INSTALLATION CONDITIONS G : INSTALLATION DIAGRAM Describes in detail installation to the new part involving repair by welding and / or cutting, but excluding painting. H : INSTALLATIOLN GUIDE Provides additional information to more efficiently help you perform the installation. I : SYMBOLS (See page IN-7) J : ILLUSTRATION OF WELD POINTS Weld method and panel position symbols (See page IN-9) K : PART NAME F13891A INTRODUCTION 2. IN-7 SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION (SAW CUT) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT LOCATION CUT WITH DISC SANDER, ETC. BRAZE (Removal) BRAZE (Installation) — WELD POINTS — SPOT WELD OR MIG PLUG WELD (See Page IN-9) CONTINUOUS MIG WELD (BUTT WELD) CONTINUOUS MIG WELD (TACK WELD) BODY SEALER F13893A INTRODUCTION IN-8 SYMBOLS MEANING ILLUSTRATION Assembly Mark — — BODY SEALER (Flat Finishing) — BODY SEALER (No flat Finishing) F13894A INTRODUCTION IN-9 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: REMOVAL INSTALLATION Weld points Weld points Remove weld point and panel position SYMBOLS MEANING ILLUSTRATION Remove Weld Points Weld method and panel position SYMBOLS MEANING ILLUSTRATION Spot Weld (Outside) MIG Plug Weld (Middle) (Inside) Spot MIG Weld HINT: Panel position symbols are as seen from the working posture. F13892A IN-16 INTRODUCTION PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2. STRUCTURE PANEL KINKS A sharp deformation angle on the panel that cannot be returned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred. INTRODUCTION 3. IN-17 IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged. INTRODUCTION IN-10 PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame. F10007 (b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced area. Cutting Okay Reinforcement Corners F10008A (c) WRONG PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged. HINT: See “Handling Precautions on Related Components” on page IN-15. F10009A (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. HINT: See “Handling Precautions on Related Components” on page IN-15. F10010 INTRODUCTION 2. IN-11 PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3mm (0.12in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3mm (0.12in.) thick. Less than 3mm F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer. F10012 (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Puncher Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) ø over 1.0 (0.04) - 1.5 (0.06) 6.4 (0.26) ø over 1.5 (0.06) over 8 (0.31) ø over F10013A (d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F10014 20
30mm Air Saw Overlap F10015A (e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 30mm (0.79 - 1.18in.) overlap. INTRODUCTION IN-12 3. INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to insure correct assembly. After installation, confirm proper fit. Body Measurement Diagrams F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. WRONG F10017A (c) CORRECT POST-WELDING REFINISHING (1) Always check the welded spots to insure they are secure. (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld. WRONG F10018A (d) SPOT WELD LOCATIONS (1) Try to avoid welding over previous spots. Tip Cutter F10019A Old Spot Locations New Spot Locations F10020A (e) SPOT WELDING PRECAUTIONS (1) The shape of the welding tip point has an effect on the strength of the weld. (2) Always insure that the seams and welding tip are free of paint. INTRODUCTION 4. Sealer Gun IN-13 ANTI-RUST TREATMENT (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hoods, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings. F10022 5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc. F10023 INTRODUCTION IN-14 6. ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.
Apply the anti-chipping paint after the top coat.
Apply the anti-chipping paint before the second coat. Anti-Chipping Paint Top Coat Second Coat Top Coat Second Coat Anti-Chipping Paint Under Coat (ED Primer) Under Coat (ED Primer) Steel Metal Steel Metal F10024A VIEWS OF THIS TEXT Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories
Each section has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions. Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. BODY DIMENSIONS Body aligning measurements. Dimension diagrams. PAINT
COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement. Under coat. Body sealer. Abbreviation of contents in this text.
The following essential procedures have been abbreviated. When actually working, conduct this work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection. PC-6 PAINT
COATING BODY PANEL UNDERCOATING AREAS HINT: 1) First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover. 2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately. 3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4) Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft. 5) Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention. 6) Be sure to seal the edge of the flange of the member and bracket with undercoating. 7) If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary. 8) Before the undercoat apply sealer allowing rust prevention to be attained. F13902 REFERENCE Referring to the notes above, undercoating should be applied according to the specifications for your country. PC-8 PAINT
COATING BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS HINT: 1) Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges. 2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3) Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas. F14028 PAINT
COATING PC-9 F14029 PAINT
COATING PC-11 BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: 1) Anti-chipping paint should be applide to some areas before the second coat and to others after the top coat. 2) If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover. F14030 PAINT
COATING PC-1 BODY PANEL SEALING AREAS HINT: 1) Prior to applying body sealer, clean the area with a rag soaked in grease,wax and silicone remover. 2) If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer. 3) Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover. 4) If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary. 1. ENGINE COMPARTMENT F14023 PAINT
COATING PC-2 2. INSIDE F14024 PAINT
COATING 3. PC-3 REAR LUGGAGE COMPARTMENT F14025 PAINT
COATING PC-4 4. DOOR PARTS F14026 POINT 1 *1: Europe Only PAINT
COATING PC-5 F14027 PAINT
COATING PC-7 FOAMED MATERIAL APPLICATION AREAS The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials HINT: 1) Use the service holes located on the reverse side of the body panel to refill with foamed materials. 2) When handling foamed material, follow the directions of the material’s manufacturer. F14031 PC-10 PAINT
COATING SILENCER SHEET INSTALLATION AREAS F13904 06 05.24 ADVANCED FUNCTIONS SECTION IV ADVANCED FUNCTIONS Descriptions of functions for more effective use Suspending and resuming guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . My places . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registering memory points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Editing memory points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting memory points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registering home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Registering area to avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting area to avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delete previous points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 67 67 69 70 71 75 75 76 76 79 80 65 06 05.24 ADVANCED FUNCTIONS  To resume guidance 1. Push the “MENU” button. Suspending and resuming guidance  To suspend guidance 1. Push the “MENU” button. 4U5025G 4U5081G 4U5024aG The screen will return to the current position map without route guidance. 2. Touch “Resume Guidance”. 2. Touch “Suspend Guidance”. INFORMATION Without route guidance, “Suspend Guidance” cannot be used. 4U5026G The screen will change to the current position map with route guidance. 66 06 05.24 ADVANCED FUNCTIONS Volume User selection Voice guidance can be used when approaching a destination. The volume of the voice or turn off voice guidance can be adjusted. 1. Push the “MENU” button. The system can memorize the following settings for up to three users.  Map direction  Map scale  Map configuration  Guidance mode  Setup  Volume  Language  Route trace  Travel time/arrival time  Right screen of dual map  Road preference  Maintenance notification 4U5024aG 4U5027G To adjust the volume, select the desired level by touching the appropriate number. If voice guidance is unneeded, touch “OFF”. The selected item is highlighted. INFORMATION 2. Touch “Volume”. During route guidance, the voice guidance continues even if the navigation screen is changed to other screens. “Adaptive Volume Control”: By turning “Adaptive Volume Control” on, the volume is turned up automatically when the vehicle speed exceeds 50 mph (80 km/h). To turn the “Adaptive Volume Control” system on, touch the button. The indicator will be highlighted. 67 06 05.24 ADVANCED FUNCTIONS 1. Push the “MENU” button. 4U5024aG  To register When a touch−screen button that is already registered is touched, the following screen appears. 4U5083G 4U5030G 2. Touch “Select User”. 1. Touch “Memorize”. The confirmation screen will be displayed. 4U5029G 2. To register, touch “Yes”. To return to . the previous screen, touch “No” or 68 To replace, touch “Yes”. To cancel the re. placement, touch “No” or 06 05.24 ADVANCED FUNCTIONS  To change user 4U5084G Touch “User number”.  To delete user 4U5085G My places — Points or areas on the map can be registered. The registered points can be used on the “Destination” screen. (See “ — Destination search by Home” on page 26 and “ — Destination search by Quick access” on page 27.) Registered areas are avoided at the time of route search. 1. Push the “MENU” button. 1. Touch “Delete”. The confirmation screen will be displayed. 4U5024aG 4U5031G 4U5032G 2. Touch “My Places”. The above message appears, then the map screen will be displayed. 2. To delete, touch “Yes”. To return to the . previous screen, touch “No” or 69 06 05.24 ADVANCED FUNCTIONS 8 9 4U5033G On this screen, the following operations can be performed. 1 Registers memory points. (See “ — Registering memory points” on page 70.) 2 Edits memory points. (See “ — Editing memory points” on page 71.) 3 Deletes memory points. (See “ — Deleting memory points” on page 75.) 4 Registers or deletes home. (See “ — Registering home” or “ — Deleting home” on pages 75 or 76.) 5 Registers areas to avoid. (See “ — Registering area to avoid” on page 76.) 6 Edits areas to avoid. (See “ — Editing area to avoid” on page 77.) 7 Deletes areas to avoid. (See “ — Deleting area to avoid” on page 79.) 70 10 Deletes previous points. (See “ — Deleting previous points” on page 80.) Number of remaining memory points Number of remaining areas to avoid — Registering memory points 4U5034G 1. Touch “Register”. 4U5035bG 2. Enter the location in the same way as for a destination search. (See “Destination search” on page 24.) After memory point registration is completed, the “Memory Point” screen will be displayed. 06 05.24 ADVANCED FUNCTIONS — Editing memory points 4U5036aG The icon, attribute, name, location and/or telephone number of a registered memory point can be edited. 4U5036aG 4U5037G 3. Touch “OK”. To edit registered information, see “ — Editing memory points” on page 71. INFORMATION 1. Touch “Edit”. Up to 106 memory points can be registered. 4U5038G 2. Touch the desired memory point button. 3. Touch the touch−screen button to be edited. “Icon”: To select icons to be displayed on the map. (See page 72.) “Quick Access”: To set an attribute. Memory points with a set attribute can be used as a “Quick access” or “Home” button. (See page 73.) “Name”: To edit memory point names. The names can be displayed on the map. (See page 74.) “Location”: To edit location information. (See page 74.) “Phone #”: To edit telephone numbers. (See page 75.) 4. Touch “OK”. 71 06 05.24 ADVANCED FUNCTIONS  To change “Icon” 1. Touch “Icon” on the “Memory Point” screen. SOUND ICONS When the vehicle approaches the memory point, the selected sound will be heard. 1. Touch “with Sound” on the “Change Icon” screen. 4U5041G RS02007 RS02008 2. Touch the desired icon. Turn the page by touching “Page 1”, “Page 2” or “with Sound”. 72 2. Touch the desired sound icon. The next screen appears when “Bell (with Direction)” is touched. Touch either or to adjust the direction. Touch “Enter”. The bell sounds only when the vehicle approaches this point in the direction that has been set. 06 05.24 ADVANCED FUNCTIONS  To change “Quick Access” It is possible to change attributes of the quick access points. Memory points with a set attribute can be used as a “Quick access” or “Home” touch−screen button. (See “ — Destination search by Home” on page 26 and “ — Destination search by Quick access” on page 27.) 1. Touch “Quick Access” on the “Memory Point” screen. 2. Touch the desired attribute. It is possible to replace a registered attribute. 4U5043aG DELETING “Quick Access” 4U5086G 1. Touch “Del.”. 4U5042aG 3. To replace the attribute, touch “Yes”. To return to the previous screen, touch “No” or . INFORMATION 4U5045G One “Home” and five “Quick access” can be set. 2. To delete an attribute, touch “Yes”. To return to the previous screen, touch “No” or . 73 06 05.24 ADVANCED FUNCTIONS  To change “Name” 1. Touch “Name” on the “Memory Point” screen. 4U5046G 2. Enter the name using the alphanumeric keys. Up to 24 letters can be entered. 3. Touch “OK”. The previous screen will be displayed. 74 DISPLAYING MEMORY POINT NAMES The name of a memory point that may be displayed on the map can be set. 4U5044G To show the name, touch “ON” on the “Memory Point” screen. To not show it, touch “OFF”.  To change “Location” 1. Touch “Location” on the “Memory Point” screen. 4U5047G 2. Touch the eight directional touch− screen button to move the cursor to the desired point on the map. 3. Touch “Enter”. The previous screen will be displayed. 06 05.24 ADVANCED FUNCTIONS  To change “Phone #” (telephone number) 1. Touch “Phone #” on the “Memory Point” screen. — Deleting memory points 4U5049G — Registering home If home has been registered, that information can be recalled by using the “Home” touch− screen button on the “Destination” screen. (See “ — Destination search by Home” on page 26.) 4U5048G 1. Touch “Delete”. 2. Enter the number using numeral keys. 3. Touch “OK”. The previous screen will be displayed. 4U5050G 4U5051G 1. Touch “Register”. 2. Touch the touch−screen button to be deleted. “Delete All”: To delete all memory points in the system. 3. To delete the memory point, touch “Yes”. To cancel the deletion, touch “No”. 75 06 05.24 ADVANCED FUNCTIONS — Deleting home 4U5052bG — Registering area to avoid Areas you want to avoid because of traffic jams, construction work or other reasons can be registered as areas to avoid. 4U5054G 4U5055G 2. Enter the location in the same way as for a destination search. (See “Destination search” on page 24.) When registration of home is completed, the “Memory Point” screen will be displayed. 4U5053G 3. Touch “OK”. To edit registered information, see “ — Editing memory points” on page 71. 76 1. Touch “Delete”. 2. To delete home, touch “Yes”. To cancel the deletion, touch “No”. 1. Touch “Register”. 4U5056aG 2. Enter the location in the same way as for a destination search, or display the map of the area to be avoided. (See “Destination search” on page 24.) 06 05.24 ADVANCED FUNCTIONS INFORMATION 4U5057G 3. Set the cursor in the center of the area to avoid, and touch “Enter”.  If a destination is input in the area to avoid or the route calculation cannot be made without running through the area to avoid, a route passing through the area to be avoided may be shown.  Up to 10 locations can be registered as points/areas to avoid. If there are 10 locations already registered, the following message will be displayed: “Unable to register additional points. Perform operation again after deleting unnecessary points.”. — Editing area to avoid The name, location and/or area size of a registered area can be edited. 4U5059G 1. Touch “Edit”. 4U5058G 4U5060G 4. Touch either or to change the size of the area to be avoided. 5. Touch “OK”. 2. Touch the desired area button. 77 06 05.24 ADVANCED FUNCTIONS  To change “Name” 1. Touch “Name” on the “Edit Area to Avoid” screen. DISPLAYING NAMES OF AREAS TO BE AVOIDED The name of an area to be avoided that may be displayed on the map can be set. 4U5061G 4U5106G 3. Touch the touch−screen button to be edited. “Name”: To edit the name of the area to avoid. The names can be displayed on the map. (See page 78.) “Location”: To edit area location. (See page 79.) “Area Size”: To edit area size. (See page 79.) “Active”: To turn on or off the area to avoid feature. To turn on the feature touch “ON” on the “Edit Area to Avoid” screen. To turn off the feature touch “OFF” on the “Edit Area to Avoid” screen. 4. Touch “OK”. 78 2. Enter the name using alphanumeric keys. Up to 24 letters can be entered. 3. Touch “OK”. The previous screen will be displayed. 4U5062G To show the name, touch “ON” on the “Edit Area to Avoid” screen. To not show it, touch “OFF”. 06 05.24 ADVANCED FUNCTIONS  To change “Location” 1. Touch “Location” on the “Edit Area to Avoid” screen.  To change “Area Size” 1. Touch “Area Size” on the “Edit Area to Avoid” screen. — Deleting area to avoid 4U5065G 4U5063G 4U5064G 1. Touch “Delete” on the “My Places” screen. 2. Touch the eight directional touch− screen button to move the cursor to the desired point on the map. 3. Touch “Enter”. The previous screen will be displayed. 2. Touch either or to change the size of the area to be avoided. 3. Touch “OK”. The previous screen will be displayed. 4U5103G 2. Touch the touch−screen button to be deleted. “Delete All”: To delete all registered areas to avoid in the system. 3. To delete the area, touch “Yes”. To cancel the deletion, touch “No”. 79 06 05.24 ADVANCED FUNCTIONS — Deleting previous points Setup The previous destination can be deleted. Setting the items shown on the “Setup” screen can be done. (See page ix.) 1. Push the “MENU” button. 4U5067G 4U5108G 3. To delete the point, touch “Yes”. To cancel the deletion, touch “No”. 4U5024aG 1. Touch “Delete Previous Points”. 2. Touch “Setup”. 4U5066G 2. Touch the touch−screen button you want to delete. “Delete All”: To delete all previous points in the system. 80 06 05.24 ADVANCED FUNCTIONS  Distance unit Distance unit can be changed. 1. Touch “Setup” on the “Menu” screen. 4U5087G  Estimated travel time The speed that is used for the calculation of the estimated travel time and the estimated arrival time can be set. 1. Touch “Setup” on the “Menu” screen. 4U5090G 4U5091G 3. Touch the items to be set. 4. Touch “OK”. The previous screen will be displayed. INFORMATION To reset all setup items, touch “Default”. 2. Touch “km” or “miles” of “Distance” to choose the distance unit. The selected button is highlighted. 3. Touch “OK”. 2. Touch “Set Speed” of the “Estimated Travel Time”. INFORMATION This function is available only in English or Spanish. To switch language, see “Select language” on page 148. 81 06 05.24 ADVANCED FUNCTIONS INFORMATION 4U5069G 3. Touch or to set the average vehicle speeds for “Residential”, “Main street”, and “Freeway”. To set the default speeds, touch “Default”. 4. After setting of the desired speeds is completed, touch “OK”. 82  The displayed time to the destination is the approximate driving time that is calculated based on the selected speeds and the actual position along the guidance route.  The time shown on the screen may vary greatly depending on progress along the route, which may be affected by road conditions such as traffic jams, and construction work.  Input key layout Key layout can be changed. 1. Touch “Setup” on the “Menu” screen. 4U5092G  It is possible to display up to 99 hours 59 minutes. 2. Touch “ABC” or “QWE” of “Keyboard Layout” to choose the Input key layout. 06 05.24 ADVANCED FUNCTIONS LAYOUT TYPE  Time zone Time zone can be changed. 1. Touch “Setup” on the “Menu” screen. 4U5072G 4U5070G 4U5093G
“ABC” type 2. Touch “Change” of “Time Zone”. The “Adjust Time Zone” screen will be displayed on the display. 4U5071G 3. Touch the desired time zone. The selected button is highlighted. “Daylight Saving Time”: Daylight saving time can be set or cancelled. To set daylight saving time, touch “ON”, and to cancel it, touch “OFF”. 4. Touch “OK”.
“QWE” type The selected button is highlighted. 3. Touch “OK”. 83 06 05.24 ADVANCED FUNCTIONS  Screen layout function ( 4U5073G (Display POI Icons) Select from among the 6 icons displayed on the “Display POI Icons” top screen, so that setting of the icons to be displayed on the map screen can be done easily. 1. Touch “Setup” on the “Menu” screen. Then touch “Setup” screen. 4U5094G 2. Touch “Change” of “  POI category change Function) Each touch−screen button and current street name on the map screen can be displayed or hidden. 1. Touch “Setup” on the “Menu” screen. 3. Touch the touch−screen button to be turned off. The button becomes dimmed. To set the default, touch “Default”. 4. Touch “OK”. to display page 2 of the 4U5095G Function”. 2. Touch “Change” of “Display POI Icons”. 84 06 05.24 ADVANCED FUNCTIONS 4U5075G  Display of building shape When the “Display Building Shapes” feature is turned on, the system will display the building shape on the map screen using a scale of 150 feet (50 m) to 300 feet (100 m). To turn the “Display Building Shapes” on: 1. Touch “Setup” on the “Menu” screen. Then touch “Setup” screen. to display page 2 of the  Notifying traffic restriction When the “Traffic Restrict. Notification” feature is turned on, the system notifies you of traffic or seasonal restrictions. To turn the “Traffic Restrict. Notification” on: 1. Touch “Setup” on the “Menu” screen. Then touch “Setup” screen. to display page 2 of the 3. Touch the category button to be changed. 4U5096G 4U5097G 4U5076G 2. Touch “ON” of “Display Building Shapes”. 4. Touch the category button to be displayed on the “Display POI Icons” top screen. 5. Touch “OK”. The selected button is highlighted. 3. Touch “OK”. 2. Touch “ON” Notification”. of “Traffic Restrict. The selected button is highlighted. 3. Touch “OK”. 85 06 05.24 ADVANCED FUNCTIONS  Voice recognition guidance When the “Voice Recognition Guidance” feature is turned on, the voice recognition guidance can be heard automatically. To turn the “Voice Recognition Guidance” on: 1. Touch “Setup” on the “Menu” screen. Then touch up” screen. to display page 2 of the “Set-  Voice guidance in all modes When the “Voice Guidance in All Modes” feature is turned on, the voice guidance in all modes can be heard. When the “Voice Guidance in All Modes” feature is turned off, voice guidance cannot be heard when using the audio system. To turn the “Voice Guidance in All Modes” on: 1. Touch “Setup” on the “Menu” screen.  Auto voice guidance When the “Auto Voice Guidance” feature is turned on, the voice guidance can be heard automatically. When the “Auto Voice Guidance” feature is turned off, the voice guidance can be heard only if the “MAP/VOICE” button is pushed. To turn the “Auto Voice Guidance” mode on: 1. Touch “Setup” on the “Menu” screen. Then touch up” screen. Then touch twice to display page 3 of the “Setup” screen. to display page 2 of the “Set- 4U5098G 4U5099G 2. Touch “ON” of “Voice Recognition Guidance”. The selected button is highlighted. 3. Touch “OK”. 86 2. Touch “ON” of “Voice Guidance in All Modes”. The selected button is highlighted. 3. Touch “OK”. 4U5100G 2. Touch “ON” of “Auto Voice Guidance”. The selected button is highlighted. 3. Touch “OK”. 06 05.24 ADVANCED FUNCTIONS  Pop−up message When the “Pop−up Message” is turned on, the Pop−up message will be displayed. To turn the “Pop−up Message” on: 1. Touch “Setup” on the “Menu” screen. Then touch twice to display page 3 of the “Setup” screen. 4U5101G 2. Touch “ON” of “Pop−up Message”. The selected button is highlighted. 3. Touch “OK”. When the “Pop−up Message” is turned off, following messages are not displayed. 4U5109G  Current position/tire change calibration The current vehicle position mark can be adjusted manually. Miscalculation of the distance caused by tire replacement can also be adjusted. 1. Touch “Setup” on the “Menu” screen. Then touch twice to display page 3 of the “Setup” screen. This message appears when the system is in the POI mode and the map scale is 1 mile (1.6 km) or greater. 4U5110G 4U5102G 2. Touch “Adjust” of “Calibration”. The message appears when the map is switched to the dual map screen mode. 87 06 05.24 ADVANCED FUNCTIONS 4U5078G 3. Touch the desired touch−screen button. POSITION/DIRECTION CALIBRATION When driving, the current vehicle position mark will be automatically corrected by GPS signals. If GPS reception is poor due to location, you can manually adjust the current vehicle position mark. 4U5104G INFORMATION For additional information on the accuracy of a current vehicle position, see “Limitations of the navigation system” on page 198. 1. Touch “Position/Direction”. 4U5079G 2. Touch the scroll arrows to move the cursor to your desired location. 3. Touch “Enter”. 88 4U5080G 4. Touch either or to adjust the direction of the current vehicle position mark. 5. Touch “Enter”. The map screen will be displayed. 06 05.24 ADVANCED FUNCTIONS TIRE CHANGE CALIBRATION The tire change calibration function will be used when replacing the tires. This function will adjust the mis−calculation caused by the circumference difference between the old and new tires. If this procedure is not performed when tires are replaced, the current vehicle position mark may be incorrectly displayed. 4U5105G To perform a distance calibration procedure, touch “Tire Change” on the “Calibration” screen. The message appears and the quick distance calibration is automatically started. A few seconds later, a map screen will be displayed. 89 06 05.24 ADVANCED FUNCTIONS 90 06 06.07 APPENDIX SECTION VII APPENDIX Limitations of the navigation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Map database information and updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 VII 197 06 06.07 APPENDIX Limitations of the navigation system This navigation system calculates the current vehicle position using satellite signals, various vehicle signals, map data, etc. However, the accurate position may not be shown depending on the satellite condition, road configuration, vehicle condition or other circumstances. The Global Positioning System (GPS) developed and operated by the U.S. Department of Defense provides an accurate current vehicle position using 3 to 4 satellites. The GPS system has a certain level of inaccuracy. While the navigation system will compensate for this most of the time, occasional positioning errors of up to 300 feet (100 m) can and should be expected. Generally, position errors will be corrected within a few seconds. 198 NOTICE 7U5027 When your vehicle is receiving signals from the satellites, the “GPS” mark appears at the top left of the screen. The GPS signal may be physically obstructed, leading to inaccurate vehicle position on the map display. Tunnels, tall buildings, trucks, or even the placement of objects on the instrument panel may obstruct the GPS signals. The GPS satellites may not send signals due to repairs or improvements being made to them. Even when the navigation system is receiving clear GPS signals, the vehicle position may not be shown accurately or inappropriate route guidance may occur in some cases. The installation of window tinting may obstruct the GPS signals. Most window tinting contains some metallic content that will interfere with GPS signal reception. We advise against the use of window tinting on vehicles equipped with navigation systems. 06 06.07 APPENDIX (a) Accurate current vehicle position may not be shown in the following cases:
When driving on a small angled Y−shaped road.
When driving on a winding road.
When driving on a slippery road such as in sand, gravel, snow, etc.
When driving on a long straight road.
When freeway and surface streets run in parallel.
After moving by ferry or vehicle carrier.
When a long route is searched during high speed driving.
When driving without setting the current position calibration correctly.
After repeating a change of direction by going forward and backward, or turning on a turntable in the parking lot.
When leaving a covered parking lot or parking garage.
When a roof carrier is installed.
When driving with tire chains installed.
When the tires are worn.
After replacing a tire or tires.
When using tires that are smaller or larger than the factory specifications.
When the tire pressure in any of the four tires is not correct. INFORMATION If your vehicle cannot receive GPS signals, you can correct the current position manually. For information on setting the current position calibration, see “
Current position/tire change calibration” on page 87. (b) Inappropriate route guidance may occur in the following cases:
When turning at an intersection off the designated route guidance.
If you set more than one destination but skip any of them, auto reroute will display a route returning to the destination on the previous route.
When turning at an intersection for which there is no route guidance.
When passing through an intersection, there is no route guidance.
During auto reroute, the route guidance may not be available for the next turn to the right or left.
It may take a long time to operate auto reroute during high speed driving. In auto reroute, a detour route may be shown.
After auto reroute, the route may not be changed.
An unnecessary U−turn may be shown or announced.
A location may have multiple names and the system will announce one or more.
Some routes may not be searched.
If the route to your destination includes gravel, unpaved roads or alleys, the route guidance may not be shown. 199 VII 06 06.07 APPENDIX
Your destination point might be shown on the opposite side of the street.
When a portion of the route has regulations prohibiting the entry of the vehicle that vary by time or season or other reasons.
The road and map data stored in your navigation system may not be complete or may not be the latest version. After replacing the tire, implement the operation described in the “
Current position/tire change calibration”. (See page 87.) This navigation system uses tire turning data and is designed to work with factory−specified tires for your vehicle. Installing tires that are larger or smaller than the originally equipped diameter may cause inaccurate display of the vehicle’s position. The tire pressure also affects the diameter of the tires so please make sure the tire pressure of all four tires is correct. 200 Map database information and updates This system uses the maps of DENSO.  2006 DENSO CORPORATION  2005 NAVTEQ. All rights reserved.  2005 Tele Atlas North America, Inc. All rights reserved. This material is proprietary and the subject of copyright protection and other intellectual property rights owned by or licensed to Tele Atlas North America, Inc. The use of this material is subject to the terms of a license agreement. You will be held liable for any unauthorized copying or disclosure of this material. Data by infoUSA Copyright  2005, All Rights Reserved.  2005 VISA Corporation National Research Bureau 2005 The Bullseye Design is a registered trademark of Target Brands, Inc. END USER TERMS The data (“Data”) is provided for your personal, internal use only and not for resale. It is protected by copyright, and is subject to the following terms and conditions which are agreed to by you, on the one hand, and DENSO CORPORATION (“[CLIENT]”) and its licensors (including their licensors and suppliers) on the other hand.  2005 NAVTEQ. All rights reserved. The Data for areas of Canada includes information taken with permission from Canadian authorities, including:  Her Majesty the Queen in Right of Canada,  Queen’s Printer for Ontario,  Canada Post Corporation, GeoBase. 06 06.07 APPENDIX TERMS AND CONDITIONS Personal Use Only. You agree to use this Data together with the navigation system for the solely personal, non−commercial purposes for which you were licensed, and not for service bureau, time−sharing or other similar purposes. Accordingly, but subject to the restrictions set forth in the following paragraphs, you may copy this Data only as necessary for your personal use to (i) view it, and (ii) save it, provided that you do not remove any copyright notices that appear and do not modify the Data in any way. You agree not to otherwise reproduce, copy, modify, decompile, disassemble or reverse engineer any portion of this Data, and may not transfer or distribute it in any form, for any purpose, except to the extent permitted by mandatory laws. Data provided in multi−disc sets may not be transferred or sold on a divided or single disc basis. Restrictions. Except where you have been specifically licensed to do so by [CLIENT], and without limiting the preceding paragraph, you may not (a) use this Data with any products, systems, or applications installed or otherwise connected to or in communication with vehicles, capable of vehicle navigation, positioning, dispatch, real time route guidance, fleet management or similar applications; or (b) with or in communication with any positioning devices or any mobile or wireless−connected electronic or computer devices, including without limitation cellular phones, palmtop and handheld computers, pagers, and personal digital assistants or PDAs. Warning. The Data may contain inaccurate or incomplete information due to the passage of time, changing circumstances, sources used and the nature of collecting comprehensive geographic data, any of which may lead to incorrect results. No Warranty. This Data is provided to you “as is,” and you agree to use it at your own risk. [CLIENT] and its licensors (and their licensors and suppliers) make no guarantees, representations or warranties of any kind, express or implied, arising by law or otherwise, including but not limited to, content, quality, accuracy, completeness, effectiveness, reliability, fitness for a particular purpose, usefulness, use or results to be obtained from this Data, or that the Data or server will be uninterrupted or error−free. Disclaimer of Warranty: [CLIENT] AND ITS LICENSORS (INCLUDING THEIR LICENSORS AND SUPPLIERS) DISCLAIM ANY WARRANTIES, EXPRESS OR IMPLIED, OF QUALITY, PERFORMANCE, MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NON−INFRINGEMENT. Some States, Territories and Countries do not allow certain warranty exclusions, so to that extent the above exclusion may not apply to you. 201 VII 06 06.07 APPENDIX Disclaimer of Liability: [CLIENT] AND ITS LICENSORS (INCLUDING THEIR LICENSORS AND SUPPLIERS) SHALL NOT BE LIABLE TO YOU IN RESPECT OF ANY CLAIM, DEMAND OR ACTION, IRRESPECTIVE OF THE NATURE OF THE CAUSE OF THE CLAIM, DEMAND OR ACTION ALLEGING ANY LOSS, INJURY OR DAMAGES, DIRECT OR INDIRECT, WHICH MAY RESULT FROM THE USE OR POSSESSION OF THE INFORMATION; OR FOR ANY LOSS OF PROFIT, REVENUE, CONTRACTS OR SAVINGS, OR ANY OTHER DIRECT, INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF YOUR USE OF OR INABILITY TO USE THIS INFORMATION, ANY DEFECT IN THE INFORMATION, OR THE BREACH OF THESE TERMS OR CONDITIONS, WHETHER IN AN ACTION IN CONTRACT OR TORT OR BASED ON A WARRANTY, EVEN IF [CLIENT] OR ITS LICENSORS HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Some States, Territories and Countries do not allow certain liability exclusions or damages limitations, so to that extent the above may not apply to you. 202 Export Control. You agree not to export from anywhere any part of the Data provided to you or any direct product there of except in compliance with, and with all licenses and approvals required under, applicable export laws, rules and regulations. Entire Agreement. These terms and conditions constitute the entire agreement between [CLIENT] (and its licensors, including their licensors and suppliers) and you pertaining to the subject matter hereof, and supersedes in their entirety any and all written or oral agreements previously existing between us with respect to such subject matter. Governing Law. The above terms and conditions shall be governed by the laws of the State of Illinois [insert “Netherlands” where European NAVTEQ Data is used], without giving effect to (i) its conflict of laws provisions, or (ii) the United Nations Convention for Contracts for the International Sale of Goods, which is explicitly excluded. You agree to submit to the jurisdiction of the State of Illinois [insert “The Netherlands” where European NAVTEQ Data is used] for any and all disputes, claims and actions arising from or in connection with the Data provided to you hereunder. Government End Users. If the NAVTEQ Data is being acquired by or on behalf of the United States government or any other entity seeking or applying rights similar to those customarily claimed by the United States government, (i) for acquisitions conducted by the Department of Defense, the NAVTEQ Data is licensed with “Limited Rights” in accordance with the rights set forth at DFARS 252.227−7013(b)(3), TECHNICAL DATA−NONCOMMERCIAL ITEMS, and NAVTEQ Data delivered or otherwise furnished with “Limited Rights” shall be marked with the following “Limited Rights Notice” set forth at DFARS 252.227−7013(f)(3), and shall be treated in accordance with such Notice: 06 06.07 APPENDIX LIMITED RIGHTS CONTRACT NO.: ______________________________ CONTRACTOR (MANUFACTURER/ SUPPLIER) NAME: NAVTEQ CONTRACTOR (MANUFACTURER/ SUPPLIER) ADDRESS: 222 Merchandise Mart Plaza, Suite 900, Chicago, Illinois 60654 The Government’s rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted by paragraph (b)(3) of the Rights in Technical Data−Noncommercial Items clause contained in the above identified contract. Any reproduction of technical data or portions thereof marked with this legend must also reproduce the markings. Any person, other than the Government, who has been provided access to such data must promptly notify the above named Contractor. and; (ii) for civilian agency acquisitions, the NAVTEQ Data is licensed in accordance with the rights set forth at FAR 52.227−14(g)(1), RIGHTS IN DATA−GENERAL (Protection of limited rights data and computer software). In the event that the Contracting Officer requires the delivery of limited rights NAVTEQ Data that has been withheld or would otherwise be withholdable in accordance with FAR 52.227−14(g)(1), the NAVTEQ Data is licensed with “Limited Rights” as set forth in the following “Limited Rights Notice” at FAR 52.227−14(g)(2) (Alternate II), which shall be affixed to the NAVTEQ Data and the NAVTEQ Data shall be treated in accordance with such Notice (which shall be marked on any reproduction of the NAVTEQ Data, in whole or in part): LIMITED RIGHTS NOTICE (JUN 1987) These data are submitted with limited rights under Government Contract No. _____ (and subcontract ______, if appropriate). These data may be reproduced and used by the Government with the express limitation that they will not, without written permission of the Contractor, be used for purposes of manufacture nor disclosed outside the Government; except that the Government may disclose these data outside the Government for the following purposes, if any, provided that the Government makes such disclosure subject to prohibition against further use and disclosure: There are no additional purposes permitting disclosure of such Data. The manufacturer/supplier of the Data is NAVTEQ, 222 Merchandise Mart Plaza, Suite 900, Chicago, Illinois 60654. If the Contracting Officer refuses to use either of the licenses provided in (i) or (ii), herein, the Contracting Officer must notify NAVTEQ North America, LLC prior to seeking additional or alternative rights in the NAVTEQ Data. 203 VII 06 06.07 APPENDIX END USER LICENSE AGREEMENT PLEASE READ THIS AGREEMENT CAREFULLY BEFORE USING THE NAVIGATION SYSTEM THIS IS A LICENSE AGREEMENT FOR YOUR COPY OF THE SPATIAL MAP DATABASE, INCLUDING LOCATION CODES AND RELATED PRODUCTS (COLLECTIVELY, THE “DATABASE”), USED IN THE NAVIGATION SYSTEM. BY USING THE NAVIGATION SYSTEM AND THE DATABASE, YOU ACCEPT AND AGREE TO BE BOUND BY ALL TERMS AND CONDITIONS SET FORTH BELOW. LICENSE GRANT Denso Corporation (“Denso”), as a licensed distributor of the DATABASE, grants to you a non−exclusive, non−perpetual license to use your copy of the DATABASE for your personal use or for your use in your business’ internal operations and not for any other purpose. This license does not include the right to grant sub−licenses. 204 OWNERSHIP The DATABASE and the copyrights and intellectual property and neighboring rights therein are owned by Tele Atlas North America, Inc. (“TANA”) and its licensors. This Agreement does not transfer any title or interest in the DATABASE, except for the license to use the DATABASE according and subject to the terms and conditions of this Agreement. You shall not alter, obscure or remove any copyright notices, trademark notices or other restrictive legends relating to the DATABASE. The DATABASE comprises confidential and proprietary information and materials of TANA. Accordingly, you shall hold the DATABASE in confidence and trust. You shall take reasonable steps to protect the DATABASE from misappropriation or misuse. You shall not extract stand−alone data from or publish any part of the DATABASE without the prior written consent of TANA and its licensors. LIMITATIONS ON USE The DATABASE is restricted for use in the specific system for which it was created. Except to the extent explicitly permitted by mandatory laws, you may not extract or reutilize any portion of the contents of the DATABASE, nor reproduce, copy, duplicate, modify, adapt, translate, disassemble, decompile, or reverse engineer any portion of the DATABASE. TRANSFER You may not transfer the DATABASE to third parties, except together with the system for which it was created, provided that you do not retain any copy of the DATABASE, and provided that the transferee agrees to all terms and conditions of this AGREEMENT. 06 06.07 APPENDIX DISCLAIMER OF WARRANTY THE DATABASE IS PROVIDED ON AN “AS IS” AND “WITH ALL FAULTS BASIS” AND DENSO AND TANA (AND THEIR LICENSORS AND SUPPLIERS) EXPRESSLY DISCLAIM ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF NON−INFRINGEMENT, MERCHANTABILITY, SATISFACTORY QUALITY, ACCURACY, TITLE AND FITNESS FOR A PARTICULAR PURPOSE. NO ORAL OR WRITTEN ADVICE OR INFORMATION PROVIDED BY DENSO OR TANA (OR ANY OF THEIR LICENSORS, AGENTS, EMPLOYEES OR THIRD PARTY PROVIDERS) SHALL CREATE A WARRANTY, AND YOU ARE NOT ENTITLED TO RELY ON ANY SUCH ADVICE OR INFORMATION. THIS DISCLAIMER OF WARRANTIES IS AN ESSENTIAL CONDITION OF THIS AGREEMENT. LIMITATION OF LIABILITY IN NO EVENT SHALL DENSO OR TANA (OR THEIR LICENSORS OR SUPPLIERS) BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, SPECIAL, INDIRECT OR EXEMPLARY DAMAGES ARISING OUT OF THIS AGREEMENT OR YOUR USE OF THE DATABASE, INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR COSTS OF COVER, LOSS OF USE OR BUSINESS INTERRUPTION OR THE LIKE, REGARDLESS OF WHETHER THE PARTY WAS ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. IN NO EVENT WILL THE TOTAL LIABILITY OF DENSO OR TANA (OR THEIR LICENSORS OR SUPPLIERS) EXCEED THE AMOUNTS PAID BY YOU FOR THE DATABASE. WARNINGS The DATABASE comprises facts and information from government and other sources reflecting circumstances in existence before you received the DATABASE, which may contain errors and omissions. Accordingly, the DATABASE may contain inaccurate or incomplete information due to the passage of time, changing circumstances, and due to the nature of the sources used. The DATABASE does not include or reflect information relating to, among other things, neighborhood safety; law enforcement; emergency assistance; construction work; road or lane closures; vehicle or speed restrictions; road slope or grade; bridge height, weight or other limits; road or traffic conditions; special events; traffic congestion; or travel time. VII 205 06 06.07 APPENDIX U.S. GOVERNMENT RIGHTS If you are an agency, department, or other entity of the United States Government, or funded in whole or in part by the United States Government, then use, duplication, reproduction, release, modification, disclosure or transfer of this commercial product and accompanying documentation, is restricted in accordance with the LIMITED or RESTRICTED rights as described in DFARS 252.227−7014(a)(1) (JUN 1995) (DOD commercial computer software definition), DFARS 227.7202−1 (DOD policy on commercial computer software), FAR 52.227−19 (JUN 1987) (commercial computer software clause for civilian agencies), DFARS 252.227−7015 (NOV 1995) (DOD technical data – commercial items clause); FAR 52.227−14 Alternates I, II, and III (JUN 1987) (civilian agency technical data and noncommercial computer software clause); and/or FAR 12.211 and FAR 12.212 (commercial item acquisitions), as applicable. In case of conflict between any of the FAR and DFARS provisions listed herein and this Agreement, the construction that provides greater limitations on the Government’s rights shall control. 206 Contractor/manufacturer is Tele Atlas North America, Inc., 11 Lafayette Street, Lebanon, NH 03766−1445. Phone: 603.643. 0330. The DATABASE is 1984−2005 by Tele Atlas North America, Inc. ALL RIGHTS RESERVED. For purpose of any public disclosure provision under any federal, state or local law, it is agreed that the DATABASE is a trade secret and a proprietary commercial product and not subject to disclosure. If you are an agency, department, or other entity of any State government, the United States Government or any other public entity or funded in whole or in part by the United States Government, then you hereby agree to protect the DATABASE from public disclosure and to consider the DATABASE exempt from any statute, law, regulation, or code, including any Sunshine Act, Public Records Act, Freedom of Information Act, or equivalent, which permits public access and/or reproduction or use of the Licensed Products. In the event that such exemption is challenged under any such laws, this Agreement shall be considered breached and any and all right to retain any copies or to use of the DATABASE shall be terminated and considered immediately null and void. Any copies of the DATABASE held by you shall immediately be destroyed. If any court of competent jurisdiction considers this clause void and unenforceable, in whole or in part, for any reason, this Agreement shall be considered terminated and null and void, in its entirety, and any and all copies of the DATABASE shall immediately be destroyed. 06 06.07 APPENDIX END USER NOTICE PLEASE READ THIS NOTICE CAREFULLY BEFORE USING THIS NAVIGATION SYSTEM The Point Of Interest Data (“POI” Data) in the navigation system is in part provided by infoUSA Inc. (“infoUSA”). By using the POI Data, you accept and agree to all terms and conditions set forth below. 1. OWNERSHIP All rights, title and interest to the infoUSA POI Data shall be retained by infoUSA. 2. LIMITATIONS ON USE Except to the extent explicitly permitted by mandatory laws, you may not extract or reutilize any portion of the contents of the POI Data, nor reproduce, copy, modify, adapt, translate, disassemble, decompile, or reverse engineer any portion of the POI Data. 3. TRANSFER You may not transfer the POI Data to third parties, except together with the system for which it was created, provided that you do not retain any copy of the POI Data. 4. DISCLAIMER OF WARRANTY EXCEPT AS STATED HEREIN, INFOUSA MAKES NO EXPRESS OR IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, ANY EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR WARRANTY OF MERCHANTABILITY. 5. LIMITATION OF LIABILITY EITHER INFOUSA OR SUPPLIER OF POI DATA SHALL NOT BE LIABLE FOR ANY INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES MADE OR ALLEGED IN CONNECTION WITH YOUR USE OF THE POI DATA. END USER LICENSE AGREEMENT Personal Use Only. You agree to use this information for solely personal, non-commercial purposes, and not for service bureau, time-sharing or other similar purposes. You may not modify the information or remove any copyright notices that appear on the information in any way. You may not decompile, disassemble or reverse engineer any portion of this information, and may not transfer or distribute it in any form, for any purpose. Without limiting the foregoing, you may not use this information with any products, systems, or applications installed or otherwise connected to or in communication with vehicles, capable of vehicle navigation, positioning, dispatch, real time route guidance, fleet management or similar applications. VII 207 06 06.07 APPENDIX No Warranty. This information is provided to you “as is,” and you agree to use it at your own risk. DENSO and its licensors (and their licensors and suppliers, collectively “DENSO”) make no guarantees, representations or warranties of any kind, express or implied, arising by law or otherwise, including but not limited to, and DENSO expressly disclaims any warranties regarding content, quality, accuracy, completeness, effectiveness, reliability, fitness for a particular purpose, non-infringement, usefulness, use or results to be obtained from this information, or that the information or server will be uninterrupted or error-free. Some states, territories and countries do not allow certain warranty exclusions, so to that extent, the above exclusion may not apply to you. 208 Disclaimer of Liability: DENSO SHALL NOT BE LIABLE TO YOU FOR ANY CLAIM, DEMAND OR ACTION, IRRESPECTIVE OF ITS NATURE, ALLEGING ANY LOSS, INJURY OR DAMAGES, WHETHER DIRECT, INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES, INCLUDING ANY LOSS OF PROFIT, REVENUE OR CONTRACTS ARISING OUT OF YOUR POSSESSION, USE OF OR INABILITY TO USE THIS INFORMATION, ANY DEFECT IN THE INFORMATION, OR THE BREACH OF THESE TERMS OR CONDITIONS, WHETHER IN AN ACTION IN CONTRACT OR TORT OR BASED ON A WARRANTY, EVEN IF DENSO OR ITS LICENSORS HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Some states, territories and countries do not allow certain liability exclusions or damages limitations, so to that extent the above may not apply to you. Indemnity. You agree to indemnify, defend and hold DENSO and its licensors (including their respective licensors, suppliers, assignees, subsidiaries, affiliated companies, and the respective officers, directors, employees, shareholders, agents and representatives of each of them) free and harmless from and against any liability, loss, injury (including injuries resulting in death), demand, action, cost, expense, or claim of any kind or character, including but not limited to attorney’s fees, arising out of or in connection with any use or possession by you of this information. END USER NOTICE The marks of companies displayed by this product to indicate business locations are the marks of their respective owners. The use of such marks in this product does not imply any sponsorship, approval, or endorsement by such companies of this product. 06 06.07 APPENDIX There are two types of areas available for route guidance. In one type of area, primarily around metropolitan centers, detailed route guidance is available for the entire area. In the other type of area, all roads are displayed on the map but route guidance is limited. The navigation route might lack precision because the data (no right turns, one−way traffic, etc.) is not complete. It is still possible to reach the destination by following the arrow direction and distance as shown on the bottom left of the screen. The arrow points in the direction of the destination. The distance shown is as measured in a straight line from the current vehicle position to the destination area. In order to provide you with as accurate map information as possible, we are always gathering information such as on road repairs and carrying out on−site investigations. However, the names of roads, streets, facilities, and their locations are often changed. In some places, construction on roads may be in progress. For that reason, information on some areas in this system might be different from the actual location. — Changing the map DVD−ROM 6U5025aG 7U5001 2. Touch “MAP ”. The display opens and the map disc is ejected. 1. Push the “LOAD· ” button. “LOAD·EJECT” screen appears. The 7U5002 VII 3. Insert the new map DVD−ROM with the label side up. 209 06 06.07 APPENDIX 4. Push the “LOAD· ” button to close the display. The map database is normally updated once a year. Contact your dealer for information about the availability and pricing of an update. CAUTION
Do not place anything on the opened display, as such items may be thrown about and possibly injure people in the vehicle during sudden braking or in an accident.
To reduce the chance of injury in the case of an accident or sudden stopping while driving, keep the display closed.
Take care not to jam your hand while the display is moving. Otherwise, you could be injured. INFORMATION Under extremely cold conditions, the display may react slowly or operation sound may become louder.
To confirm the database version and disc coverage area 1. Push the “MENU” button. 4U5024aG 2. Touch “Map DVD”. RS02001 NOTICE Do not obstruct the display while it is moving. It could damage your navigation system. 210 Make sure the version of the database on this screen. (The database version on the screen above may be different from the actual screen.) 06 06.07 APPENDIX To display the disc coverage area, touch “Covered Area”. Confirm the covered area on the screen. Contact your dealer to find out if there is a more recent update released. VII 211 06 06.07 APPENDIX 212 06 05.26 AUDIO/VIDEO SYSTEM SECTION VI AUDIO/VIDEO SYSTEM Quick reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Using your audio/video system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Audio/video system operating hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 VI 151 06 05.26 AUDIO/VIDEO SYSTEM Quick reference 1 2 3 6U5062a 4 5 6 7 152 Function menu display screen To control the radio, CD changer or DVD player, touch the touch−screen buttons. For details, see page 154. “TUNE·FILE” knob Turn this knob to move the station band and files up or down. For details, see pages 157 and 167. “AM·SAT” button Push this button to choose an AM station. For details, see pages 154 and 157. “FM” button Push this button to choose an FM station. For details, see pages 154 and 157. “DISC·AUX” button Push this button to turn the CD changer, DVD player and AUX on. For details, see pages 154, 156, 162 and 171. “SCAN” button Push this button to scan radio stations. For details, see pages 158, 165, 168, 173 and 175. “LOAD· ” button Push this button to display the “LOAD·EJECT” screen or close the display. For details, see page 160. 06 05.26 AUDIO/VIDEO SYSTEM 8 9 10 “AUDIO” button Push this button to display the audio control screen. For details, see page 153. “SEEK/TRACK” button Push either side of this button to seek up or down for a station, or to access a desired track, file or chapter. For details, see pages 158, 164, 167,172 and 175. “PWR·VOL” knob Push this knob to turn the audio system on and off, and turn it to adjust the volume. For details, see page 153. Using your audio/video system — — Some basics This section describes some of the basic features of your audio system. Some information may not pertain to your system. Your audio system works when the ignition switch is set at ACC or ON. 6U5001a NOTICE To prevent the battery from being discharged, do not leave the audio system on longer than necessary when the engine is not running. (a) Turning the system on and off “PWR·VOL”: Push this knob to turn the audio system on and off. Turn this knob to adjust the volume. The system turns on in the last mode used. “AUDIO”: Push this button to display touch− screen buttons for audio system (audio control mode). You can select the function that enables automatic return to the previous screen from the audio screen. See page 146 for details. 153 VI 06 05.26 AUDIO/VIDEO SYSTEM 6U5058 Push “AM·SAT”, “FM” or “DISC·AUX” button to turn on the desired mode. The selected mode turns on immediately. Push these buttons if you want to switch from one mode to another. If the disc is not set, the CD changer does not turn on. You can turn off the CD changer by ejecting all the discs. If the audio system was previously off, then the entire audio system will be turned off when you eject all the discs. If the other function was previously playing, it will come on again. 154 6U5013G 6U5014G RS02020 The touch−screen buttons for radio, CD changer and DVD player operation are displayed on the function touch−screen button display screen when the audio control mode is selected. Touch them lightly and directly on the screen. The selected switch is highlighted. INFORMATION  If the system does not respond to a touch of a touch−screen button, move your finger away from the screen and then touch it again. 6U5020G  You cannot operate dimmed touch− screen buttons.  Wipe off fingerprints on the surface of the display using a glass cleaning cloth. 06 05.26 AUDIO/VIDEO SYSTEM (b) Automatic sound levelizer (ASL) When the audio sound becomes difficult to be heard due to road noise, wind noise or other noises while driving, the system adjusts to the optimum volume according to the noise level. To turn this function on, touch “ASL” on the audio control screen. (c) Tone and balance How good an audio program sounds to you is largely determined by the mix of the treble, midrange, and bass levels. In fact, different kinds of music and vocal programs usually sound better with different mixes of treble, mid−range, and bass. A good balance of the left and right stereo channels and of the front and rear sound levels is also important. Keep in mind that if you are listening to a stereo recording or broadcast, changing the right/left balance will increase the volume of one group of sounds while decreasing the volume of another. (d) Selecting screen size (with rear seat entertainment system) 6U5012aG 6U5032aG Touching “SOUND” displayed on the screen at the audio control mode will display the sound control mode. Adjust the tone and balance as follows: To adjust the tone, touch “+” or “−” on the screen. To adjust the balance between the front and rear speakers, touch “FRONT” or “REAR” on the screen, and to adjust the balance between the left and right, touch “L” or “R” on the screen. “TREB”: Adjusts high−pitched tones. “MID”: Adjusts mid−pitched tones. “BASS”: Adjusts low−pitched tones. As the yellow display approaches “+”, each tone is more emphasized. Touching “WIDE” displayed on the screen in the video control mode will display the wide mode control screen. “NORMAL”: Displays a 3
4 screen, with either side in black. “WIDE 1”: Widens the 3
4 screen horizontally to fill the screen. “WIDE 2”: Widens the 3
4 screen vertically and horizontally, in the same ratio, to fill the screen. When you touch returns. , the previous screen 155 VI 06 05.26 AUDIO/VIDEO SYSTEM (e) Your CD changer When you insert a disc, touch “LOAD” and gently push the disc in with the label side up. This CD changer can store up to four discs. The changer will play from track 1 through to the end of the disc. Then it will play from track 1 of the next disc. The changer is intended for use with 12 cm (4.7 in.) discs only. 6U5003 NOTICE  Do not stack up two discs for insertion, or it will cause damage to the changer. Insert only one disc into slot at a time.  Never try to disassemble or oil any part of the changer. Do not insert anything other than a disc into the slot. 156 (f) Your DVD player (with rear seat entertainment system) The sound of the rear seat entertainment system can be enjoyed by pushing the “DISC·AUX” button. (g) AUX adapter The sound of portable audio players connected to the AUX adapter can be enjoyed. Push the “DISC·AUX” button to switch to AUX mode. For details, refer to the “Owner’s Manual”. 06 05.26 AUDIO/VIDEO SYSTEM — Radio operation 6U5060 6U5014G 6U5059 (a) Listening to the radio Push these buttons to choose either an AM or FM station. “AM”, “FM1” or “FM2” appears on the screen. Turn the knob clockwise to step up the station band or counterclockwise to step down. Your radio automatically changes to stereo reception when a stereo broadcast is received. “ST” appears on the screen. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. In this case, “ST” disappears from the screen. (b) Presetting a station 1. Tune in the desired station. 2. Touch one of the touch−screen buttons (1 — 6) you want and hold it until a beep is heard. This sets the station to the touch−screen button and the frequency appears on the touch−screen button. Each radio mode (AM, FM1 or FM2) can store up to 6 stations. To change the preset station to a different one, follow the same procedure. The preset station memory is cancelled when the power source is interrupted by battery disconnection or a blown fuse. 157 VI 06 05.26 AUDIO/VIDEO SYSTEM (c) Selecting a station Tune in the desired station using one of the following methods. Preset tuning: Touch the touch−screen button (1 — 6) for the station you want. The touch−screen button is highlighted and the station frequency appears on the screen. Seek tuning: Push the “SEEK/TRACK” button on either side. The radio will begin seeking up or down for a station of the nearest frequency and will stop on reception. Each time you push the button, the stations will be searched automatically one after another. To scan all the frequencies: Touch “SCAN” on the screen or push the “SCAN” button briefly. “SCAN” appears on the screen. The radio will find the next station and stay there for a few seconds, and then scan again. To select a station, touch “SCAN” or push the “SCAN” button again. To scan the preset stations: Touch “SCAN” on the screen or push the “SCAN” button for longer than a second. “P. SCAN” appears on the screen. The radio will tune in the next preset station, stay there for a few seconds, and then move to the next preset station. To select a station, touch “SCAN” or push the “SCAN” button again. 158 (d) Radio Data System Your audio system is equipped with Radio Data Systems (RDS). RDS mode provides you to receive text messages from radio stations that utilize RDS transmitters. When RDS is on, the radio can — only select stations of a particular program type, — display messages from radio stations, — search for a stronger signal station. RDS features are available for the use only on FM stations which broadcast RDS information. 6U5015G “TYPE 
” If the system receives no RDS stations, “NO PTY” appears on the display. Each time you touch “TYPE ” or “TYPE
”, the program type changes as in the following:  ROCK  MISC (Miscellaneous)  INFORM (Information)  EASY LIS (Easy listening)  CLS/JAZZ (Classical music and Jazz)  R & B (Rhythm and Blues)  RELIGION  ALARM (Emergency message) 06 05.26 AUDIO/VIDEO SYSTEM 6U5016G “TYPE SEEK” When a program is set, “TYPE SEEK” appears. Touch the switch and the system starts to seek the station in the relevant program type. If any type program station is not found, “NOTHING” appears on the display. RS02021 “MSG” (MESSAGE) If the system receives a radio text from RDS station, “MSG” appears on the display. Touch “MSG”, and a text message is displayed on the screen. This function is available only when the vehicle is not moving. When the system can show the station name, “RDS” appears on the display. Each time you touch “MSG” or “MSG OFF”, indication on the display changes from the band to the station name, a radio text in this order. 6U5017G (e) Traffic announcement “TRAF” A station that regularly broadcasts traffic information is automatically located. When you touch “TRAF”, “TRAF SEEK” appears on the display and the radio will start seeking any traffic program station. If no traffic program station is found, “NOTHING” appears on the display. If a traffic program station is found, the name for traffic program station is displayed for a while until a traffic announcement is received. 159 VI 06 05.26 AUDIO/VIDEO SYSTEM — CD changer operation 6U5025aG 7U5001 2. Touch “LOAD”. The display opens. (a) Inserting discs The ignition switch must be set at ACC or ON. Your CD changer can store up to 4 discs. You can set a disc at the lowest empty disc number. 1. Push the “LOAD· ” button. “LOAD·EJECT” screen appears. 160 The 3. The amber indicators at either side of the slot start blinking. When the indicators change to green, insert only one disc. After the disc is loaded, the amber indicators at either side of the slot start blinking again. When the indicators change to green, you can insert the next disc. 4. Push the “LOAD· ” button to close the display. The changer will automatically start playing from the last disc you inserted. If the label faces down, the disc cannot be played. In this case, “CD CHECK” appears on the screen. CAUTION 6U5006  Do not place anything on the opened display, as such items may be thrown about and possibly injure people in the vehicle during sudden braking or in an accident.  To reduce the chance of injury in case of an accident or sudden stop while driving, keep the display closed.  Take care not to jam your hand while the display is moving. Otherwise, you could be injured. 06 05.26 AUDIO/VIDEO SYSTEM NOTICE The display opens and the amber indicators at either side of the slot start blinking. After the disc is ejected, the amber indicators change to green. A disc can be inserted.  All the discs: (b) Ejecting discs  A single disc alone:  Do not obstruct the display while it is moving. It could damage your audio system.  Do not insert one disc stacked on top of another one or feed them in continuously, to prevent discs from getting stuck in the changer. 1. Push the “LOAD· ” button. “LOAD·EJECT” screen appears. The 7U5001 INFORMATION 6U5026aG Under extremely cold conditions, the display may react slowly or operation sound may become louder. 1. Push the “LOAD· ” button. “LOAD·EJECT” screen appears. The 2. Touch “ALL CD 6U5026aG ”. The display opens and the amber indicators at either side of the slot start blinking. After the disc is ejected, the blinking indicators stay on. 2. Touch the disc number to be ejected. 161 VI 06 05.26 AUDIO/VIDEO SYSTEM 3. Remove the disc. The indicators start blinking again and the next disc is ejected. If a disc is not remove within 15 seconds after it is ejected, the operation will be canceled. When all the discs are removed, the amber indicators change to green. A disc can be inserted. 6U5019G 6U5061 The numbers of the trays where the disc is not set are dimmed. (c) Playing a disc Push the “DISC·AUX” button if the discs are already loaded in the changer. “CD CHANGER” appears on the screen. The discs set in the changer are played continuously, starting with the last disc you inserted. The disc number of the disc currently being played, the track number and the time from the beginning of the program appear on the screen. When play of one disc ends, the first track of the following disc starts. When play of the final disc ends, play of the first disc starts again. The changer will skip any empty disc trays. 162 06 05.26 AUDIO/VIDEO SYSTEM Vehicles with rear entertainment system — If the DVD player is turned on, push the “DISC·AUX” button again to switch to the CD changer. If the rear seat entertainment system is on, pushing the “DISC·AUX” button switches the sound of the front audio system and that of the rear seat entertainment system. 6U5020G (d) Selecting a desired disc Touch the desired disc number on the screen. The selected disc number is highlighted. The changer will start playing the selected disc from the first track. 6U5020G (e) Playing an audio disc Push the “AUDIO” button to display this screen. VI 163 06 05.26 AUDIO/VIDEO SYSTEM 6U5008 6U5021G Touch the desired track number. The changer will start playing the selected track from the beginning. SELECTING A DESIRED TRACK “SEEK/TRACK” button: Use for a direct access to a desired track. Push either side of the “SEEK/TRACK” button and repeat it until the desired track number appears on the screen. As you release the button, the changer will start playing the selected track from the beginning. “TRACK LIST”: The desired track can be selected from a list. This function is available only when the vehicle is not moving. Touch “TRACK LIST”. The track list is displayed. 164 : By touching this touch−screen button, the list moves up by 6 track groups. If this button is touched when the top page of the list is displayed, the last page is displayed. : By touching this touch−screen button, the list moves down by 6 track groups. If this button is touched when the last page of the list is displayed, the top page is displayed. Vehicles with rear entertainment system — While the DVD player is in operation, the chapter or track can be changed by pushing either side of the “SEEK/TRACK” button. Fast forward: Push “” side of the “SEEK/ TRACK” button and hold it to fast forward the disc. When you release the button, the changer will resume playing from that position. Reverse: Push “” side of the “SEEK/ TRACK” button and hold it to reverse the disc. When you release the button, the changer will resume playing. 06 05.26 AUDIO/VIDEO SYSTEM 6U5020G SEARCHING FOR A DESIRED TRACK OR DISC Searching for a desired track — Touch “SCAN” on the screen or push the “SCAN” button briefly while the disc is playing. “SCAN” appears on the screen. The changer will play the next track for 10 seconds, then scan again. To select a track, touch “SCAN” on the screen or push the “SCAN” button a second time. If the changer reaches the end of the disc, it will continue scanning at track 1. After all the tracks are scanned in one pass, normal play resumes. Searching for a desired disc — Touch “SCAN” on the screen or push the “SCAN” button for longer than a second while the disc is playing. “D·SCAN” appears on the screen. The program at the beginning of each audio disc will be played for 10 seconds. To continue listening to the program of your choice, touch “SCAN” on the screen or push the “SCAN” button a second time. After all the audio discs are scanned in one pass, normal play resumes. 6U5020G OTHER FUNCTIONS “RPT”: Use it for automatic repeat of the track or disc you are currently listening to. Repeating a track — Touch “RPT” briefly while the track is playing. “RPT” appears on the screen. When the track is finished, the changer will automatically go back to the beginning of the track and play the track again. To cancel it, touch “RPT” once again. Repeating a disc — Touch “RPT” for longer than a second while the disc is playing. “D·RPT” appears on the screen. When the disc is finished, the changer will automatically go back to the beginning of the disc and play the disc again. To cancel it, touch “RPT” once again. 165 VI 06 05.26 AUDIO/VIDEO SYSTEM “RAND”: Use it for automatic and random selection. Playing the tracks on one disc in random order — Touch “RAND” briefly while the disc is playing. “RAND” appears on the screen. The system selects a track on the disc being listened to in random order. To cancel it, touch “RAND” once again. Playing the tracks on all the audio discs in random order — Touch “RAND” for longer than a second while the disc is playing. “D·RAND” appears on the screen. The system selects a track on all the audio discs in the changer in random order. To cancel it, touch “RAND” once again. If a CD−TEXT disc is inserted, the title of the disc and track will be displayed. Up to 29 letters can be displayed. SELECTING A DESIRED FOLDER 6U5022G “FOLDER”: Touch this touch−screen button to go to the next folder. “FOLDER”: Touch this touch−screen button to go to the previous folder. “FOLDER LIST”: The desired folder can be selected in a list. This function is available only when the vehicle is not moving. Touch “FOLDER LIST”. The folder list is displayed. (f) Playing a MP3/WMA disc Push the “AUDIO” button and touch a MP3/WMA disc number to display this screen. 6U5023G Touch the desired folder number. The changer will start playing the first file of the selected folder. : By touching this touch−screen button, the list moves up by 6 folder groups. If this touch−screen button is touched when the top page of the list is displayed, the last page is displayed. 166 06 05.26 AUDIO/VIDEO SYSTEM : By touching this touch−screen button, the list moves down by 6 folder groups. If this touch−screen button is touched when the last page of the list is displayed, the top page is displayed. “FILE”: The file list is displayed. “DETAIL”: Details of the file currently playing is displayed. This function is available only when the vehicle is not moving. 6U5008 6U5060 SELECTING A DESIRED FILE “SEEK/TRACK” button: Use for direct access to a desired file. Push either side of the “SEEK/TRACK” button and repeat it until the desired file number appears on the display. As you release the button, the changer will start playing the selected file from the beginning. When “RAND” or “FLD·RPT” is on, the file number within the folder you are currently being listened to appears. Fast forward: Push “” side of the “SEEK/ TRACK” button and hold it to fast forward the disc. When you release the button, the changer will resume playing from that position. Reverse: Push “” side of the “SEEK/ TRACK” button and hold it to reverse the disc. When you release the button, the changer will resume playing. “TUNE·FILE” knob: Use for direct access to a desired file in the disc. Turn the “TUNE·FILE” knob to step up or down all the files in the disc you are currently listening to. The file number appears on the display. When “RAND” or “FLD. RPT” is on, all the files in the folder you are currently being listened to can be stepped up or down. 167 VI 06 05.26 AUDIO/VIDEO SYSTEM 6U5023G “FILE”: The desired file can be selected in a list. This function is available only when the vehicle is not moving. Touch “FILE”. The file list is displayed. 6U5024G Touch the desired file number. The changer will start playing the selected file from the beginning. : By touching this touch−screen button, the list moves up by 6 file groups. If this touch−screen button is touched when the top page of the list is displayed, the last page is displayed. : By touching this touch−screen button, the list moves down by 6 file groups. If this touch−screen button is touched when the last page of the list is displayed, the top page is displayed. “FOLDER”: The folder list is displayed. “DETAIL”: Details of the file currently playing is displayed. This function is available only when the vehicle is not moving. 168 6U5022G SEARCHING FOR A DESIRED FILE Touch “SCAN” on the screen or push the “SCAN” button briefly while the disc is playing. “SCAN” appears on the screen. The changer will play the next file in the folder for 10 seconds, then scan again. To select a file, touch “SCAN” on the screen or push the “SCAN” button a second time. If the changer reaches the end of the folder, it will continue scanning from file 1. After all the files are scanned in one pass, normal play resumes. 06 05.26 AUDIO/VIDEO SYSTEM 6U5022G SEARCHING FOR A DESIRED FOLDER Touch “SCAN” on the screen or push the “SCAN” button for longer than a second while the disc is playing. “FLD.SCAN” appears on the screen. The program at the beginning of each folder will be played for 10 seconds. To continue listening to the program of your choice, touch “SCAN” on the screen or push the “SCAN” button a second time. After all the folders are scanned in one pass, normal play resumes. 6U5022G OTHER FUNCTIONS “RPT”: Use it for automatic repeat of the file or folder you are currently listening to. Repeating a file — Touch “RPT” briefly while the file is playing. “RPT” appears on the screen. When the file is finished, the changer will automatically go back to the beginning of the file and play the file again. To cancel it, touch “RPT” once again. Repeating a folder — Touch “RPT” for longer than a second while the folder is playing. “FLD.RPT” appears on the screen. When the folder is finished, the changer will automatically go back to the beginning of the folder and play the folder again. To cancel it, touch “RPT” once again. “RAND”: Use it for automatic and random selection of the folder or the disc which you are currently listening to. Playing the files in one folder in random order — Touch “RAND” briefly while the disc is playing. “RAND” appears on the screen. The system selects a file in the folder you are currently listening to. To cancel it, touch “RAND” once again. Playing the files in all the folders on one disc in random order — Touch “RAND” for longer than a second while the disc is playing. “FLD.RAND” appears on the screen. The system selects a file in all the folders. To cancel it, touch “RAND” once again. When a file is skipped or the system is inoperative, touch “RAND” to reset. VI 169 06 05.26 AUDIO/VIDEO SYSTEM (g) If the player malfunctions If “CD ERROR” appears on the screen, audio signals of the disc cannot be read or the system has trouble. Push the “DISC” button once again. If the changer does not operate, check that the disc surface is not soiled or damaged. If the disc is O.K., the temperature of the changer’s internal mechanism may be raised because of high external temperature. Remove the disc from the changer to cool it. If the changer still does not operate, have it checked by your dealer. If an MP3/WMA disc contains CD−DA files, only CD−DA files are played. If an MP3/WMA disc contains files other than CD−DA, only MP3/WMA files are played. —DVD player operation The DVD player can play DVD video, audio CD, video CD, CD text, dts−CD or MP3 disc only when a disc is loaded in the DVD player. A WMA disc cannot be played. Refer to “Rear seat entertainment system” for details. For appropriate discs for this player, see “Audio/video system operating hints” on page 189. (a) Inserting the disc 6U5063 Insert the disc into the slot with the label side up. An adapter must be used for 8 cm (3 in.) discs which are loaded in the same manner as for 12 cm (4.7 in.) discs. 170 6U5064 The indicator light turns on while the disc is loaded. If the label faces forward, the disc cannot be played. In this case, “DISC CHECK” appears on the screen. If a disc which is not playable is inserted, “DISC CHECK” will also appear on the screen. For appropriate discs for this player, see “Audio/video system operating hints” on page 189. NOTICE Never try to disassemble or oil any part of the DVD player. Do not insert anything other than a disc into the slot. 06 05.26 AUDIO/VIDEO SYSTEM 6U5065 (b) Ejecting a disc Push the button. 6U5061 (c) Playing a disc Push the “DISC·AUX” button if a disc is already loaded in the player. “DVD” appears on the screen. (If the CD changer is turned on, push the “DISC” button again to switch to the DVD player.) 6U5029G (d) Operating an audio CD PLAYING AN AUDIO CD CD text only — The disc title and track title will appear on the screen when pushing the “DISC·AUX” button. Push the “AUDIO” button to display this screen. VI 171 06 05.26 AUDIO/VIDEO SYSTEM 6U5008 6U5193G Touch the desired track number. The player will start playing the selected track from the beginning. SELECTING A DESIRED TRACK “SEEK/TRACK” button: Use for direct access to a desired track. Push either side of the “SEEK/TRACK” button and repeat it until the desired track number appears on the display. As you release the button, the player will start playing the selected track from the beginning. “TRACK LIST”: The desired track can be selected from a list. This function is available only when the vehicle is not moving. Touch “TRACK LIST”. The track list is displayed. 172 : By touching this touch−screen button, the list moves up by 6 track groups. If this touch−screen button is touched when the top page of the list is displayed, the last page is displayed. : By touching this touch−screen button, the list moves down by 6 track groups. If this touch−screen button is touched when the last page of the list is displayed, the top page is displayed. Fast forward: Touch “” side of “SEEK/ TRACK” button and hold it to fast forward the disc. When you release the button, the player will resume playing from that position. Reverse: Touch “” side of the “SEEK/ TRACK” button and hold it to reverse the disc. When you release the button, the player will resume playing. 06 05.26 AUDIO/VIDEO SYSTEM 6U5029G SEARCHING FOR A DESIRED TRACK Touch “SCAN” on the screen or push the “SCAN” button. “SCAN” will be highlighted on the screen. The player will play the next track for 10 seconds, then scan again. To select a track, touch “SCAN” on the screen or push the “SCAN” button a second time. If the player reaches the end of the disc, it will continue scanning at track 1. After all the tracks are scanned in one pass, normal play resumes. 6U5029G OTHER FUNCTIONS “RPT”: Use it for automatic repeat of the track you are currently listening to. Touch “RPT” while the track is playing. When the track is finished, the player will automatically go back to the beginning of the track and play the track again. To cancel it, touch “RPT” once again. “RAND”: Use it for automatic and random selection of the disc which you are currently listening to. When “RAND” is touched, the system selects a track in the disc you are currently listening to. To cancel it, touch “RAND” once again. If a CD−TEXT disc is inserted, the title of the disc and track will be displayed. Up to 29 letters can be displayed. 6U5030G (e) Operating a MP3 DISC PLAYING A MP3 DISC Push the “AUDIO” button to display this screen. VI 173 06 05.26 AUDIO/VIDEO SYSTEM SELECTING A DESIRED FOLDER “FOLDER”: Touch this touch−screen button briefly to go to the next folder. “FOLDER”: Touch this touch−screen button briefly to go to the previous folder. To jump up to the first folder, touch and hold this touch−screen button until the beep sounds. “FOLDER LIST”: The desired folder can be selected in a list. This function is available only when the vehicle is not moving. Touch “FOLDER LIST”. The folder list is displayed. 6U5050G Touch the desired folder number. The player will start playing the first file of the selected folder. 174 : By touching this touch−screen button, the list moves up by 6 folder groups. If this touch−screen button is touched when the top page of the list is displayed, the last page is displayed. : By touching this touch−screen button, the list moves down by 6 folder groups. If this touch−screen button is touched when the last page of the list is displayed, the top page is displayed. “FILE”: The file list is displayed. “DETAIL”: Details of the file currently playing is displayed. This function is available only when the vehicle is not moving. 6U5008 6U5050G 06 05.26 AUDIO/VIDEO SYSTEM SELECTING A DESIRED FILE “SEEK/TRACK” button: Use for direct access to a desired file. Push either side of the “SEEK/TRACK” button and repeat it until the desired file number appears on the display. As you release the button, the player will start playing the selected file from the beginning. Fast forward: Push “” side of the “SEEK/ TRACK” button and hold it to fast forward the disc. When you release the button, the player will resume playing from that position. Reverse: Push “” side of the “SEEK/ TRACK” button and hold it to reverse the disc. When you release the button, the player will resume playing. “FILE”: The desired file can be selected in a list. This function is available only when the vehicle is not moving. Touch “FILE”. The file list is displayed. 6U5051G Touch the desired file number. The player will start playing the selected file from the beginning. : By touching this touch−screen button, the list moves up by 6 file groups. If this touch−screen button is touched when the top page of the list is displayed, the last page is displayed. : By touching this touch−screen button, the list moves down by 6 file groups. If this touch−screen button is touched when the last page of the list is displayed, the top page is displayed. “FOLDER”: The folder list is displayed. “DETAIL”: Details of the file currently playing is displayed. This function is available only when the vehicle is not moving. 6U5030G SEARCHING FOR A DESIRED FILE Touch “SCAN” on the screen or push the “SCAN” button briefly. “SCAN” appears on the screen. The DVD player will play the next file in the folder for 10 seconds, then scan again. To select a file, touch “SCAN” on the screen or push the “SCAN” button a second time. If the player reaches the end of the folder, it will continue scanning from file 1. After all the files are scanned in one pass, normal play resumes. 175 VI 06 05.26 AUDIO/VIDEO SYSTEM 6U5030G SEARCHING FOR A DESIRED FOLDER Touch and hold “SCAN” on the screen or push the “SCAN” button until the beep sounds. “FLD.SCAN” appears on the screen. The DVD player will play the file at the beginning of each folder for 10 seconds, then scan again. To select a file, touch “SCAN” on the screen or push the “SCAN” button a second time. After all the folders are scanned in one pass, normal play resumes. 176 6U5030G OTHER FUNCTIONS “RPT”: Use it for automatic repeat of the file or folder you are currently listening to. Repeating a file — Touch “RPT” briefly while the file is playing. “RPT” appears on the screen. When the file is finished, the player will automatically go back to the beginning of the file and play the file again. To cancel it, touch “RPT” once again. Repeating a folder — Touch and hold “RPT” until the beep sounds while the folder is playing. “FLD.RPT” appears on the screen. When the folder is finished, the player will automatically go back to the beginning of the folder and play the folder again. To cancel it, touch “RPT” once again. “RAND”: Use it for automatic and random selection of the folder which you are currently listening to or of all the folders. Playing the files in one folder in random order — Touch “RAND” briefly. “RAND” appears on the screen. The system selects a file in the folder you are currently listening to. To cancel it, touch “RAND” once again. Playing the files in all the folders in random order — Touch and hold “RAND” until the beep sounds. “FLD.RAND” appears on the screen. The system selects a file in the folders of all the trays which are set and plays it. To cancel it, touch “RAND” once again. When a file is skipped or the system is inoperative, touch “RAND” to reset. 06 05.26 AUDIO/VIDEO SYSTEM (f) Operating a DVD video disc NOTE: The playback condition of some DVD video discs may be determined by a DVD video software producer. This DVD player plays a disc as the software producer intended. So some functions may not work properly. Be sure to read the instruction manual for the DVD video disc separately provided. For the detailed information about DVD video discs, see “(h) DVD player and DVD video disc information”. Precautions on DVD video disc When recording with a DVD video or video CD, audio tracks may not record in some cases while the menu is displayed. As audio will not play in this case, verify that the video tracks are playing and then activate playback. When playback of a disc is completed:  If an audio CD or MP3 disc is playing, the first track or file starts.  If a DVD video or video CD is playing, playback will stop or the menu screen will be displayed. The title/chapter number and playback time display may not appear while playing back certain DVD video discs. CAUTION Conversational speech on some DVDs is recorded at a low volume to emphasize the impact of sound effects. If you adjust the volume assuming that the conversations represent the maximum volume level that the DVD will play, you may be startled by louder sound effects or when you change to a different audio source. The louder sounds may have a significant impact on the human body or pose a driving hazard. Keep this in mind when you adjust the volume. 6U5031aG This “DVD Hint!” screen appears when the video screen is first displayed after the ignition switch is set at ACC or ON. Touch “OK” when you read the message. VI 177 06 05.26 AUDIO/VIDEO SYSTEM “Hide Buttons”: Touching this will turn off the controls from the screen. RS02020 PLAYING A DVD DISC Push the “AUDIO” button to display this screen. When you touch “WIDE”, the screen mode can be changed. It you touch “PICTURE” when the vehicle is completely stopped and the parking brake is applied, the video screen returns. 6U5035aG 6U5036aG DISPLAYING DVD CONTROLS If you touch a part of the screen, where controls are not located while watching video, DVD controls will appear. “Page2”: Touching this will display on the second page of DVD controls. “Page1”: Touching this will display the top page of DVD controls. 178 If “ ” appears on the screen when you touch a control, the operation relevant to the control is not permitted. DESCRIPTION OF DVD CONTROLS  Top page of DVD video controls “Menu” and “Top Menu”: If you touch any of the above controls, the menu screen for DVD video appears. (For the operation, see the manual that come with the DVD video disc provided separately.) : The menu control key appears on the screen. (See page 179.) : Touching this will pause the video screen. When you touch this again, the video screen advances frame by frame. : Touching this will fast reverse during playback. : Touching this will stop the video screen.
: Touching this will pause during playback and resume normal play during pause or slow forward.

: Touching this will fast forward during playback and forward slowly during pause. 06 05.26 AUDIO/VIDEO SYSTEM  Second page of DVD video controls “Setup”: The initial set up screen appears. (See page 181.) “Search”: The title search screen appears. (See page 179.) “Return”: Touching this will display the predetermined scene and start playing from there. “AUDIO”: The audio changing screen appears. (See page 180.) “Subtitle”: The subtitle changing screen appears. (See page 180.) “Angle”: The angle selection screen appears. (See page 180.) 6U5037aG SELECTING A MENU ITEM Enter the menu item using ,
,  and  and touch “Enter”. The player starts playing video for that menu item. (For details, see the manual that comes with the DVD video disc provided separately.) Each time you touch “Move Buttons”, the controls on the screen move upward and downward. When you touch “< > > ON [ENTER] to Customize [EXIT] to Quit Page 3 of 4 REPAIR MANUAL SUPPLEMENT: DAYTIME RUNNING LIGHTS – EL014-06 Activation Procedure (Continued) 10. In the “SETTING CHANGE DRL FUNCTION” screen, press the “YES” button. December 12, 2006 SETTING CHANGE DRL FUNCTION ARE YOU SURE YOU WANT TO CHANGE From To ON OFF [YES] [NO] 11. Verify that the Daytime Running Lights (DRL) have been deactivated. ? to Change to Abort CUSTOMIZE COMPLETE DRL FUNCTION The setting has been changed to: ON Confirm the item operation is as desired. PRESS [ENTER] Page 4 of 4 REAR DRIVESHAFT/PROPELLER SHAFT CLUNK/THUMP NOISE Technical Service Information Bulletin Models: ’03 – ’07 GX 470 May 29, 2007 TSIB UPDATE NOTICE: The information contained in this TSIB supercedes TSIB No. DL001-06. TSIB No. DL001-06 is now obsolete and should be discarded. Introduction Applicable Vehicles Parts Information Some owners of 2003 – 2007 model year GX 470 vehicles may experience a clunk/thump noise from the rear of the vehicle or a “bump-from-behind” sensation just before or after coming to a stop. A new rear propeller shaft assembly and revised rear suspension control arms have been developed to improve this condition. S 2003 – 2007 model year GX 470 vehicles. PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 37110–6A480 37110–60A40 Shaft Assembly, Propeller (DLC) 1 N/A 04006–09160 Rear Suspension Control Arm Kit 1 Required Tools & Material Warranty Information TOOLS & MATERIAL QUANTITY Miscellaneous Hand Tools As Needed OP CODE DESCRIPTION TIME OFP DL5005 R & R Rear Driveshaft Assembly, Lower Control Arms, and Upper Control Arms 2.5 37110–6A480 T1 T2 91 50 Applicable Warranty*: This repair is covered under the Lexus Powertrain Warranty. This warranty is in effect for 72 months or 70,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Lexus Supports ASE Certification Page 1 of 4 DRIVELINE & DIFFERENTIAL DL002-07 Title: REAR DRIVESHAFT/PROPELLER SHAFT CLUNK/THUMP NOISE – DL002-07 Repair Procedure May 29, 2007 1. Test drive vehicle and confirm noise condition. NOTE: Check for the painted matchmarks on the transfer flange and differential flange when installing the NEW propeller shaft assembly. If the matchmarks are NOT visible, be sure to install the NEW propeller shaft in the same orientation as the original propeller shaft. 2. Remove and replace the 2-piece propeller shaft assembly. For more information, refer to the Technical Information System (TIS): S 2003, 2004, or 2005 model year GX 470 Repair Manual, Drivetrain – Driveshaft/Propeller Shaft – “Propeller Shaft Assy: Overhaul”. S 2006 or 2007 model year GX 470 Repair Manual, Drivetrain – Driveshaft/Propeller Shaft – “Propeller Shaft: Propeller Shaft Assembly: Removal”. S 2006 or 2007 model year GX 470 Repair Manual, Drivetrain – Driveshaft/Propeller Shaft – “Propeller Shaft: Propeller Shaft Assembly: Installation”. A. Remove the propeller shaft assembly. a. Remove the 4 nuts and 4 washers. Matchmarks b. Remove the 4 nuts, 4 bolts, and 4 washers and then the propeller shaft assembly. Matchmarks Page 2 of 4 REAR DRIVESHAFT/PROPELLER SHAFT CLUNK/THUMP NOISE – DL002-07 Repair Procedure (Continued) May 29, 2007 B. Install the NEW propeller shaft assembly. a. Align the matchmarks on the yoke and the differential flange. b. Install the propeller shaft assembly with the 4 bolts, 4 nuts, and 4 washers. Torque: 88 NSm (898 kgfScm, 65 ftSlbf) Matchmarks c. Align the matchmarks on the yoke and the transfer flange. d. Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 NSm (898 kgfScm, 65 ftSlbf) Matchmarks 3. Remove and replace the LH and RH upper control arm assemblies one side at a time. Refer to TIS: S 2003, 2004, or 2005 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Upper Control Arm Assy: Replacement”. S 2006 or 2007 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Suspension: Rear Upper Control Arm: Removal”. S 2006 or 2007 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Suspension: Rear Upper Control Arm: Installation”. Upper Control Arm Identification LEFT Upper Control Arm has YELLOW Paint Mark RIGHT Upper Control Arm has BLUE Paint Mark Page 3 of 4 REAR DRIVESHAFT/PROPELLER SHAFT CLUNK/THUMP NOISE – DL002-07 Repair Procedure (Continued) May 29, 2007 4. Remove and replace the LH and RH lower control arm assemblies one side at a time. Refer to TIS: S 2003, 2004, or 2005 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Lower Control Arm Assy LH: Replacement”. S 2006 or 2007 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Suspension: Rear Lower Control Arm: Removal”. S 2006 or 2007 model year GX 470 Repair Manual, Suspension – Rear Suspension – “Suspension: Rear Lower Control Arm: Installation”. Lower Control Arm Identification LEFT Lower Control Arm RIGHT Lower Control Arm Hole in Bushing Frame Side Hole in Bushing Bushing Bushing Front of Vehicle Axle Side 5. Test drive vehicle and confirm repair effectiveness. Page 4 of 4 Technical Service BULLETIN SECOND ROW SEAT BACK NOISE Models: ’03 – ’07 4Runner March 22, 2004 TSB REVISION NOTICE: S April 11, 2007: 2007 model year has been added to Applicable Vehicles. S March 17, 2006: 2004 – 2006 model years have been added to Applicable Vehicles. Previous versions of this TSB should be discarded. Introduction Applicable Vehicles Warranty Information The following field-fix procedure was developed to minimize the possibility of noise from the second row passenger side (right side) seat back latch. S 2003 – 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP NV4002 Adjust Second Row Passenger Side (Right Side) Seat Back Striker** 1.0 72601–35020 T1 T2 91 57 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. ** This field-fix procedure applies to the second row passenger side (right side) ONLY. This procedure does NOT apply to the second row driver side (left side). Toyota Supports ASE Certification Page 1 of 3 NVH NV003-04 Title: SECOND ROW SEAT BACK NOISE – NV003-04 Revised Repair Procedure March 22, 2004 For reference refer to the Technical Information System (TIS), applicable model year 4Runner Repair Manual: Exterior/interior Trim: Roof Headlining Assy: Replacement. 1. Check passenger side second row seat back latch to striker alignment. 2. Determine if the striker is centered in the seat back latch by slowly moving the passenger side second seat back toward the striker. Visually check to see if the striker is centered in the seat back latch. HINT: Wear marks on the top or bottom portion of the striker indicate a possible misalignment issue. If wear marks are found to be on top of the striker, the striker must be adjusted downward to remedy the condition and vice versa. Wear Marks 3. If striker misalignment is detected, continue with step 4. If the striker is found to be centered in the seat latch and there are NO wear marks evident on the top or bottom surfaces of the striker, the following field fix will NOT be effective. 4. Remove the passenger side second row seat back striker and elongate the bottom mounting hole to allow striker adjustment. (For necessary interior disassembly instructions to access the second row seat back striker, refer to TIS, applicable model year 4Runner Repair Manual: Exterior/interior Trim: Roof Headlining Assy: Replacement: steps 1 – 23). A. Remove the three bolts that secure the second row seat back latch striker to the vehicle body. B. Remove 1 mm of striker plate material from the top and bottom of the bottom striker plate bolt hole to elongate the hole and create striker adjustability as shown in the illustration. Bottom Hole Elongate hole by removing 1 mm of striker plate material from top and bottom of the bottom hole. Page 2 of 3 SECOND ROW SEAT BACK NOISE – NV003-04 Revised Repair Procedure (Continued) March 22, 2004 5. Reinstall striker to vehicle body and adjust striker to center of seat latch. A. Install the passenger side second row seat back striker by threading each of the three (3) bolts into the body. Do NOT tighten the three (3) bolts at this time. B. Rotate the seat back toward the striker and align the striker in the center of the seat back latch. C. Tighten the three (3) bolts to secure the striker in place. 6. Reassemble the vehicle interior in reverse order of disassembly. For reference, refer TIS, applicable model year 4Runner Repair Manual: Exterior/interior Trim: Roof Headlining Assy: Replacement. Page 3 of 3 FRONT SEAT SQUEAK NOISE Technical Service BULLETIN Models: ’04 – ’07 Toyota & Scion May 23, 2006 Introduction Applicable Vehicles Required Tools & Material Warranty Information Some customers may experience a squeak noise due to contact between the seat track locating pin(s) and the floor pan location hole(s). The following procedure describes the repair method to correct this condition. S 2004 – 2007 model year Toyota and Scion vehicles. TOOLS & MATERIAL QUANTITY Flat Blade Screwdriver (Taped Tip) 1 Power Cut-off Tool (or equivalent) 1 OP CODE DESCRIPTION TIME NV5011 R & R Front Seat Track Pins (1 seat) 0.5 Combo A Opposite Side 0.5 OFP 72011–##### 72012–##### T1 T2 91 99 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 5 NVH NV004-06 Title: FRONT SEAT SQUEAK NOISE – NV004-06 Pin Location Parts Location May 23, 2006 The following table indicates the location and the number of seat track locating pins that should be removed from the seat track assembly: MODEL NUMBER OF PINS TO REMOVE PIN LOCATION 4Runner 2 Front, Inner, & Outer Track Avalon 2 Front, Inner, & Outer Track Camry 2 Front, Inner, & Outer Track Corolla 2 Front, Inner, & Outer Track Echo 2 Front, Inner, & Outer Track FJ Cruiser 2 Front, Inner, & Outer Track Highlander 1 (Inner Side ONLY) Front & Inner Track ONLY Land Cruiser 2 Front, Inner, & Outer Track Matrix 2 Front, Inner, & Outer Track Prius 2 Front, Inner, & Outer Track RAV4 2 Front, Inner, & Outer Track Scion tC 2 Front, Inner, & Outer Track Scion xA 2 Front, Inner, & Outer Track Scion xB 2 Front, Inner, & Outer Track Sequoia 2 Front, Inner, & Outer Track Sienna 2 Front, Inner, & Outer Track Solara 2 Front, Inner, & Outer Track Tacoma 2 Front, Inner, & Outer Track Tundra 2 Front, Inner, & Outer Track Yaris 2 Front, Inner, & Outer Track Typical View of Driver’s Side Seat Inner Seat Track Seat Track Locating Pin Page 2 of 5 Outer Seat Track FRONT SEAT SQUEAK NOISE – NV004-06 Repair Procedure May 23, 2006 CAUTION: S Wear safety gloves to prevent injury to your hands. S Work must be started more than 90 seconds after the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a backup power source. If work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may deploy.) S The yaw rate sensor is installed under the front RH seat. Be careful NOT to step on the yaw rate sensor after the seat has been removed. HINT: S The installation is the reverse order of removal. However, when there is a special point concerning installation, it is indicated. S Use the same procedure on the RH side as on the LH side. S When removing/installing and performing repairs on the passenger seat, perform the Occupant Classification System Zero Point Calibration as outlined in the Diagnostics section of the applicable model year Repair Manual for each model. 1. Disconnect the negative (–) battery terminal. 2. Remove the plastic front seat track covers — Use a screwdriver to disengage the claws and carefully remove the plastic seat track covers. Typical Outer Seat Track Cover NOTE: Tape the screwdriver tip before use. NOTE: Refer to the appropriate Toyota or Scion Repair Manual for each model for detailed instructions on how to remove the plastic seat track covers. Typical Inner Seat Track Cover : Claw Page 3 of 5 FRONT SEAT SQUEAK NOISE – NV004-06 Repair Procedure (Continued) May 23, 2006 3. Remove the plastic rear seat track covers — Use the taped screwdriver to disengage the claws and carefully remove the plastic seat track covers. 4. Remove the LH front seat assembly. A. Move the seatback to the full upright position. B. Remove the four (4) seat track securing bolts. : Claw C. Disconnect the electrical connectors and remove the complete seat assembly. 5. Remove the seat track locating pins. A. With the seat removed from the vehicle, tilt the seat assembly backward to gain access to the seat track locating pins. Seat Rail Cut Off at 2 mm or Less Seat Locator Pin B. Use a power cut-off tool (or equivalent) to cut off the two (2) locating pins leaving 2 mm (0.1 in.) or less of each pin. Front Floor Cross Member IMPORTANT: Do NOT permit the power cut-off tool to contact the seat track. ONLY cut off the shaft of the pin (near the base of the seat track). NOTE: The seat track locating pins’ function is to ease installation during manufacturing and does NOT provide any other function. 6. Clean and paint bare metal surfaces. A. Remove any metal shavings from the seat track/seat assembly. B. Clean the bare metal surface of the remainder of the seat track locating pin with wax, grease, and silicone remover. C. To prevent corrosion, coat any bare metal surfaces still attached to the seat track with a brush-on type paint. 7. Install LH front seat assembly. A. Place the seat on the cabin floor. B. Reconnect all electrical connectors under the seat. C. Install all four (4) seat track retaining bolts (fingertight). Page 4 of 5 FRONT SEAT SQUEAK NOISE – NV004-06 Repair Procedure (Continued) May 23, 2006 D. Tighten the two (2) front seat track attaching bolts. NOTE: The bolt torque specification varies by model. Please refer to the Repair Manual for the correct bolt torque for the model you are working on. E. Tighten the two (2) rear seat track attaching bolts. NOTE: The bolt torque specification varies by model. Please refer to the Repair Manual for the correct bolt torque for the model you are working on. F. Reinstall all plastic seat track covers. 8. Repeat steps 1 – 6 for the RH seat assembly. 9. Reconnect the negative (–) battery terminal. 10. Test power seat operation and seat heater (if equipped) for proper operation. 11. Initialize front passenger occupant classification system and re-initialize any other power systems. S Refer to TSB No. PD008-05, “Power System Initialization During PDS.” S Refer to TSB No. PD014-06, “Power System Initialization During PDS.” 12. Inspect SRS warning light operation. 13. Test drive vehicle and confirm that the seat squeak has been eliminated. Page 5 of 5 Technical Service BULLETIN September 18, 2006 Introduction UPPER/LOWER WINDSHIELD TICK NOISE Models: ’03 – ’07 Toyota & ’04 – ’07 Scion If a creak, tick, or rattle noise is heard at the top or bottom of the windshield, the source of the noise may be the two windshield stoppers bonded to the top of the windshield or the windshield retainers bonded to the lower edge of the windshield. This bulletin provides the recommended repair procedure to eliminate these types of noises from the windshield area. NOTE: Some vehicles have both stoppers and retainers while others may only have stoppers at the top of the windshield. Use the chart in this bulletin to determine the location of the windshield holding devices. Applicable Vehicles Required Tools & Material S 2003 – 2007 model year Toyota vehicles. S 2004 – 2007 model year Scion vehicles. TOOLS & MATERIAL QUANTITY – 1 Snap-On H55A 1 T1 Basic Hand Tools Hacksaw “Mini” for 10-in. Blades (or equivalent) Warranty Information PART NUMBER OP CODE DESCRIPTION TIME OFP NV5019 Remove Top Windshield Locating Pins (2) 0.4 56116–##### NV5020 Remove Bottom Windshield Locating Pins (2) 0.3 56114–##### T2 91 41 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 6 NVH NV009-06 Title: UPPER/LOWER WINDSHIELD TICK NOISE – NV009-06 Required SSTs ITEM NO. 1 SPECIAL SERVICE TOOLS (SSTs) Plastic Pry Tool Set* September 18, 2006 PART NUMBER QTY DRW** 00002–06000–01 1 20 NOTE: S All components from this kit/set are required. COMPONENT(S) OF KIT/SET S Plastic Panel Clip Removal Tool (P/N 00002–06001–01) S Plastic Emblem Removal Tool (P/N 00002–06002–01) * Essential SSTs. ** Drawer number in SST Storage System. NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Page 2 of 6 UPPER/LOWER WINDSHIELD TICK NOISE – NV009-06 Pin Locations September 18, 2006 PIN LOCATION MODEL TOP OF WINDSHIELD QTY BOTTOM OF WINDSHIELD QTY 4Runner Yes 2 N/A N/A Avalon Yes 2 Yes 2 Camry (All Models) Yes 2 Yes 2 Celica Yes 2 N/A N/A Corolla Yes 2 N/A N/A ECHO Yes 2 N/A N/A FJ Cruiser Yes 2 N/A N/A Highlander Yes 2 N/A N/A Land Cruiser Yes 2 N/A N/A Matrix Yes 2 N/A N/A MR2 Spyder Yes 2 N/A N/A Prius Yes 2 N/A N/A RAV4 Yes 2 N/A N/A Scion tC Yes 2 N/A N/A Scion xA Yes 2 N/A N/A Scion xB Yes 2 N/A N/A Sequoia Yes 2 N/A N/A Sienna Yes 2 N/A N/A Solara Yes 2 Yes 2 Tacoma Yes 2 N/A N/A Tundra Yes 2 N/A N/A Yaris Yes 2 N/A N/A Pin Locations Page 3 of 6 UPPER/LOWER WINDSHIELD TICK NOISE – NV009-06 Repair Procedure September 18, 2006 Upper Windshield Glass Stoppers: 1. Remove both sun visors and both A-pillar garnishes, and then carefully lower the front of the headliner to gain access to the windshield stoppers (refer to the appropriate model year Repair Manual for the proper procedure). NOTE: It is very important that the front of the headliner be lowered carefully and slowly. Applying too much downward force on the headliner will cause it to develop a permanent crease in the surface material. The stoppers are located on the inside of the passenger compartment behind the windshield glass blackout section (near the top front edge of the metal roof opening). The stoppers are typically located 20 – 25 cm (7.9 – 9.8 in.) inboard of the top corners of the windshield glass. 2. Cut OFF the tip of the plastic stopper as shown in the illustration. HINT: It is sometimes necessary to bend the metal body tab down to gain access to the shaft of the stopper. 20 – 25 cm (7.9 – 9.8 in.) 20 – 25 cm (7.9 – 9.8 in.) Windshield Glass Roof Panel Glass Stopper Windshield Glass Roof Panel Fragment of Glass Stopper Glass Stopper Page 4 of 6 Cut UPPER/LOWER WINDSHIELD TICK NOISE – NV009-06 Repair Procedure (Continued) September 18, 2006 3. Once the tip of the stopper has been removed, use a screwdriver to open a gap between the roof panel and the remainder of the plastic windshield stopper. Opening Gap Roof Panel 4. Test drive vehicle prior to reassembly to confirm that the noise has been eliminated. 5. Reassemble the vehicle. Lower Windshield Retainers: 1. Carefully remove the plastic cowl cover at the base of the windshield and store it in a safe location for reinstallation later (refer to the appropriate model year Repair Manual for the proper procedure). Page 5 of 6 UPPER/LOWER WINDSHIELD TICK NOISE – NV009-06 Repair Procedure (Continued) September 18, 2006 2. Locate the lower windshield retainers. The retainers are typically located 140 – 200 mm (5.5 – 7.9 in.) inboard of the lower corners of the windshield. The flat portion of the retainer is adhered to the backside of the windshield with double-sided, foam-backed tape. Pin is Attached to Plastic Block Underneath Windshield 3. Use a “Mini” Hacksaw with a fine tooth 10-inch blade to cut OFF the pin portion of the glass retainer flush with the flat portion of the windshield retainer (diagram below shows the windshield retainer location to cut off the plastic pin). View From Underneath Windshield 4. Test drive the vehicle to confirm the elimination of the noise. 5. Reassemble the vehicle. Page 6 of 6 Technical Service BULLETIN January 3, 2007 Introduction Applicable Vehicles REFINISHING REPLACEMENT BUMPER COVERS Models: All ’06 – ’07 Toyota & Scion In cases where a bumper cover is being replaced, a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. S 2006 – 2007 model year Toyota and Scion vehicles. Required Tools & Material TOOLS & MATERIALS RECOMMENDED PRODUCT QUANTITY Mild Soap — Ph neutral (no wax type) 3Mt Car Shampoo (or equivalent) As Needed Sanding Pad 3Mt ScotchBrite (Gray) 37448 Sanding Paste Wax, Grease, & Silicone Remover Plastic Part Adhesion Promoter See Paint Manufacturer’s Recommendations Primer and Paint NOTE: Please visit www.3m.com/automotive to find the nearest store that sells 3M automotive products. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PAINT PA001-07 Title: REFINISHING REPLACEMENT BUMPER COVERS – PA001-07 Refinishing Procedure January 3, 2007 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. NOTE: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. NOTE: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow the application instructions on the container label. Fish eyes or other paint irregularities may result from NOT following the instructions. 6. Apply a generous amount of sanding paste with a gray 3Mt ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. NOTE: NEVER use a red shop towel to wipe the surface (contains silicone). 10. Ensure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer ’s recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer’s recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer’s recommendations. Page 2 of 3 REFINISHING REPLACEMENT BUMPER COVERS – PA001-07 Refinishing Procedure (Continued) January 3, 2007 14. If heat is applied to cure the paint, ensure the surface temperature does NOT exceed 176_F (80_C). For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer’s local representative. Wash with Soap & Water Rinse & Towel Dry Degrease Step 1 Scrub with Sanding Paste Wash with Soap & Water Rinse & Towel Dry Degrease Step 2 Apply Adhesion Promoter Apply Primer Apply Top Coat Page 3 of 3 PAINT STAINS UNDER RAPGARD Technical Service BULLETIN Models: ’07 Toyota & Scion November 20, 2006 TSB REVISION NOTICE: S March 2, 2007: The T1 code in the Warranty Information table has been updated. Previous versions of this TSB should be discarded. Introduction On some vehicles, when Rapgard is removed, the paint may have a stained appearance. These stains appear to be under the clear coat and should not be considered a defect in the paint (clear coat or color coat). The stain patterns are usually under wrinkles in the Rapgard. These wrinkles sometimes trap water and cause the paint to stain from the trapped moisture, especially on horizontal surfaces, such as the hood, roof, and trunk. Stains can be removed by heating the stained surface to remove the trapped moisture. Stains Applicable Vehicles Warranty Information S 2007 model year Toyota and Scion vehicles. OP CODE DESCRIPTION TIME OFP BD6004 Remove Paint Stain Under Rapgard 0.6 53301–##### T1 T2 99 99 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 PAINT PA002-06 Title: PAINT STAINS UNDER RAPGARD – PA002-06 Revised Required Tools & Material Repair Procedure November 20, 2006 TOOLS & MATERIALS QUANTITY Infrared Lamp or Heat Gun 1 Aluminum Foil or Damp Cloth 1 Thermometer 1 1. Use the aluminum foil or damp cloth to cover plastic/rubber parts that are near the stain. 2. Apply heat to the stain using an infrared lamp or heat gun. NOTE: Apply heat for 5 – 10 minutes at 158_F – 176_F (70_C – 80_C). Do NOT allow the surface to become hotter than 176_F (80_C). Measure the temperature with a thermometer. 3. After applying heat for 5 minutes, examine the area to determine if the stain has been removed. If the stain still exists, continue to apply heat and re-examine the stain 5 minutes later. Page 2 of 2 Technical Service BULLETIN November 16, 2004 IRON PARTICLE RUST CONTAMINATION REPAIR Models: ’94 – Current Toyota & ’04 – Current Scion TSB REVISION NOTICE: S December 16, 2004: Text has been revised to more accurately describe cleaner (Auto MagicR Special Cleaner Concentratet is not an oxalic acid solution); Applicable Vehicles has been defined more clearly. The previous TSB should be discarded. Introduction Applicable Vehicles Condition Inspection The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust. S 1994 – Current model year Toyota vehicles. S 2004 – Current model year Scion vehicles. During rail transportation or extended storage near industrial areas, vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints, but can be easily felt when brushing a hand across horizontal body surfaces such as hood, roof, or deck lid. CAUTION: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be attempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. Repair Warranty Information Washing the affected paint surfaces with Auto MagicR Special Cleaner Concentratet is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto MagicR Special Cleaner Concentratet is described in this bulletin. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PAINT PA005-04 Title: IRON PARTICLE RUST CONTAMINATION REPAIR – PA005-04 Revised Required Tools & Materials TOOLS & MATERIALS November 16, 2004 QUANTITY Auto MagicR Special Cleaner Concentratet #713* 1 Rubber Gloves, Aprons, Boots Eye Protection Sponges or Wash Mitts As Needed Pail or Bucket * General Precautions Contact the main office of Auto Wax Company Inc. (1–800–826–0828 or www.automagic.biz) to find a local source for Auto MagicR Special Cleaner Concentrate.t WARNING: Auto MagicR Special Cleaner Concentratet is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use. CAUTION: Consult local or state regulations regarding the handling, use, and disposal of Auto MagicR Special Cleaner Concentratet prior to use. Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result. Repair Procedure 1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water. 2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface. 3. Thoroughly rinse vehicle with fresh water. 4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal. 5. Dry vehicle with a soft terry cloth towel and apply a non–abrasive, non–silicone glaze to obtain a high–gloss finish. Page 2 of 2 Technical Service BULLETIN March 30, 2007 Introduction POWER SYSTEM INITIALIZATION DURING PDS Models: ’07 Applicable Toyota The following is a list of the vehicle systems (Power Window, Sliding Roof, Tire Pressure Warning System [TPWS], etc.) that need initialization during Pre-Delivery Service (PDS) and the TSB numbers containing details on initializing each specific system. NOTE: Items in RED also need to be initialized any time the battery has been disconnected. Applicable Vehicles Power System Initialization Table S 2007 model year Applicable Toyota vehicles listed in the following table. INITIALIZATION SYSTEM ITEMS MODEL NAME 4Runner Warranty Information BACK DOOR POWER WINDOW COMPASS POWER WINDOW POWER BACK DOOR POWER SLIDING DOOR SLIDING ROOF DIRECT TPWS PD082Ć06 PD089Ć06 PD083Ć06 - - PD083Ć06 PD085Ć06 Avalon - PD058Ć06 PD057Ć06 - - PD055Ć06 PD069Ć06 Camry - PD006Ć06 - - - - PD007Ć06 Camry HV - PD016Ć06 - - - - PD019Ć06 Corolla - PD041Ć06 - - - - PD043Ć06 FJ Cruiser - PD093Ć05 - - - - - Highlander - PD088Ć06 - - - - PD073Ć06 Highlander HV - PD087Ć06 - - - - - Land Cruiser - PD063Ć06 - - - - PD074Ć06 Matrix - PD053Ć06 - - - - PD060Ć06 Prius - - PG003Ć06 - - - PD100Ć06 RAV4 - - - - - - PD086Ć06 Sequoia PD050Ć06 PD051Ć06 - - - - PD068Ć06 Sienna - PD118Ć06 PD116Ć06 PD115Ć06 PD114Ć06 PD117Ć06 PD119Ć06 Solara - PD035Ć06 PD030Ć06 - - PD029Ć06 PD034Ć06 Tacoma - PD105Ć06 - - - - PD075Ć06 Tundra - PD004Ć07 - - - - PD005Ć07 OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 PRE-DELIVERY SERVICE PD010-07 Title: Technical Service BULLETIN July 16, 2004 Introduction WHEEL FILM FOR BRAKE ROTOR RUST PREVENTION Models: All Models with Wheel Film To prevent brake rotor rust from forming during transportation and storage, wheel film will be adopted instead of using a cardboard type anti–rust cover. The purpose of the wheel film is to protect the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel as long as possible. NOTE: S Retain the wheel film on the disc wheel during vehicle display and storage. S Do not remove the wheel film right away at Pre–Delivery Service (PDS) if the vehicle will be stored after PDS. S Remove the wheel film just prior to delivery to customers. Features of Wheel Film: Material: Polyethylene Color: Transparent Wheel Film Applicable Vehicles Warranty Information S All Models with wheel film. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE–DELIVERY SERVICE PD017-04 Title: WHEEL FILM FOR BRAKE ROTOR RUST PREVENTION – PD017-04 Removal Procedure July 16, 2004 Firmly hold the outer end of the wheel film to pull it off. NOTE: S If film adhesive residue is found on the disc wheel, remove it with a soft cloth dipped in ethyl alcohol (ethanol). Do not use thinner to remove the adhesive residue. S When the wheel film is removed below an ambient temperature of 0_C (32_F), it is possible that the film may tear. For ease of film removal in cold conditions, please warm the film above 0_C (32_F) using one of the following methods: – Splash (hot) water on the wheel film. – Warm wheel film with cotton cloth soaked in hot water. – Warm wheel film with heat gun. Be sure not to overheat the film and wheel. – Warm wheel film by infrared heater (lamp) for paint. Be sure not to overheat the film and wheel. – Warm wheel film by steam car wash. – Park vehicle indoors (e.g. garage, etc.) for an extended period of time. Disposal Procedure Page 2 of 3 Please follow local laws for disposal. Polyethylene film will not generate harmful gasses when it is burned. WHEEL FILM FOR BRAKE ROTOR RUST PREVENTION – PD017-04 Introduction Schedule MODEL (FRONT & REAR) July 16, 2004 2003 2004 PLANT 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 Avalon TMMK Camry Celica JAPAN NUMMI TMMC Front Rear Corolla Front Rear JAPAN Highlander Matrix TMMC Front Rear MR2 Prius JAPAN RAV4 Solara TMMK Scion xA Scion xB JAPAN Scion tC This is a tentative schedule. There is a possibility that the introduction timing may be delayed on some models. Page 3 of 3 Technical Service BULLETIN June 21, 2007 Introduction 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) Models: ’08 4Runner Pre-Delivery Service is a critical step in satisfying your dealership’s new car customers. Customer feedback indicates the following areas deserve special attention when performing PDS: S Careful inspection for paint chips/scratches and body dents/dings. S Proper operation of electrical accessories (including interior light, clock, and radio reset). S Interior cleanliness. S Proper function of mechanical systems. Customer retention and proper maintenance of vehicles has been a major focus for Toyota. To help remind customers that regular oil changes are essential to the proper maintenance of their vehicle, dealers are required to begin installing a first oil change reminder sticker prior to delivery. By doing this, customers will be reminded to return to your dealership for their first oil change. Your current oil change reminder sticker may be used. (See PDS Check Sheet item G09.) A new PDS form has been developed for the 2008 model year 4Runner. Some check points have been added, expanded, or clarified. TSBs are available for items in bold red type. Warranty Policy If the need for additional repairs or adjustment is noted during the Pre-Delivery Service, the required service should be performed under warranty. Reimbursement will be managed under the warranty policy. The Warranty Policy and Procedures Manual requires that you maintain the completed PDS check sheet in the customer’s file. If you cannot produce a completed form for each retailed vehicle upon TMS and/or Region/Distributor audit, the PDS payment amount will be subject to debit. An additional Repair Order completed in conjunction with normal PDS must have time punch/flags for service. If multiple repairs are performed, separate time flags must be punched for each repair. Reimbursement Information OP CODE DESCRIPTION TIME OFP 001013 Pre-Delivery Service (PDS) 0.9 N/A Toyota Supports ASE Certification T1 T2 N/A N/A Page 1 of 5 PRE-DELIVERY SERVICE PD069-07 Title: 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 2008 Model Year PDS Check Sheet Page 2 of 5 June 21, 2007 TOYOTA 4RUNNER 2008 PRE-DELIVERY SERVICE CHECK SHEET * Inspect or install when equipped or required 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 June 21, 2007 Before Inspection When performing new car Pre-Delivery Service, install Short Pin before moving vehicle from storage lot so that FUNCTIONAL OPERATION checks can begin as soon as vehicle is moved into the service stall. A01 Install Short Pin A02 Initialize driver’s door power window A03 Initialize moon roof* A04 Initialize back door power window Functional Operation Apply parking brake and turn ignition “ON,” place gear selector in reverse, turn on lights and rear defogger. Unlock all doors, release fuel door, release back door. B01 Check dome, courtesy, map, and sun visor lights* B02 Check warning/indicator lights, gauges, and horn B03 Check windshield wipers and washers B04 Check headlights, instrument lights, turn signals, emergency flashers, and brake lights B05 Check inside/outside rear view mirror operation/adjustment B06 Check cigarette lighter* and power outlets Check the power outlets using an electrical accessory designed for this use. B07 Check moon roof* B08 Check audio/navigation*/backup camera* system and set clock* For navigation, set the destination search area to local position. B09 Check Rear Seat Entertainment System operation* B10 Install shift-lock override button cover Walkaround Inspection Starting at the left front door, check window and door lock operation and the operation of all power windows and door locks from master power switch, on vehicles so equipped. While walking around vehicle in a counterclockwise direction, open left rear door and check operation of window regulator and door lock, set child safety door locks to the normal (unlocked) position. Assure tightness of interior garnishes and check seat belts. Inspect luggage compartment contents and lights at rear of vehicle. Repeat checks at right rear door. Inspect right front door window regulator and lock operation and garnishes. Check seat and seat belt operation. Continue on around to the front of the vehicle checking lights. C01 Check window operation C02 Check door and door lock operation, including wireless remote control/theft deterrent system* C03 Check that engine starts with all keys C04 Check that child safety door locks are in normal (unlocked) position C05 Check seats and seat belt operation C06 Check rear defogger C07 Check side marker, tail, backup, and license plate lights C08 Check luggage compartment light* and trim appearance C09 Adjust spare tire pressure and check jack and tool installation C10 Check headlight aim Refer to the Repair Manual for procedures. * Inspect or install when equipped or required Page 3 of 5 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 Under Hood June 21, 2007 D01 Check engine oil and ATM fluid levels D02 Check brake and power steering fluid levels Visually inspect using see-through reservoirs. D03 Check engine coolant level D04 Check battery state-of-charge using Digital Battery System Analyzer Refer to TSB No. PG001-06, “Battery Maintenance for In-Stock Vehicles & Pre-Delivery.” NOTE: Battery SOC should be a minimum of 75%. Please enter the SOC Reading on the space provided on the check sheet and attach the printout to the check sheet. D05 Inspect for fuel, oil, coolant, and other fluid leaks Under Vehicle (On Hoist) E01 Remove disc brake anti-rust covers/anti-corrosion wheel film Visually inspect rotors for rust. NOTE: For best rotor rust prevention, retain wheel film on vehicle until just prior to customer delivery. E02 Inspect tires for defects/damage and adjust tire pressure (including spare tire) The recommended tire inflation pressure changes with tire size, driving conditions, and vehicle model. For precise tire pressure information, refer to the Owner’s Manual and/or tire information label located on the vehicle. Sidewall “Maximum” cold tire inflation pressure should not be used for normal driving. E03 Activate tire pressure monitor E04 Install wheel covers/caps/spare tire wheel covers* E05 Inspect for fuel, oil, coolant, and other fluid leaks Road Test Page 4 of 5 A complete road test helps assure customer satisfaction. Drive vehicle over a variety of road surfaces and driving conditions. Check for unusual noises and driving performance. F01 Check cold engine operation Check starting and fast idle operation performance. F02 Check engine operation during warm-up Check that engine operates smoothly during warm-up. Check for unusual noise, engine vibration, rough idle, etc. F03 Check engine at normal operating temperature Check engine performance over a broad range of driving conditions, including idle quality, acceleration, cruise, and deceleration. F04 Check automatic transmission operation Check automatic transmission operation, including operation in each range, neutral start switch, and shift lock system. F05 Check brake and parking brake operation Check brake function, including unusual noise, parking brake performance, and all related brake system indicator lights. * Inspect or install when equipped or required 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 June 21, 2007 Road Test (Continued) F06 Check steering operation and off-center/vehicle pull/flutter Check steering function. Check steering off-center/vehicle pull/flutter. F07 Inspect for abnormal noises and vibration F08 Inspect for squeaks and rattles F09 Check heater and A/C operation F10 Check cruise control operation Check cruise control, including On-Off switch, “SET/COAST,” “RESUME/ACCEL,” and “CANCEL” functions. F11 Check front seat heater operation* F12 Set/calibrate compass* F13 Check Rear Height Control Air Suspension* Final Inspection & Cleaning G01 Remove interior protective covers, unnecessary labels, tags, etc. (Remove protective covers just before delivery to the customer) Remove plastic covers from door panels, seats, head restraints, and sun visors, as required. Remove labels, tags, and stickers (except those containing owner information). NOTE: Consumer information labels, such as airbag information warning and bumper information labels, MUST be left on the vehicle until delivery to a retail customer. G02 G03 G04 G05 G06 G07 G08 G09 Visually inspect all interior parts for installation, damage, fit, dirt, etc. Remove Rapgard TM protective film Wash and clean vehicle Inspect paint finish for scratches, chips, rust, dents, damage, etc. Install roof rack cross bars Install receiver towing hitch cap Inspect exterior body parts for proper installation, damage, rust, etc. Place oil change sticker on inside of windshield, top left corner Complete the mileage or date recommendation and apply the oil change reminder sticker to the inside of the windshield, top left corner. You may use your current oil change reminder sticker or order new stickers by calling 1–800–527–6283. G10 Install front and rear license plates * Inspect or install when equipped or required Page 5 of 5 Technical Service BULLETIN August 10, 2006 Introduction Applicable Vehicles Warranty Information Installation Procedure FRONT & REAR LICENSE PLATE INSTALLATION DURING PDS Models: ’07 4Runner The following procedure is recommended for front and rear license plate installation on 2007 model year 4Runner vehicles. S 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Front License Plate 1. Align the holes on the license plate to the dimples on the front bumper. 2. Install two (2) self-tapping screws through the license plate and into the front bumper at the dimples. NOTE: S Do NOT drill holes into the bumper. S Do NOT overtighten the screws. Dimples Use self-tapping screws of a non-corroding type with the following dimensions: Nominal Length: 16.5 mm (0.65 in.) – 20.0 mm (0.79 in.) 6.0 mm (0.24 in.) Diameter: 6.0 mm (0.24 in.) 16.5 – 20.0 mm (0.65 – 0.79 in.) Toyota Supports ASE Certification Page 1 of 2 PRE-DELIVERY SERVICE PD079-06 Title: FRONT & REAR LICENSE PLATE INSTALLATION DURING PDS – PD079-06 Installation Procedure (Continued) August 10, 2006 Rear License Plate 1. Align the installation holes on the rear license plate with the holes on the back door. 2. Install two (2) bolts through the license plate and into the holes (welded nuts) in the back door. Use bolts of a non–corroding type having the following dimensions: Nominal Length: 25.0 mm (0.98 in.) or shorter Diameter: 6.0 mm (0.24 in.) Pitch: 1.0 mm (0.04 in.) NOTE: If bolts longer than 25 mm (0.98 in.) are used, the back door window glass may be damaged or broken. Page 2 of 2 Technical Service BULLETIN August 10, 2006 Introduction ROOF RACK CROSS BAR INSTALLATION DURING PDS Models: ’07 4Runner To prevent paint damage during transportation, the roof rack cross bars are kept inside the vehicle so that the Rapgardt protective film can remain in place on the roof panel. Install the roof rack cross bars to the roof rack rails according to the following procedure during Pre-Delivery Service (PDS). NOTE: To prevent damage to the front and rear roof rack leg covers, install the cross bar stoppers at each end of the right and left roof rack rails. Applicable Vehicles Warranty Information Installation Procedure S 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – 1. Loosen the adjustment knobs on each cross bar joint. NOTE: Do NOT remove adjustment knobs completely. Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE PD080-06 Title: ROOF RACK CROSS BAR INSTALLATION DURING PDS – PD080-06 Installation Procedure (Continued) August 10, 2006 2. Slide the cross bar ends into the grooves of the right and left roof rack rails with the arrow on each cross bar facing forward. Front NOTE: The cross bars will create wind noise at highway speeds if they are installed backwards. Arrow Mark 3. Align the ends of the front and rear cross bars with the paint marks on the roof rack as illustrated. Then securely tighten the knobs. Front Paint Mark NOTE: Installation positions of cross bars shown above are most effective to reduce wind noise. 4. Install the right and left rear roof rack leg covers. A A. Insert the protrusion at the front of the cover into the roof rack rail. B. Place the cover on the leg, aligning each rear end. At this time, do NOT press the cover down. C. Engage the cover claws located towards the outside of the vehicle. D. Engage the cover claws located towards the inside of the vehicle. NOTE: If the inside and outside cover claws are pressed down at the same time, the cover claws may be damaged. E. Check that the cover is installed securely. Page 2 of 3 D Outside Rear C B ROOF RACK CROSS BAR INSTALLATION DURING PDS – PD080-06 Installation Procedure (Continued) 5. Install the cross bar stopper at the front and rear ends of the right and left roof rack rail. August 10, 2006 Front NOTE: Cross bar stoppers are installed to prevent damage caused by interference between the cross bar and the front and rear roof rack leg covers. Cross Bar Stopper Rear Cross Bar Stopper Page 3 of 3 Technical Service BULLETIN August 15, 2006 SHORT PIN INSTALLATION DURING PDS Models: ’07 4Runner TSB REVISION NOTICE: S October 27, 2006: The “Introduction” section has been updated, and the “DTC Clearing Procedure” section has been added. Previous versions of this TSB should be discarded. Introduction Applicable Vehicles Required SSTs To minimize battery discharge during transportation and storage, the Short Pin has been removed at the assembly plant and temporarily stored in the engine compartment Relay Block. Reinstall the Short Pin into its original location and confirm all related DTCs are cleared during Pre-Delivery Service (PDS). S 2007 model year 4Runner vehicles. ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW** TOY220036 1 9 01002744 1 9 Toyota Diagnostic Tester Kit* 1 NOTE: S All components from this kit/set are required. S 12 Megabyte Diagnostic Tester Program Card (P/N 01002593–005) with version 13.4a Software (or later) is required. CAN Interface Module Kit* 2 NOTE: S All components from this kit/set are required. * Essential SSTs. ** Drawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE PD081-06 Title: SHORT PIN INSTALLATION DURING PDS – PD081-06 Revised Installation Procedure The Short Pin is stored in the blank space of the Relay Block in the engine compartment. August 15, 2006 Engine Compartment Relay Block During Pre-Delivery Service (PDS), install the Short Pin in the Relay Block as shown. NOTE: S Removing the Short Pin cuts off power sources relating to the DOME, RADIO No. 1, and ECU-B fuses. S The Short Pin does not function as a fuse, so install it only in the position shown. S If the vehicle is stored in the dealership for a long period of time after PDS, disconnect the negative (–) battery terminal to prevent battery discharge. Refer to TSB No. PG001-06, “Battery Maintenance for In-Stock Vehicles & Pre-Delivery,” for battery maintenance information. Page 2 of 3 Relay Block Install Short Pin Here (Original Location) Remove This Short Pin SHORT PIN INSTALLTION DURING PDS – PD081-06 Revised DTC Clearing Procedure August 15, 2006 With the Short Pin removed, the occupant classification ECU and Center Airbag Sensor Assembly (airbag ECU) may detect the interruption in battery voltage (B+) and store a DTC. Clear DTC B1150 and B1794 after installing the Short Pin. 1. Connect the Diagnostic Tester to the DLC3. 2. Turn the ignition switch to the “IG-ON” position. 3. Using the Diagnostic Tester, check any other codes being output. HINT: If any DTCs besides DTC B1150 and B1794 remain, repair the applicable system according to the Repair Manual. DLC3 Diagnostic Tester 4. Erase DTC (B1150 and B1794) and Freeze Frame Data. Page 3 of 3 Technical Service BULLETIN August 15, 2006 Introduction INITIALIZATION OF BACK DOOR POWER WINDOW DURING PDS Models: ’07 4Runner This bulletin outlines the initialization procedure for the back door power window on the 4Runner. To minimize the battery discharge during transportation and storage, the Short Pin has been removed at the assembly plant, resulting in the following feature being inoperative: S One-touch open and close with jam protection. Use the following initialization procedure after installing the Short Pin during Pre-Delivery Service (PDS) and whenever the battery has been disconnected. NOTE: Any time the battery terminal has been disconnected, the back door power window MUST be re-initialized. Applicable Vehicles Warranty Information Initialization Procedure S 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Make sure the Short Pin is installed in its original location. (Refer to TSB No. PD081-06, “Short Pin Installation During PDS.”) Short Pin Original Location Toyota Supports ASE Certification Page 1 of 2 PRE-DELIVERY SERVICE PD082-06 Title: INITIALIZATION OF BACK DOOR POWER WINDOW DURING PDS – PD082-06 Initialization Procedure (Continued) August 15, 2006 1. Turn ignition switch to the “ON” position. 2. Push the back door power window switch to the “DOWN” side to open the window. 3. Push and hold the back door power window switch to the “UP” side until the window closes. Continue holding it for approximately 1 second. 4. Check for proper operation of the “one-touch open/close” functions by pushing the switch briefly to the “DOWN” and “UP” positions. NOTE: Jam protection function becomes effective through the above initialization procedure. Page 2 of 2 Completely Closed Technical Service BULLETIN August 15, 2006 Introduction DRIVER'S DOOR POWER WINDOW & MOON ROOF INITIALIZATION Models: ’07 4Runner This bulletin outlines the initialization procedure for the driver’s door power window and the moon roof on 2007 model year 4Runner vehicles. If the battery has been disconnected, the ECU will not be able to detect and memorize the driver’s door power window and moon roof positions, resulting in the following features being inoperative: S One-touch open and close of driver’s door power window with jam protection. S One-touch slide open and close of moon roof with jam protection. S One-touch tilt up and down of moon roof with jam protection. Use the following initialization procedure during Pre-Delivery Service (PDS) and whenever the battery has been disconnected. NOTE: Any time the battery terminal has been disconnected, the driver’s door power window and moon roof MUST be re-initialized. Applicable Vehicles Warranty Information Initialization Procedure S 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Driver’s Door Power Window 1. Turn the ignition to the “ON” position. NOTE: At this time, the power switch for the driver’s door window should be blinking. 2. Push down and hold the driver’s door power window switch to completely open the window. Toyota Supports ASE Certification Power Window Switch Page 1 of 3 PRE-DELIVERY SERVICE PD083-06 Title: DRIVER’S DOOR POWER WINDOW & MOON ROOF INITIALIZATION – PD083-06 Initialization Procedure (Continued) 3. Pull and hold up the driver’s door power window switch until the window closes. Continue holding the switch for approximately one second until the switch changes from blinking to a constant illumination. August 15, 2006 Completely Closed 4. Check for proper operation of the “one-touch open/close” by pushing the switch briefly to the “DOWN” and “UP” positions. NOTE: Jam protection function becomes effective through the above initialization procedure. TROUBLESHOOTING: If power window is unable to close after initialization, perform the following procedure. NOTE: If the power window switch is continuously operated for a long time, the power window motor will stop to prevent additional load on the motor. Continuing to press the power window switch even after the motor has stopped will cause the switch to blink and will restrict the AUTO UP/DOWN function and remote UP/DOWN function. If this happens, wait for a few minutes before attempting to reset the motor again. 1. Disconnect the negative (–) battery terminal. After 10 seconds, reconnect the battery terminal. 2. Turn the ignition switch to the “ON” position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately one second after the door glass is fully closed. " Check for proper operation of the AUTO UP/DOWN function. 3. If the power window motor is still unable to close: Turn the ignition switch to the “ON” position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately 12 seconds after the door glass is fully closed. " Check for proper operation of the AUTO UP/DOWN function. Page 2 of 3 DRIVER’S DOOR POWER WINDOW & MOON ROOF INITIALIZATION – PD083-06 Initialization Procedure (Continued) August 15, 2006 Moon Roof 1. Turn the ignition to the “ON” position. 2. Push and hold the “TILT UP” side of the switch until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm [0.39 in.] at the rear). 3. Check for proper operation of the “one-touch slide open/close” and “one-touch tilt up/down” functions by pushing the switch briefly to the “SLIDE OPEN” and “TILT UP” positions. Approx. 10 mm NOTE: Jam protection function becomes effective through the above initialization procedure. Page 3 of 3 TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION Models: ’07 4Runner August 16, 2006 Introduction The 2007 model year 4Runner vehicles are equipped with a direct-type Tire Pressure Warning System (TPWS). Each tire (including the spare tire) has a tire pressure warning valve/sensor, and the measured tire pressure data is transmitted to the Tire Pressure Warning System antenna/receiver to the Tire Pressure Warning System ECU. During Pre-Delivery Service (PDS), the tire pressure warning valves/sensors must be activated according to the procedure in this bulletin. Applicable Vehicles Required SSTs S 2007 model year 4Runner vehicles. ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW** TOY220036 1 9 01002744 1 9 Toyota Diagnostic Tester Kit* NOTE: S All components from this kit/set are required. S 12 Megabyte Diagnostic Tester Program Card (P/N 01002593–005) with version 13.4a Software (or later) is required. 1 CAN Interface Module Kit* 2 NOTE: S All components from this kit/set are required. * Essential SSTs. ** Refers to drawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE Technical Service BULLETIN PD085-06 Title: TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION – PD085-06 Reference August 16, 2006 S The Low Tire Pressure Warning Light will blink until all the tire pressure warning valves/sensors are activated. S The Diagnostic Trouble Codes (DTCs) listed below may be stored in the TPWS ECU until the tire pressure warning valves/sensors are activated. S The DTCs will automatically clear when the tire pressure warning valves/sensors are activated. *1: *2: Activation Procedure Low Tire Pressure Warning Light DTC NO. *1 DTC NO. *2 DTC EXPLANATION 11 C2111 Transmitter ID1 Operation Stop (sleep mode) 12 C2112 Transmitter ID2 Operation Stop (sleep mode) 13 C2113 Transmitter ID3 Operation Stop (sleep mode) 14 C2114 Transmitter ID4 Operation Stop (sleep mode) 15 C2115 Transmitter ID5 Operation Stop (sleep mode) DTC No. indicated by blinking of the Low Tire Pressure Warning Light. DTC No. indicated on the Toyota Diagnostic Tester. 1. Connect the Diagnostic Tester. 2. Turn the ignition switch to the “ON” position and check that the Low Tire Pressure Warning Light blinks. Low Tire Pressure Warning Light Page 2 of 3 TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION – PD085-06 Activation Procedure (Continued) 3. Press or remove the valve core to reduce the tire inflation pressure rapidly by 6 psi (0.4 kgf/cm2, 40 kPa), or more, within 30 seconds. August 16, 2006 Core If the tire inflation pressure is NOT reduced by 6 psi (0.4 kgf/cm2, 40 kPa), or more, within 30 seconds, the tire pressure warning valves/sensors will NOT be activated. NOTE: This operation is required for the system to be activated and must be performed for each tire (including the spare tire), one at a time. 4. Using the Diagnostic Tester, check for TPWS DTCs. S If NO DTCs are stored, go to step 5. S If DTCs C2111 – C2115 are stored, repeat step 3. S If any other DTCs are stored, refer to the Repair Manual. 5. Adjust all tires (including the spare tire) to the standard tire inflation pressure and confirm that the Low Tire Pressure Warning Light is OFF. TIRE SIZE P265/70R16 111S P265/65R17 110S TIRE PRESSURE (psi, kgf/cm2, kPa) 32 2.2, 32, 2 2 220 NOTE: S If there is great difference between the current temperature of the tire and wheel (for example: shop temperature) and expected temperature (for example: outdoor temperature), this needs to be considered when adjusting the tire pressure. S Adjust the tire pressure when the tires are cold. Page 3 of 3 Technical Service BULLETIN August 16, 2006 Introduction INITIAL CALIBRATION OF COMPASS DURING PDS Models: ’07 4Runner The compass indicates the direction that the vehicle is heading by detecting the direction and strength of the Earth’s magnetic field and processing this data using the compass sensor and microcomputer. Detection of the direction and strength of the Earth’s magnetic field varies according to the area in which the vehicle is used and is affected by the residual magnetism of the vehicle. For this reason, the geographic direction displayed may also deviate from the direction determined by the Earth’s magnetic field according to the area in which the vehicle is used. Perform the initial calibration of the compass at the dealership prior to vehicle delivery. Compass Display “Multifunction” Switch Applicable Vehicles Warranty Information S 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE PD089-06 Title: INITIAL CALIBRATION OF COMPASS DURING PDS – PD089-06 Compass Calibration Procedure August 16, 2006 1. Turn the ignition switch to the “ON” position and push and hold the switch for 6 seconds until the zone number appears on the compass display. 2. Push the switch to select the number of the zone where the vehicle is located. See the map below for zone reference. A. Samoa: Guam: Saipan: North America 1 15 2 14 3 13 4 12 5 8 6 7 Page 2 of 3 9 10 11 5 7 7 INITIAL CALIBRATION OF COMPASS DURING PDS – PD089-06 Compass Calibration Procedure (Continued) August 16, 2006 3. Start the engine and push and hold the switch for about 9 seconds until “C” appears on the display. 4. Drive the vehicle slowly at 5 mph (8 km/h), or less, in a circle until the direction is displayed. If there is NOT enough space to drive in a circle, turn the car around as shown, doing two three-point turns in succession. After driving in 1 to 3 circles in the above method, calibration is complete with the direction shown on the display. NOTE: S Do NOT perform calibration of the compass in a place where the Earth’s magnetic field is subject to interference by artificial magnetic fields (underground parking, under a steel tower, between buildings, roof parking, near a railroad crossing, near a large vehicle, etc.) S During calibration, do NOT operate electric systems (moon roof, power windows, etc.) as they may interfere with the calibration. Page 3 of 3 TOYOTA 4RUNNER B. FUNCTIONAL OPERATION Apply parking brake and turn ignition “ON,” place gear selector in reverse, turn on lights and rear defogger. Unlock doors, release fuel door, release back door. F. ROAD TEST 01 INSTALL SHORT PIN ......... 02 Initialize driver’s door power window . . . . . . . . . . . . . . . . 03 Initialize moon roof* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 Initialize back door power window . . . . . . . . . . . . . . . . . . 01 02 03 04 05 06 07 08 09 10 A complete road test helps assure customer satisfaction. Drive vehicle over a variety of road surfaces and driving conditions. Check for unusual noise and driving performance. Check dome, courtesy, map, and sun visor lights*.. Check warning/indicator lights, gauges, and horn . . Check windshield wipers and washers . . . . . . . . . . . . Check headlights, instrument lights, turn signals, emergency flashers, and brake lights . . . . . . . . . . . . . . Check inside/outside rear view mirror operation/adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check cigarette lighter* and power outlets . . . . . . . . . Check moon roof* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check audio/navigation*/backup camera* system and set clock* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Rear Seat Entertainment System operation* . Install shift-lock override button cover . . . . . . . . . . . . . Enter Odometer Reading Reading Before Test Reading After Test 01 02 03 04 05 06 C. WALKAROUND INSPECTION Start at left front door. Check window and door lock operation (from master power switch, if equipped). Continue around vehicle in a counterclockwise direction checking each door and window operation, child door locks, seat belts, interior condition, all lights, luggage compartment contents. Remove rubber body plugs from glove box for installation during UNDER VEHICLE inspection. Finish by checking headlight aim and continue into UNDER HOOD checks. 01 Check window operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Check door and door lock operation, including wireless remote control/theft deterrent system* . . . . . . 03 Check that engine starts with all keys . . . . . . . . . . . . . . . 04 Check that child safety door locks are in normal (unlocked) position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Check seats and seat belt operation . . . . . . . . . . . . . . . . 06 Check rear defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 Check side marker, tail, backup, and license plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 Check luggage compartment light* and trim appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Adjust spare tire pressure and check jack and tool installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Check headlight aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 08 09 10 11 12 13 Check cold engine operation . . . . . . . . . . . . . . . . . . . . . . . Check engine operation during warm–up . . . . . . . . . . . . Check engine at normal operating temperature . . . . . . Check automatic transmission operation . . . . . . . . . . . . Check brake and parking brake operation . . . . . . . . . . . Check steering operation and off-center/ vehicle pull/flutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect for abnormal noises and vibration . . . . . . . . . . . Inspect for squeaks and rattles . . . . . . . . . . . . . . . . . . . . . Check heater and A/C operation . . . . . . . . . . . . . . . . . . . . Check cruise control operation . . . . . . . . . . . . . . . . . . . . . Check front seat heater operation* . . . . . . . . . . . . . . . . . . . Set/calibrate compass* . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Rear Height Control Air Suspension* . . . . . . . . . G. FINAL INSPECTION AND CLEANING 01 Remove interior protective covers, unnecessary labels, tags, etc. (Remove protective covers just before delivery to the customer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Visually inspect all interior parts for installation, damage, fit, dirt, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Remove RapgardTM protective film . . . . . . . . . . . . . . . . . . . 04 Wash and clean vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 Inspect paint finish for scratches, chips, rust, dents, damage, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 Install roof rack cross bars . . . . . . . . . . . . . . . . . . . . . . . . . 07 Install receiver towing hitch cap . . . . . . . . . . . . . . . . . . . . . 08 Inspect exterior body parts for proper installation, damage, rust, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Place oil change sticker on inside of windshield, top left corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install front and rear license plates . . . . . . . . . . . . . . . . . . . D. UNDER HOOD 01 02 03 04 Check engine oil and ATM fluid levels . . . . . . . . . . . . . . . Check brake and power steering fluid levels . . . . . . . . . . . Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . Check battery state-of-charge using Digital Battery System Analyzer (SOC Reading: ________%) . . . . . . . . . . 05 Inspect for fuel, oil, coolant, and other fluid leaks . . . . COMMENTS Completion and retention of this form is required to comply with Toyota’s Warranty Policy. TECHNICIAN’S SIGNATURE SERVICE MANAGER’S SIGNATURE NAME (PLEASE PRINT) NAME (PLEASE PRINT) Date Dealer Name OK E. UNDER VEHICLE (ON HOIST) 01 Remove disc brake anti-rust covers/anti-corrosion wheel film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Inspect tires for defects/damage and adjust tire pressure (including spare tire) . . . . . . . . . . . . . . . . . . . . 03 Activate tire pressure monitor . . . . . . . . . . . . . . . . . . . . . 04 Install wheel covers/caps/spare tire wheel covers* . . . 05 Inspect for fuel, oil, coolant, and other fluid leaks . . . . Adjust/ Repair OK A. BEFORE INSPECTION Adjust/ Repair 2007 PRE-DELIVERY SERVICE CHECK SHEET Dealer Code * Inspect or Install when Equipped/Required We hereby certify that all items on this form have been checked and corrected for proper operation as required. Vehicle Identification Number (Sticker) Technical Service BULLETIN August 16, 2006 Introduction 2007 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) Models: ’07 4Runner Pre-Delivery Service is a critical step in satisfying your dealership’s new car customers. Customer feedback indicates the following areas deserve special attention when performing PDS: S Careful inspection for paint chips/scratches and body dents/dings. S Proper operation of electrical accessories (including interior light, clock, and radio reset). S Interior cleanliness. S Proper function of mechanical systems. Customer retention and proper maintenance of vehicles has been a major focus for Toyota. To help remind customers that regular oil changes are essential to the proper maintenance of their vehicle, dealers are required to begin installing a first oil change reminder sticker prior to delivery. By doing this, customers will be reminded to return to your dealership for their first oil change. Your current oil change reminder sticker may be used. (See PDS Check Sheet item G09.) A new PDS form has been developed for the 2007 model year 4Runner. Some check points have been added, expanded, or clarified. TSBs are available for items in bold red type. Warranty Policy If the need for additional repairs or adjustment is noted during the Pre-Delivery Service, the required service should be performed under warranty. Reimbursement will be managed under the warranty policy. The Warranty Policy and Procedures Manual requires that you maintain the completed PDS check sheet in the customer’s file. If you cannot produce a completed form for each retailed vehicle upon TMS and/or Region/Distributor audit, the PDS payment amount will be subject to debit. An additional Repair Order completed in conjunction with normal PDS must have time punch/flags for service. If multiple repairs are performed, separate time flags must be punched for each repair. Reimbursement Information OP CODE DESCRIPTION TIME OFP 001013 Pre-Delivery Service (PDS) 0.9 N/A Toyota Supports ASE Certification T1 T2 N/A N/A Page 1 of 5 PRE-DELIVERY SERVICE PD099-06 Title: 2007 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD099-06 2007 Model Year PDS Check Sheet Page 2 of 5 August 16, 2006 TOYOTA 4RUNNER 2007 PRE-DELIVERY SERVICE CHECK SHEET * Inspect or install when equipped or required 2007 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD099-06 August 16, 2006 Before Inspection When performing new car Pre-Delivery Service, install Short Pin before moving vehicle from storage lot so that FUNCTIONAL OPERATION checks can begin as soon as vehicle is moved into the service stall. A01 Install Short Pin A02 Initialize driver’s door power window A03 Initialize moon roof* A04 Initialize back door power window Functional Operation Apply parking brake and turn ignition “ON,” place gear selector in reverse, turn on lights and rear defogger. Unlock all doors, release fuel door, release back door. B01 Check dome, courtesy, map, and sun visor lights* B02 Check warning/indicator lights, gauges, and horn B03 Check windshield wipers and washers B04 Check headlights, instrument lights, turn signals, emergency flashers, and brake lights B05 Check inside/outside rear view mirror operation/adjustment B06 Check cigarette lighter* and power outlets Check the power outlets using an electrical accessory designed for this use. B07 Check moon roof* B08 Check audio/navigation*/backup camera* system and set clock* For navigation, set the destination search area to local position. B09 Check Rear Seat Entertainment System operation* B10 Install shift-lock override button cover Walkaround Inspection Starting at the left front door, check window and door lock operation and the operation of all power windows and door locks from master power switch, on vehicles so equipped. While walking around vehicle in a counterclockwise direction, open left rear door and check operation of window regulator and door lock, set child safety door locks to the normal (unlocked) position. Assure tightness of interior garnishes and check seat belts. Inspect luggage compartment contents and lights at rear of vehicle. Repeat checks at right rear door. Inspect right front door window regulator and lock operation and garnishes. Check seat and seat belt operation. Continue on around to the front of the vehicle checking lights. C01 Check window operation C02 Check door and door lock operation, including wireless remote control/theft deterrent system* C03 Check that engine starts with all keys C04 Check that child safety door locks are in normal (unlocked) position C05 Check seats and seat belt operation C06 Check rear defogger C07 Check side marker, tail, backup, and license plate lights C08 Check luggage compartment light* and trim appearance C09 Adjust spare tire pressure and check jack and tool installation C10 Check headlight aim Refer to the Repair Manual for procedures. * Inspect or install when equipped or required Page 3 of 5 2007 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD099-06 Under Hood August 16, 2006 D01 Check engine oil and ATM fluid levels D02 Check brake and power steering fluid levels Visually inspect using see-through reservoirs. D03 Check engine coolant level D04 Check battery state-of-charge using Digital Battery System Analyzer Refer to TSB No. PG001-06, “Battery Maintenance for In-Stock Vehicles & Pre-Delivery.” NOTE: Battery SOC should be a minimum of 75%. Please enter the SOC Reading on the space provided on the check sheet and attach the printout to the check sheet. D05 Inspect for fuel, oil, coolant, and other fluid leaks Under Vehicle (On Hoist) E01 Remove disc brake anti-rust covers/anti-corrosion wheel film Visually inspect rotors for rust. NOTE: For best rotor rust prevention, retain wheel film on vehicle until just prior to customer delivery. E02 Inspect tires for defects/damage and adjust tire pressure (including spare tire) The recommended tire inflation pressure changes with tire size, driving conditions, and vehicle model. For precise tire pressure information, refer to the Owner’s Manual and/or tire information label located on the vehicle. Sidewall “Maximum” cold tire inflation pressure should not be used for normal driving. E03 Activate tire pressure monitor E04 Install wheel covers/caps/spare tire wheel covers* E05 Inspect for fuel, oil, coolant, and other fluid leaks Road Test Page 4 of 5 A complete road test helps assure customer satisfaction. Drive vehicle over a variety of road surfaces and driving conditions. Check for unusual noises and driving performance. F01 Check cold engine operation Check starting and fast idle operation performance. F02 Check engine operation during warm-up Check that engine operates smoothly during warm-up. Check for unusual noise, engine vibration, rough idle, etc. F03 Check engine at normal operating temperature Check engine performance over a broad range of driving conditions, including idle quality, acceleration, cruise, and deceleration. F04 Check automatic transmission operation Check automatic transmission operation, including operation in each range, neutral start switch, and shift lock system. F05 Check brake and parking brake operation Check brake function, including unusual noise, parking brake performance, and all related brake system indicator lights. * Inspect or install when equipped or required 2007 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD099-06 August 16, 2006 Road Test (Continued) F06 Check steering operation and off-center/vehicle pull/flutter Check steering function. Check steering off-center/vehicle pull/flutter. F07 Inspect for abnormal noises and vibration F08 Inspect for squeaks and rattles F09 Check heater and A/C operation F10 Check cruise control operation Check cruise control, including On-Off switch, “SET/COAST,” “RESUME/ACCEL,” and “CANCEL” functions. F11 Check front seat heater operation* F12 Set/calibrate compass* F13 Check Rear Height Control Air Suspension* Final Inspection & Cleaning G01 Remove interior protective covers, unnecessary labels, tags, etc. (Remove protective covers just before delivery to the customer) Remove plastic covers from door panels, seats, head restraints, and sun visors, as required. Remove labels, tags, and stickers (except those containing owner information). NOTE: Consumer information labels, such as airbag information warning and bumper information labels, MUST be left on the vehicle until delivery to a retail customer. G02 G03 G04 G05 G06 G07 G08 G09 Visually inspect all interior parts for installation, damage, fit, dirt, etc. Remove Rapgard TM protective film Wash and clean vehicle Inspect paint finish for scratches, chips, rust, dents, damage, etc. Install roof rack cross bars Install receiver towing hitch cap Inspect exterior body parts for proper installation, damage, rust, etc. Place oil change sticker on inside of windshield, top left corner Complete the mileage or date recommendation and apply the oil change reminder sticker to the inside of the windshield, top left corner. You may use your current oil change reminder sticker or order new stickers by calling 1–800–527–6283. G10 Install front and rear license plates * Inspect or install when equipped or required Page 5 of 5 Technical Service BULLETIN March 16, 2004 DIRECT TIRE PRESSURE WARNING SYSTEM Models: ’04 – ’07 4Runner TSB REVISION NOTICE: S December 21, 2006: 2007 model year has been added to Applicable Vehicles. S August 19, 2005: 2006 model year has been added to Applicable Vehicles. The “Required SSTs” section has been updated to the current software version. S January 12, 2005: Applicable Vehicles has been updated to include 2005 model year. Previous versions of this TSB should be discarded. NOTE: Read this TSB in its entirety BEFORE performing any diagnosis to the Tire Pressure Warning System. Introduction A direct Tire Pressure Warning System (TPWS) is now standard equipment on all 2004 – 2007 model year 4Runner vehicles. A tire pressure sensor (or tire pressure monitor) is attached to each wheel directly sensing the air pressure of each tire. The Tire Pressure Warning System detects the pressure of each tire, including the spare tire, and illuminates a Tire Pressure Warning Light ( ! ) to inform the driver of low tire pressure. Each pressure sensor has a unique ID number. When tires are swapped, wheels changed, or any work is preformed on a tire, these ID numbers must be recorded. In the event that the IDs are not recorded when service is performed, it will be necessary to register the pressure sensor ID numbers. Individual tire pressure sensors need to be registered when: S Tire pressure monitor ID numbers of the Data List are incorrect. S Replacing the tire pressure monitor valve sub-assembly. S Replacing the tire pressure monitor ECU. S Performing a tire swap from vehicle to vehicle. Applicable Vehicles Warranty Information S 2004 – 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 6 PRODUCT GENERAL INFORMATION PG001-04 Title: DIRECT TIRE PRESSURE WARNING SYSTEM – PG001-04 Revised Required SSTs ITEM NO. SPECIAL SERVICE TOOLS (SSTs) March 16, 2004 PART NUMBER QTY DRW** TOY220036 1 9 01002744 1 9 Toyota Diagnostic Tester Kit* 1 NOTE: S All components from this kit/set are required S 12 Megabyte Diagnostic Tester Program Card (P/N 01002593–005) with version 13.0a Software (or later) is required CAN Interface Module Kit* 2 NOTE: S All components from this kit/set are required * Essential SSTs. ** Refers to drawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Page 2 of 6 DIRECT TIRE PRESSURE WARNING SYSTEM – PG001-04 Revised Tire Pressure Adjustment Procedure March 16, 2004 Locating the Tire Pressure Sensor ID It may be necessary to physically locate the tire pressure sensor ID numbers if: S You are replacing one or more tire pressure sensors. S No tire pressure sensor ID numbers are present in the Data List. S Tires have been swapped for any reason and original ID numbers were not recorded. Follow the screen flow below to locate and identify the current tire pressure sensor ID numbers. A TOYOTA DIAGNOSTIC TOOLSET PROGRAM CARD Version 13.0a B C *APPLICATION SELECT* FUNCTION SELECT FOR NORTH AMERICA 1: DIAGNOSIS 2: CUSTOMIZE 3: ECU REPROGRAM 08/01/05 PRESS [ENTER] 1: 2: 3: 4: 5: 6: 7: 8: 9: 0: OBD/MOBD ENHANCED OBD II CARB OBD II BREAK–OUT BOX NVH AUTOPROBE O2 RPM CHECK SNAPSHOT REVIEW SETUP GAS ANALYSIS D E F VEHICLE SELECT OBD/MOBD MENU DIAGNOSTIC MENU TIRE PRESSURE NEW VEHICLE (Select appropriate 4Runner) 1: 2: 3: 4: 5: 6: 7: 8: CODES (ALL) ENGINE AND ECT ABS / VSC TIRE PRESSURE CCS IMMOBILISER SRS AIRBAG BODY 1: DATA LIST 2: DTC INFO 4: SNAPSHOT 5: UTILITY 7: SIGNAL CHECK G MODE STATUS NORMAL MAIN TIRE . . . . . . . . . . . 5 2ND TIRE . . . . . . . . . . . . 5 SELECT SW . . . . . . MAIN VEHICLE SPD . . . . 0MPH REGIT ID1 C$0####### REGIT ID2 C$0####### REGIT ID3 C$0####### REGIT ID4 C$0####### REGIT ID5 C$0####### TRANS STATUS . . FINISH INITIAL SW . . . . . . . . OFF NOTE: Each REGIT ID1 – ID5 is unique for every sensor. Be sure to record these ID numbers BEFORE attempting registration (example of a valid ID number: C$0BB90030). The last seven digits of the ID number are the actual transmitter ID. If these ID numbers are not unique, proceed to page 3 and locate the physical ID numbers. Page 3 of 6 DIRECT TIRE PRESSURE WARNING SYSTEM – PG001-04 Revised Tire Pressure Adjustment Procedure (Continued) March 16, 2004 Scroll through the Data List to the REGIT ID1, ID2, ID3, ID4 and ID5. These are the ID numbers that are currently registered to the vehicle. Write down the transmitter ID numbers from the Data List, or use the transmitter ID numbers that were obtained from each tire pressure sensor. If replacing one sensor, the current transmitter ID numbers must be written down BEFORE the registration procedure can be performed. If REGIT ID1, ID2, ID3, ID4 and ID5 display all zeros or “#” signs, there are no current ID numbers registered in the Tire Pressure Monitoring System. Follow the steps below if there are no codes present on the Data List. If the ID numbers were present, proceed to “Tire Pressure ID Registration Procedure” on page 5. Follow the procedure below to locate the tire pressure sensor ID numbers on each sensor: 1. Deflate tire and break the top bead. CAUTION: Extreme caution must be used to ensure that the tire removal arm does not break the tire pressure sensor while attempting to break the bead on the rim. 2. Depress the tire enough to inspect the tire pressure sensor. NOTE: It is not necessary to remove the tire from the rim to inspect for this ID. 3. On the front of the sensor there is a 7–digit ID number as shown in the figure below. Write this number down for future reference (it will be input using the Diagnostic Tester). 7–Digit ID Number 4. Reseat the tire back to the wheel and set the tire pressure of all wheels to the specified value. 5. Remount the tire and wheel assembly to the vehicle. 6. Torque all wheels to the vehicle according to vehicle recommendations. 7. Go to the “Tire Pressure ID Registration Procedure” on page 5. Page 4 of 6 DIRECT TIRE PRESSURE WARNING SYSTEM – PG001-04 Revised Tire Pressure ID Registration Procedure March 16, 2004 1. Connect the Diagnostic Tester to DLC3. 2. Turn the ignition switch to the ON position. Toyota Diagnostic Tester DLC3 CAN Interface Module Follow the screen flow below: A TOYOTA DIAGNOSTIC TOOLSET PROGRAM CARD Version 13.0a B C *APPLICATION SELECT* FUNCTION SELECT FOR NORTH AMERICA 1: 2: 3: 4: 5: 6: 7: 8: 9: 0: 1: DIAGNOSIS 2: CUSTOMIZE 3: ECU REPROGRAM 08/01/05 PRESS [ENTER] D E VEHICLE SELECT OBD/MOBD MENU NEW VEHICLE (Select appropriate 4Runner) 1: 2: 3: 4: 5: 6: 7: 8: 9: CODES (ALL) ENGINE AND ECT ABS / VSC TIRE PRESSURE CCS IMMOBILISER SRS AIRBAG BODY BACK–DOOR OBD/MOBD ENHANCED OBD II CARB OBD II BREAK–OUT BOX NVH AUTOPROBE O2 RPM CHECK SNAPSHOT REVIEW SETUP GAS ANALYSIS F ↓ DIAGNOSTIC MENU TIRE PRESSURE 1: DATA LIST 2: DTC INFO 4: SNAPSHOT 5: UTILITY 7: SIGNAL CHECK (continued next page) Page 5 of 6 DIRECT TIRE PRESSURE WARNING SYSTEM – PG001-04 Revised Tire Pressure ID Registration Procedure (Continued) March 16, 2004 (continued from previous page) G H UTILITY TIRE PRESSURE UTILITY REGIST TIRE SET 1: REGIST TIRE SET Tires are registered in the MAIN SET The registration process will take 300 seconds. Do you wish to continue? PRESS [YES] or [NO] I UTILITY REGIST TIRE SET Register all transmitter ID for all tires including the spare tire within 300 seconds. Codes are printed on each transmitter. PRESS [ENTER] [YES] J* (See Note) UTILITY REGIST TIRE SET Total Tires: 5 Number of inputted ID codes: 0 Time: 300 seconds PRESS [ENTER] K UTILITY REGIST TIRE SET THE REGISTRATION SUCCEEDED. PRESS [ENTER] * NOTE: S Ensure that all 5 ID numbers are input. S Down arrow on Diagnostic Tester creates alpha characters. S Up arrow on Diagnostic Tester creates numeric characters. S Left and right arrow on Diagnostic Tester to scroll characters. 3. View Data List and ensure that all tires are reading tire pressure and temperature correctly. Drive the vehicle and ensure that the tire pressure warning light ( ! ) does not illuminate. Page 6 of 6 Technical Service BULLETIN January 26, 2006 BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY Models: All Models & Model Years TSB REVISION NOTICE: S November 28, 2006: “Required SSTs” have been updated (SST P/N 00002–MCGR8 has been added). “Recommended Equipment” has been removed (superseded by SST P/N 00002–MCGR8). Screen prints and text have been updated in the “Battery Inspection Procedure”. “Battery Service Procedure” has been renamed “Battery Inspection Results”. Two sections have been added for SST P/N 00002–MCGR8: “Battery Charging Procedure” and “Battery Charging Results”. PLEASE READ ENTIRE TSB. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG017–02. TSB No. PG017–02 is now obsolete and should be discarded. Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life. As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the dealer’s responsibility to maintain the specified State of Charge (SOC) of the vehicle’s battery while in stock and assure proper State of Charge (SOC) at delivery. To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers. Applicable Vehicles Warranty Information S All models and model years. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 10 PRODUCT GENERAL INFORMATION PG001-06 Title: BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Required SSTs ITEM NO. SPECIAL SERVICE TOOLS (SSTs) January 26, 2006 PART NUMBER QTY DRW** 00002–V8150–KIT 1 19 00002–MCGR8 1 N/A*** Digital Battery System Analyzer* 1 NOTE: S All components from this kit/set are required GR8 Battery Diagnostic Station* 2 NOTE: S All components from this kit/set are required * Essential SSTs. ** Drawer number in SST Storage System. *** Not located in SST Storage System. NOTE: S The Digital Battery System Analyzer (P/N 00002–V8150–KIT) supersedes the Midtronics MICROPRO 815 Digital Battery Tester (P/N 00002–MP815–T). P/N 00002–MP815–T is now obsolete. S The GR8 Battery Diagnostic Station (P/N 00002–MCGR8) supersedes the Automatic Trickle Charger (P/N 00002–YA122–01) and Fast Battery Chargers (Associated P/N ASE6003 and Christie P/N CAPPDQ). P/N 00002–YA122–01, ASE6003, and CAPPDQ are now obsolete. S Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Battery Inspection Procedure All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/N 00002–V8150–KIT) no more than 48 hours prior to customer vehicle delivery. IMPORTANT NOTE FOR HYBRID VEHICLES: In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002–V8150–KIT) is to be used ONLY on the AUXILIARY (12 volt) battery. 1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.) 2. Select the correct USER ID (if applicable) and press the NEXT soft key. Page 2 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Inspection Procedure (Continued) January 26, 2006 3. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the NVS–8150 Instruction Manual. 4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu. 5. Choose BATTERY TEST and press the SELECT soft key. 6. Select IN VEHICLE and press the NEXT soft key. Page 3 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Inspection Procedure (Continued) 7. Select MODEL and press the NEXT soft key. NOTE: S “MODEL” or “STOCK #” MUST be used to receive a warranty code if the tester determines that the battery is bad. S “MODEL” and “STOCK #” are linked to custom algorithms and are the most accurate testing procedures. 8. Select the appropriate model and press the NEXT soft key. 9. Select OEM battery type and press the NEXT soft key. 10. Choose the correct battery (model number and CCA) and press the NEXT soft key. Page 4 of 10 January 26, 2006 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Inspection Procedure (Continued) January 26, 2006 11. Aim the infrared (IR) temperature measurement sensor at the negative (–) battery post and press the NEXT soft key. The battery is now being tested. The progress bar fills in across the screen while testing. 12. Read or print the battery test results (press the PRINT soft key to print). Battery Inspection Results Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: “GOOD BATTERY” Return the battery to service. 2. Battery Condition: “GOOD–RECHARGE” Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002–MCGR8) and return it to service. Page 5 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Inspection Results (Continued) January 26, 2006 3. Battery Condition: “CHARGE & RETEST” Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002–MCGR8) and retest. NOTE: Failure to fully charge the battery before retesting may cause false readings. 4. Battery Condition: “REPLACE BATTERY” Replace the battery. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out–of–vehicle test before replacing it. 5. Battery Condition: “BAD CELL–REPLACE” Replace the battery. The decision indicates a bad cell within the battery. CAUTION: S If “FROZEN BATTERY” is displayed as the test result, allow the battery to reach a temperature of 40°F (4°C) before retesting. S NEVER CHARGE A FROZEN BATTERY. GASES MAY FORM, CRACKING THE CASE AND CAUSING BATTERY ACID TO LEAK. Battery Charging Procedure If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002–MCGR8). 1. Connect the charger cables to the positive (+) and negative (–) battery terminals. 2. Plug the charger into the 110V outlet and turn the switch to the ON position. 3. Select appropriate USER ID (if applicable) and press the NEXT soft key. Page 6 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Charging Procedure (Continued) January 26, 2006 4. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the GR8 Instruction Manual. 5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu. 6. Select CHARGING from the Main Menu screen and press the SELECT soft key. 7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key. Page 7 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Charging Procedure (Continued) 8. Select IN VEHICLE and press the NEXT soft key. 9. Select MODEL and press the NEXT soft key. NOTE: S “MODEL” or “STOCK #” MUST be used to receive a warranty code if the tester determines that the battery is bad. S “MODEL” and “STOCK #” are linked to custom algorithms and are the most accurate testing procedures. 10. Select the appropriate model and press the NEXT soft key. 11. Select OEM battery type and press the NEXT soft key. Page 8 of 10 January 26, 2006 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Charging Procedure (Continued) January 26, 2006 12. Choose the correct battery (model number and CCA) and press the NEXT soft key. The battery will be tested before charging will occur. The progress bar fills in across the screen while testing. The charger starts charging upon completion of testing. The screen displays the status of charge. 13. Read or print the battery test results. P 1/4: BATTERY RESULTS P 2/4: STATE OF CHARGE (SOC) P 3/4: STATE OF HEALTH (SOH) P 4/4: WARRANTY CODE To print: Align the Midtronics IR Printer (P/N 00002–A0870, component of P/N 00002–V8150–KIT) in front of the IR port on the charger and select the PRINT soft key. Page 9 of 10 BATTERY MAINTENANCE FOR IN–STOCK VEHICLES & PRE–DELIVERY – PG001-06 Revised Battery Charging Results January 26, 2006 Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: “GOOD BATTERY” Return the battery to service. 2. Battery Condition: “REPLACE BATTERY” Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out–of–vehicle test before replacing it. 3. Battery Condition: “BAD CELL–REPLACE” Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. Battery Replacement If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to the failed battery for proper warranty parts and claim processing. Include the Vehicle Identification Number (VIN) and warranty code on the Warranty Battery Label. WARRANTY BATTERY LABEL ETIQUETA PARA BATERIA DE GARANTIA (Please Print / Llénese con Letra de Molde Por Favor) Dealer Code Código de Agencia Vehicle Identification Number (VIN) Número de Identificación de Vehículo (NIV) Repair Order No. No. de Orden de Reparación Veh. Date of First Use Fecha de Primer Uso del Veh. 08/02 Battery Maintenance Repair Date Fecha de Reparación Failure Code Código de Falla Original Install Date Fecha de Instalación Original (Svc. part replacement only/ solamente para el reemplazo de partes de servicio) Battery Mos. In Svc. Número de meses que Batería está en servicio 00404–BTTRY–LABEL Recommended Battery Maintenance: In addition to this new pre–delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently. To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (–) battery cable should always be disconnected to reduce battery discharge. When the negative (–) battery cable is reconnected, please check and reset electrical components, such as the clock, radio, etc., and re–initialize all applicable systems/functions. Refer to the appropriate model and year service bulletins for specific details. For example: S TSB No. PD008–05, “Power System Initialization During PDS” (2005 model year) S TSB No. PD014–06, “Power System Initialization During PDS” (2006 model year) Page 10 of 10 Technical Service BULLETIN March 2, 2005 TIRE POSITIONING BEFORE NEW VEHICLE DELIVERY Models: ’05 – ’07 All Toyota & Scion TSB REVISION NOTICE: S May 26, 2006: 2007 model year has been added to Applicable Vehicles. Previous versions of this TSB should be discarded. Introduction During the manufacturing process, tire characteristics are measured. Tires are then mounted on the vehicle as matched sets to help reduce conditions such as pulling or drifting. If the wheels are replaced or refinished before vehicle delivery, it is important that the tires remain on the vehicle in the same location and in the same direction of rotation. Please refer to the following procedure to ensure that the original tires stay in the same location on the vehicle. Applicable Vehicles Installation Procedure S All 2005 – 2007 model year Toyota and Scion vehicles. 1. Mark the tire installation position on the inward facing tire sidewall. Example: Front Right = FR, Front Left = FL, Rear Right = RR, Rear Left = RL 2. Install the original tires on the new or refinished wheels with the marked side facing inwards. 3. Place the tire/wheel assemblies on the vehicle in the marked positions. NOTE: Torque the wheel nuts to the proper torque value in sequence. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 PRODUCT GENERAL INFORMATION PG002-05 Title: Technical Service BULLETIN November 28, 2006 Introduction DIRECTĆTYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS Models: ’04 – ’07 Applicable Toyota & Scion The Tire Pressure Warning System (TPWS) monitors the difference in tire pressure in all four or five tires (if the vehicle is equipped with a full-size spare tire) through radio wave signals from a tire pressure valve/sensor mounted in each wheel. This bulletin provides an overview and diagnostic information for the direct-type TPWS. Applicable Vehicles S 2004 – 2007 model year 4Runner vehicles. S 2005 – 2006 model year Tundra vehicles. S 2005 – 2007 model year Sequoia vehicles. S 2006 – 2007 model year Land Cruiser, Prius, RAV4, and Tacoma vehicles. S 2007 model year Avalon, Camry, Solara, and Scion tC vehicles. Required SSTs ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW** TOY220036 1 9 01002744 1 9 Toyota Diagnostic Tester Kit* 1 NOTE: S All components from this kit/set are required. S 12 Megabyte Diagnostic Tester Program Card (P/N 01002593–005) with version 13.4a Software (or later) is required. CAN Interface Module Kit* 2 NOTE: S All components from this kit/set are required. * Essential SSTs. ** Drawer number in SST Storage System. NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 12 PRODUCT GENERAL INFORMATION PG004-06 Title: DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Summary of TPWS/ Component Operation November 28, 2006 The following illustration is an example of the TPWS component locations on 2004 – 2007 model year 4Runner vehicles: Tire Pressure Monitor ECU Combination Meter (Low Tire Pressure Warning Light) Tire Pressure Sensor Front RH Tire Pressure Monitor Receiver (With Antenna) Tire Pressure Sensor Front LH Tire Pressure Sensor Rear LH Tire Pressure Sensor Rear RH Tire Pressure Sensor Spare Tire Tire Pressure Sensor Tire Pressure Monitor ECU DLC3 Tire Pressure Monitor Receiver (with Antenna) Meter Tire Pressure Sensor For exact location of each vehicle’s TPWS components, refer to the Technical Information System (TIS), applicable model and model year Repair Manual: Tire and Wheel (refer to component or parts location). For additional information on the TPWS components and operation, refer to TIS, applicable model and model year New Car Features: Chassis and Drivetrain. Page 2 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Summary of TPWS/ Component Operation (Continued) November 28, 2006 S Tire Pressure Warning Valve/Sensor: Each wheel (including the spare tire on certain vehicles) has a tire pressure warning valve/sensor integrated into the air valve with a unique ID number that measures the tire pressure and tire temperature and then transmits the information to the antenna/receiver mounted inside the vehicle through a radio wave signal. The unique ID number must be manually entered into the ECU using the Diagnostic Tester whenever the tire pressure warning valve/sensor is replaced or after a tire and wheel are exchanged. Vehicles equipped with a tire pressure warning valve/sensor inside the spare tire are listed in the following table: MODEL MODEL YEAR 4Runner 2004 – 2007 Avalon 2007 Camry (with Full-size Spare) 2007 Land Cruiser 2006 – 2007 RAV4 2006 – 2007 Sequoia 2005 – 2007 Solara (with Full-size Spare) 2007 Tacoma 2006 – 2007 Tundra 2005 – 2006 Valve Portion Air Hole ID Code Disc Wheel Rim Valve/Sensor Position Grommet Nut NOTE: S All Japan-built vehicles require the tire pressure warning valve/sensors to be activated (”wake up”) during Pre-Delivery Service (PDS). S Each tire pressure warning valve/sensor is equipped with a lithium battery that has an average life span of 10 years. S If a tire pressure warning valve/sensor is removed from the wheel, the grommet MUST be inspected and replaced if damaged. Page 3 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Summary of TPWS/ Component Operation (Continued) November 28, 2006 S Tire Pressure Warning System Antenna/Receiver: The antenna/receiver receives each tire pressure, tire temperature, and the unique tire pressure warning valve/sensor ID numbers through radio wave signals from the tire pressure warning valve/sensors and then transmits the information to the TPWS ECU. S Tire Pressure Warning System ECU: The ECU takes each tire pressure, tire temperature, and unique tire pressure warning valve/sensor ID information from the antenna/receiver and compares it to the specified value, which was registered during PDS. If the information received does NOT match the specified value registered in the ECU, it will transmit a signal to illuminate the Tire Pressure Warning System Indicator Light located on the combination meter. If the ECU is replaced, it is necessary to manually enter the tire pressure valve/sensor ID numbers using the Diagnostic Tester. S Tire Pressure Warning System Indicator Light: The Tire Pressure Warning System Indicator Light on the combination meter is illuminated or flashes continuously when the ECU senses that the tire pressure, tire temperature, and/or unique ID number does NOT match the specified value registered in the ECU. Tire Pressure Warning System Indicator Light Conditions for the Tire Pressure Warning System Indicator Light “ON” or “Flashing” are listed in the following table: Page 4 of 12 CONDITION CAUSE REPAIR After turning the key ON, the TPWS Indicator Light illuminates for 3 seconds and then turns OFF Normal — “System Check” Normal Condition TPWS Indicator Light is ON and will NOT turn OFF Low tire pressure has been detected Check that all tire pressures are set to the tire inflation pressure indicated on the vehicle loading specification label After turning the key ON, the TPWS Indicator Light flashes for 1 minute and then turns ON steady or flashes continuously System Failure See the “System Concerns & Repair Methods” sections in this TSB DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Summary of TPWS/ Component Operation (Continued) November 28, 2006 S Initialization/“SET” Switch: When initializing the TPWS, the present tire pressure is set as the standard pressure (for example: 32 psi). The TPWS determines a decrease in air pressure by comparing the standard pressure to the tire inflation pressure received from the tire pressure warning valve/sensor. Reasons for initializing the system include: S When rotating tires that have different tire pressures in the front and rear. S When changing or adjusting the tire pressure. S When changing tire size or when tires are replaced. The vehicles listed in the following table are equipped with an Initialization/“SET” switch: MODEL MODEL YEAR Avalon 2007 Camry 2007 Land Cruiser 2006 – 2007 Prius 2006 – 2007 Scion tC 2007 Solara 2007 Sequoia 2005 – 2007 Tacoma 2006 – 2007 Tundra 2005 – 2006 ILLUSTRATION OF INITIALIZATION/“SET” SWITCH S “MAIN/2nd” Switch (Land Cruiser vehicles ONLY): Land Cruiser is the ONLY Toyota vehicle with the “MAIN/2nd” switch. This allows the owner to have two different sets of tires and wheels, with two different sets of tire pressure warning valve/sensor ID numbers. For example, the second set would be used for snow tires. Therefore, register both the main and the second set of tire pressure warning valve/sensor ID numbers in the TPWS ECU using the Diagnostic Tester. Depending on what set of tire pressure warning valve/sensor ID numbers are being registered, the “MAIN/2nd” switch must be set in the correct position (i.e., “MAIN” for regular use tires and “2nd” for snow use tires). S “MAIN/2nd” switch in the UP position — The TPWS ECU is programmed to read the main set of tire pressure warning valve/sensor ID numbers. S “MAIN/2nd” switch in the DOWN position — The TPWS ECU is programmed to read the second set of tire pressure warning valve/sensor ID numbers. TPWS “MAIN/2nd” Switch Page 5 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Diagnostic Tester Setup When diagnosing the TPWS with the Diagnostic Tester, it must be set up to read the tire pressures in “psi – gauge” (psi – g). Follow the screens below from the Diagnostic Tester to convert the tire pressures to psi – g. A B *APPLICATION SELECT* TOYOTA DIAGNOSTIC TOOLSET PROGRAM CARD Version 13.4a 1: DIAGNOSIS 2 CUSTOMIZE 3: ECU REPROGRAM 07/16/06 Press D SETUP MENU 1: 2 3: 4: 5: 6: 7: 8: 9: Page 6 of 12 November 28, 2006 CLOCK/CALENDAR PRINTER BAUD PRINTER SELECT UNIT CONVERSION BRAND SELECT DATA BASE SELECT BACKLIGHT SET ENH OBDII HELP SELF TEST E UNIT CONVERSION AIR/FUEL PRESSURE abs gauge gauge kPa mmHg inHg psi psi inH20 C FUNCTION SELECT FOR NORTH AMERICA 1: OBD/MOBD 2 ENHANCED OBD II 3: CARB OBD II 4: BREAK-OUT BOX 5: NVH 6: AUTOPROBE 7: 02 RPM CHECK 8: SNAPSHOT REVIEW 9: SETUP 0: GAS ANALYSIS DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 System Concerns & Repair Methods COMMON SYMPTOM Cannot register the sensor ID numbers in the ECU using the Diagnostic Tester. CAUSE November 28, 2006 REPAIR SUGGESTIONS TPWS ECU is initialized. Jump terminals TC & CG at the DLC3 connector for 30 seconds to reset the TPWS ECU. (Land Cruiser: jump terminals TC & E1 at the DLC1 connector.) Diagnostic Tester software is incorrect or incompatible. Update software via TIS. “MAIN/2nd” switch is in the incorrect position (Land Cruiser ONLY). Ensure correct switch position and make sure loose objects do not contact the switch. 1)Record all sensor ID numbers from the Diagnostic Tester Data List. Cannot complete Pre-Delivery Service (PDS) activation “wake up” procedure. Tire/wheel swapped prior to delivery to customer. NOTE: Vehicles built in North America come with the transmitter y activated sensors already ( (awake). k ) V Vehicles hi l b built il iin JJapan require the transmitter sensors to be activated during PDS. Sensor ID numbers are not registered. DTCs: C2111 C2112 C2113 C2114 C2115 One or more tire pressures display “–14 psi-g” & “–40_F” on the Diagnostic Tester Data List. DTCs: C2121 C2122 C2123 C2124 C2125 C2177 2)Break down tires and compare the sensor ID numbers to what is recorded in the TPWS ECU. 3)If incorrect, register the correct sensor ID numbers using the Diagnostic Tester. 1)Break down tires and record all sensor ID numbers. 2)Register the sensor ID numbers in the TPWS ECU using the Diagnostic Tester. 1)Tire pressure decrease is not fast enough. Transmitters are not activated (in sleep mode). 1)Sensor ID numbers are not registered. 2)Tire/wheel swapped prior to delivery to customer. 2)Loosen the valve core when releasing air pressure from the tire to activate (”wake up”) the sensor (6 psi-g within 30 seconds). 1)Record all sensor ID numbers from the Diagnostic Tester Data List. 2)Break down tires and compare the sensor ID numbers to what is recorded in the TPWS ECU. 3)If incorrect, register the correct sensor ID numbers using the Diagnostic Tester. TPWS ECU or antenna/receiver malfunction. Refer to the diagnostic procedure for checking the TPWS ECU and/or antenna/receiver located in the applicable Repair Manual on TIS. Transmitters are inoperative. Replace sensors. Page 7 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 System Concerns & Repair Methods (Continued) COMMON SYMPTOM REPAIR SUGGESTIONS One or more tire pressures display “–14 psi-g” & “–40_F” on the Diagnostic Tester Data List. Land Cruiser ONLY: C2131 C2132 C2133 C2134 C2135 C2177 Tire pressure reads higher than actual vehicle loading label specification. Page 8 of 12 CAUSE November 28, 2006 Check position of “MAIN/2nd” “MAIN/2nd” switch is in switch. (“MAIN” for the main set of tires and “2nd” for second set of the incorrect position (Land Cruiser ONLY). tire pressure warning valve/sensor ID numbers.) Initialization is incorrect or incomplete. Adjust and set tire pressures according to the vehicle loading label specification. (Label is inside the driver’s door jamb.) DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Registration Procedure November 28, 2006 Registration of tire pressure warning valve/sensor ID numbers: 1. Jump TC and CG at DLC3 with the key ON and eEngine OFF for 30 seconds (Land Cruiser — Jump TC and E1 at DLC 1). 2. Register the 7-digit IDs: A B C DIAGNOSTIC MENU TIRE PRESSURE UTILITY TIRE PRESSURE UTILITY REGIST TIRE SET 1: DATA LIST 2: DTC INFO 1: REGIST TIRE SET 4: SNAPSHOT 5: UTILITY 7: SIGNAL CHECK Tires are registered in the MAIN SET The registration process will take 300 seconds. Do you wish to continue? PRESS [YES] or [NO] [ENTER] [YES] [ENTER] E D UTILITY REGIST TIRE SET UTILITY REGIST TIRE SET Register all transmitter ID for all tires including the spare tire within 300 seconds. Codes are printed on each transmitter. Total Tires: 5 Number of inputted ID codes: 0 Time: 300 seconds PRESS [ENTER] PRESS [ENTER] [ENTER] F UTILITY REGIST TIRE SET THE REGISTRATION SUCCEEDED. PRESS [ENTER] [ENTER] 3. Confirm the actual tire pressure to the Diagnostic Tester Data List and set according to the tire inflation pressure indicated on the vehicle loading specification label. 4. Confirm that the Tire Pressure Warning System Indicator Light is OFF. 5. Push and hold the Initialization/“SET” switch (if equipped) until the Low TPWS Light blinks 3 times and then release the switch. Keep the ignition key ON for 5 minutes for the system to initialize. The registration is complete. Page 9 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 November 28, 2006 Diagnostic Flow Chart Low Tire Pressure Warning Light is ON Land Cruiser vehicles ONLY Check position of “MAIN/ 2nd” switch “2nd” What position is the “MAIN/2nd” switch in? “MAIN” Do one or more tires have damage causing an air leak? YES Using a tire pressure gauge, check ALL tire pressures (including the spare if equipped) with a full-size spare Return switch to “MAIN” position & explain to customer purpose of “2nd/MAIN” switch YES Is the tire pressure low? Fix or replace tire(s) NO NO 1) Adjust tire pressure according to Tire and Loading Information label on driver’s door jamb 2) Check that Low TPWS Light goes OFF after 5 minutes of key ON and engine OFF. Did Low TPWS Light turn OFF? YES Repair Complete NO (Continued on next page) Page 10 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Diagnostic Flow Chart (Continued) November 28, 2006 (Continued from previous page) Use Diagnostic Tester to check for stored DTCs NO DTCs Which DTCs are stored? Confirm actual tire pressure to Diagnostic Tester Data List Other DTCs Follow Diagnostic Procedure in Repair Manual DTC C2111, C2112, C2113, C2114, & C2115 HINT: “TIREPRESS” displays “–14 psi–g” on Diagnostic Tester Data List 1) From TPWS Diagnostic Menu, select “ALL” Data List 2) Display “ALL TIREPRESS” 3) Increase tire pressure to 44 psi 4) Remove the air pressure by 6 psi for 30 seconds HINT: It may be necessary to loosen the valve core to quickly reduce the tire pressure for each tire one at a time. “TIREPRESS” that does NOT change on Diagnostic Tester Data List when performing step 4 is the valve/sensor out of specification or –14 psi–g. DTC C2121, C2123, C2124, C2125, C2131, C2132, C2133, C2134, C2135, C2177 HINT: “TIREPRESS displays “–14psi–g” on Diagnostic Tester Data List 1) From TPWS Diagnostic Menu, select “ALL” Data List 2) Display “ALL TIREPRESS” 3) Decrease air pressure from valve core HINT: “TIREPRESS” that does NOT change on Diagnostic Tester Data List when performing step 3 is the valve/sensor out of specification or –14 psi–g. 4) Repeat step 3 for each tire one at a time 5) From Diagnostic Tester Data List, write down “TIREPRESS” data valve/sensor ID number that corresponds to each tire Are all tire pressures displayed on Diagnostic Tester Data List within factory specification? (Continued on next page) Page 11 of 12 DIRECT-TYPE TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TIPS – PG004-06 Diagnostic Flow Chart (Continued) November 28, 2006 (Continued from previous page) Are all tire pressures displayed on Diagnostic Tester Data List within factory specification? Remove tire from wheel & confirm actual valve/sensor ID numbers to number registered in ECU NO YES Repair Complete 1) Adjust tire pressure according to Tire and Loading Information label on driver’s door jamb 2) Confirm the actual tire pressure to the Diagnostic Tester Data List 3) If vehicle is equipped with Initialization/SET switch, initialize system by pressing & holding “SET” switch until Low TPWS Light blinks 3 times & then turns OFF Page 12 of 12 NO Is valve/sensor ID number correct? Register correct valve/sensors ID number into ECU using Diagnostic Tester YES Replace valve/sensor Technical Service BULLETIN REPLACEMENT CERTIFICATION LABELS Models: All Models January 18, 2002 TSB UPDATE NOTICE: The information contained in this TSB updates PG006–01 dated May 4, 2001. Revised text is red and underlined. The changes will take place February 1, 2002. Introduction Replacement Certification Labels (vinyl label affixed to driver’s door or door post) may be available from Toyota providing the request meets one of the criteria listed below. Certification Label Location MFD.BY:TOYOTA MOTOR MANUFACTURING CANADA INC. 10/01 GVWR 3935LB GAWR FR 1970LB RR 1985LB THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY, BUMPER, AND THEFT PREVENTION STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. XT0XX00X0X000000 PASS.CAR C/TR:3L5/FB14 MODEL:ZZE134L – DHPNKA A/TM:–04A/U341F MADE IN CANADA S26 AA01904759 Applicable Vehicles Certification Label Criteria S All Toyota vehicles. 1. The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair. NOTE: S Processing a new label will be delayed significantly if the original certification label is not available. S A replacement label MAY NOT be available if the vehicle is more than 5 years old and the old label does not accompany this request. 2. The label is stolen. Procurement Procedure To request a replacement label, complete a copy of the form on the back of this bulletin. Your dealer parts account will be billed $25.00 for each replacement of a damaged or stolen label. NOTE: All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG008-02 Title: APPLICATION FOR REPLACEMENT CERTIFICATION LABEL REASON FOR REPLACEMENT ACCIDENT DAMAGE STOLEN OTHER MFD.BY: TOYOTAMOTOR MANUFACTURING CANADA INC. 10/01 GVWR3935LBGAWRFR1970LBRR1985LB THISVEHICLECONFORMSTOALLAPPLICABLE FEDERALMOTORVEHICLESAFETY, BUMPER, AND THEFTPREVENTIONSTANDARDS IN EFFECT ON THE DATEOFMANUFACTURESHOWNABOVE. XT0XX00X0X000000 PASS.CAR C/TR:3L5/FB14MODEL:ZZE134L–DHPNKA A/TM:–04A/U341FMADEINCANADA S26AA01904759 REASON/EXPLANATION ATTACH ORIGINAL LABEL HERE PLEASE PROVIDE CORRECT VIN NOTE: Original label MUST accompany this application or order will be significantly delayed. DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD LABEL TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA 90509–2991 Technical Service BULLETIN November 24, 2003 ADJUSTMENT OF TIRE INFLATION PRESSURE Models: ’04 – ’07 4Runner TSB REVISION NOTICE: S December 21, 2006: 2005 – 2007 model years have been added to Applicable Vehicles. S December 15, 2003: In Temperature Compensation Examples, word changes have been made to clarify the calculations. Previous versions of this TSB should be discarded. Introduction The purpose of this bulletin is to provide additional details regarding the tire pressure warning system on the 4Runner, as well as provide guidelines for temperature compensation of tire pressure – taking into account changes in ambient temperature and actual tire temperature. Seasonal temperature change can dramatically alter tire pressure. In addition, popular pencil type tire pressure gauges and service station air pumps have been proven on many occasions to be inaccurate and misleading. Low Tire Pressure Detection Timing: The tire pressure at each wheel is monitored when the ignition is ON. If the tire pressure falls below 27 PSI while the ignition is ON, the warning light will illuminate. Tire Pressure vs. Tire Temperature: Air in a tire expands and contracts as the temperature of the tire changes, changing the tire’s air pressure. Tire temperature is dependent on “cold” tire pressure, driving distance and speed, ambient temperature and road surface temperature. The “cold” tire pressure for the 4Runner is 220 Kpa (31.9 PSI), shown as 32 PSI in the Owner’s Manual. When adjusting tire pressures for your customer, you have to consider all of these factors, plus the difference between the temperature in the workshop and the lowest outside temperature you expect to have in your area in the next few weeks. “Cold” tire pressure, as recommended by the tire manufacturer (and shown on the tire pressure label in our vehicles), is generally considered to be the pressure in a tire that has not been driven the previous 4 hours, and has been parked outdoors. Applicable Vehicles Warranty Information S 2004 – 2007 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRODUCT GENERAL INFORMATION PG009-03 Title: ADJUSTMENT OF TIRE INFLATION PRESSURE – PG009-03 Revised Tire Pressure Adjustment November 24, 2003 Recommended Tire Pressure Adjustment: As noted above, there are many variables that can affect tire pressure in operation. However, you can use these guidelines to optimize the pressure when you set it in the workshop: S Use a high quality accurate tire pressure gauge, and check its accuracy regularly. S Consider the difference in the air temperature in the workshop and the lowest ambient temperature you expect in the next few weeks (especially in winter). S Use the chart (Figure 1) to compensate for temperature of the tires when you adjust the pressure. S Use temperature compensation Example 1 for the spare tire. Temperature Compensation Example 1 Assumed conditions: S The vehicle’s spare tire pressure is being adjusted. S The 4Runner has been parked overnight outside your shop (vehicle has “cold” tires), or is the spare tire for the vehicle. S Your workshop temperature is 68_F (20_C), and you expect the lowest ambient temperature in your area to be 14_F (–10_C). Calculations: S Compute the temperature difference between the seasonable lowest temperature and the workshop temperature: 68_F (20_C) – [14_F (–10_C)] = 54_F or 30_C. S Using the tire pressure chart (Figure 1), find the intersection of the cold tire line at the point corresponding to 54_F or 30_C, and read off the value on the tire pressure change axis. In this case it would be about 4.6 PSI. S Compute the actual tire pressure the tires should be filled to: 31.9 + 4.6 PSI = 36.5 PSI. In this example the tires would need to be filled to 37 PSI to compensate for the seasonal temperature difference. Temperature Compensation Example 2 Assumed conditions: S The 4Runner has been driven to your shop on surface streets for about 30 minutes (vehicle has “warm” tires). S Your workshop temperature is 68_F (20_C), and you expect the lowest ambient temperature in your area to be 14_F (–10_C). Calculations: S Compute the temperature difference between the seasonable lowest temperature and the workshop temperature: 68_F (20_C) – [14_F (–10_C)] = 54_F or 30_C. S Using the tire pressure chart (Figure 1), find the intersection of the warm tire line at the point corresponding to 54_F or 30_C, and read off the value on the tire pressure change axis. In this case it would be about 6.7 PSI. S Compute the actual tire pressure the tires should be filled to: 31.9 + 6.7 PSI = 38.6 PSI. In this example the tires would need to be filled to 39 PSI to compensate for the seasonal temperature difference and the heat in the tires from the short drive to your dealer. Page 2 of 3 ADJUSTMENT OF TIRE INFLATION PRESSURE – PG009-03 Revised Temperature Compensation Example 3 November 24, 2003 Assumed conditions: S The 4Runner has been driven to your shop on the highway for at least 60 minutes (vehicle has “hot” tires). S Your workshop temperature is 68_F (20_C), and you expect the lowest ambient temperature in your area to be 14_F (–10_C). Calculations: S Compute the temperature difference between the seasonable lowest temperature and the workshop temperature: 68_F (20_C) – [14_F (–10_C)] = 54_F or 30_C. S Using the tire pressure chart (Figure 1), find the intersection of the hot tire line at the point corresponding to 54_F or 30_C, and read off the value on the tire pressure change axis. In this case it would be about 9.0 PSI. S Compute the actual tire pressure the tires should be filled to: 31.9 + 9.0 PSI = 40.9 PSI. In this example the tires would need to be filled to 41 PSI to compensate for the seasonal temperature difference and the heat in the tires from the long, high–speed drive to your dealer. From these examples you can see that while the “cold” tire pressure specified for the tires is 32 PSI in the Owner’s Manual, you may need to inflate the tires to 41 PSI, or more, depending on seasonal weather conditions and initial tire temperature. Figure 1: Tire Pressure Chart 14 13 12 Tire Pressure Change (PSI) Tire Pressure Chart 11 Example 3 10 9 8 7 Example 2 6 5 Example 1 4 3 2 1 0 0_F or 0_C 18_F or 10_C 36_F or 20_C 54_F or 30_C 72_F or 40_C 90_F or 50_C 108_F or 60_C Temperature DIFFERENCE Between Seasonable Lowest Temperature and Workshop Temperature Cold Tire – Car not driven for 4 hours and parked outside prior to air pressure leak Warm Tire – Car has just been driven a short distance in traffic Hot Tire – Car has just been driven for at least 1 hour of highway driving Page 3 of 3 Technical Service BULLETIN REPLACEMENT VIN PLATES Models: All Models January 18, 2002 TSB UPDATE NOTICE: The information contained in this TSB updates PG007–01 dated May 4, 2001. Revised text is red and underlined. The changes will take place February 1, 2002. Introduction Replacement VIN plates (metal plates riveted to dashboard) may be available from Toyota providing the request meets the criteria listed below. VIN Plate Location Applicable Vehicles Replacement VIN Plate Criteria S All Toyota vehicles. S The vehicle is in an accident and the plate is damaged. NOTE: The original plate to be replaced MUST accompany the request. NOTE: If a plate is stolen, be sure to contact the State Police or your State’s Department of Motor Vehicles (DMV). In most cases the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims. Procurement Procedure To request a replacement plate, complete a copy of the form on the back of this page. Note that the damaged VIN plate MUST accompany the request form. Your dealer parts account will be billed $25.00 for each replacement of a damaged plate. NOTE: All replacement plates for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG009-02 Title: APPLICATION FOR REPLACEMENT VIN PLATE REASON FOR REPLACEMENT ACCIDENT DAMAGE OTHER REASON/EXPLANATION PLEASE PROVIDE CORRECT VIN ATTACH DAMAGED PLATE HERE DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD PLATE TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA. 90509–2991 SPECIAL SERVICE TOOLS Technical Service BULLETIN Models: All ’06 Toyota & Scion & ’07 Camry February 22, 2007 Introduction This TSB contains information regarding Special Service Tools (SSTs) distributed or added to the SST program during the 2006 model year as well as those that apply to 2007 model year Camry. Essential SSTs are listed by tool number, tool name, model application, and SST Storage System drawer number. NOTE: Special Service Tools can be ordered through the Toyota/Scion SST Program by calling SPX/OTC at 1–800–933–8335. Applicable Vehicles Warranty Information S All 2006 model year Toyota and Scion vehicles. S 2007 model year Camry. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 SPECIAL SERVICE TOOLS SS001-07 Title: SPECIAL SERVICE TOOLS – SS001-07 Essential Special Service Tools TOOL NUMBER February 22, 2007 APPLICATION DRW* 09216–42010 Belt Tension Wrench Set S This tool is designed to assist the technician servicing the engine V–drive belts. Camry, RAV4 1 09387–00130 Counter Drive Gear Nut Wrench S This tool is used in conjunction with a torque wrench to properly torque the counter drive gear nut on automatic transaxles. Camry 1 09564–33010 Differential Preload Adapter S This tool is used in conjunction with a torque wrench to assist in determining/ adjusting counter driven gear preload on automatic transaxles. Camry 1 09961–01270 Torque Wrench Adapter S This tool is used in conjunction with a torque wrench to assist in tightening the front suspension lower arm sub–assembly. RAV4 1 09223–56010–01 Crankshaft Rear Oil Seal Replacer S This tool will have a primary function of assisting in the installation of rear main oil seals. It can also be used to install the front disc brake dust cover to the axle hub bearing assembly. Various Models 7 00002–GTMAR Gap Tool S This tool is used to determine body panel measurements and interior trim fit. ALL 20 Various Models 21 ALL ** 09843–18060 00002–MCGR8 SPECIAL SERVICE TOOLS (SSTs) SRS Service Wire S This wire will help validate and test SRS circuit integrity and assist with diagnosis. Battery Diagnostic Station S The GR8 Battery Diagnostic station will diagnose and automatically charge all Toyota/Scion 12–volt batteries (including hybrid AMGs) in 1 hour or less. It also has jump start capability and a “Power Supply Mode” for maintaining ideal battery conditions while flash reprogramming vehicles. * Drawer number in SST Storage System. ** Essential SSTs not located in SST Storage System. Page 2 of 2 Technical Service BULLETIN April 26, 2007 Introduction TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE Models: ’01 – ’08 Applicable Toyota Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field–fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU’s information. NOTE: Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices responsible for managing the operation of a system or subsystem. For the purposes of this bulletin, the term “ECU” is used as a generic label for the following SAE J1930 standard references: S Powertrain Control Module (PCM) S Engine Control Module (ECM) S Transmission Control Module (TCM) S Or any other Toyota specific control unit Applicable Vehicles S 2001 – 2008 model year applicable Toyota vehicles. NOTE: NOT all models are capable of flash reprogramming. Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY N/A 00451–00001–LBL Authorized Modification Label 1 NOTE: Authorized Modification Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the Dealer Daily Dealer Support Materials System, or by calling the MDC at 1–800–622–2033. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 23 SPECIAL SERVICE TOOLS SS002-07 Title: TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Required Tools & Equipment REQUIRED EQUIPMENT April 26, 2007 SUPPLIER PART NUMBER QTY ADE TSPKG1 1 TIS Techstream* NOTE: Software version 2.00.008 or later is required. NOTE: Additional Techstream units may be ordered by calling ADE at 1–800–368–6787. REQUIRED SPECIAL SERVICE TOOLS (SSTs) SUPPLIER PART NUMBER QTY DRW** Digital Battery System Analyzer* SPX/OTC 00002–V8150–KIT 1 19 GR8 Battery Diagnostic Station* SPX/OTC 00002–MCGR8 1 – * ** Essential SSTs. Drawer number in SST Storage System. NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Page 2 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Process Overview April 26, 2007 Techstream ECU flash reprogramming is a 4–step process: 1. Verify the vehicle’s applicability for recalibration and locate desired calibration file. Vehicle applicability can be determined by the following methods: S Techstream ECU Reprogram Function S Techstream Health Check Function NOTE: Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin. S TIS Calibration Search S TIS TSB Search NOTE: TIS searches can be performed by picking Division/Model/Year, current calibration ID, or VDS code. 2. Connect the GR8 Battery Diagnostic Station. The GR8 Battery Diagnostic Station includes a Power Supply Mode that maintains battery voltage at 13.5 volts during ECU reprogramming. NOTE: ECU damage may occur if the correct battery charger and mode setting are NOT used. 3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process. 4. Affix the Authorized Vehicle Modification Label. Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label. Page 3 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure April 26, 2007 The following steps describe how to properly flash reprogram an ECU using the Techstream diagnostic application. NOTE: Ensure Techstream has been updated with the latest version of software. 1. Verify the vehicle’s applicability for recalibration and locate desired calibration file. A. ECU Reprogram Method: a. Establish a vehicle connection. b. Click the ECU Reprogramming button on the System Select tab (Figure 1). Figure 1 Page 4 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 c. Select available ECU(s) from the Calibration Update Check List (Figure 2). NOTE: Multiple ECUs can be selected. d. Click the green arrow button (bottom right of screen) to retrieve current calibration ID(s) and check for available calibration updates. Figure 2 Page 5 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 e. Available calibration updates are indicated by a Yes in the Calibration Update column (Figure 3). Click the Yes link to access the appropriate service bulletin on TIS. NOTE: S Prior to flash reprogramming, check applicable systems for DTCs and note any DTCs. S Clicking the Yes link will automatically launch TIS and perform a calibration search. Figure 3 Page 6 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 f. Log in to TIS. (If already logged in, skip this step.) g. To access the calibration file, click the service bulletin link in the Document Title column of the Calibration Search Result portlet (Figure 4). NOTE: Only Toyota Certified Technicians and above may access calibration files. Figure 4 Page 7 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 B. Health Check Method. a. Establish a vehicle connection. b. Click the Health Check button on the System Select tab (Figure 5). Figure 5 Page 8 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 c. Choose desired ECU group(s) in the Health Check dialog box (Figure 6). d. Click Next. Figure 6 e. Click Continue to view Health Check results (Figure 7). Figure 7 Page 9 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 f. Available calibration updates are indicated by a Yes link in the Cal. Update? column. Click the Yes link to access the appropriate service bulletin on TIS (Figure 8). NOTE: S Note any DTCs stored in systems that will be flash reprogrammed. S Clicking the Yes link will automatically launch TIS and perform a calibration search. Figure 8 g. Log in to TIS. (If already logged in, skip this step.) Page 10 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 h. To review the TSB and access the calibration file, click the service bulletin link in the Document Title column of the Calibration Search Result portlet. NOTE: Only Toyota Certified Technicians and above may access calibration files. Figure 9 Page 11 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 2. Connect the GR8 Battery Diagnostic Station. A. Connect the GR8 Battery Diagnostic Station to the car and turn it on. B. Select Power Supply Mode by following the screen flow below (Figure 10). NOTE: S ECU damage may occur if the correct battery charger and mode setting are NOT used. S Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. S For details on how to use the GR8 Battery Diagnostic Station, please refer to the GR8 Instructions Manual, located on TIS, Diagnostics – Battery. Figure 10 Confirm Power Supply Mode is Selected Page 12 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 3. Click the appropriate calibration ID (Figure 11) and reprogram the vehicle’s ECU with Techstream. A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle’s current calibration ID to the Previous Calibration ID in the Calibration Identification Chart. NOTE: S Calibration files are embedded as live links in the service bulletin. S Some vehicles require special preparation — please review the selected TSB carefully. Figure 11 Page 13 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) B. Click Open to load calibration file information (Figure 12). NOTE: Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media. Figure 12 Page 14 of 23 April 26, 2007 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 NOTE: Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below. S Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming. S Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle’s electrical load while reprogramming. S Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C). S Confirm cable connections between the vehicle and Techstream are secure. S Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming. S Set parking brake. S Complete ALL flash calibration updates provided for each ECU. S If the battery’s state of charge or capacity are in question, test with SST. No. 00002–V8150–KIT “Digital Battery Analyzer,” and follow TSB No. PG001–06, “Battery Maintenance for In–Stock Vehicles & Pre–Delivery”. S The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8 Battery Diagnostic Station, please refer to the GR8 Instructions Manual, located on TIS, Diagnostics – Battery. C. Click Next to start the calibration update process. Figure 13 Page 15 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 D. Select Techstream VIM as the desired programming device. Then click Next. Figure 14 E. Confirm the following: S PC is connected to VIM. S VIM is connected to DLC3 connector. S Ignition is ON and engine is OFF or “READY” OFF (hybrid vehicles). Figure 15 Page 16 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 F. Verify correct current calibration and new calibration information. NOTE: S The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU. S Each calibration file may contain up to three separate calibrations. S Figure 16 shows an example of the update procedure for a two–processor ECU. Figure 16 G. Turn ignition OFF. Figure 17 Page 17 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 H. Confirm the following: S Ignition is ON and engine is OFF or “READY” OFF (hybrid vehicles). S Hood is open. S All accessories are OFF. S Battery voltage is above 11.4 volts. NOTE: Verify the vehicle is connected to a battery charger before continuing — If battery voltage falls below 11.4 volts, ECU damage may occur. Figure 18 NOTE: If key cycle is NOT done properly, reprogramming will stop at 10% and Cal 1 will fail to load. Page 18 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) I. April 26, 2007 Do NOT disturb the vehicle during flash reprogramming. NOTE: S ECU flash reprogramming may take anywhere from 3 – 30 minutes per calibration file. S Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 – 7 minutes). Figure 19 NOTE: S If vehicle requires only ONE calibration update, then proceed to step N in this bulletin. S If vehicle requires a SECOND calibration update, then continue as follows: S For serial communication vehicles, go to step J. S For CAN communication vehicles, go to step L. Page 19 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 J. Cal 1 has completed the update process. S Turn ignition OFF for a minimum of 10 seconds. S Confirm ignition is returned to the ON position. Figure 20 K. Confirm ignition is ON. Figure 21 NOTE: If key cycle is NOT done properly, reprogramming will stop at 10% and Cal 1 will fail to load. Page 20 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 L. Do NOT disturb the vehicle during flash reprogramming. Figure 22 M. Turn ignition OFF for a minimum of 10 seconds. Then confirm ignition is returned to the ON position. Figure 23 Page 21 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 N. Confirm ignition is ON. Figure 24 O. Confirm all calibrations were updated as specified in the service bulletin. Figure 25 NOTE: Some DTCs may have been set during the reprogramming process. Clear all DTCs after restoring vehicle. Page 22 of 23 TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE – SS002-07 Operation Procedure (Continued) April 26, 2007 4. Affix Authorized Modification Label. A. Using a permanent marker or ball point pen, complete the Authorized Modifications Label and attach to the vehicle (Figure 26). The Authorized Modifications Label is available through the MDC, P/N 00451–00001–LBL. Figure 26. SAMPLE OF COMPLETED AUTHORIZED MODIFICATIONS LABEL Replacement ECU Part Number Calibration ID(s) Dealer Code THE FOLLOWING MODIFICATIONS HAVE BEEN MADE: 89661–08120 30806000, 50805000 THESE MODIFICATIONS HAVE BEEN APPROVED AS APPROPRIATE BY EPA AND CARB DEALER CODE: 31301 DATE: 8/2/06 CHANGE AUTHORITY: TSB TC007–03 Date Completed TSB or Campaign Number B. Attach the label under the hood in the location determined by the specific vehicle TSB or Campaign. NOTE: Wait 60 – 90 seconds for ink to set before handling. Page 23 of 23 Technical Service BULLETIN November 16, 2001 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE Models: All ’02 – ’07 Toyota & ’04 – ’07 Scion Models TSB REVISION NOTICE: S March 21, 2007: The OP Code for “Preliminary Check & Road Test” and the note have been updated in Warranty Information. S April 4, 2006: 2007 model year has been added to Applicable Vehicles. S October 21, 2005: 2003 – 2006 model years for Toyota models and 2004 – 2006 model years for Scion models have been added to Applicable Vehicles. A note has been added to the illustration in Repair Procedure 3. S March 1, 2004: The note in Step 2-A of the “Wheel Alignment & Tire Characteristics” Section has been changed. S December 21, 2001: OP Codes updated in Warranty Information. All previous versions of this TSB should be discarded. Introduction This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints. This information supplements Repair Manual procedures when the symptoms are: S The driver holds the steering wheel without exerting steering effort while driving straight ahead, the vehicle drifts to the right or the left. S While driving straight ahead, the driver has to steer either to the right or the left to maintain straight driving. Applicable Vehicles Warranty Information S 2002 – 2007 model year Toyota vehicles. S 2004 – 2007 model year Scion vehicles. OP CODE DESCRIPTION TIME OFP 044184 Combo A Combo B Combo C Combo D Combo E Preliminary Check & Road Test Switch Front Tire/Wheel & Road Test Reverse the Front One Side Tire Check Front Wheel Alignment Adjust Front Wheel Alignment Adjust Camber Setting Dismount and Mount Tire and Balance Wheel and Tire Assembly Each additional Wheel 0.6 0.5 0.7 1.2 0.7 0.7 45046 09020 45046–09020 420091 Combo A 0.5 T1 T2 31 99 42611–08010 0.3 NOTE: OP Code 044184 and the above combination codes apply to all models with the EXCEPTION of Combo E for MR2 model. Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 12 months or 20,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 11 STEERING ST005-01 Title: REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Contents November 16, 2001 This bulletin is divided into the following sections: Wheel Alignment and Tire Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 3–4 Repair Procedure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5 Repair Procedures 1. Important Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 6–7 3. Vehicle Pulling Caused by Wheel Alignment . . . . . . . . . . . . . . . . . . . Pages 7–8 4. Vehicle Pulling Caused by Tire Conicity . . . . . . . . . . . . . . . . . . . . . . . Pages 8–10 5. Camber Adjustment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 10–11 Page 2 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Wheel Alignment & Tire Characteristics November 16, 2001 1. Relationship Between Wheel Alignment and Vehicle Pulling to One Side When the cross camber or caster of the front wheel alignment is large, it can cause vehicle pulling. WHEEL ALIGNMENT DIRECTION OF VEHICLE PULLING Camber Vehicle pulls in direction of wheel with large camber value Caster Vehicle pulls in direction of wheel with small caster value CAMBER Straight-Ahead Driving CASTER Direction of Pull Front P’ T’ P T a’ a Caster Trail (Large) Caster Trail (Small) O F O’ F’ P, P’: Driving Force a, a’: Steering Axes O, O’: Center of Tire-Road Contact Area F, F’: Reactive Force If the cross camber or caster is within the specified range (30’ or less), noticeable vehicle pulling will not occur due to side-to-side differences in camber or caster. NOTE: On a flat road, if the cross camber or caster is 30’ or less and the steering wheel is held without exerting steering effort for 100 m (109 yards) when driving at 100 km/h (62 mph), the alignment-induced drift distance is approximately 0.5 m (1.64 ft). Page 3 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Wheel Alignment & Tire Characteristics (Continued) November 16, 2001 2. Relationship Between Tire Characteristics and Vehicle Pulling to One Side When radial tires are rotating, they have the characteristic of generating force in the lateral direction between the tire and the road surface. This lateral force is comprised of two factors: S Ply-steer, which changes direction according to the rotation direction of the tires. S Conicity, which is generated in a fixed direction regardless of the tire rotation direction. If these lateral forces are too strong, vehicle pulling will occur. A. Ply-Steer Lateral force due to ply-steer is produced by the construction of the belts inside the tire tread. With radial tires, the wire of the belt is slanted as shown in the illustration below. Thus, it is in the lateral direction that tire tread easily changes shape (stretches), and lateral force is generated between the tire and the road surface in the lateral direction. Rotation Direction Easily-Stretched Direction Wire Ply–Steer (Direction of Force Generation Varies According to Tire Rotation) Belt NOTE: Lateral force from ply-steer prevents vehicle drift caused by road slant, so in many cases lateral force to the left is provided to compensate for road slant to the right. B. Conicity Conicity is lateral force resulting from uneven formation of the left and right sides of the tire. The direction the lateral force is exerted depends on the hardness of the side walls and the difference in height between the left/right sides of the tire. Hard Part Conicity (Direction Is Fixed Regardless of Direction of Tire Rotation) NOTE: S In the case of vehicle pulling caused by tires, the lateral force which is exerted as a result of conicity has the greatest effect. On a flat road, if the steering wheel is held without exerting steering effort for 100 m (109 yards) when travelling at 100 km/h (62 mph), the vehicle may drift as much as 1.5 m (5 ft). S When vehicle pulling is due to conicity, the amount of drift can be reduced and the direction of drift can be changed by changing the location of the tire or reversing the tire when installing it on the wheel. Page 4 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedure Flow Chart November 16, 2001 START Preliminary Check S Tire Pressure S Vehicle height S Brake Dragging NO Is there steering off center? *ROAD TEST Does the vehicle lead/pull? YES NO COMPLETE YES Adjust front tie rods. See TSB ST003-01 YES Are the tires uni–directional type? NO NO ROAD TEST Does the vehicle still lead/pull? Cross switch front tire and wheel assemblies (left & right) YES Choose the position of front tire & wheel assemblies where there is least amount of pull. YES Does the vehicle lead/pull in the same direction as before? NO YES Check front wheel alignment. Is it within specification? NO Is the lead/pull stronger than before? NO YES Reverse the front left side tire and rebalance it. Adjust front wheel alignment. ROAD TEST Does the vehicle still lead/pull? NO ROAD TEST Does the vehicle still lead/pull? YES YES Does the vehicle lead/pull to the left? COMPLETE YES NO Increase right front camber and decrease left front camber until lead/pull is eliminated. NO NO NOTE: Do not exceed 1_ of cross camber. Do not exceed adjustment range. Increase left front camber and decrease right front camber until lead/pull is eliminated. ROAD TEST Does the vehicle still lead/pull? YES Contact your regional office. * Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 35 mph. Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph without exerting steering effort on the steering wheel. (1) The vehicle goes straight but the steering wheel has some angle. (2) The vehicle does not go straight. STEERING OFF CENTER STEERING PULL Page 5 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures November 16, 2001 1. IMPORTANT NOTICE Before repairing vehicle pulling to one side, it is necessary to clearly identify the cause of the pulling condition. Frequently, the cause of the vehicle pulling to one side is diagnosed as wheel alignment. However, the actual cause may be lateral force generated by the tires. Performing wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This would then cause other problems such as uneven tire wear, etc. 2. Troubleshooting First determine whether vehicle pulling to one side is caused by a wheel alignment problem or tire characteristics, then decide which repairs to make. A. Perform the following checks and correct as necessary. a. Check tires for size, wear and for proper inflation pressure. b. Check whether the vehicle is noticeably tilted backward/forward or left/right. NOTE: Tilting of the vehicle produces a left-right difference in the camber and caster and can cause vehicle pulling to one side. c. Check brakes for dragging. B. Confirm problem symptoms. With the customer accompanying you, drive the vehicle to confirm if the customer’s complaint involves vehicle pulling to one side or steering wheel off center. If the problem is steering wheel off center, adjust the front tie rods on the vehicle. Refer to Toyota TSB ST003-01. Also check the direction of vehicle pulling and the extent of the pulling. C. Decide if vehicle pulling is due to wheel alignment or tires. a. Switch the left and right front tires (If the tires are non-unidirectional). b. Conduct a drive test to check whether the direction that the vehicle pulls has changed. Page 6 of 11 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION No change in vehicle pulling condition Front wheel alignment Proceed to Repair Procedure 3. Vehicle pulling caused by Wheel Alignment (Page 6) Vehicle pulling eliminated Tire conicity Repair complete. Vehicle Pulling Caused by Tire Conicity (Page 3 and 6) Vehicle pulling direction is reversed Tire conicity Proceed to Repair Procedure 4. Vehicle Pulling Caused by Tire Conicity (Page 7) REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures (Continued) November 16, 2001 Helpful hints to determine cause of vehicle pulling: S The direction of lateral force from tire conicity becomes reversed when the left and right tires are switched. Therefore, if the pulling direction changes when the tires are switched, it can be concluded that vehicle pulling is caused by tire conicity. ORIGINAL TIRE POSITIONS Vehicle Pulling Direction (Right) TIRES SWITCHED Lateral Force by Conicity The Vehicle is Pulled to the Right by the Lateral Force Exerted to the Right. Vehicle Pulling Direction (Left) Lateral Force by Conicity The Direction of the Tires Which Exerted Lateral Force to the Right has Been Changed, so the Tires Now Exert Lateral Force to the Left and the Vehicle Now Pulls to the Left. S If the pulling direction does not change after the front tires are switched, the cause of vehicle pulling is not tire conicity. In this case, the likely cause is a front wheel alignment condition. 3. Vehicle Pulling Caused by Wheel Alignment When it is determined by troubleshooting that the vehicle pulling to one side is caused by wheel alignment, perform repairs according to the following procedure. Vehicle Pulling to One Side Check Front Wheel Alignment Not Within Specification Within Specification Adjust Front Wheel Alignment Road Test OK Within Specification But Vehicle Pulls Vehicle Still Pulls Adjust Cross Camber to Eliminate Vehicle Pulling NOTE: Do not exceed 1_ of cross camber. Page 7 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures (Continued) November 16, 2001 WHEN VEHICLE PULLS TO LEFT WHEN VEHICLE PULLS TO RIGHT Increase right front camber and decrease left front camber until vehicle pulling is eliminated Increase left front camber and decrease right front camber until vehicle pulling is eliminated NOTE: S Keep the cross camber within 1_ or less. S Keep the camber of each wheel within specifications (+/–45’ of center value). S If adjustment exceeds the specifications, uneven tire wear will result. 4. Vehicle Pulling Caused by Tire Conicity When it is determined by troubleshooting that the vehicle pulling to one side is caused by tire conicity, perform repairs according to the following procedures. Indication of Tire Conicity as a Cause: When the front tires are switched, the pulling direction changes. Proceed to STEP 1. STEP 1: Remove the front left tire from the wheel and reverse the tire. Then perform a road test and check for change in the pulling direction. HINT: By performing this operation, it can be checked whether the left or right tire exerts a stronger lateral force. Either tire can be reversed. Shown here is an example of the left tire reversed. If Vehicle Pulls in the Same Direction: Go to STEP 2. The lateral force generated by the right front tire is greater than the left tire, so the vehicle is pulling due to the lateral force of the right tire. ORIGINAL TIRE POSITIONS Vehicle Pulling Direction LEFT TIRE REVERSE INSTALLATION Vehicle Pulling Direction (Same Direction) Reversed Lateral Force by Conicity (Smaller) Page 8 of 11 Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) Lateral Force by Conicity (Larger) REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures (Continued) November 16, 2001 If Vehicle Pulls in the Opposite Direction: Go to STEP 2. The lateral force generated by the left front tire is greater than the right tire, so the vehicle is pulling due to the lateral force of the left tire. ORIGINAL TIRE POSITIONS LEFT TIRE REVERSE INSTALLATION Vehicle Pulling Direction Vehicle Pulling Direction (Opposite Direction) Reversed Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) If Vehicle Pull Is Eliminated: Repair Is Now Complete. The lateral force generated by the left and right front tires is virtually the same, so the lateral force is neutralized and the vehicle travels straight ahead. The repair operation is now completed. STEP 2: Rotate the larger lateral force front tire with the rear tire and check the change in the vehicle pulling. NOTE: By shifting the front tire with the larger lateral force to the rear, the vehicle pulling level is usually reduced. If Vehicle Is Still Pulling: Go to STEP 3. If Vehicle Pull Is Eliminated: Repair Is Now Complete. Page 9 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures (Continued) November 16, 2001 STEP 3: Adjust cross camber to eliminate vehicle pulling. HINT: If the tires are placed in the positions they were in during tire rotation when the least amount of vehicle pulling occurred, wheel alignment can be performed with a minimal amount of adjustment. WHEN VEHICLE PULLS TO LEFT WHEN VEHICLE PULLS TO RIGHT Increase right front camber and decrease left front camber until vehicle pulling is eliminated Increase left front camber and decrease right front camber until vehicle pulling is eliminated NOTE: S Keep the cross camber within 1_ or less. S Keep the camber of each wheel within specifications (+/–45’ of center value). S If adjustment exceeds the specifications, uneven tire wear will result. 5. Camber Adjustment Method NOTE: After the camber has been adjusted, inspect the toe-in. NOTE: The method of camber adjustment differs for different models, so please refer to the repair manual of the vehicle involved. (This is a sample from the Sienna Repair Manual). A. Remove the front wheels and ABS speed sensor clamp. B. Remove the two nuts on the lower side of the shock absorber. C. Coat the threads of the nuts with engine oil. D. Temporarily install the two nuts. E. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. F. Tighten the nuts. Torque: 210 NSm (2,150 kgfScm, 155 ftSlbf) Page 10 of 11 1 2 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – ST005-01 Revised Repair Procedures (Continued) November 16, 2001 G. Install the front wheels. Torque: 104 NSm (1,050 kgfScm, 77 ftSlbf) H. Check the camber. NOTE: Adjusting value for the set bolts is 6’ – 30’ (0.1_ – 0.5_). When making an adjustment of more than 45’, replace the upper and lower steering knuckle set bolts with the adjusting bolts. If the camber is NOT within the specification, use the table shown to estimate how much additional camber adjustment will be required, and select the appropriate camber adjusting bolt. I. Follow steps 5-a through 5-h again. Between steps 5-b and 5-c, exchange one or two selected bolts. HINT: When exchanging the two bolts, exchange one bolt each time. If Vehicle Pull Is Eliminated: Repair Is Now Complete. If Vehicle Is Still Pulling: Contact Your Regional Office for Further Assistance. Page 11 of 11 Technical Service BULLETIN October 24, 2006 Introduction Applicable Vehicles Warranty Information SHOCK ABSORBER REPLACEMENT CRITERIA Models: ’06 – ’07 Toyota The purpose of this TSB is to provide a quick reference to assist in making easy judgements regarding shock absorber and strut replacements. S 2006 – 2007 model year Toyota vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 4 SUSPENSION SU007-06 Title: SHOCK ABSORBER REPLACEMENT CRITERIA – SU007-06 Inspection October 24, 2006 Strut Type: LEVEL 5 LEVEL 4 LEVEL 3 LEVEL 2 LEVEL 1 Oil leak, covering top, spring seat, and part of strut body Oil leak, covering entire strut body, spring seat, and knuckle bracket Abnormal oil leak — Replace the shock absorber Abnormal oil leak — Replace the shock absorber Oil Seal Case OIL LEAK CRITERIA Spring Seat Knuckle Bracket Page 2 of 4 CONDITION Slight oil seepage from oil seal case Moderate oil seepage from oil seal case Oil leak/drip on the seal case, extending below the spring seat ACTION Normal oil evaporation — NOT necessary to replace the shock absorber Normal oil evaporation — NOT necessary to replace the shock absorber Abnormal oil leak — Replace the shock absorber SHOCK ABSORBER REPLACEMENT CRITERIA – SU007-06 Inspection (Continued) October 24, 2006 Shock Absorber Type with Spring Seat: LEVEL 5 LEVEL 4 Oil Seal Case LEVEL 3 LEVEL 2 LEVEL 1 Oil leak, covering top, spring seat, and part of shock body Oil leak, covering entire shock body and spring seat, and extending to lower bushing Abnormal oil leak — Replace the shock absorber Abnormal oil leak — Replace the shock absorber 1/3 L OIL LEAK CRITERIA L Lower Bushing Lower Bracket CONDITION Slight oil seepage from oil seal case Moderate oil seepage from oil seal case Oil leak/drip on the seal case, extending below the spring seat ACTION Normal oil evaporation — NOT necessary to replace the shock absorber Normal oil evaporation — NOT necessary to replace the shock absorber Abnormal oil leak — Replace the shock absorber Page 3 of 4 SHOCK ABSORBER REPLACEMENT CRITERIA – SU007-06 Inspection (Continued) October 24, 2006 Shock Absorber Type: LEVEL 5 LEVEL 4 LEVEL 3 LEVEL 2 LEVEL 1 OIL LEAK CRITERIA L 1/3 L L 1/2 L Page 4 of 4 CONDITION Slight oil seepage, covering approximately 1/4 of outer tube Moderate oil seepage, covering approximately 1/3 of outer tube Oil leak/drip down outer tube Oil leak, covering 1/2 of outer tube Oil leak, covering entire shock body and extending to lower bushing ACTION Normal oil evaporation — NOT necessary to replace the shock absorber Normal oil evaporation — NOT necessary to replace the shock absorber Abnormal oil leak — Replace the shock absorber Abnormal oil leak — Replace the shock absorber Abnormal oil leak — Replace the shock absorber Technical Service BULLETIN June 13, 2007 INITIAL CALIBRATION OF COMPASS DURING PDS Models: ’08 4Runner TSB REVISION NOTICE: S August 17, 2007: The zone reference illustration in step 2 has been updated. Previous versions of this TSB should be discarded. Introduction Some 2008 model year 4Runner vehicles are equipped with a compass in the rear view mirror. Use the following procedure to complete initial calibration of the compass during Pre-Delivery Service (PDS). Compass Display “Multifunction” Switch Applicable Vehicles Warranty Information S 2008 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE PD059-07 Title: INITIAL CALIBRATION OF COMPASS DURING PDS – PD059-07 Revised Compass Calibration Procedure June 13, 2007 1. Turn the ignition switch to the “ON” position and push and hold the switch for 6 seconds until the zone number appears on the compass display. 2. Push the switch to select the number of the zone where the vehicle is located. See the map below for zone reference. A. Samoa: Guam: Saipan: North America 1 15 2 14 3 13 4 12 5 8 6 7 Page 2 of 3 9 10 11 5 8 8 INITIAL CALIBRATION OF COMPASS DURING PDS – PD059-07 Revised Compass Calibration Procedure (Continued) June 13, 2007 3. Start the engine and push and hold the switch for about 9 seconds until “C” appears on the display. 4. Drive the vehicle slowly at 5 mph (8 km/h), or less, in a circle until the direction is displayed. If there is NOT enough space to drive in a circle, turn the car around as shown, doing two three-point turns in succession. After driving in 1 to 3 circles in the above method, calibration is complete with the direction shown on the display. NOTE: S Do NOT perform calibration of the compass in a place where the Earth’s magnetic field is subject to interference (underground parking, under a steel tower, between buildings, roof parking, near a railroad crossing, near a large vehicle, etc.) S During calibration, do NOT operate electric systems (moon roof, power windows, etc.) as they may interfere with the calibration. Page 3 of 3 Technical Service BULLETIN June 13, 2007 Introduction Applicable Vehicles SHORT PIN INSTALLATION DURING PDS Models: ’08 4Runner To minimize battery discharge during transportation and storage, the Short Pin has been removed at the assembly plant and temporarily stored in the engine compartment Relay Block. Reinstall the Short Pin into its original location and confirm all related DTCs are cleared during Pre-Delivery Service (PDS). S 2008 model year 4Runner vehicles. Required Tools & Equipment REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY ADE TSPKG1 1 TIS Techstream* NOTE: Software version 2.00.008 or later is required. * Essential SST. NOTE: S Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1–800–368–6787. S The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRE-DELIVERY SERVICE PD060-07 Title: SHORT PIN INSTALLATION DURING PDS – PD060-07 Installation Procedure The Short Pin is stored in the blank space of the Relay Block in the engine compartment. June 13, 2007 Engine Compartment Relay Block During Pre-Delivery Service (PDS), install the Short Pin in the Relay Block as shown. Relay Block NOTE: S Removing the Short Pin cuts off power sources relating to the DOME, RADIO No. 1, and ECU-B fuses. S The Short Pin does not function as a fuse, so install it only in the position shown. S If the vehicle is stored in the dealership for a long period of time after PDS, disconnect the negative (–) battery terminal to prevent battery discharge. Refer to TSB No. PG001-06, “Battery Maintenance for In-Stock Vehicles & Pre-Delivery,” for battery maintenance information. DTC Clearing Procedure Install Short Pin Here (Original Location) Remove This Short Pin With the Short Pin removed, the occupant classification ECU and Center Airbag Sensor Assembly (airbag ECU) may detect the interruption in battery voltage (B+) and store a DTC. Clear DTC B1150 and B1794 after installing the Short Pin. 1. Connect TIS Techstream to the DLC3. 2. Turn the ignition switch to the “IG-ON” position. 3. Using TIS Techstream, check any other codes being output. HINT: If any DTCs besides DTC B1150 and B1794 remain, repair the applicable system according to the Repair Manual. 4. Erase DTCs (B1150 and B1794) and Freeze Frame Data. Page 2 of 2 Technical Service BULLETIN June 13, 2007 Introduction INITIALIZATION OF BACK DOOR POWER WINDOW DURING PDS Models: ’08 4Runner This bulletin outlines the initialization procedure for the back door power window on the 4Runner. To minimize the battery discharge during transportation and storage, the Short Pin has been removed at the assembly plant, resulting in the following feature being inoperative: S One-touch open and close with jam protection. Use the following initialization procedure after installing the Short Pin during Pre-Delivery Service (PDS) and whenever the battery has been disconnected. NOTE: Any time the battery terminal has been disconnected, the back door power window MUST be re-initialized. Applicable Vehicles Warranty Information Initialization Procedure S 2008 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Make sure the Short Pin is installed in its original location. (Refer to TSB No. PD060-07, “Short Pin Installation During PDS.”) Short Pin Original Location Toyota Supports ASE Certification Page 1 of 2 PRE-DELIVERY SERVICE PD061-07 Title: INITIALIZATION OF BACK DOOR POWER WINDOW DURING PDS – PD061-07 Initialization Procedure (Continued) June 13, 2007 1. Turn ignition switch to the “ON” position. 2. Push the back door power window switch to the “DOWN” side to open the window. 3. Push and hold the back door power window switch to the “UP” side until the window closes. Continue holding it for approximately 1 second. 4. Check for proper operation of the “one-touch open/close” functions by pushing the switch briefly to the “DOWN” and “UP” positions. NOTE: Jam protection function becomes effective through the above initialization procedure. Page 2 of 2 Completely Closed Technical Service BULLETIN June 13, 2007 Introduction DRIVER'S DOOR POWER WINDOW & MOON ROOF INITIALIZATION Models: ’08 4Runner This bulletin outlines the initialization procedure for the driver’s door power window and the moon roof on 2008 model year 4Runner vehicles. If the battery has been disconnected, the ECU will not be able to detect and memorize the driver’s door power window and moon roof positions, resulting in the following features being inoperative: S One-touch open and close of driver’s door power window with jam protection. S One-touch slide open and close of moon roof with jam protection. S One-touch tilt up and down of moon roof with jam protection. Use the following initialization procedure during Pre-Delivery Service (PDS) and whenever the battery has been disconnected. NOTE: Any time the battery terminal has been disconnected, the driver’s door power window and moon roof MUST be re-initialized. Applicable Vehicles Warranty Information Initialization Procedure S 2008 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Driver’s Door Power Window 1. Turn the ignition to the “ON” position. NOTE: At this time, the power switch for the driver’s door window should be blinking. 2. Push down and hold the driver’s door power window switch to completely open the window. Toyota Supports ASE Certification Power Window Switch Page 1 of 3 PRE-DELIVERY SERVICE PD062-07 Title: DRIVER’S DOOR POWER WINDOW & MOON ROOF INITIALIZATION – PD062-07 Initialization Procedure (Continued) 3. Pull and hold up the driver’s door power window switch until the window closes. Continue holding the switch for approximately one second until the switch changes from blinking to a constant illumination. June 13, 2007 Completely Closed 4. Check for proper operation of the “one-touch open/close” by pushing the switch briefly to the “DOWN” and “UP” positions. NOTE: Jam protection function becomes effective through the above initialization procedure. TROUBLESHOOTING: If power window is unable to close after initialization, perform the following procedure. NOTE: If the power window switch is continuously operated for a long time, the power window motor will stop to prevent additional load on the motor. Continuing to press the power window switch even after the motor has stopped will cause the switch to blink and will restrict the AUTO UP/DOWN function and remote UP/DOWN function. If this happens, wait for a few minutes before attempting to reset the motor again. 1. Disconnect the negative (–) battery terminal. After 10 seconds, reconnect the battery terminal. 2. Turn the ignition switch to the “ON” position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately one second after the door glass is fully closed. " Check for proper operation of the AUTO UP/DOWN function. 3. If the power window motor is still unable to close: Turn the ignition switch to the “ON” position. Halfway close the door glass by pressing the switch. Then fully pull up on the switch until the door glass is fully closed, and continue holding the switch for approximately 12 seconds after the door glass is fully closed. " Check for proper operation of the AUTO UP/DOWN function. Page 2 of 3 DRIVER’S DOOR POWER WINDOW & MOON ROOF INITIALIZATION – PD062-07 Initialization Procedure (Continued) June 13, 2007 Moon Roof 1. Turn the ignition to the “ON” position. 2. Push and hold the “TILT UP” side of the switch until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm [0.39 in.] at the rear). 3. Check for proper operation of the “one-touch slide open/close” and “one-touch tilt up/down” functions by pushing the switch briefly to the “SLIDE OPEN” and “TILT UP” positions. Approx. 10 mm NOTE: Jam protection function becomes effective through the above initialization procedure. Page 3 of 3 TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION Models: ’08 4Runner June 18, 2007 Introduction 2008 model year 4Runner vehicles are equipped with a direct-type Tire Pressure Warning System (TPWS). Each tire (including the spare tire) has a tire pressure warning valve/sensor, and the measured tire pressure data is transmitted to the Tire Pressure Warning System antenna/receiver to the Tire Pressure Warning System ECU. During Pre-Delivery Service (PDS), the tire pressure warning valves/sensors must be activated according to the procedure in this bulletin. S 2008 model year 4Runner vehicles. Applicable Vehicles Required Tools & Equipment REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY ADE TSPKG1 1 TIS Techstream* NOTE: Software version 2.00.008 or later is required. * Essential SST. NOTE: S Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1–800–368–6787. S The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE Technical Service BULLETIN PD064-07 Title: TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION – PD064-07 Reference June 18, 2007 S The Low Tire Pressure Warning Light will blink until all the tire pressure warning valves/sensors are activated. S The Diagnostic Trouble Codes (DTCs) listed below may be stored in the TPWS ECU until the tire pressure warning valves/sensors are activated. S The DTCs will automatically clear when the tire pressure warning valves/sensors are activated. *1: *2: Activation Procedure Low Tire Pressure Warning Light DTC NO. *1 DTC NO. *2 DTC EXPLANATION 11 C2111 Transmitter ID1 Operation Stop (sleep mode) 12 C2112 Transmitter ID2 Operation Stop (sleep mode) 13 C2113 Transmitter ID3 Operation Stop (sleep mode) 14 C2114 Transmitter ID4 Operation Stop (sleep mode) 15 C2115 Transmitter ID5 Operation Stop (sleep mode) DTC No. indicated by blinking of the Low Tire Pressure Warning Light. DTC No. indicated on TIS Techstream. 1. Connect TIS Techstream. 2. Turn the ignition switch to the “ON” position and check that the Low Tire Pressure Warning Light blinks. Low Tire Pressure Warning Light Page 2 of 3 TIRE PRESSURE WARNING VALVE/SENSOR ACTIVATION – PD064-07 Activation Procedure (Continued) June 18, 2007 3. Press or remove the valve core to reduce the tire inflation pressure rapidly by 6 psi (0.4 kgf/cm2, 40 kPa), or more, within 30 seconds. Core If the tire inflation pressure is NOT reduced by 6 psi (0.4 kgf/cm2, 40 kPa), or more, within 30 seconds, the tire pressure warning valves/sensors will NOT be activated. NOTE: This operation is required for the system to be activated and must be performed for each tire (including the spare tire), one at a time. 4. Using TIS Techstream, check for TPWS DTCs. S If NO DTCs are stored, go to step 5. S If DTCs C2111 – C2115 are stored, repeat step 3. S If any other DTCs are stored, refer to the Repair Manual. 5. Adjust all tires (including the spare tire) to the standard tire inflation pressure and confirm that the Low Tire Pressure Warning Light is OFF. TIRE SIZE TIRE PRESSURE (psi, kgf/cm2, kPa) P265/70R16 111S P265/65R17 110S 32 2.2, 32, 2 2 220 NOTE: S If there is great difference between the current temperature of the tire and wheel (for example: shop temperature) and expected temperature (for example: outdoor temperature), this needs to be considered when adjusting the tire pressure. S Adjust the tire pressure when the tires are cold. Page 3 of 3 Technical Service BULLETIN June 18, 2007 Introduction Applicable Vehicles Warranty Information Installation Procedure LICENSE PLATE INSTALLATION DURING PDS Models: ’08 4Runner The following procedure is recommended for front and rear license plate installation on 2008 model year 4Runner vehicles. S 2008 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Front License Plate 1. Align the holes on the license plate to the dimples on the front bumper. 2. Install two (2) self-tapping screws through the license plate and into the front bumper at the dimples. NOTE: S Do NOT drill holes into the bumper. S Do NOT overtighten the screws. Dimples Use non-corroding self-tapping screws with the following dimensions: Nominal Length: 16.5 mm (0.65 in.) – 20.0 mm (0.79 in.) 6.0 mm (0.24 in.) Diameter: 6.0 mm (0.24 in.) 16.5 – 20.0 mm (0.65 – 0.79 in.) Toyota Supports ASE Certification Page 1 of 2 PRE-DELIVERY SERVICE PD065-07 Title: LICENSE PLATE INSTALLATION DURING PDS – PD065-07 Installation Procedure (Continued) June 18, 2007 Rear License Plate 1. Align the installation holes on the rear license plate with the holes on the back door. 2. Install two (2) bolts through the license plate and into the holes (welded nuts) in the back door. Use non-corroding bolts with the following dimensions: Nominal Length: 25.0 mm (0.98 in.) or shorter Diameter: 6.0 mm (0.24 in.) Pitch: 1.0 mm (0.04 in.) NOTE: If bolts longer than 25 mm (0.98 in.) are used, the back door window glass may be damaged or broken. Page 2 of 2 Technical Service BULLETIN June 18, 2007 Introduction ROOF RACK CROSS BAR INSTALLATION DURING PDS Models: ’08 4Runner To prevent paint damage during transportation, the roof rack cross bars are kept inside the vehicle so that the Rapgardt protective film can remain in place on the roof panel. Install the roof rack cross bars to the roof rack rails according to the following procedure during Pre-Delivery Service (PDS). NOTE: To prevent damage to the front and rear roof rack leg covers, install the cross bar stoppers at each end of the right and left roof rack rails. Applicable Vehicles Warranty Information Installation Procedure S 2008 model year 4Runner vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – 1. Loosen the adjustment knobs on each cross bar joint. NOTE: Do NOT remove adjustment knobs completely. Toyota Supports ASE Certification Page 1 of 3 PRE-DELIVERY SERVICE PD066-07 Title: ROOF RACK CROSS BAR INSTALLATION DURING PDS – PD066-07 Installation Procedure (Continued) June 18, 2007 2. Slide the cross bar ends into the grooves of the right and left roof rack rails with the arrow on each cross bar facing forward. Front NOTE: The cross bars will create wind noise at highway speeds if they are installed backwards. Arrow Mark 3. Align the ends of the front and rear cross bars with the paint marks on the roof rack as illustrated. Then securely tighten the knobs. Front Paint Mark NOTE: Placing the cross bars at the paint marks on the roof rack side rails minimizes wind noise generated by the cross bars. 4. Install the right and left rear roof rack leg covers. A A. Insert the protrusion at the front of the cover into the roof rack rail. B. Place the cover on the leg, aligning each rear end. At this time, do NOT press the cover down. C. Engage the cover claws located toward the outside of the vehicle. D. Engage the cover claws located toward the inside of the vehicle. NOTE: If the inside and outside cover claws are pressed down at the same time, the cover claws may be damaged. E. Check that the cover is installed securely. Page 2 of 3 D Outside Rear C B ROOF RACK CROSS BAR INSTALLATION DURING PDS – PD066-07 Installation Procedure (Continued) 5. Install the cross bar stopper at the front and rear ends of the right and left roof rack rail. June 18, 2007 Front NOTE: Cross bar stoppers are installed to prevent damage caused by interference between the cross bar and the front and rear roof rack leg covers. Cross Bar Stopper Rear Cross Bar Stopper Page 3 of 3 Technical Service BULLETIN June 21, 2007 Introduction 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) Models: ’08 4Runner Pre-Delivery Service is a critical step in satisfying your dealership’s new car customers. Customer feedback indicates the following areas deserve special attention when performing PDS: S Careful inspection for paint chips/scratches and body dents/dings. S Proper operation of electrical accessories (including interior light, clock, and radio reset). S Interior cleanliness. S Proper function of mechanical systems. Customer retention and proper maintenance of vehicles has been a major focus for Toyota. To help remind customers that regular oil changes are essential to the proper maintenance of their vehicle, dealers are required to begin installing a first oil change reminder sticker prior to delivery. By doing this, customers will be reminded to return to your dealership for their first oil change. Your current oil change reminder sticker may be used. (See PDS Check Sheet item G09.) A new PDS form has been developed for the 2008 model year 4Runner. Some check points have been added, expanded, or clarified. TSBs are available for items in bold red type. Warranty Policy If the need for additional repairs or adjustment is noted during the Pre-Delivery Service, the required service should be performed under warranty. Reimbursement will be managed under the warranty policy. The Warranty Policy and Procedures Manual requires that you maintain the completed PDS check sheet in the customer’s file. If you cannot produce a completed form for each retailed vehicle upon TMS and/or Region/Distributor audit, the PDS payment amount will be subject to debit. An additional Repair Order completed in conjunction with normal PDS must have time punch/flags for service. If multiple repairs are performed, separate time flags must be punched for each repair. Reimbursement Information OP CODE DESCRIPTION TIME OFP 001013 Pre-Delivery Service (PDS) 0.9 N/A Toyota Supports ASE Certification T1 T2 N/A N/A Page 1 of 5 PRE-DELIVERY SERVICE PD069-07 Title: 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 2008 Model Year PDS Check Sheet Page 2 of 5 June 21, 2007 TOYOTA 4RUNNER 2008 PRE-DELIVERY SERVICE CHECK SHEET * Inspect or install when equipped or required 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 June 21, 2007 Before Inspection When performing new car Pre-Delivery Service, install Short Pin before moving vehicle from storage lot so that FUNCTIONAL OPERATION checks can begin as soon as vehicle is moved into the service stall. A01 Install Short Pin A02 Initialize driver’s door power window A03 Initialize moon roof* A04 Initialize back door power window Functional Operation Apply parking brake and turn ignition “ON,” place gear selector in reverse, turn on lights and rear defogger. Unlock all doors, release fuel door, release back door. B01 Check dome, courtesy, map, and sun visor lights* B02 Check warning/indicator lights, gauges, and horn B03 Check windshield wipers and washers B04 Check headlights, instrument lights, turn signals, emergency flashers, and brake lights B05 Check inside/outside rear view mirror operation/adjustment B06 Check cigarette lighter* and power outlets Check the power outlets using an electrical accessory designed for this use. B07 Check moon roof* B08 Check audio/navigation*/backup camera* system and set clock* For navigation, set the destination search area to local position. B09 Check Rear Seat Entertainment System operation* B10 Install shift-lock override button cover Walkaround Inspection Starting at the left front door, check window and door lock operation and the operation of all power windows and door locks from master power switch, on vehicles so equipped. While walking around vehicle in a counterclockwise direction, open left rear door and check operation of window regulator and door lock, set child safety door locks to the normal (unlocked) position. Assure tightness of interior garnishes and check seat belts. Inspect luggage compartment contents and lights at rear of vehicle. Repeat checks at right rear door. Inspect right front door window regulator and lock operation and garnishes. Check seat and seat belt operation. Continue on around to the front of the vehicle checking lights. C01 Check window operation C02 Check door and door lock operation, including wireless remote control/theft deterrent system* C03 Check that engine starts with all keys C04 Check that child safety door locks are in normal (unlocked) position C05 Check seats and seat belt operation C06 Check rear defogger C07 Check side marker, tail, backup, and license plate lights C08 Check luggage compartment light* and trim appearance C09 Adjust spare tire pressure and check jack and tool installation C10 Check headlight aim Refer to the Repair Manual for procedures. * Inspect or install when equipped or required Page 3 of 5 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 Under Hood June 21, 2007 D01 Check engine oil and ATM fluid levels D02 Check brake and power steering fluid levels Visually inspect using see-through reservoirs. D03 Check engine coolant level D04 Check battery state-of-charge using Digital Battery System Analyzer Refer to TSB No. PG001-06, “Battery Maintenance for In-Stock Vehicles & Pre-Delivery.” NOTE: Battery SOC should be a minimum of 75%. Please enter the SOC Reading on the space provided on the check sheet and attach the printout to the check sheet. D05 Inspect for fuel, oil, coolant, and other fluid leaks Under Vehicle (On Hoist) E01 Remove disc brake anti-rust covers/anti-corrosion wheel film Visually inspect rotors for rust. NOTE: For best rotor rust prevention, retain wheel film on vehicle until just prior to customer delivery. E02 Inspect tires for defects/damage and adjust tire pressure (including spare tire) The recommended tire inflation pressure changes with tire size, driving conditions, and vehicle model. For precise tire pressure information, refer to the Owner’s Manual and/or tire information label located on the vehicle. Sidewall “Maximum” cold tire inflation pressure should not be used for normal driving. E03 Activate tire pressure monitor E04 Install wheel covers/caps/spare tire wheel covers* E05 Inspect for fuel, oil, coolant, and other fluid leaks Road Test Page 4 of 5 A complete road test helps assure customer satisfaction. Drive vehicle over a variety of road surfaces and driving conditions. Check for unusual noises and driving performance. F01 Check cold engine operation Check starting and fast idle operation performance. F02 Check engine operation during warm-up Check that engine operates smoothly during warm-up. Check for unusual noise, engine vibration, rough idle, etc. F03 Check engine at normal operating temperature Check engine performance over a broad range of driving conditions, including idle quality, acceleration, cruise, and deceleration. F04 Check automatic transmission operation Check automatic transmission operation, including operation in each range, neutral start switch, and shift lock system. F05 Check brake and parking brake operation Check brake function, including unusual noise, parking brake performance, and all related brake system indicator lights. * Inspect or install when equipped or required 2008 MY 4RUNNER PRE-DELIVERY SERVICE (PDS) – PD069-07 June 21, 2007 Road Test (Continued) F06 Check steering operation and off-center/vehicle pull/flutter Check steering function. Check steering off-center/vehicle pull/flutter. F07 Inspect for abnormal noises and vibration F08 Inspect for squeaks and rattles F09 Check heater and A/C operation F10 Check cruise control operation Check cruise control, including On-Off switch, “SET/COAST,” “RESUME/ACCEL,” and “CANCEL” functions. F11 Check front seat heater operation* F12 Set/calibrate compass* F13 Check Rear Height Control Air Suspension* Final Inspection & Cleaning G01 Remove interior protective covers, unnecessary labels, tags, etc. (Remove protective covers just before delivery to the customer) Remove plastic covers from door panels, seats, head restraints, and sun visors, as required. Remove labels, tags, and stickers (except those containing owner information). NOTE: Consumer information labels, such as airbag information warning and bumper information labels, MUST be left on the vehicle until delivery to a retail customer. G02 G03 G04 G05 G06 G07 G08 G09 Visually inspect all interior parts for installation, damage, fit, dirt, etc. Remove Rapgard TM protective film Wash and clean vehicle Inspect paint finish for scratches, chips, rust, dents, damage, etc. Install roof rack cross bars Install receiver towing hitch cap Inspect exterior body parts for proper installation, damage, rust, etc. Place oil change sticker on inside of windshield, top left corner Complete the mileage or date recommendation and apply the oil change reminder sticker to the inside of the windshield, top left corner. You may use your current oil change reminder sticker or order new stickers by calling 1–800–527–6283. G10 Install front and rear license plates * Inspect or install when equipped or required Page 5 of 5 Technical Service BULLETIN March 6, 2007 Introduction Applicable Vehicles Required Tools & Material Repair Procedure DRIVESHAFT ASSEMBLY REPLACEMENT Models: ’90 – ’07 Toyota The purpose of this bulletin is to provide information regarding anti–corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. S 1990 – 2007 model year Toyota vehicles. TOOLS & MATERIAL Toyota Brake Cleaner or Equivalent Non–Residue Solvent PART NUMBER QUANTITY 00289–2BC00 As Needed Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti–corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC003-07 Title: Technical Service BULLETIN March 6, 2007 Introduction Applicable Vehicles Required Tools & Material Repair Procedure DRIVESHAFT ASSEMBLY REPLACEMENT Models: ’04 – ’07 Scion The purpose of this bulletin is to provide information regarding anti–corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. S 2004 – 2007 model year Scion vehicles. TOOLS & MATERIAL Toyota Brake Cleaner or Equivalent Non–Residue Solvent PART NUMBER QUANTITY 00289–2BC00 As Needed Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti–corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC004-07 Title: Technical Service BULLETIN June 28, 2007 Introduction Applicable Vehicles WORLD STANDARD AUTOMATIC TRANSMISSION FLUID Models: ’04 – ’08 Toyota World Standard (WS) Automatic Transmission Fluid (ATF) was introduced to reduce maintenance costs and increase the mileage between scheduled maintenance checks. Here are some important tips when working with ATF-WS in Toyota vehicles requiring its use. S 2004 – 2008 model year Toyota vehicles equipped with automatic transaxle requiring ATF-WS. Required SSTs SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTY DRW** 00002–11100–02 1 – Transmission Fill System* NOTE: All components from this kit/set are required. * Essential SST. ** Drawer number in SST Storage System. NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 TRANSMISSION & CLUTCH TC010-07 Title: WORLD STANDARD AUTOMATIC TRANSMISSION FLUID – TC010-07 Important Information June 28, 2007 S 100,000 Maintenance Interval — Inspection only; ATF-WS does NOT require any flushing or changing during the life of the vehicle. S The use of Genuine Toyota ATF-WS is recommended. S The use of additives or aftermarket fluids that are considered compatible or substitutes may result in shift concerns and damage to the internal transmission components. S ATF-WS is NOT compatible with T-IV or Dexron ATF. S Containers storing Toyota ATF-WS should always be sealed — If exposed to the atmosphere, ATF-WS may absorb moisture and potentially cause shift concerns if used in operation. S One time use only. S When performing repairs on ATF-WS equipped transaxles, it is important to use only new, clean ATF–WS when refilling the ATM. S ATF-WS equipped ATMs may use the overflow type procedure — Any fluid drained from the overflow plug should be discarded following proper local regulations and never reused. Failure to do so could result in shift concerns and damage to the internal transmission components. Page 2 of 2 Technical Service BULLETIN September 1, 2006 AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION Models: All ’06 – ’07 Toyota & Scion TSB REVISION NOTICE: S February 9, 2007: The location arrows have been updated in the illustrations for transmission model U15# (Japan built and TMMWV built). Previous versions of this TSB should be discarded. Introduction The purpose of this TSB is to assist in the identification and location of serial numbers on 2006 – 2007 model year automatic transmissions. NOTE: S Per Toyota Warranty Policy & Procedure Policy 4.23: Whenever a remanufactured or OEM automatic transmission is replaced, the serial number from the back of the failed component must be entered in the “Transmission Serial Number” field, which can be found on the “Additional Information” tab of the warranty claim. S When writing a Product Report, the serial number MUST be provided. S Warranty policy requires shipment of ALL replaced transmissions to AWTEC, even if the transmission is replaced with a new service unit. Applicable Vehicles Warranty Information S 2006 – 2007 model year Toyota and Scion vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 5 TRANSMISSION & CLUTCH TC012-06 Title: AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC012-06 Revised Identification Procedure TRANSMISSION MODEL MODEL MODEL YEAR ENGINE 4Runner 2006 1GR 2UZ Example: 06 A P 0 00001 FJ Cruiser 2007 1GR Land Cruiser 2006 2007 2UZ Sequoia 2006 2UZ Tacoma 2006 1GR 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) P: Transmission Model Code (A750 (A750*)) 0: Plant Code 00001: 5–Digit 5 Digit Serial Number Tundra 2006 1GR 2UZ MODEL MODEL YEAR ENGINE A750E/F TRANSMISSION MODEL September 1, 2006 SERIAL NUMBER Location: Right Rear on Transmission Case Above Transmission Pan (as shown below) SERIAL NUMBER Example: 06 A A 0 00001 U14# RAV4 2006 2AZ 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) A: Transmission Model Code (U14#) 0: Plant Code 00001: 5–Digit Serial Number Location: Slightly Off Center to the Left on Top of Bell Housing of Transmission (as shown below) Page 2 of 5 AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC012-06 Revised Identification Procedure (Continued) TRANSMISSION MODEL MODEL MODEL YEAR ENGINE September 1, 2006 SERIAL NUMBER Example: 06 A L 0 00001 Camry U15# (Japan Built) TRANSMISSION MODEL U15# (TMMWV Built) 2006 2AZ Highlander 2006 2007 3MZ RAV4 2006 2GR MODEL MODEL YEAR ENGINE Avalon 2006 2007 2GR Camry (NAP) 2006 2AZ Sienna 2006 2007 3MZ Solara 2006 2007 2AZ 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) L: Transmission Model Code (U15#) 0: Plant Code 00001: 5–Digit 5 Digit Serial Number Location: Slightly Off Center to the Left on Top of Bell Housing of Transmission (as shown below) SERIAL NUMBER Example: 5 6 01 00001 5: Plant (TMMWV) 6: Year of Manufacture 01 Month 01: M th off M Manufacture f t (J (January)) 00001: 5–Digit Serial Number Location: Slightly Off Center to the Left on Top of Bell Housing of Transmission (as shown below) Page 3 of 5 AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC012-06 Revised Identification Procedure (Continued) TRANSMISSION MODEL MODEL MODEL YEAR ENGINE Corolla 2006 2007 1ZZ Matrix 2007 2ZZ RAV4 2006 2AZ Scion tC 2006 2007 2AZ MODEL MODEL YEAR ENGINE Matrix 2006 1ZZ Scion xA 2006 1NZ Scion xB 2006 1NZ Yaris 2006 1NZ U34# Page 4 of 5 SERIAL NUMBER Example: 06 A B 0 00001 U24# TRANSMISSION MODEL September 1, 2006 06: Year of Manufacture A Month A: M h off M Manufacture f (A – M, “I” not used) B: Transmission Model Code (U24#) 0: Plant Code 00001: 5–Digit g Serial Number Location: Slightly Off Center to the Left on Top of Bell Housing of Transmission (as shown below) SERIAL NUMBER Example: 06 A G 0 00001 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) G T G: Transmission i i M Model d lC Code d (U34#) 0: Plant Code 00001: 5–Digit 5 Digit Serial Number Location: Left Side of Transmission Bell Housing Roughly 3/4 Up (as shown below) AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC012-06 Revised Identification Procedure (Continued) TRANSMISSION MODEL MODEL MODEL YEAR ENGINE September 1, 2006 SERIAL NUMBER Example: 2A 06 GI 00001 U660E Camry 2007 2GR 2: Plant ID (TMH) A: Unit ID (U660E) 06: Year of Manufacture G: Month of Manufacture (A – M, “I” not used) I: Plant Line Number 00001: 5–Digit Serial Number Location: Top of Bell Housing Towards Front of Transmission — Serial Number will be Stamped in Transmission Case (as shown below) Page 5 of 5 September 1, 2006 Introduction REMANUFACTURED AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION Models: All ’06 – ’07 Toyota & Scion The purpose of this TSB is to assist in the identification and location of serial numbers on 2006 – 2007 model year remanufactured automatic transmissions. NOTE: S Per Toyota Warranty Policy & Procedure Policy 4.23: Whenever a remanufactured or OEM automatic transmission is replaced, the serial number from the back of the failed component must be entered in the “Transmission Serial Number” field, which can be found on the “Additional Information” tab of the warranty claim. S When writing a Product Report, the serial number MUST be provided. S Warranty policy requires shipment of ALL replaced transmissions to AWTEC, even if the transmission is replaced with a new service unit. Applicable Vehicles Warranty Information S 2006 – 2007 model year Toyota and Scion vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 4 TRANSMISSION & CLUTCH Technical Service BULLETIN TC013-06 Title: REMANUFACTURED AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC013-06 Identification Procedure September 1, 2006 NOTE: Serial numbers on remanufactured transmissions are highlighted with paint. TRANSMISSION MODEL MODEL MODEL YEAR ENGINE 4Runner 2006 1GR 2UZ FJ Cruiser 2007 1GR Land Cruiser 2006 2007 2UZ Sequoia 2006 2UZ Tacoma 2006 1GR Tundra 2006 1GR 2UZ MODEL MODEL YEAR ENGINE A750E/F TRANSMISSION MODEL SERIAL NUMBER Example: 06 A P 0001 A 06: Year 06 Y off M Manufacture f t A: Month of Manufacture (A – M, “I” not used) P: Transmission Model Code 0001: 4–Digit Serial Number A: Remanufactured Service Digit Location: Right Rear on Transmission Case in Front of Tail Shaft Flange (as shown below) SERIAL NUMBER Example: 06 A A 0001 A U14# RAV4 2006 2AZ 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) A: Transmission Model Code (U140#) 0001: 4–Digit Serial Number A: Remanufactured Service Digit Location: Slightly Off Center to the Right on Top of Bell Housing of Transmission (as shown below) Page 2 of 4 REMANUFACTURED AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC013-06 Identification Procedure (Continued) TRANSMISSION MODEL U15# TRANSMISSION MODEL MODEL MODEL YEAR ENGINE Avalon 2006 2007 2GR Camry 2006 2AZ Highlander 2006 2007 3MZ RAV4 2006 2GR Solara 2006 2007 2AZ MODEL MODEL YEAR ENGINE Corolla 2006 2007 1ZZ Matrix 2007 2ZZ RAV4 2006 2AZ Scion tC 2006 2007 2AZ September 1, 2006 SERIAL NUMBER Example: 06 A L 0001 A 06: Year of Manufacture A: Month of Manufacture (A – M, M “I” not used) L: Transmission Model Code (U15##) 0001: 4–Digit g Serial Number A: Remanufactured Service Digit Location: Slightly Off Center to the Right on Top of Bell Housing of Transmission (as shown below) SERIAL NUMBER Example: 06 A B 0001 A U24# 06: Year of Manufacture A: Month of Manufacture (A ( – M, “I” not used)) B T B: Transmission i i M Model d lC Code d 0001: 4–Digit Serial Number A: Remanufactured Service Digit Location: Slightly Off Center to the Rear of Transmission (as shown below) Page 3 of 4 REMANUFACTURED AUTOMATIC TRANSMISSION SERIAL NUMBER LOCATION – TC013-06 Identification Procedure (Continued) TRANSMISSION MODEL MODEL MODEL YEAR ENGINE Matrix 2006 1ZZ Scion xA 2006 Scion xB 2006 Yaris 2006 SERIAL NUMBER Example: 06 A G 0001 A 06: Year of Manufacture A: Month of Manufacture (A – M, “I” not used) G T G: Transmission i i M Model d lC Code d 0001: 4–Digit Serial Number A: Remanufactured Service Digit U34# Page 4 of 4 September 1, 2006 1NZ Location: Top Canter of Transmission Bell Housing on Case Rim (as shown below) Technical Service BULLETIN REPLACEMENT VIN PLATES Models: All Toyota Models November 20, 2007 TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG009–02. TSB No. PG009–02 is now obsolete and should be discarded. The changes will take place January 1, 2008. Introduction Replacement VIN plates (metal plates riveted to dashboard) may be available from Toyota providing the request meets the criteria listed in this TSB. VIN Plate Location Applicable Vehicles Warranty Information S All Toyota vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRODUCT GENERAL INFORMATION PG007-07 Title: REPLACEMENT VIN PLATES – PG007-07 Replacement VIN Plate Criteria November 20, 2007 A replacement VIN plate may be requested ONLY if: S The vehicle is in an accident and the VIN plate is damaged. S The vehicle was stolen and the VIN plate is damaged but still available. NOTE: S The original VIN plate being replaced MUST accompany the request. S If the VIN plate is stolen, be sure to contact the State Police or your State’s Department of Motor Vehicles (DMV). In most cases, the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement VIN plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims. Procurement Procedure To request a replacement VIN plate, complete a copy of the form at the end of this bulletin. Note that the damaged VIN plate MUST accompany the request form. Your dealer parts account will be billed $40.00 for each replacement of a damaged VIN plate. NOTE: All replacement VIN plates are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Page 2 of 3 REPLACEMENT VIN PLATES – PG007-07 November 20, 2007 APPLICATION FOR REPLACEMENT VIN PLATE REASON FOR REPLACEMENT ACCIDENT DAMAGE OTHER REASON/EXPLANATION PLEASE PROVIDE CORRECT VIN ATTACH DAMAGED PLATE HERE NOTE: S The original VIN plate being replaced MUST accompany the request. S If a VIN plate is stolen, be sure to contact the State Police or your State’s Department of Motor Vehicles (DMV). In most cases the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement VIN plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims. S Your dealer parts account will be billed $40.00 for the replacement VIN plate. DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME DEPT. MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD VIN PLATE TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA. 90509–2991 Page 3 of 3 Technical Service BULLETIN August 6, 2007 Introduction SRS COMPONENT DISPOSAL AS HAZARDOUS MATERIAL TREATMENT Models: ’98 – ’08 Toyota (SRS–Equipped) Some hazardous material treatment and handling regulations at the state and local level now define the pre–disposal deployment of airbag and pre–tensioner assemblies as hazardous material treatment. Hazardous material treatment may require special training, certification or licensing in certain areas. TMS recommends dealership personnel carefully review and follow all local and state regulations and, where necessary, contract with Environmental Protection Agency (EPA) Licensed Hazardous Waste Transportation and Disposal facilities. TMS no longer recommends the manual deployment of SRS components as a general practice method of disposal. Employment of an EPA Licensed Hazardous Waste Transportation and Disposal contractor is encouraged. Reasons for the change in practice: S Previously, deployed SRS components were considered to be non–hazardous waste and airbag deployment was an acceptable practice when performed safely by properly equipped service facilities. S The EPA has deferred the responsibility of determining if airbags, deployed or un–deployed, constitute hazardous waste to the discretion of each state. S Within the past several years, a number of states have ruled the deployment of airbags to be considered treatment of hazardous waste, requiring practicing dealerships to obtain a HAZMAT treatment facility permit. S Airbag disposal practices and protocols vary from state to state and are continuously evolving. For information on local regulations, contacts for EPA Licensed Hazardous Waste Transportation and Disposal providers, an up–to–date list of states that require “waste treatment permits” for SRS component deployment, as well as more information about airbag recycling opportunities, please consult the Environmental Assistance Network (EAN). website http://www.ccar-greenlink.org/tms and enter the keywords “airbag disposal”. Applicable Vehicles Warranty Information S 1998 – 2008 model year Toyota vehicles equipped with SRS. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 SPECIAL SERVICE TOOLS SS004-07 Title: SRS COMPONENT DISPOSAL AS HAZARDOUS MATERIAL TREATMENT – SS004-07 Repair Manual Changes Special Service Tools Toyota service publications explain in detail the procedures for pre–disposal deployment of airbag and pre–tensioner assemblies. These practices should ONLY be used by EPA Licensed Hazardous Waste Transportation and Disposal facilities or dealership technicians IF allowable by local/state regulation. All future service publications will include additional cautions advising dealership associates to review and abide by all applicable regulations prior to performing any pre–disposal deployment or disposal activity. Special Service Tools (SSTs) for airbag and pre–tensioner deployment are no longer classified as essential SSTs. These tools will continue to be available through the SST program for dealerships choosing to continue airbag deployment in compliance with state and local governance. Refer to the following table for a list of current pre–disposal deployment SSTs and applications. COMPONENT NAME PART NUMBER APPLICATION 09082–00705–01 Tool kit containing SSTs listed below Airbag Deployment Tool 09082–00700 Airbag ignition source/ triggering device Seat Belt Pretensioner Wire 09082–00740 Connects deployment tool to seat belt pretensioner assembly Side Airbag Deployment Wire 09082–00750 Connects deployment tool to side airbag assembly Driver/Passenger Deployment Wire 09082–00760 Airbag Deployment Wire Sub–Harness #5 09082–00770 Airbag Deployment Wire Sub–Harness #6 09082–00780 Wire “A” 09082–10801 Wire “B” 09082–20801 Wire “C” 09082–30801 Airbag Deployment Tool Kit Connects deployment tool to airbag assembly NOTE: SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Page 2 of 2 August 6, 2007 Technical Service BULLETIN July 31, 2007 Introduction AUTOMATIC TRANSMISSION SHIPPING BAG FOR WARRANTY RECOVERY Models: ’91 – ’08 Toyota (w/ATM) The automatic transmission shipping bag is available from the Material Distribution Center (MDC) to assist in sealing an automatic transmission from leaking during shipping. This bag is primarily intended to be used when shipping ATMs for which plastic shipping containers are not yet available. This TSB contains ATM bag ordering and shipping information. NOTE: If an automatic transmission leaks while being shipped, it may be returned to sender. S 1991 – 2008 model year Toyota vehicles equipped with automatic transmission. Applicable Vehicles Parts Information * Ordering Information MDC MATERIAL NUMBER PART NAME QTY COST 00108–01090 ATM Poly Bag Box Liner for Warranty Recovery 1* $0.00 Five bags in each. Maximum quantity is 1 five–pack per order. 1. Go to Dealer Daily. 2. Click on the Parts link. 3. Click on the Dealer Support Materials Catalog link. The ATM bag is located on page 25 of the catalog. 4. To order ATM shipping bags, follow the information on Form 1450 (available on page 13). Shipping Information Warranty Information IMPORTANT SHIPPING HINTS: S When shipping a transmission or transaxle, ensure as much fluid as possible is drained from the transmission and torque converter. S Clean the remaining fluid off of the case. S Ensure the torque converter hold–down strap is securely installed. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC012-07 Title: Technical Service BULLETIN October 23, 2007 Introduction EXTERIOR COLOR AND SCRATCH RESISTANT AND ANTI-ACID PAINT Models: ’07 All Models Most colors on Toyota vehicles sold in the U.S. use a combination of scratch resistant and/or acid rain resistant exterior (body color) paint finishes. These types of finishes provide improved resistance to minor scratching and acid rain. This bulletin outlines the precautions that should be taken when polishing or refinishing anti–scratch automotive type paint surfaces. The repair of acid rain damaged paint surfaces is explained in TSB No. BO020–91, “Prevention and Repair of Acid Rain Damage”. Applicable Vehicles Warranty Information S 2007 model year Toyota vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 4 PAINT PA003-07 Title: EXTERIOR COLOR AND SCRATCH RESISTANT AND ANTI–ACID PAINT – PA003-07 Paint Application MODEL PLANT 4Runner TMC Avalon TMMK TMMK Camry TMC NUMMI & TMMC Corolla TMC FJ Cruiser TMC Highlander TMC SCRATCH RESISTANT PAINT ANTI–ACID PAINT All Except 056 All Except 056 All Colors All Colors 056 1D4 1E9 1F4 202 3Q3 070 1D4 1E3 202 3Q7 4Q2 6UO 8P4 8R5 – – – 040 1D4 1G3 202 3R3 4Q2 All Except 040 All Except 040 6U6 776 8S4 8T5 – – All Colors All Colors 040 1D4 1G3 202 3R3 4Q2 All Except 040 All Except 040 6U6 776 8S4 8T5 – – All Colors All Colors 040 1E3 1E7 209 3P1 4Q2 All Except 040 All Except 040 775 8P4 – – – – All Colors All Colors 040 1E3 1E7 209 3P1 775 All Except 040 All Except 040 8P4 – – – – – All Colors All Colors – Only 1D4, 3P2, 5A3, 8T6, 211 Only 1D4, 3P2, 5A3, 8T6, 211 All Exce Exceptt 040 All Exce Exceptt 040 All Colors All Colors 2JR 2JT 2JU 2JV 2JW (058/ (058/ (058/ (058/ (058/ 1D4) 3P2) 5A3) 8T6) 211) 040 1C0 4R3 6T5 8N6 8P4 202 3Q3 – – – – Highlander g 040 1C0 202 4R3 6T5 8N6 HV – – – – – – 056 1D2 1E9 1F7 202 3Q2 All Except 056 All Except 056 4R3 8R3 – – – – All Colors All Colors 040 1E3 1E7 209 3L5 8P1 All Except 040 All Except 040 8P4 8Q5 – – – – All Colors All Colors 040 1F7 1G3 202 3R3 4S2 All Except 040 All Except 040 6UO 8S2 – – – – All Colors All Colors 040 070 1E0 1F7 202 3R3 All Except 040 All Except 040 4R4 6T6 8R3 8S6 – – All Colors All Colors 040 071 1D6 1F9 202 3Q7 All Except 040 All Colors 4Q2 4T3 6T8 8S6 – – All Colors All Colors 056 071 1D7 1F9 3Q3 4Q2 All Except 056 All Except 056 6UO 8R5 8S6 – – – All Colors All Colors TMC Land Cruiser Matrix Prius RAV4 Sequoia Sienna Page 2 of 4 EXTERIOR COLOR AVAILABILITY October 23, 2007 TMMC TMC TMC TMMI TMMI EXTERIOR COLOR AND SCRATCH RESISTANT AND ANTI–ACID PAINT – PA003-07 Paint Application (Continued) MODEL PLANT Solara TMMK SCRATCH RESISTANT PAINT ANTI–ACID PAINT All Colors All Colors 070 1D4 1G3 202 3P0 8Q5 8T7 – – – – – 040 1E7 209 3L5 3P1 4Q2 All Except 040 All Except 040 Deck 8P1 8P4 – – – – All Colors All Colors Cab 040 1E7 209 3L5 3P1 4Q2 All Except 040 All Except 040 8P1 8P4 – – – – All Colors All Colors TMMTX 040 1D6 1F9 202 3L5 3Q3 All Except 040 All Colors TMMI 4Q2 4T3 6T8 8S6 8T9 – All Colors All Colors 068 1E7 1F8 209 3P0 4S9 All Except 068 All Except 068 6S3 8P4 8T0 8T1 – – All Colors All Colors 068 1E0 1E7 209 3R3 6U4 All Except 068 All Except 068 777 8R3 8S6 – – – All Colors All Colors Cab Tacoma EXTERIOR COLOR AVAILABILITY October 23, 2007 TMMBC NUMMI Deck Tundra Yaris TMC Yaris Hatchback Page 3 of 4 EXTERIOR COLOR AND SCRATCH RESISTANT AND ANTI–ACID PAINT – PA003-07 Polishing Tips October 23, 2007 Polishing Tips for Anti–Scratch Finishes: Since this type of paint technology is meant to resist scratching, it is important to understand that sanding and polishing to remove scratches is quite difficult and will require significantly more time to finesse the paint surface to achieve an acceptable appearance. S Use an ultra–fine grit sandpaper to remove scratches. S Soak sandpaper in soapy water for at least one hour (overnight preferred) prior to sanding the paint surface (this will reduce the possibility of rescratching the paint surface). S Use polishing compounds and materials specifically designed to be used with clearcoated urethane paint finishes. Refinish Recommendations: NOTE: To improve appearance and durability of the refinished paint surface, it is recommended that a clearcoat be used when refinishing color 202 (non–metallic black). All metallic and pearl coat finishes MUST be clearcoated. Please refer to the specific refinish recommendations issued by the paint manufacturer used by the body/paint shop. Refinish materials providing similar scratch resistant qualities to that of the original factory finish have been developed by the refinish paint suppliers in the U.S. Please contact your refinish supplier for a list of appropriate refinish materials as well as specific refinish instructions. Page 4 of 4 Technical Service BULLETIN REPLACEMENT CERTIFICATION LABELS Models: All Toyota Models November 20, 2007 TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG008–02. TSB No. PG008–02 is now obsolete and should be discarded. The changes will take place January 1, 2008. Introduction Replacement Certification Labels (vinyl label affixed to driver’s door or door post) may be available from Toyota providing the request meets one of the criteria listed in this TSB. Certification Label Location MFD.BY:TOYOTA MOTOR MANUFACTURING, KENTUCKY, INC. 06/07 GVWR 4345LB GAWR FR 2668LB RR 2359LB THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY, BUMPER, AND THEFT PREVENTION STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. 4T0XX00X0X000000 PASS.CAR C/TR:8S4/FB13 ACV40L CEANKA A/TM: 03A/U250E Applicable Vehicles Warranty Information 64393 S All Toyota vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRODUCT GENERAL INFORMATION PG008-07 Title: REPLACEMENT CERTIFICATION LABELS – PG008-07 Certification Label Criteria November 20, 2007 A replacement certification label may be requested if: S The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair. S The label is stolen. NOTE: S Processing of a replacement label will be delayed if the original (or copy/picture) certification label does NOT accompany the request. S A replacement label MAY NOT be available if the vehicle is more than 5 years old. Procurement Procedure To request a replacement label, complete a copy of the form at the end of this bulletin. Your dealer parts account will be billed $40.00 for each replacement of a damaged or stolen label. NOTE: All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Page 2 of 3 REPLACEMENT CERTIFICATION LABELS – PG008-07 November 20, 2007 APPLICATION FOR REPLACEMENT CERTIFICATION LABEL REASON FOR REPLACEMENT ACCIDENT DAMAGE STOLEN OTHER REASON/EXPLANATION ATTACH ORIGINAL LABEL HERE PLEASE PROVIDE CORRECT VIN NOTE: S Processing of a replacement label will be delayed if the original (or copy/picture) certification label does NOT accompany the request. S A replacement label MAY NOT be available if the vehicle is more than 5 years old. S Your dealer parts account will be billed $40.00 for the replacement label. DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME DEPT. MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD LABEL TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA 90509–2991 Page 3 of 3 Technical Service BULLETIN August 11, 2007 Introduction ABSORBED GLASS MAT (AGM) BATTERY INFORMATION Models: ’01 – ’08 Toyota This TSB provides background on the differences and similarities between AGM (Absorbed–electrolyte Glass Mat) batteries and flooded lead acid batteries. It also explains charging procedures performed by the GR8 Battery Diagnostic Station (SST P/N 00002–MCGR8) and its ability to charge AGM batteries at higher current levels then a standard battery charger. S 2001 – 2008 model year Toyota vehicles equipped with an AGM battery. Applicable Vehicles Required Tools & Equipment SPECIAL SERVICE TOOLS (SSTs) GR8 Battery Diagnostic Station* * SUPPLIER PART NUMBER QTY SPX/OTC 00002–MCGR8 1 Essential SSTs. NOTE: The GR8 Battery Diagnostic Station (P/N 00002–MCGR8) supersedes the Automatic Trickle Charger (P/N 00002–YA122–01) and Fast Battery Chargers (Associated P/N ASE6003 and Christie P/N CAPPDQ). P/N 00002–YA122–01, ASE6003, and CAPPDQ are now obsolete. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 SPECIAL SERVICE TOOLS SS006-07 Title: ABSORBED GLASS MAT (AGM) BATTERY INFORMATION – SS006-07 Battery Comparison August 11, 2007 Differences between AGM and flooded lead acid batteries: S AGM batteries have thin, sponge–like, glass mat separators that absorb all liquid electrolytes. S Flooded lead acid batteries have free, liquid electrolyte all around the plates and separators. S Flooded lead acid batteries can easily release gas that is formed during a charge, while AGM battery life is diminished if gas is formed during charging. Similarities between AGM and flooded lead acid batteries: S Both share the exact same lead acid chemistry. S Both share the same charge and discharge principles. S Both are safely charged by vehicle charging systems. S When discharged, both can be recharged at high current levels. Battery Charging Information Damage to AGM batteries becomes an issue when the charge rate is NOT monitored and controlled by the charger (i.e., quick chargers). The performance of an AGM battery can be irreversibly reduced if the charge rate remains too high, allowing the battery to overheat and vent. Once an AGM battery loses water (venting), the glass mats will become dry, causing the battery to lose conductance, power, and performance. In most vehicle charging systems, the alternator limits the charging rate by limiting the output voltage (about 14.4V). For example, an AGM battery may be observed charging at 60A and 13.5V. As the battery recharges, the charging voltage will increase from 13.5V to approximately 14.4V (voltage will vary based on temperature, control sophistication, etc.), and the current will decrease from 60A to about 0A. The charging system voltage regulators prevent both AGM and flooded lead acid batteries from being overcharged and venting. By controlling the voltage, the charging rate (current) can be controlled. The discontinued Special Service Tool (SST) Automatic Trickle Charger (SST P/N 00002–YA122–01) maintained a manual charging limit of 10A to accomplish a safe recharge rate for AGM batteries. This low amp charge was low enough to prevent the AGM battery from overheating and venting since the charger had no way of monitoring battery temperature/condition. The GR8 Battery Diagnostic Station (SST P/N 00002–MCGR8) is a customized diagnostic fast charger that monitors battery temperature/conditions and contains custom charging rates for ALL model batteries used for Toyota and Scion vehicles. As such, it safely charges good batteries as fast as possible to a point where they can be returned to service and eliminates wasted charging time by quickly diagnosing bad batteries. Page 2 of 3 ABSORBED GLASS MAT (AGM) BATTERY INFORMATION – SS006-07 Battery Charging Information (Continued) August 11, 2007 Based on the characteristics and performance measures of each individual battery (i.e., custom charging rate), the GR8 Battery Diagnostic Station will apply the fastest charging rate that is safe for that particular battery. S When the GR8 Battery Diagnostic Station performance measurements indicate that an AGM battery qualifies for fast–charging, it will be charged at whatever current level it will accept, but the charging voltage will be controlled so that it does NOT exceed 14.4V, and the battery temperature will NOT exceed 135°F (57°C). S When the GR8 Battery Diagnostic Station performance measurements indicate that an AGM battery does NOT qualify for fast–charging, the charge session will only continue if the battery qualifies for “Recovery” mode (part of which means, NO defects or other serious performance issues were found). It is recommended that ALL Toyota and Scion vehicle batteries be charged using the GR8 Battery Diagnostic Station. NOTE: S NEVER connect the GR8 Battery Diagnostic Station to remote battery terminals. S ALWAYS connect the GR8 Battery Diagnostic Station DIRECTLY to the vehicle battery. For assistance on charging procedures, refer to the GR8 Instruction Manual or TSB No. PG001–06, “Battery Maintenance for In–Stock Vehicles & Pre–Delivery”. The GR8 Instruction Manual can be found on the Technical Information System (TIS), Diagnostics – Battery – “GR8 Instruction Manual”. Page 3 of 3 March 25, 2008 T-SB-0020-08 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability YEAR(S) MODEL(S) 1998 – 2009 4Runner, Avalon, Camry, Camry HV, Corolla, FJ Cruiser, Highlander, Highlander HV, Land Cruiser, Matrix, Prius, RAV4, Sequoia, Sienna, Solara, Tacoma, Tundra ADDITIONAL INFORMATION Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – © 2008 Toyota Motor Sales, USA Page 1 of 2 Page 2 of 2 March 25, 2008 T-SB-0020-08 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Required Tools & Equipment REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY ADE TSPKG1 1 TIS techstream* NOTE: Software version 2.20.015 or later is required. * Essential SST. NOTE • Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787. • The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: • Wheel alignment has been adjusted. • Any chassis components have been removed/installed or replaced. Repair Procedure 1. Disconnect the cable from the negative (–) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (–) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window, sunroof, power lift door, etc.). © 2008 Toyota Motor Sales, USA SEAT BELT EXTENDER Technical Service BULLETIN Models: ’08 Toyota & Scion March 12, 2008 Introduction Toyota and Scion customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. Seat Belt S The extender is available in 6-inch, 9-inch, 12-inch, 15-inch, and 18-inch lengths. S The extender is available only in black. Extender S Owners are informed of the Seat Belt Extender availability through the Toyota Owner’s Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota or Scion dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place an order through Dealer Daily. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label on the part and review the “Owner Instructions” (page 7) with the customer. The dealership should give a copy of the completed worksheet and Owner Instructions to the customer and keep the originals in the customer’s file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label . . . . . . . . . . Page 2 Application Charts . . . . . . . . . . . . . . . . . . . . Pages 3 – 5 Part Number Information . . . . . . . . . . . . . . Page 6 Owner Instructions . . . . . . . . . . . . . . . . . . . Page 7 Seat Belt Extender Worksheet . . . . . . . . . Page 8 Applicable Vehicles Warranty Information S 2008 model year Toyota and Scion vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 8 BODY BO001-08 Title: SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Procedure March 12, 2008 1. Customer requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the worksheet. 3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places an order for the part through Dealer Daily. 4. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed worksheet. 6. Dealer places copy of the completed worksheet in the customer’s records. DEALER MEASURE CUSTOMER & COMPLETE WORKSHEET PLACE ORDER THROUGH DEALER DAILY PARTS SUPPLY SHIP SEAT BELT EXTENDER TO DEALER DEALER TEST FIT CUSTOMER WITH PART COMPLETE LABEL AND ADVISE CUSTOMER OWNER RECEIVE COPY OF WORKSHEET & USE OF EXTENDER FILE WORKSHEET IN CUSTOMER RECORDS Sample Seat Belt Extender Customer Information Label CAUTION THIS SEAT BELT EXTENDER IS TO BE USED ONLY BY: ON VEHICLE: VIN: SEATING POSITION: USE BY OTHERS, OR IN ANOTHER SEATING POSITION, OR IN ANOTHER VEHICLE COULD REDUCE SEAT BELT RESTRAINT IN AN ACCIDENT AND RESULT IN PERSONAL INJURY. Page 2 of 8 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Sienna Front Seat Belt Extender Applications Sienna Rear Seat Belt Extender Applications March 12, 2008 FRONT SEAT — EXTENDER APPLICATION MODEL TYPE 2008 Sienna All Models R–8 REAR SEAT — EXTENDER APPLICATION MODEL Sienna TYPE 2008 Rear Seat 2nd Row RH – 7 Passengers Q–6 Rear Seat 2nd Row RH – 8 Passengers R–8 Rear Seat 2nd Row LH R–8 Rear Seat 2nd Row & 3rd Row Center Seat Rear Seat 3rd Row Right/Left Side Q–6 R–8 Example of 2008 MY Sienna 8 Passengers R–8 R–8 R–8 Q–6 Q–6 R–8 R–8 R–8 7 Passengers R–8 Q–6 R–8 Q–6 R–8 R–8 R–8 Page 3 of 8 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Front Seat Belt Extender Applications March 12, 2008 TOYOTA FRONT SEAT — EXTENDER APPLICATION MODEL TYPE 2008 4Runner K–6 Avalon K–6 Camry R–8 Camry HV R–8 Corolla R–8 FJ Cruiser K–6 Highlander Highlander HV R–8 All Models R–8 Land Cruiser R–8 Matrix R–8 Prius R–8 RAV4 R–8 Sequoia R–8 Solara R–8 Tacoma Tundra Yaris Bench Type Front Seat R–7 Separate Type Front Seat R–8 All models R–8 K–6 SCION FRONT SEAT — EXTENDER APPLICATION MODEL TYPE Scion tC Scion xB Scion xD Page 4 of 8 2008 K–6 All Models R–8 K–6 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Rear Seat Belt Extender Applications March 12, 2008 TOYOTA REAR SEAT — EXTENDER APPLICATION MODEL 4Runner TYPE 2008 Without 3rd Row Seat R–8 With 3rd Row Seat K–5 Avalon T–1 Camry R–8 Camry HV R–8 Corolla R–8 FJ Cruiser R–8 Highlander R–8 Highlander HV R–8 All Models Land Cruiser K–7, (K–8*3) Matrix T–1 Prius R–8 RAV4 R–8 Sequoia*2 R–8 Solara R–8 Tacoma Tundra Yaris Access Cab T–1 Double Cab T–1 CrewMax R–8 Double Cab R–8 All Models R–8 *2 An extender may not be used for the center rear seatbelt except for Sienna and Land Cruiser. *3 Middle seat position for 2nd and 3rd row seats. SCION REAR SEAT — EXTENDER APPLICATION MODEL TYPE Scion tC Scion xB 2008 K–5 All Models Scion xD K–5 K–5 NOTE: A seat belt extender must NOT be used for the center rear seat belt. Page 5 of 8 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Part Number Information PART NUMBER PREFIX: 73399– SERIES Page 6 of 8 March 12, 2008 LENGTH 6 INCH 9 INCH 12 INCH 15 INCH 18 INCH K–5 –35010 –35020 –35030 –35040 –35050 K–6 –35060 –35070 –35080 –35090 –35100 K–7 –60010 –60020 –60030 –60040 –60050 K–8 –60060 –60070 –60080 –60090 –60100 Q–6 –AE061 –AE071 –AE081 –AE091 –AE101 R–7 –48010 –48020 –48030 –48040 –48050 R–8 –50060 –50070 –50080 –50090 –50100 T–1 –01110 –01120 –01130 –01140 –01150 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 Owner Instructions March 12, 2008 Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota or Scion dealer free of charge. Please visit your local Toyota or Scion dealer so that the dealer can order the proper required length extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota or Scion dealer. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons of the extender and the seat belt are both facing outward as shown. Seat Belt Release You will hear a click when the tab locks into the buckle. When not in use, remove the extender and store in the vehicle for future use. Seat Belt Extender Buckle CAUTION: On vehicles equipped with SRS – Occupant Classification System (OCS)*, it is critical that the extender tab be buckled into the buckle AFTER the occupant sits down in the seat. Leaving extender installed in the buckle before sitting down will cause the OCS to be in the “airbag off” or disarmed state. * OCS will enable or disable the passenger front and side airbags based on passenger weight and seat belt latch position classifying the passenger as a child or adult. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S NEVER use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. S The Seat Belt Extender must never be used with any child safety seats. S Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. Page 7 of 8 SEAT BELT EXTENDER: ’08 TOYOTA & SCION – BO001-08 March 12, 2008 SEAT BELT EXTENDER WORKSHEET PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED CAUTION: S To minimize the chance and/or severity of injury in an accident, the Seat Belt Extender must only be used: 1 By the person for whom it was provided. 2 In the seat position for which it was provided. S The Seat Belt Extender must never be used with any child safety seats. S When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use. DEALER DEALER CODE SEAT BELT EXTENDER APPLICATION DEALER NAME APPLICANT APPLICANT NAME ADDRESS ADDRESS CITY & STATE EMPLOYEE NAME MODEL YEAR ZIP CITY & STATE BODY TYPE SEATING POSITION ZIP PHONE VEHICLE IDENTIFICATION NUMBER DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH 1. 2. Place the seat in the position the applicant normally uses. With the applicant in the seat, wearing the thickest coat expected to be worn, pull belt all the way out and try to buckle belt. S If belt latches into buckle and feels comfortable against upper chest area, an extender is not needed. S If belt does not buckle, continue with Step 3. S If buckle latches but belt has no slack remaining, continue with Step 3. 3. Measure distance between applicant’s navel and seat belt buckle (Dimension A) and enter on Worksheet. 4. With belt all the way out, measure distance between latch tip and buckle tip (Dimension B) and enter on Worksheet. NOTE: If belt latches but there is no slack enter zero as Dimension B. 5. Subtract Dimension B from Dimension A and record number in Check Number box on Worksheet. 6. Seat Belt Extender length is Dimension B rounded up to next extender length (without exceeding Check Number). NOTE: If extender length exceeds Check Number, an extender cannot be provided to the customer. CAUTION: On vehicles equipped with SRS – Occupant Classification System (OCS), it is critical that the extender tab be buckled into the buckle AFTER the occupant sits down in the seat. Leaving extender installed in the buckle before sitting down will cause the OCS to be in the “airbag off” or disarmed state. Dimension A: NAVEL TO BUCKLE Buckle Navel Dimension B: LATCH TO BUCKLE Latch A B Buckle SEAT BELT EXTENDER CALCULATION DIMENSION A: DIMENSION B: CHECK NUMBER: SEAT BELT EXTENDER AUTHORIZATION S The same Seat Belt Extender can be used for right and left seating applications. Each Seat Belt Extender will have a label identifying the owner, VIN and seating position. S Applicant’s Signature: Date: (Actual user of Seat Belt Extender) Page 8 of 8 Technical Service BULLETIN January 19, 2008 Introduction REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE Models: ’08 Toyota This bulletin contains general vehicle pulling diagnosis and repair procedures along with specific information to help correct pulling complaints. This information supplements Repair Manual procedures for the following symptoms: S When the driver holds the steering wheel without exerting steering effort while driving straight ahead, the vehicle drifts to the right or the left. S While driving straight ahead, the driver has to steer either to the right or the left to maintain straight driving. Applicable Vehicles Warranty Information S 2008 model year Toyota vehicles. OP CODE DESCRIPTION TIME 044184 Preliminary Check & Road Test 0.6 Combo A Switch Front Tire/Wheel & Road Test 0.5 Combo B Reverse the Front One Side Tire 0.7 Combo C Check Front Wheel Alignment 1.2 Combo D Adjust Front Wheel Alignment 0.7 Combo E Adjust Camber Setting 0.7 420091 Dismount and Mount Tire and Balance Wheel and Tire Assembly 0.5 Each additional Wheel 0.3 Combo A OFP T1 T2 45046 09020 45046–09020 31 99 42611–08010 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 12 months or 20,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 11 SUSPENSION SU001-08 Title: REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Contents January 19, 2008 This bulletin is divided into the following sections: Wheel Alignment and Tire Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 3–4 Repair Procedure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5 Repair Procedures 1. Important Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 6–7 3. Vehicle Pulling Caused by Wheel Alignment . . . . . . . . . . . . . . . . . Pages 7–8 4. Vehicle Pulling Caused by Tire Conicity . . . . . . . . . . . . . . . . . . . . . Pages 8–10 5. Camber Adjustment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 10–11 Page 2 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Wheel Alignment & Tire Characteristics January 19, 2008 1. Relationship Between Wheel Alignment and Vehicle Pulling When the cross camber or caster of the front wheel alignment is large, it can cause vehicle pulling. WHEEL ALIGNMENT DIRECTION OF VEHICLE PULLING Camber Vehicle pulls in direction of wheel with large camber value Caster Vehicle pulls in direction of wheel with small caster value CAMBER Straight-Ahead Driving CASTER Direction of Pull Front P’ T’ P T a’ a Caster Trail (Large) Caster Trail (Small) O F O’ F’ P, P’: Driving Force a, a’: Steering Axes O, O’: Center of Tire-Road Contact Area F, F’: Reactive Force If the cross camber or caster is within the specified range (30’ or less), noticeable vehicle pulling will not occur due to side-to-side differences in camber or caster. NOTE: On a flat road, if the cross camber or caster is 30’ or less and the steering wheel is held without exerting steering effort for 109 yards (100 m) when driving at 62 mph (100 km/h), the alignment-induced drift distance is approximately 1.64 ft (0.5 m). Page 3 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Wheel Alignment & Tire Characteristics (Continued) January 19, 2008 2. Relationship Between Tire Characteristics and Vehicle Pulling to One Side When radial tires are rotating, they have the characteristic of generating lateral force between the tire and the road surface. This lateral force is comprised of two factors: S Ply-steer, which changes direction according to the rotation direction of the tires. S Conicity, which is generated in a fixed direction regardless of the tire rotation direction. If these lateral forces are too strong, vehicle pulling will occur. A. Ply–Steer Lateral force due to ply-steer is produced by the construction of the belts inside the tire tread. With radial tires, the wire of the belt is slanted as shown in the illustration below. Thus, it is in this direction that tire tread easily changes shape (stretches), and lateral force is generated between the tire and the road surface. Rotation Direction Easily–Stretched Direction Wire Ply–Steer (Direction of Force Generation Varies According to Tire Rotation) Belt NOTE: Lateral force from ply-steer prevents vehicle drift caused by road slant, so in many cases lateral force to the left is provided to prevent or minimize vehicle drift. B. Conicity Conicity is lateral force resulting from uneven formation of the left and right sides of the tire. The direction the lateral force is exerted depends on the hardness of the side walls and the difference in height between the left/right sides of the tire. Hard Part Conicity (Direction Is Fixed Regardless of Direction of Tire Rotation) NOTE: S In the case of vehicle pulling caused by tires, the lateral force which is exerted as a result of conicity has the greatest effect. On a flat road, if the steering wheel is held without exerting steering effort for 109 yards (100 m) when travelling at 62 mph (100 km/h), the vehicle may drift as much as 5 ft (1.5 m). S When vehicle pulling is due to conicity, the amount of drift can be reduced and the direction of drift can be changed by changing the location of the tire or reversing the tire when installing it on the wheel. Page 4 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedure Flow Chart January 19, 2008 START Preliminary Check S Tire Pressure S Vehicle height S Brake Dragging NO Is there steering off center? *ROAD TEST Does the vehicle lead/pull? YES NO COMPLETE YES Adjust front tie rods. See TSB ST003-01 YES Are the tires uni–directional type? NO NO ROAD TEST Does the vehicle still lead/pull? Cross switch front tire and wheel assemblies (left & right) YES Choose the position of front tire & wheel assemblies where there is least amount of pull. YES Does the vehicle lead/pull in the same direction as before? NO YES Check front wheel alignment. Is it within specification? NO Is the lead/pull stronger than before? NO YES Reverse the front left side tire and rebalance it. Adjust front wheel alignment. ROAD TEST Does the vehicle still lead/pull? NO ROAD TEST Does the vehicle still lead/pull? YES YES Does the vehicle lead/pull to the left? COMPLETE YES NO Increase right front camber and decrease left front camber until lead/pull is eliminated. NO NO NOTE: Do not exceed 1_ of cross camber. Do not exceed adjustment range. Increase left front camber and decrease right front camber until lead/pull is eliminated. ROAD TEST Does the vehicle still lead/pull? YES Contact your regional office. * Select a flat road where the vehicle can be driven in a straight line for 109 yards (100 m) at a constant speed of 35 mph (56 km/h). Please confirm safety and set the steering wheel to its straight position. Drive the vehicle in a straight line for 109 yards (100 m) at a constant speed of 35 mph (56 km/h) without exerting steering effort on the steering wheel. (1) The vehicle goes straight but the steering wheel has some angle. (2) The vehicle does not go straight. STEERING OFF CENTER STEERING PULL Page 5 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures January 19, 2008 1. Important Notice Before repairing vehicle pulling, it is necessary to clearly identify the cause of the pulling condition. Frequently, the cause of the vehicle pulling is diagnosed as wheel alignment. However, the actual cause may be lateral force generated by the tires. Performing wheel alignment when tire force is the cause could result in the wheel alignment being set at a value outside of specifications. This may then result in other problems such as uneven tire wear, etc. 2. Troubleshooting First determine whether vehicle pulling is caused by a wheel alignment problem or tire characteristics, then decide which repairs to make. A. Perform the following checks and correct as necessary. a. Check tires for size, wear and for proper inflation pressure. b. Check whether the vehicle is noticeably tilted backward/forward or left/right. NOTE: Tilting of the vehicle produces a left–right difference in the camber and caster and can cause vehicle pulling. c. Check brakes for dragging. B. Confirm problem symptoms. With the customer accompanying you, drive the vehicle to confirm if the customer’s complaint involves vehicle pulling to one side or steering wheel off center. If the problem is steering wheel off center, adjust the front tie rods on the vehicle. Refer to Toyota TSB No. ST003-01. Also check the direction of vehicle pulling and the extent of the pulling. C. Determine if vehicle pulling is due to wheel alignment or tires. a. Switch the left and right front tires (If the tires are non-unidirectional). b. Conduct a drive test to check whether the vehicle pulling direction has changed. Page 6 of 11 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION No change in vehicle pulling condition Front wheel alignment Proceed to Repair Procedure 3. Vehicle pulling caused by Wheel Alignment (Page 7) Vehicle pulling eliminated Tire conicity Repair complete. Vehicle Pulling Caused by Tire Conicity (Page 4 and 8) Vehicle pulling direction is reversed Tire conicity Proceed to Repair Procedure 4. Vehicle Pulling Caused by Tire Conicity (Page 8) REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures (Continued) January 19, 2008 Helpful hints to determine cause of vehicle pulling: S The direction of lateral force from tire conicity becomes reversed when the left and right tires are switched. Therefore, if the pulling direction changes when the tires are switched, it can be concluded that vehicle pulling is caused by tire conicity. ORIGINAL TIRE POSITIONS Vehicle Pulling Direction (Right) TIRES SWITCHED Lateral Force by Conicity The Vehicle is Pulled to the Right by the Lateral Force Exerted to the Right. Vehicle Pulling Direction (Left) Lateral Force by Conicity The Direction of the Tires Which Exerted Lateral Force to the Right has Been Changed, so the Tires Now Exert Lateral Force to the Left and the Vehicle Now Pulls to the Left. S If the pulling direction does not change after the front tires are switched, the cause of vehicle pulling is not tire conicity. In this case, the likely cause is a front wheel alignment condition. 3. Vehicle Pulling Caused by Wheel Alignment When it is determined by troubleshooting that the vehicle pulling is caused by wheel alignment, perform repairs according to the following procedure. Vehicle Pulling to One Side Check Front Wheel Alignment Not Within Specification Within Specification Adjust Front Wheel Alignment Road Test OK Within Specification But Vehicle Pulls Vehicle Still Pulls Adjust Cross Camber to Eliminate Vehicle Pulling NOTE: Do not exceed 1_ of cross camber. Page 7 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures (Continued) January 19, 2008 WHEN VEHICLE PULLS TO LEFT WHEN VEHICLE PULLS TO RIGHT Increase right front camber and decrease left front camber until vehicle pulling is eliminated Increase left front camber and decrease right front camber until vehicle pulling is eliminated NOTE: S Keep the cross camber within 1_ or less. S Keep the camber of each wheel within specifications (+/–45’ of center value). S If adjustment exceeds the specifications, uneven tire wear will result. 4. Vehicle Pulling Caused by Tire Conicity When it is determined by troubleshooting that the vehicle pulling is caused by tire conicity, perform repairs according to the following procedures. Indication of Tire Conicity as a Cause: When the front tires are switched, the pulling direction changes. Proceed to STEP 1. STEP 1: Remove the front left tire from the wheel and reverse the tire. Then perform a road test and check for change in the pulling direction. HINT: By performing this operation, it can be checked whether the left or right tire exerts a stronger lateral force. Either tire can be reversed. Shown here is an example of the left tire reversed. If Vehicle Pulls in the Same Direction: Go to STEP 2. The lateral force generated by the right front tire is greater than the left tire, so the vehicle is pulling due to the lateral force of the right tire. ORIGINAL TIRE POSITIONS Vehicle Pulling Direction LEFT TIRE REVERSE INSTALLATION Vehicle Pulling Direction (Same Direction) Reversed Lateral Force by Conicity (Smaller) Page 8 of 11 Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) Lateral Force by Conicity (Larger) REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures (Continued) January 19, 2008 If Vehicle Pulls in the Opposite Direction: Go to STEP 2. The lateral force generated by the left front tire is greater than the right tire, so the vehicle is pulling due to the lateral force of the left tire. ORIGINAL TIRE POSITIONS LEFT TIRE REVERSE INSTALLATION Vehicle Pulling Direction Vehicle Pulling Direction (Opposite Direction) Reversed Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) Lateral Force by Conicity (Larger) Lateral Force by Conicity (Smaller) If Vehicle Pull Is Eliminated: Repair Is Now Complete. STEP 2: Rotate the larger lateral force front tire with the rear tire and check the change in the vehicle pulling. NOTE: By shifting the front tire with the larger lateral force to the rear, vehicle pulling is usually reduced. If Vehicle Is Still Pulling: Go to STEP 3. If Vehicle Pull Is Eliminated: Repair Is Now Complete. Page 9 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures (Continued) January 19, 2008 STEP 3: Adjust cross camber to eliminate vehicle pulling. HINT: If the tires are placed in the positions they were in during tire rotation when the least amount of vehicle pulling occurred, wheel alignment can be performed with a minimal amount of adjustment. WHEN VEHICLE PULLS TO LEFT WHEN VEHICLE PULLS TO RIGHT Increase right front camber and decrease left front camber until vehicle pulling is eliminated Increase left front camber and decrease right front camber until vehicle pulling is eliminated NOTE: S Keep the cross camber within 1_ or less. S Keep the camber of each wheel within specifications (+/–45’ of center value). S If adjustment exceeds the specifications, uneven tire wear will result. 5. Camber Adjustment Method NOTE: S After the camber has been adjusted, inspect the toe-in. S The method of camber adjustment differs for different models, so please refer to the repair manual of the vehicle involved. (This is a sample from the Sienna Repair Manual). A. Remove the front wheels and ABS speed sensor clamp. B. Remove the two nuts on the lower side of the shock absorber. C. Coat the threads of the nuts with engine oil. D. Temporarily install the two nuts. E. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. F. Tighten the nuts. 1 2 Page 10 of 11 REPAIR MANUAL SUPPLEMENT: VEHICLE PULLING TO ONE SIDE – SU001-08 Repair Procedures (Continued) January 19, 2008 G. Install the front wheels. Torque: 104 NSm (1,050 kgfScm, 77 ftSlbf) H. Check the camber. NOTE: Adjusting value for the set bolts is 6’ – 30’ (0.1_ – 0.5_). When making an adjustment of more than 45’, replace the upper and lower steering knuckle set bolts with the adjusting bolts. If the camber is NOT within the specification, use the table shown to estimate how much additional camber adjustment will be required, and select the appropriate camber adjusting bolt. I. Follow steps 5-A through 5-H again. Between steps 5-B and 5-C, exchange one or two selected bolts. HINT: When exchanging the two bolts, exchange one bolt each time. If Vehicle Pull Is Eliminated: Repair Is Now Complete. If Vehicle Is Still Pulling: Contact Toyota Technical Assistance. Page 11 of 11 FOREWORD This manual has been prepared for use when performing terminal repairs, wire repairs, or connector repairs on vehicles. A step–by–step section on connector repair and terminal repair is included. There is a section of charts with terminal and connector illustrations, part numbers, and notes on terminal removal. By using this guide, a satisfactory repair of the wiring harness and connectors in Toyota vehicles will be easy to achieve. All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.
2002 All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. G (Cont. next page) 1 2 3 4 5 M:11063 F:11065 M:11064 F:11066 M:11181 F:11182 6 7 8 9 10 G–6 402 Waterproof Type [1] 11 10 1.0 M:11863 1 0 III 1.0 F:11856 M:11188 F:11189 13 1.3 F:10737 18 1.8 Wire Harness Repair Manual (RM1022E) F:11166 F:11243 F:11363 F:11428 F:11252 M : Male M:10580 M:10475 F:10476 M:10590 F:10609 F:10474 M:10575 M:10892 F:10893 M:11006 F:11007 M:11270 F:11271 M:10842 F:10843 M:10886 F:10887 M:10898 F:10899 M:10900 F:10901 M:11072 F:10923 M:10959 F:10947 M:10948 F:10949 M:11002 F:11003 M:11004 F:11005 M:11008 F:11009 F : Female M:11191 F:11192 M:11173 F:11174 F:10711 M:10592 23 2.3 M:11171 F:11172 M:10650 F:10532 M:10648 F:10598 M:11486 F:11019 M:11029 F:11030 M:11137 F:11038 M:11050 F:11051 M:11069 F:11070 M:11073 F:11075 M:11074 F:11075 M:11141 F:11142 M:11155 F:11156 M:11168 F:11162 F:10572 M:11247 F:11248 M:11272 F:11273 F:11207 F:10974 F:11246 F:11025 F:11250 M:11015 F:11016 M:11131 F:11132 M:11244 F:11245 M:11295 F:11245 F:11068 F:11255 F:10834 F:11140 F:11285 F:10845 M:10868 F:10869 M:10941 F:10942 M:11027 F:11028 M:11122 F:11037 M:11177 F:11178 M:11291 F:11292 F:11149 F:12028 F:10902 F:10943 F:11144 F:11153 F:10919 F:11150 F:11858 F:11154 F:10981 F:11152 F:11163 F:11020 F:11235 F:11143 F:11145 F:11261 F:11294 F:11349 M:11348 M:11078 F:11077 F:11317 M:10987 F:10988 M:11033 F:11034 M:11193 F:11194 M:11196 F:11197 M:11289 F:11290 F:11599 F:10854 F:11024 F:11049 F:11232 M:10930 F:10931 M:10890 F:10891 M:10890 F:11190 M:10896 F:10897 F:11231 APPENDIX–PART NUMBER LIST F:11062 M:10495 F:10496 2 3 II 2.3 M:11169 F:11170 Waterproof Type [1] (Cont’d) 12 15 10 1.0 40 80 F:11215 F:11214 1 0 III 1.0 13 1.3 F:11698 M:11088 F:11089 18 1.8 APPENDIX–PART NUMBER LIST Wire Harness Repair Manual (RM1022E) 23 2.3 M:11086 F:11087 F:11151 2 3 II 2.3 M : Male F : Female G–7 403 G G 404 48 4.8 63 6.3 77 7.7 80 8.0 1 M:10982 F:10983 F:11400 M:10246 F:10247 M:10114 F:10115 M:10836 F:10837 M:11183 F:11184 Wire Harness Repair Manual (RM1022E) HB4 PIN F:11237 M:10156 F:10157 4 M:10989 F:10990 M:11035 F:11036 5 6 8 9 10 11 23 F:11095 F:11659 F:11096 M:11945 F:11660 M:10577 M:10240 F:10241 F:10554 M:10244 F:10353 1 0 III+4 1.0 III+4.8 8 F:12020 2 3+6 3 2.3+6.3 F:10686 M:11160 F:11161 2 3 II+4.8 2.3 II+4 8 M:10749 F:10844 F:10940 M:10945 F:10946 M:11021 F:11022 M:11412 F:11413 F:10939 M:10894 F:10895 M:11239 F:11643 F:11332 F:11784 F:11195 2 3 II+6.3 2.3 II+6 3 II F:11323 M:11241 F:11242 2 3 II+8.0 2.3 II+8 0 M:11044 F:11045 4 8+8 0 4.8+8.0 M : Male 34 M:10838 F:10839 M:11031 F:11032 TLC TODC 3 M:10840 F:10841 M:10944 F:10841 M:10347 F:10249 F : Female M:11138 F:11139 F:12021 APPENDIX–PART NUMBER LIST HB3 2 M:10927 F:10928 G–8 Waterproof Type [2] Non–waterproof Type [1] 1 (Cont. next page) 2 3 4 5 F:11988 F:11921 6 7 8 9 10 11 10 1.0 1 0 II 1.0 M:11967 F:11919 1 0 III 1.0 F:11924 F:11909 13 1.3 M:11052 F:11053 M:11186 F:11187 F:11471 F:11107 Wire Harness Repair Manual (RM1022E) F:11436 F:11319 F:11948 F:11616 F:11165 M:11532 F:11533 M:11623 F:10630 F:11494 F:11450 F:11041 F:11642 F:11083 F:11657 18 1.8 1 8 II 1.8 M:10437 F:10355 23 2.3 2 3 II 2.3 M:10824 F:10825 M:10833 F:10825 M:11299 F:10825 M:11300 F:10825 M:10849 F:10850 M:10859 F:10860 M:11060 F:10860 M:10905 F:10906 M:10934 F:10935 M:11159 F:11148 F:11080 M:10907 F:10908 F:11098 F:11071 F:11227 F:11079 F:10823 F:11278 F:10835 F:11608 F:10855 F:10962 F:10504 M:10384 F:10414 F:10601 M:10794 F:10795 M:10858 F:10795 M:11399 F:10795 M:11012 F:11013 M:11023 F:10904 M:11100 F:11090 M:11085 F:10789 M:10796 F:10797 M:11110 F:10797 M:11099 F:10933 M:11101 F:10996 M:10998 F:11001 M:11010 F:11011 M:11587 F:11011 F : Female F:10672 F:10957 F:10964 F:11280 F:10322 M:11528 F:11529 M:10798 F:10799 M:11534 F:11535 F:10669 M:10800 F:10801 M:11102 F:10997 M:11536 F:11537 M:10829 F:10830 M:11538 F:11539 F:10966 F:10822 F:10965 G–9 405 M : Male M:10870 F:10871 M:11026 F:10871 M:11097 F:10871 M:11146 F:11147 M:10573 F:10365 APPENDIX–PART NUMBER LIST M:11211 F:11212 M:11368 F:11369 G G 406 12 10 1.0 1 0 II 1.0 13 14 15 16 F:11129 F:10764 F:11408 F:11219 17 18 19 20 21 22 25 F:11220 28 34 F:11218 F:11221 G–10 Non–waterproof Type [1] (Cont’d) F:11391 F:11925 1 0 III 1.0 F:11911 M:11654 F:11556 F:11913 F:11179 M:11573 F:11574 M:11570 F:11571 F:11125 F:11264 M:11962 F:11927 M:11926 F:11915 M:11503 F:11502 M:11133 F:11055 F:11628 F:11043 Wire Harness Repair Manual (RM1022E) M:10722 18 1.8 F:10658 F:10973 F:10697 F:10656 F:10696 F:10743 1 8 II 1.8 23 2.3 2 3 II 2.3 F:11424 M:10513 F:10432 M:10325 F:10326 M:10802 F:10803 M:11530 F:11531 M:10804 F:10805 M:11541 F:11542 F:10967 F:11604 F:10968 F:11121 F:11661 M : Male F:11433 F : Female M:10806 F:10807 F:10852 M:10827 F:10828 M:10808 F:10809 M:11167 F:10848 F:11417 M:10818 F:10819 M:10810 F:10811 M:10820 F:10821 M:10977 F:10875 F:11552 APPENDIX–PART NUMBER LIST 13 1.3 F:11914 Non–waterproof Type [2] 1 M:11258 F:11259 48 4.8 F:10911 2 M:10915 F:10916 M:11093 F:11094 3 F:10980 4 M:11135 F:11136 M:11878 F:11742 5 F:10912 M:10178 F:10179 63 6.3 M:10213 F:10214 6 M:10975 F:10976 M:10283 F:10216 F:11778 8 M:10963 F:10926 F:11091 F:11092 F:11583 F:11615 M:10172 F:10173 F:11686 M:10174 F:10175 9 10 M:10861 F:10862 12 13 14 17 22 M:10176 F:10177 F:10619 APPENDIX–PART NUMBER LIST F:10786 Wire Harness Repair Manual (RM1022E) F:10792 77 7.7 M:10994 F:10995 80 8.0 M:10356 F:10357 M:10958 F:10903 M:11655 F:11579 F:11684 FOG LP FOG–LP F:10956 M:10866 F:10867 F:11314 F:11685 F:10481 FTC HEAD LANP HEAD–LANP F:10489 F:10487 F:10490 F:10488 F:10428 M:10131 LAC F:10133 M:10289 LC F:10645 MFPC F : Female F:10301 F:10302 F:10303 F:10304 F:10372 F:10369 G–11 407 M : Male F:10132 1 2 (Cont. next page) 3 MIC 4 5 6 7 8 F:10378 9 10 12 F:10152 13 14 15 G–12 408 Non–waterproof Type [3] 16 F:10062 OBD II F:11665 PULSE LOCK F:10294 F:11116 SFPC F:10351 F:10371 F:11114 F:11113 F:11115 F:10070 Wire Harness Repair Manual (RM1022E) SP F:10071 F:10362 F:10376 M:10401 F:10402 TLC M:10466 F:10467 TNS TODC M:10719 F:10528 M:10182 F:10183 F:10635 M:10470 F:10471 M:10040 F:10274 M:10044 F:10045 1 0+1 8 1.0+1.8 1 0 II+1.8 1.0 II+1 8 II F:11225 F:11565 1 0 III+2.3 1.0 III+2 3 II M:11613 F:11042 1 3+2 3 II 1.3+2.3 F:11056 2 3+6 3 2.3+6.3 M : Male F:10463 F : Female APPENDIX–PART NUMBER LIST SL Non–waterproof Type [3] (Cont’d) 17 MIC 18 20 22 23 24 25 26 32 F:10037 OBD II PULSE LOCK F:10295 F:10296 F:10350 SFPC Wire Harness Repair Manual (RM1022E) APPENDIX–PART NUMBER LIST SL SP TLC TNS M:10552 F:10526 M:10599 F:10587 F:10765 F:10925 TODC 1 0+1 8 1.0+1.8 F:10918 F:10763 M:11223 F:11226 1 0 II+1.8 1.0 II+1 8 II M:11223 F:11224 M:11222 F:11392 F:11390 1 0 III+2.3 1.0 III+2 3 II 1 3+2 3 II 1.3+2.3 F:11671 F:11594 F:11595 F:11469 M:11504 F:11469 M:10920 F:10921 M:11208 F:10921 F:11423 F:11877 M:11158 F:11058 2 3+6 3 2.3+6.3 M : Male F : Female G–13 409 410 4 M:11126 F:11118 5 M:10985 F:10986 6 2 3 II+4.8 2.3 II+4 8 8 M:10876 F:10877 10 M:11596 F:11527 F:11130 F:10993 11 M:10872 F:10873 12 M:10878 F:10879 14 M:10812 F:10813 15 M:10814 F:10815 16 M:10884 F:10885 19 M:10882 F:10883 20 M:10816 F:10817 24 M:10880 F:10881 G–14 Non–waterproof Type [4] 26 M:11631 F:10932 F:11279 F:11701 M:10909 F:10910 2 3 II+8.0 2.3 II+8 0 4 8+8 0 4.8+8.0 F:10888 Wire Harness Repair Manual (RM1022E) M : Male F:10889 F:10447 F : Female APPENDIX–PART NUMBER LIST 6 3+7 7 6.3+7.7 M:10856 F:10857 G–2 APPENDIX–REPORTING OF WIRE HARNESS PROBLEM REPORTING OF WIRE HARNESS PROBLEM It is more difficult to understand the cause of wire harness problems and to make production improvements, due to the number of wire harness routings and connectors and their wide scope of use. The position of the problem occurrence and the problem cause will be very clear if you proceed with wire harness/connector repairs. We request that when you perform repairs, you fill in the attached ”WIRE HARNESS/CONNECTOR PROBLEM CHECK SHEET” and send it to your distributor. Toyota Motor Corporation will be able to make production improvements more quickly and surely based on the results of the above mentioned reports (Check Sheets). G Wire Harness Repair Manual (RM1022E) 398 G–3 APPENDIX–REPORTING OF WIRE HARNESS PROBLEM G Wire Harness Repair Manual (RM1022E) 399 G–4 APPENDIX–REPORTING OF WIRE HARNESS PROBLEM G Wire Harness Repair Manual (RM1022E) 400 G–5 APPENDIX–REPORTING OF WIRE HARNESS PROBLEM G Wire Harness Repair Manual (RM1022E) 401 G–1 APPENDIX–WIRE HARNESS REPAIR KIT WITH CASE WIRE HARNESS REPAIR KIT WITH CASE (REFERENCE ONLY) We would like to recommend to you use of the ”Wire Harness Repair Kit with the Case” according to your after service market demand. Example: or G [portable type] [stationary type] Remark: This kind of kit is not available from Toyota Motor Corporation. Wire Harness Repair Manual (RM1022E) 397 B–2 TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR CONNECTOR REPAIR The repair parts now in supply are limited to those connectors having common shapes and terminal cavity numbers. Therefore, when there is no available replacement connector of the same shape or terminal cavity number, please use one of the alternative methods described below. Make sure that the terminals are placed in the original order in the connector cavities, if possible, to aid in future diagnosis. 1. When a connector with a different number of terminals than the original part is used, select a connector having more terminal cavities than required, and replace both the male and female connector parts. EXAMPLE: You need a connector with six terminals, but the only replacement available is a connector with eight terminal cavities. Replace both the male and female connector parts with the eight terminal part, transferring the terminals from the old connectors to the new connectors. 2. When several different type terminals are used in one connector, select an appropriate male and female connector part for each terminal type used, and replace both male and female connector parts. B EXAMPLE: You need to replace a connector that has two different types of terminals in one connector. Replace the original connector with two new connectors, one connector for one type of terminal, another connector for the other type of terminal. 3. When a different shape of connector is used, first select from available parts a connector with the appropriate number of terminal cavities, and one that uses terminals of the same size as, or larger than, the terminal size in the vehicle. The wire lead on the replacement terminal must also be the same size as, or larger than, the nominal size of the wire in the vehicle. (”Nominal” size may be found by looking at the illustrations in the section F or by direct measurement across the diameter of the insulation). Replace all existing terminals with the new terminals, then insert the terminals into the new connector. EXAMPLE: You need to replace a connector that is round and has six terminal cavities. The only round replacement connector has three terminal cavities. You would select a replacement connector that has six or more terminal cavities and is not round, then select terminals that will fit the new connector. Replace the existing terminals, then insert them into the new connector and join the connector together. Wire Harness Repair Manual (RM1022E) 12 B–47 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Low Fit and Lever Type Connector [Case 1] Lever 1. Cut the connection of the connector (1) (2) Push the place indicated by the arrow. The lock is released and lever is lifted up. (3) Lift the lever up until it stops. an (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. Lever 2. Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. HINT: If the lever is locked at the lower position, follow the procedure [Case 1]. (1) to (3) and lift the lever up fully. Wire Harness Repair Manual (RM1022E) 57 B–48 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely locked. Lever Lever is not locked [Case 2] Lever 1. Cut the connection of the connector (1) (2) Hold the area indicated by the arrow in the illustration The lock is released and the lever is lifted up. (3) Lift the lever up fully. (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. Wire Harness Repair Manual (RM1022E) 58 B–49 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS 2. Lever Lever is not locked Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely locked. [Case 3] 1. Cut the connection of the connector (1) (2) Pick the part indicated in the illustration by fingers. The lock is released and the lever is lifted up. (3) Lift the lever up fully. Lever Wire Harness Repair Manual (RM1022E) 59 B–50 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. 2. Lever Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. HINT: If the lever is locked at the lower position, follow the procedure [Case 3]. (1) to (3) and lift the lever up fully. (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely fitted Lever is not locked Wire Harness Repair Manual (RM1022E) 60 B–51 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Double locking device pin Coil spring The connector with secondary locking device 1. Area used
Wire harness for SRS airbag deployment Pin Convex part Primary locking device Lock 2. Cut the connection of the connector. (1) Release the double locking. (2) Release the primary locking and separate the connector. NOTICE: Do not hold the wire harness to pull it. 3. Connect the connector (1) Lock Install the primary locking device and connect the connector. (2) Install the double locking device. NOTICE: The double locking device can not be installed unless the primary locking device is installed. Wire Harness Repair Manual (RM1022E) 61 B–52 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Connector fixed by bolts 1. Area used
Engine control computer harness 2. Connector A (1) Remove the connector A. (2) Loose the bolt using a tool like driver until the connector B can be removed by hand and separate the connector. HINT: If the bolt can not be removed, roll it while pulling forward. Connector B 3. Lass than 1mm Cut the connection of the connector. (1) Connector B Connector A Bolt Connection of the connector Temporarily fit the connector B. (2) Tighten the bolt by using tool like driver and fit the connector B completely. NOTICE:
Tighten the bolt until feeling it lighter. Then confirm that the width of chink of the connector B is less than 1mm.
The bolt can be rolled after it is fitted.
If the impact wrench is used, do not let it rolling more than three seconds. (The housing may be deformed by generated heat)
Be sure and connect the connector B straight. Do not incline it while connecting. (3) Connect the connector A. Cross–section of the bolt Wire Harness Repair Manual (RM1022E) 62 B–53 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS 1. Cut the connection of the connector (1) Push down on locking arm to unlock. Then hold the back ribs of connector to remove connector. (2) Cut the Connection of the connector. Hold back rib to pull connector Locking Arm NOTICE: Do not hold the wire harness to pull it. 2. back ribs Connect the Connector (1) (2) Align the direction of locking feature in same direction and mate the connector holding the back ribs in straight direction. Insert it until a lock securely locks, and pull the connector lightly after the insertion, and confirm that a lock is enabled. Wire Harness Repair Manual (RM1022E) 63 B–1 TERMINAL AND CONNECTOR REPAIR–PREPARATORY ITEMS PREPARATORY ITEMS Tool Gauge Crimping tool AMP Part No. 169060 For caulking press sleeves Special tool Refer to the following illustration To remove the terminal SST 09991–00500 To remove the 0.64 connector terminal Caliper 0–150 mm To measure the diameter of the core Press sleeve 82999–12010 (Red) 82999–12020 (Blue) 82999–12030 (Yellow) To connect wires 08231–00045 To waterproof the connected section Others Silicon tape B Special Tool Reference: HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. (mm) Preparation of the SST to release the 0.64 connector terminal. SST 09991–00500 HINT: This is a SST for releasing terminals from 0.64 connectors. Wire Harness Repair Manual (RM1022E) 11 B–4 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 1. Identify the connector and the terminal type. Confirm whether the connector you require is the non–waterproof, waterproof or combined terminal type connector from the pictures provided in the following charts. Connector Description Non–Waterproof Type Those connectors which are not of the waterproof or combined terminal type. Waterproof Type Waterproof material (hole plug or terminal packing) is provided on the terminal/connector body. Combined Terminal Type Terminals of different shape/size are located in one connector. B 1. Terminal with Wire Identify the part number of the terminal with wire by picking out the corresponding illustration from the pictures provided on the following charts. HINT: In some of the illustrations, there are two part numbers for the same illustration of terminal with wire, because although the shapes of the terminals are completely the same, there is a difference in with /without gold–plating (gilded). Remark: The length of the wire connected to the terminal is approximately 150 mm. Wire Harness Repair Manual (RM1022E) 14 B–5 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE:
When the terminal used is gold plated, be sure to replace it with a gold plated terminal when marking repairs.
Do not use male and female terminals which are made of different materials from each other. 2. Connector Body (a) (b) Identify the part number of the corresponding terminal with wire according to the above–mentioned 1. Identify the part number of the connector body by picking out the correct one from the illustrations according to the number of terminals and the shape. HINT: If you can find no connector which matches the type you require, pick out male and female connector bodies as a set which have more terminals than you require. For the combined terminal type connector body, pick out and appropriate connector body for each terminal being used. (a) Example: When two types of terminal are used in one connector body, pick out a male and female for two different connector bodies. Example: Back of the Connector Body (b) The part number has been stamped on the back of the connector body. (This will continue to be done to new types of connector.) P/N 90980–10854 Wire Harness Repair Manual (RM1022E) 15 B B–6 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 3. Hole Plug/Terminal Packing (a) Hole Plug (b) Identify the part number of the appropriate terminal with wire/connector body from the illustrations of waterproof type connector according to the above–mentioned 1 and 2. Identify the part number of the hole plug/terminal packing from the corresponding illustration. Connector Body Terminal Packing B 4. Small (Red) Sleeve When connecting two wires using a sleeve, select the sleeve according to the following table. Medium (Blue) Large (Yellow) Wire Outside Diameter Sleeve Size (Color) 0.2–1.0 mm Small (Red) 1.0–2.0 mm Medium (Blue) 3.0–5.0 mm Large (Yellow) (a) When size is based on the outside diameter of the wire. Wire Outside Diameter Insulation Calipers Wire Harness Repair Manual (RM1022E) 16 B–7 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT ∗ 0.3 0.5 0.85 1.25 0.3 S M M 0.5 M M 0.85 M 1.25 2 3 5 M M L L M M M L L M M M L L L M M M M L L L 2 M M L L L L –– 3 L L L L L L –– 5 L L L L –– –– –– ∗ (b) When size is based on the nominal size of the wire. Sleeve size S : Small (Red) M : Medium (Blue) L : Large (Yellow) ∗ Nominal size of the wire Nominal Size of Wire HINT: To calculate the ”Nominal Size” of the wire. Nominal size = 3.14 x (Diameter of stripped wire harness)2 4 Wire Lead Diameter B Calipers Twist Evenly HINT: Outside Diameter and Nominal Size Wire Outside Diameter Nominal Size Insulation Stripped Wire Harness Section Wire Harness Repair Manual (RM1022E) 17 B–8 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 2. Disconnect the Terminal from the Connector. 1. Disconnect Connector To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Press down type is mainly used. Example: Pull Up Press Down Press Down Pull Up B 2. Refereance: Prepare the Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. (mm) 3. Example: Up Tool Disengage the double locking device or terminal retainer. (a) (b) Terminal Retainer Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Use a special tool or the terminal pick to unlock the double locking device. NOTICE: Do not remove the terminal retainer from connector body. Wire Harness Repair Manual (RM1022E) 18 B–9 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type A (For 1.0II, 1.8, 2.3II, 4.8 and 8.0 of Non–Waterproof Type Connector) Raise Up (1) Special Tool Using the special tool, raise the retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (number of terminals, etc.), so check the position before inserting it. Terminal Retainer Terminal Retainer B [Retainer at Full Lock Position] Terminal Retainer Stopper [Retainer at Temporary Lock Position] Good Bad Good [Male] Bad [Female] Type B (For 1.8, 1.0 and TLC of Non–Waterproof Type Connector) Special Tool Wire Harness Repair Manual (RM1022E) 19 B–10 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (1) Press the special tool at a 45° angle into the locking lug access hole as shown. Raise the double locking device up as far as possible. Access Hole Remove the special tool and open the double locking device NOTICE: TLC housing is not be reusable. Please replace it with the new one after replacement of the terminal. (2) Tab B ∗ ∗ Open ∗ [Male] Retainer ∗ ∗ Double Locking Device. [Female] Type C (For TNS, FTC Type Connector) (1) Widen the side lock part of the retainer from side to side using the special tool. Side Lock Wire Harness Repair Manual (RM1022E) 20 Open B–11 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Inset the special tool into the chink between the retainer and the terminal itself. Then pry it to the direction of the arrow shown in the illustration and push the retainer up to release the lock. NOTICE:
Do not insert the special tool too much. It may cause damage on the fit section of the terminal and the wire harness.
TNS housing is not reusable. Please replace it with the new one after replacement of the terminal. (2) Special tool Lock Type D (For 1.3 of Non–Waterproof Type Connector) [Case 1] Use the special tool to unlock the double locking device. (1) ∗ ∗ Special Tool ∗ ∗ ∗ Double Locking Device. Wire Harness Repair Manual (RM1022E) 21 B–12 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT [Case 2] (1) Using the special tool, push the terminal retainer locking lug (clip) and pull the terminal retainer up to the temporary lock position. Locking Lug Special Tool Locking Lug Special Tool [Retainer at Full Lock Position] Special Tool Terminal Retainer Terminal Retainer [Retainer at Temporary Lock Position] [Case 3] (1) Using the special tool, raise the retainer up to the temporary lock position. [Retainer at Full Lock Position] Stopper Terminal Retainer [Retainer at Temporary Lock Position] [Case 4] Service hole Wire Harness Repair Manual (RM1022E) 22 B–13 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (1) Insert the special tool into the service hole and move it to the direction of the arrow to release the lock on the side A. (2) Push the lock on the side B up by the special tool and release the lock. Then pull the retainer forward. A Special tool B Appearance when the double locking is released Wire Harness Repair Manual (RM1022E) 23 B–14 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type E (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof Type Connector) HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector body Black or White : Gray Black or White : Dark Gray Gray or White : Black [Case 1] Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Special Tool Terminal Retainer Special Tool Special Tool Terminal Retainer Access Hole (  Mark) Special Tool [Female] [Male] Wire Harness Repair Manual (RM1022E) 24 B–15 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insert the special tool into the terminal retainer access hole (  Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. (1) Example: Terminal Retainer at Full Lock Position [Male] Access hole Temporary Lock Position [Female] HINT: In some cases insert the special tool from the access hole on the flank of the housing. Wire Harness Repair Manual (RM1022E) 25 B–16 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT [Case 2] Type which cannot be pulled as far as Power Lock HINT: There are few cases of this type of connector Example: Terminal Retainer [Male] Press Down Press Down [Female] (1) Example: Insert the tool straight into the access hole of terminal retainer as shown. Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] Wire Harness Repair Manual (RM1022E) 26 B–17 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type F (For C–Type Connector) Service hole (1) Insert the special tool into the service hole. (2) Move the special tool to the direction of the arrow and release the lock. Retainer HINT: Lift the retainer up after moving it to the direction of the thin arrow shown in the illustration. (3) Special tool Lock Pull the retainer forward by hand and remove the retainer from the housing. Type G
Insert the special tool into the position shown in the illustration. Pry it to the direction of the arrow and push the lock up to release it. Wire Harness Repair Manual (RM1022E) 27 B–18 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type H (For 1.0II Type Connector) Move the special tool into the notch of the retainer to the direction of the arrow with the edge of the housing as the fulcrum. Then the pull the retainer out. NOTICE: Do not insert the special tool into areas except notches. (This may damage the seal ring that is attached behind the retainer.) (1) (2) As same as the procedure (1), pull the retainer straight out using hand after releasing the lock on the other side. Retainer (Yellow) Notch NOTICE:
Do not remove the seal rubber when pulling the terminal out.
If the seal rubber is peeled off when puling the terminal out, press it down to stick it to the original condition.
Be sure and not fit the connector when the retainer is not installed. Seal rubber Type I (For SFPC Type Connector) (1) Open the cover (white) Condition of cover opening Side Lock Side Lock Remove the side lock of the retainer. (One side) (3) Remove the center lock of the housing. (4) Remove the side lock of the retainer. (The other side) NOTICE:
Following the above order is not required.
No center lock on the housing with ten poles. (2) Center Lock Wire Harness Repair Manual (RM1022E) 28 B–19 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (5) Move the retainer until it becomes the initial condition. Retainer Initial condition Type J [Male] (1) Remove the rubber plug. (2) Push the lock of the inner using the special tool. Pull the wire to the direction of the arrow pushing the lock up and remove the inner from the outer. Rubber Plug Outer Lock (3) Inner [Female] (1) Remove the rubber plug. (2) Insert the special tool into the outer shown in the illustration. Then push the area A of the inner and remove the inner from the outer. Rubber Plug Special tool Outer B Inner A Illustration from side B Wire Harness Repair Manual (RM1022E) 29 B–20 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type J (For Insulation Displacement Connector) Separate Connector Using a special tool, release the lock and separate the connector into 2. (1) Special Tool NOTICE: Do not apply too muck force to the lock arm. Lock Special Tool w/ Cover : Open Connector Cover Using a special tool, release the lock and open the cover. (2) Cover NOTICE: Do not apply too much force to the lock arm. Special Tool Raise Up Special Tool Insert Mark Type K (0.64 Type Connector) (1) Special Tool Terminal Retainer Using the special tool, raise the retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (number of terminals, etc.), so check the position before inserting it. Terminal Retainer [Retainer at Full Lock Position] Terminal Retainer Stopper [Retainer at Temporary Lock Position] Wire Harness Repair Manual (RM1022E) 30 B–21 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Good Bad Special Tool Type L (0.64 of Insulation Displacement Connector (IDC) Type) Remove the Lower Housing Using a special tool, release the lock and remove the lower housing. (1) Special Tool Lock Special Tool Lock NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to prevent mistakes when putting them together. Remove the Upper Housing Using a special tool, release the lock and remove the upper housing from the lock housing. (2) NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to prevent mistakes when putting them together. Special Tool Lock Housing Upper Housing Type M (0.64 of Splash Proof Connector) (1) Release Terminal retainer. Insert Special Tool at the location shown in the figure left. Wire Harness Repair Manual (RM1022E) 31 B–22 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Move Special Tool in the direction of arrow. Terminal Retainer [Retainer at Lock Position] Terminal Retainer [Retainer at Unlock Position] (2) Rear Holder Release Rear holder. Insert Special Tool at the location shown in the figure left. Move Special Tool in the direction of arrow. NOTICE:
Do not remove Rear holder from Connector housing.
If Rear holder completely comes off the housing, replace Connector with a new one. Rear Holder [Rear Holder at Lock Position] Rear Holder [Rear Holder at Unlock Position] Wire Harness Repair Manual (RM1022E) 32 B–23 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Rear Holder 4. Locking Clip Disconnect Terminal from Connector (a) Determine the primary locking system from the charts. 1. Lock Located on terminal 2. Lock Located on connector 3. Method of entry and operation (b) Push the terminal gently into the connector and hold it in this position. (c) Insert the special tool into the connector in the direction shown in the chart. Move the locking clip to the unlock position and hold it there. NOTE: Do not apply excessive force to the terminal. Do not pry on the terminal with the special tool. Pull Out Connector Wire Harness ”Waterproof Type” (d) Terminal Retainer (e) Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTE: Do not use too much force. If the terminal does not come out easily, repeat steps (a) through (e). Special Tool Locking Clip Wire Harness Repair Manual (RM1022E) 33 B–24 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT ”Non–Waterproof Type” Locking Clip Terminal Retainer 4.8 Type Insert the SST into the connector in the direction shown in the chart. (g) Insert the SST fully to the tool hole, and push the terminal lance. NOTICE:
The terminal has a lance shape, therefore, the housing may be damaged and the terminal may get stuck if forcibly pried by wires etc.
Insert the SST so that the stopper portion surface is facing up. (f) 0.64 Type Stopper Portion Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTICE: Removal of the terminal from housing cavity will cause damage to the wire seal section, deteriorating waterproofing performance. Replace the connector with a new one. (h) Tool Hole SST Terminal Lance NOTICE: Do not insert the special tool into the female terminal box. If you do so, replace the terminal with the new one whether the terminal is broken or not. Non–waterproof type TLC housing NOTICE: As for Non–waterproof type TLC housing, insert the special tool into the housing from wire harness side. Insert the tool from wire harness side Wire Harness Repair Manual (RM1022E) 34 B–25 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insulation Displacement Connector Type Tool Hole Using a special tool, push the terminal lance from the tool hole. (b) Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTICE:
Do not use too much force. If the terminal does not come out easily, repeat step (a).
Always change the wire with the repair wire, in accordance with page B–27. (a) Special Tool Special Tool Terminal Lance 0.64 Type Special Tool Tool Hole Special Tool Terminal Lance Wire Harness Repair Manual (RM1022E) 35 B–26 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 5. Terminal Deformation (1) Terminal Bending in Vertical Direction Inspect the terminal and the connector for damage. NOTE:
The locking clip is easily damaged.
Do not reuse the damaged part. 1° or less 1° or less (2) Terminal Bending in Horizontal Direction 3° or less Wire Harness Repair Manual (RM1022E) 36 B–27 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 1. Step 3. Replace the terminal. Cut the Old Terminal from the Harness. (a) Existing terminal Use the new wire lead as a guide for proper length. NOTE: If the length of wire removed is not approximately the same length as the new piece, the following problems may develop:
Too short –– tension on the terminal, splice, or the connector, causing and open circuit.
Too long –– excessive wire near the connector, may get pinched or abraded, causing a short circuit. Cut New Terminal with lead HINT: When connecting a wire harness at there or more spots to the same connector, cut the wire harness as shown on the left. 2. Select the correct replacement terminal with lead, from the supply parts. 3. Strip insulation from wire on the harness and replacement terminal lead. 82998–12200 Stripped insulation length (A) approximately 8 to 11 mm A Existing Harness A Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.) away from the end of the existing harness at vehicle side and also from the end of the repair wire. Supplied lead with New Terminal Wire Harness Repair Manual (RM1022E) 37 B–28 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE: Take care not to damage the wire when stripping the wire harness lead. After finishing the operation, visually inspect the wire. If there is any damage, perform the operation again. Good Example: HINT: If the wire size is not known, start with largest stripper hole and work down until a clean strip of the insulation is removed without nicking or cutting the wire lead. Bad Example: (Wire insulation is Stripped at a Slant) (Wire Lead is Cut) (Insulation Remains on the Lead) 4. Wire Harness Outside Diameter Select Correct Size of Sleeve from the Supply Parts. Measure the diameter of wire by using the measuring device as following:
When size is based on the outside diameter of the wire harness Measure the outside diameter of the wire harness by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the insulation on the lead and taking a reading. (a) Insulation Calipers Nominal Size of the Wire Wire Lead Diameter Calipers
When size is based on the nominal size of the wire lead. Measure the diameter of the wire lead by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the wire lead and taking a reading. HINT: To calculate the ”nominal size” of wire Twist Evenly Nominal size= 3.14 x (Diameter of wire lead)2 4 Wire Harness Repair Manual (RM1022E) 38 B–29 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Small (Red) Use the table to determine proper sleeve size Part Number Medium (Blue) Nominal size of wire (Outside Diameter of wire) Small 82999–12010 0.3 or less (1.0 – 0.2 mm) Medium 82999–12020 0.5 – 1.25 (2.0 – 1.0 mm) Large 82999–12030 2 or more (5.0 – 3.0 mm) Large (Yellow) NOTE: For details, refer to sleeve size table on item 4 of STEP 1 5. Good Example Two Stripped Wires Sleeve (Blue) Crimp the Replacement Terminal Lead to the Harness Lead. (a) Overlap the two stripped wire ends inside the sleeve as illustrated on the left. Pressure–Contact Section Bad Example Wire in Short Position Wire Bend HINT: You might find it easier if you use a miniature special tool as a guide as you insert wires into the sleeve. Special Tool Wire Harness Repair Manual (RM1022E) 39 B–30 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Crimping Tool The crimping tool (AMP Part No. 169060) has color marks on it. Place the sleeve in the correct section of the tool according to the color of the sleeve itself. HINT: For the crimping tool, AMP ”Part No. 169060” is convenient to use. Sleeve Color Marks (c) ”CLOSE HERE” With the center of the sleeve correctly placed between the crimping jaws, squeeze the crimping tool until either end comes into contact at the section marked by ”CLOSE HERE”. Contact HINT: Check to see that the sleeve and wires are still in the correct position before closing the crimping tool ends with steady pressure. (d) Pull the joined wires to either end. Make sure that they are joined firmly by the sleeve. NOTICE: If the joined wires come loose the splice is defective, so replace the sleeve and repeat the procedure. (e) ”INS” Position 6. 10 mm (0.39 in.) Crimp both ends of the sleeve with the crimping tool at the ”INS” position. Protect Joined Section Wrap silicon tape around the joins to protect them from moisture. NOTE: This job is required in repairs of the engine compartment, under the floor and other moisture entry positions. Three or More Times Wire Harness Repair Manual (RM1022E) 40 B–31 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Three or More Times 10 mm (0.39 in.) HINT:
Before starting the operation, thoroughly wipe dirt and grease off the sections to be joined.
If the adhesive surfaces of two tapes come in contact they will stick together and will not come apart, so do not remove the backing film except when using the tape.
Do not let oil and dust, etc. get on the tape surface. (a) (b) (c) (d) Wrap the remaining part of the sleeve with half of the tape overlapping at each turn. (e) Firmly wrap the tape two times or more about 10 mm (0.39 in.) from the other end of the sleeve, then wrap the tape back towards the start again and firmly finish winding the tape around the center of the sleeve. Tape overlapping 10 mm (0.39 in.) Ready about 100 mm (3.94 in.) of silicon tape (Part No. 08231–00045) and peel off the film. Stretch the silicon tape until its width is reduced by half. About 10 mm (0.39 in.) from the end of the sleeve, wrap the silicon tape around the sleeve three or more times while stretching the tape. Two or More Times Finish Wire Harness Repair Manual (RM1022E) 41 B–32 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 4. Install the terminal into the connector. HINT: (a) Make sure the terminal is positioned correctly. (b) Insert the terminal until the locking clip locks firmly. (c) Insert the terminal with terminal retainer in the temporary lock position, if equipped. NOTE: If reusing a terminal, check that the locking clip is still in good condition and in the proper position. Locking clip (a) Special Tool (b) If it is on the terminal and not in the proper position, use the special tool to gently bend the locking clip back to the original shape. Check that the other parts of the terminal are in their original shape. NOTICE: Do not readjust or reuse the terminal lance of the insulation displacement connector type terminal. Always change the wire with the repair wire. ”Insulation Displacement Connector” Terminal Lance Special Tool NOTICE: As for 0.64 type terminal, do not adjust the terminal lance with the special tool. ”0.64 Type” Terminal Lance Splash Proof Type Connector Special Tool NOTICE:
Removal of the terminal from housing cavity will cause damage to rubber plug material (the wire seal), deteriorating waterproofing performance. Be sure to replace the housing with a new one.
Check the withdrawn terminal for the following if trying to use it again.
It is free of deformation and damage
It is free of adherents such as rubber plug material (wire seal)
Replace any deformed terminal. Wire Harness Repair Manual (RM1022E) 42 B–33 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 1. Wire Push the Terminal into the Connector until you hear a ”click”. NOTE: Not all terminals will give and audible ”click”. ”Click” ”0.64 IDC Type” ”Click” ”Insulation Displacement Connector” ”Click” Good Example: Bad Example: NOTICE:
After repairing, never let only one harness stretch.
In cese that it becomes short, do over again using the repair wire. Wire Harness Repair Manual (RM1022E) 43 B–34 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 2. Double Locking Type Connector (with terminal retainer or double locking device) The connector is fitted with a terminal retainer, or a double locking device, it is in the temporary lock position at insert the terminal. Type A (For 1.0, 1.0II, 1.3, 1.8, 2.3II 4.8 and 8.0 of Non–Waterproof Type Connector) Terminal Retainer (a) Example: Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. Double Locking Device Good (b) Insert the terminal until the locking clip locks firmly. Bad ∗ Terminal In Short Position HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. [Female] NOTE: If the terminal to locking clip does not lock firmly, the double locking device cannot lock or terminal retainer does not lock at full lock position so the terminal backs out from connector. Good Bad [Male] ∗ Terminal In Short Position (c) Close terminal retainer or double locking device. The connector is fitted with a terminal retainer, or a double locking device, return it to the full lock position. Wire Harness Repair Manual (RM1022E) 44 B–35 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Full Lock Position [Female] Full Lock Position [Female] Full Lock Position [Male] Terminal Retainer at Temporary Lock Position Type B (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof Type) (For Male Connector) (a) Terminal Locking Clip Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. (b) Insert the terminal until the locking clip locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. Wire Harness Repair Manual (RM1022E) 45 B–36 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTE: If the terminal to locking clip does not lock firmly, terminal retainer can not lock at full lock position so the terminal backs out from connector. Bad Example: Terminal in Short Position Terminal Locking Clip Terminal Retainer (c) [Case 1] ”For Case 1” Push the terminal retainer in to the full lock position. Full Lock Position ”For Case 2” Raise the terminal retainer up to the full lock position. [Case 2] Full Lock Position Terminal Retainer at Temporary Lock Position (For Female Connector) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. (a) Terminal Locking Clip Wire Harness Repair Manual (RM1022E) 46 B–37 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insert the terminal until the locking clip locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. (b) Bad Example: Terminal in Short Position NOTE: If the terminal to locking clip does not lock firmly, terminal retainer can not lock at full lock position so the terminal backs out from connector. Terminal Locking Clip [Case 1] (c) ”For Case 1” Push the terminal retainer in to the full lock position. Full Lock Position ”For Case 2” Raise the terminal retainer up to the full lock position. [Case 2] Full Lock Position Wire Harness Repair Manual (RM1022E) 47 B–38 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type C (For 0.64 Type Connector) (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. Temporary Lock Position (b) Insert the terminal until the terminal lance locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. NOTE: If the terminal to terminal lance does not lock firmly, the double locking device cannot lock or terminal retainer does not lock at full lock position so the terminal backs out from connector. (c) Close terminal retainer. The connector is fitted with a terminal retainer, return it to the full lock position. Full Lock Position Type D (For 0.64 Splash Proof Type Connector) (a) Verify that the terminal retainer is at unlocked position. Terminal Retainer Wire Harness Repair Manual (RM1022E) 48 B–39 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Verify that Rear Holder is at unlocked position. Upper lock NOTICE: If Rear holder or wire seal has been removed, replace it with new one. Lower lock (c) Insert the terminal fully into the housing until it is locked. HINT: The terminal has a longer insertion stroke than conventional ones. (d) Set Rear holder to locked position. Push Rear holder in the direction of arrow until it is locked. (e) Verify that Rear holder is at the specified position. The rear end of Rear holder is flush with the rear end of Housing. Rear Holder Rear Holder Housing rear end Wire Harness Repair Manual (RM1022E) 49 B–40 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Verify that the lock (upper side) is at the specified position under locked status. Lock check position, upper Lock normal engagement position Incomplete lock engagement Wire Harness Repair Manual (RM1022E) 50 B–41 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Verify that the lock (lower side) is at the specified position under the locked status. Lock check position, lower Lock normal engagement position Incomplete lock engagement (f) Set Terminal retainer to Lock position. Insert Special tool into the hole specified in the left and push Terminal retainer. Insert Special Tool Special Tool hole (U shaped) Wire Harness Repair Manual (RM1022E) 51 B–42 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (g) Verify that Terminal retainer is inserted to the specified position. NOTICE: If Terminal retainer is stopped at its middle of insertion, holding wire, push Terminal to help it for full insertion. Wire Harness Repair Manual (RM1022E) 52 B–43 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT SPECIAL EXAMPLE
First fit the section A. A
Install the lock of the section A first. A
Install the lock of the retainer and pull the white cover until you hear a click sound. B
Install the convex part (A) of the outer part correctly to the section B of the inner part. A Wire Harness Repair Manual (RM1022E) 53 B–44 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Cover Insulation Displacement Connector w/ Cover : CLOSE COVER NOTICE: Securely lock it HINT: When replacing it to a new connector, cut off the fixing band without leaving it. Fix Band UNITE CONNECTOR Make the projection of the front lock of the upper housing meet the ditch of the front lock of the lower housing and fix the rear lock. NOTICE:
After uniting, securely lock it for not leaving the rear lock arm deformed.
Make sure that the terminals will not become loose by pulling the wires lightly. Wire Harness Repair Manual (RM1022E) 54 B–45 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insulation Displacement Connector (0.64 Type) Lock Housing (a) Install the upper housing to the lock housing. NOTICE:
Securely Lock it.
Be careful not to mistake the upper housing and lower housing when putting together. Upper Housing (b) Upper Housing Attached Lock Housing Make the projection of the front lock of the upper housing attached lock housing meet the ditch of the front lock of the lower housing and fix the rear lock. NOTICE:
Afteruniting, securely lock it for not leaving the rear lock arm deformed.
Make sure that the terminals will not become loose by pulling the wires lightily.
Be careful not to mistake the upper housing and lower housing when putting together. Lower Housing 3. When properly installed, pulling gently on the wire lead will prove the terminal is locked in the connector. Wire Pull Wire Harness Repair Manual (RM1022E) 55 B–46 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE: If you working on the waterproof type, make sure that a rubber plug or a terminal gasket is inserted into the housing securely. 4. Secure the Repaired Wire to the Harness If the wire is not in the conduit, or secured by other means, wrap vinyl tape around the bundle to keep it together with the other wires. 5. Connect Connector
Fit the male connector to the female terminal. NOTICE:
Do not twist the connector when fitting.
Insert it until fully locked. Wire Harness Repair Manual (RM1022E) 56 B–1 TERMINAL AND CONNECTOR REPAIR–PREPARATORY ITEMS PREPARATORY ITEMS Tool Gauge Crimping tool AMP Part No. 169060 For caulking press sleeves Special tool Refer to the following illustration To remove the terminal SST 09991–00500 To remove the 0.64 connector terminal Caliper 0–150 mm To measure the diameter of the core Press sleeve 82999–12010 (Red) 82999–12020 (Blue) 82999–12030 (Yellow) To connect wires 08231–00045 To waterproof the connected section Others Silicon tape B Special Tool Reference: HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. (mm) Preparation of the SST to release the 0.64 connector terminal. SST 09991–00500 HINT: This is a SST for releasing terminals from 0.64 connectors. Wire Harness Repair Manual (RM1022E) 11 B–2 TERMINAL AND CONNECTOR REPAIR–CONNECTOR REPAIR CONNECTOR REPAIR The repair parts now in supply are limited to those connectors having common shapes and terminal cavity numbers. Therefore, when there is no available replacement connector of the same shape or terminal cavity number, please use one of the alternative methods described below. Make sure that the terminals are placed in the original order in the connector cavities, if possible, to aid in future diagnosis. 1. When a connector with a different number of terminals than the original part is used, select a connector having more terminal cavities than required, and replace both the male and female connector parts. EXAMPLE: You need a connector with six terminals, but the only replacement available is a connector with eight terminal cavities. Replace both the male and female connector parts with the eight terminal part, transferring the terminals from the old connectors to the new connectors. 2. When several different type terminals are used in one connector, select an appropriate male and female connector part for each terminal type used, and replace both male and female connector parts. B EXAMPLE: You need to replace a connector that has two different types of terminals in one connector. Replace the original connector with two new connectors, one connector for one type of terminal, another connector for the other type of terminal. 3. When a different shape of connector is used, first select from available parts a connector with the appropriate number of terminal cavities, and one that uses terminals of the same size as, or larger than, the terminal size in the vehicle. The wire lead on the replacement terminal must also be the same size as, or larger than, the nominal size of the wire in the vehicle. (”Nominal” size may be found by looking at the illustrations in the section F or by direct measurement across the diameter of the insulation). Replace all existing terminals with the new terminals, then insert the terminals into the new connector. EXAMPLE: You need to replace a connector that is round and has six terminal cavities. The only round replacement connector has three terminal cavities. You would select a replacement connector that has six or more terminal cavities and is not round, then select terminals that will fit the new connector. Replace the existing terminals, then insert them into the new connector and join the connector together. Wire Harness Repair Manual (RM1022E) 12 B–3 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT TERMINAL REPLACEMENT These steps must be followed when replacing a terminal. Step 1. Identify the connector and the terminal type. B Step 2. Disconnect the terminal from the connector. Step 3. Replace the terminal. Step 4. Install the terminal into the connector. Wire Harness Repair Manual (RM1022E) 13 B–4 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 1. Identify the connector and the terminal type. Confirm whether the connector you require is the non–waterproof, waterproof or combined terminal type connector from the pictures provided in the following charts. Connector Description Non–Waterproof Type Those connectors which are not of the waterproof or combined terminal type. Waterproof Type Waterproof material (hole plug or terminal packing) is provided on the terminal/connector body. Combined Terminal Type Terminals of different shape/size are located in one connector. B 1. Terminal with Wire Identify the part number of the terminal with wire by picking out the corresponding illustration from the pictures provided on the following charts. HINT: In some of the illustrations, there are two part numbers for the same illustration of terminal with wire, because although the shapes of the terminals are completely the same, there is a difference in with /without gold–plating (gilded). Remark: The length of the wire connected to the terminal is approximately 150 mm. Wire Harness Repair Manual (RM1022E) 14 B–5 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE:
When the terminal used is gold plated, be sure to replace it with a gold plated terminal when marking repairs.
Do not use male and female terminals which are made of different materials from each other. 2. Connector Body (a) (b) Identify the part number of the corresponding terminal with wire according to the above–mentioned 1. Identify the part number of the connector body by picking out the correct one from the illustrations according to the number of terminals and the shape. HINT: If you can find no connector which matches the type you require, pick out male and female connector bodies as a set which have more terminals than you require. For the combined terminal type connector body, pick out and appropriate connector body for each terminal being used. (a) Example: When two types of terminal are used in one connector body, pick out a male and female for two different connector bodies. Example: Back of the Connector Body (b) The part number has been stamped on the back of the connector body. (This will continue to be done to new types of connector.) P/N 90980–10854 Wire Harness Repair Manual (RM1022E) 15 B B–6 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 3. Hole Plug/Terminal Packing (a) Hole Plug (b) Identify the part number of the appropriate terminal with wire/connector body from the illustrations of waterproof type connector according to the above–mentioned 1 and 2. Identify the part number of the hole plug/terminal packing from the corresponding illustration. Connector Body Terminal Packing B 4. Small (Red) Sleeve When connecting two wires using a sleeve, select the sleeve according to the following table. Medium (Blue) Large (Yellow) Wire Outside Diameter Sleeve Size (Color) 0.2–1.0 mm Small (Red) 1.0–2.0 mm Medium (Blue) 3.0–5.0 mm Large (Yellow) (a) When size is based on the outside diameter of the wire. Wire Outside Diameter Insulation Calipers Wire Harness Repair Manual (RM1022E) 16 B–7 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT ∗ 0.3 0.5 0.85 1.25 0.3 S M M 0.5 M M 0.85 M 1.25 2 3 5 M M L L M M M L L M M M L L L M M M M L L L 2 M M L L L L –– 3 L L L L L L –– 5 L L L L –– –– –– ∗ (b) When size is based on the nominal size of the wire. Sleeve size S : Small (Red) M : Medium (Blue) L : Large (Yellow) ∗ Nominal size of the wire Nominal Size of Wire HINT: To calculate the ”Nominal Size” of the wire. Nominal size = 3.14 x (Diameter of stripped wire harness)2 4 Wire Lead Diameter B Calipers Twist Evenly HINT: Outside Diameter and Nominal Size Wire Outside Diameter Nominal Size Insulation Stripped Wire Harness Section Wire Harness Repair Manual (RM1022E) 17 B–8 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 2. Disconnect the Terminal from the Connector. 1. Disconnect Connector To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Press down type is mainly used. Example: Pull Up Press Down Press Down Pull Up B 2. Refereance: Prepare the Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. (mm) 3. Example: Up Tool Disengage the double locking device or terminal retainer. (a) (b) Terminal Retainer Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Use a special tool or the terminal pick to unlock the double locking device. NOTICE: Do not remove the terminal retainer from connector body. Wire Harness Repair Manual (RM1022E) 18 B–9 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type A (For 1.0II, 1.8, 2.3II, 4.8 and 8.0 of Non–Waterproof Type Connector) Raise Up (1) Special Tool Using the special tool, raise the retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (number of terminals, etc.), so check the position before inserting it. Terminal Retainer Terminal Retainer B [Retainer at Full Lock Position] Terminal Retainer Stopper [Retainer at Temporary Lock Position] Good Bad Good [Male] Bad [Female] Type B (For 1.8, 1.0 and TLC of Non–Waterproof Type Connector) Special Tool Wire Harness Repair Manual (RM1022E) 19 B–10 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (1) Press the special tool at a 45° angle into the locking lug access hole as shown. Raise the double locking device up as far as possible. Access Hole (2) Remove the special tool and open the double locking device NOTICE: TLC housing is not be reusable. Please replace it with the new one after replacement of the terminal. Tab B ∗ ∗ Open ∗ [Male] Retainer ∗ ∗ Double Locking Device. [Female] Type C (For TNS, FTC Type Connector) (1) Widen the side lock part of the retainer from side to side using the special tool. Side Lock Wire Harness Repair Manual (RM1022E) 20 Open B–11 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (2) Inset the special tool into the chink between the retainer and the terminal itself. Then pry it to the direction of the arrow shown in the illustration and push the retainer up to release the lock. NOTICE:
Do not insert the special tool too much. It may cause damage on the fit section of the terminal and the wire harness.
TNS housing is not reusable. Please replace it with the new one after replacement of the terminal. Special tool Lock Type D (For 1.3 of Non–Waterproof Type Connector) [Case 1] Use the special tool to unlock the double locking device. (1) ∗ ∗ Special Tool ∗ ∗ ∗ Double Locking Device. Wire Harness Repair Manual (RM1022E) 21 B–12 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT [Case 2] (1) Using the special tool, push the terminal retainer locking lug (clip) and pull the terminal retainer up to the temporary lock position. Locking Lug Special Tool Locking Lug Special Tool [Retainer at Full Lock Position] Special Tool Terminal Retainer Terminal Retainer [Retainer at Temporary Lock Position] [Case 3] (1) Using the special tool, raise the retainer up to the temporary lock position. [Retainer at Full Lock Position] Stopper Terminal Retainer [Retainer at Temporary Lock Position] [Case 4] Service hole Wire Harness Repair Manual (RM1022E) 22 B–13 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (1) Insert the special tool into the service hole and move it to the direction of the arrow to release the lock on the side A. (2) Push the lock on the side B up by the special tool and release the lock. Then pull the retainer forward. A Special tool B Appearance when the double locking is released Wire Harness Repair Manual (RM1022E) 23 B–14 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type E (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof Type Connector) HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector body Black or White : Gray Black or White : Dark Gray Gray or White : Black [Case 1] Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Special Tool Terminal Retainer Special Tool Special Tool Terminal Retainer Access Hole (  Mark) Special Tool [Female] [Male] Wire Harness Repair Manual (RM1022E) 24 B–15 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (1) Insert the special tool into the terminal retainer access hole (  Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Example: Terminal Retainer at Full Lock Position [Male] Access hole Temporary Lock Position [Female] HINT: In some cases insert the special tool from the access hole on the flank of the housing. Wire Harness Repair Manual (RM1022E) 25 B–16 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT [Case 2] Type which cannot be pulled as far as Power Lock HINT: There are few cases of this type of connector Example: Terminal Retainer [Male] Press Down Press Down [Female] (1) Example: Insert the tool straight into the access hole of terminal retainer as shown. Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] Wire Harness Repair Manual (RM1022E) 26 B–17 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type F (For C–Type Connector) Service hole (1) Insert the special tool into the service hole. (2) Move the special tool to the direction of the arrow and release the lock. Retainer HINT: Lift the retainer up after moving it to the direction of the thin arrow shown in the illustration. (3) Special tool Lock Pull the retainer forward by hand and remove the retainer from the housing. Type G
Insert the special tool into the position shown in the illustration. Pry it to the direction of the arrow and push the lock up to release it. Wire Harness Repair Manual (RM1022E) 27 B–18 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type H (For 1.0II Type Connector) (1) Move the special tool into the notch of the retainer to the direction of the arrow with the edge of the housing as the fulcrum. Then the pull the retainer out. NOTICE: Do not insert the special tool into areas except notches. (This may damage the seal ring that is attached behind the retainer.) (2) As same as the procedure (1), pull the retainer straight out using hand after releasing the lock on the other side. Retainer (Yellow) Notch NOTICE:
Do not remove the seal rubber when pulling the terminal out.
If the seal rubber is peeled off when puling the terminal out, press it down to stick it to the original condition.
Be sure and not fit the connector when the retainer is not installed. Seal rubber Type I (For SFPC Type Connector) (1) Open the cover (white) Condition of cover opening Side Lock Side Lock (2) Remove the side lock of the retainer. (One side) (3) Remove the center lock of the housing. (4) Remove the side lock of the retainer. (The other side) NOTICE:
Following the above order is not required.
No center lock on the housing with ten poles. Center Lock Wire Harness Repair Manual (RM1022E) 28 B–19 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (5) Move the retainer until it becomes the initial condition. Retainer Initial condition Type J [Male] (1) Remove the rubber plug. (2) Push the lock of the inner using the special tool. Pull the wire to the direction of the arrow pushing the lock up and remove the inner from the outer. Rubber Plug Outer Lock (3) Inner [Female] (1) Remove the rubber plug. (2) Insert the special tool into the outer shown in the illustration. Then push the area A of the inner and remove the inner from the outer. Rubber Plug Special tool Outer B Inner A Illustration from side B Wire Harness Repair Manual (RM1022E) 29 B–20 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type J (For Insulation Displacement Connector) (1) Special Tool Separate Connector Using a special tool, release the lock and separate the connector into 2. NOTICE: Do not apply too muck force to the lock arm. Lock Special Tool (2) w/ Cover : Open Connector Cover Using a special tool, release the lock and open the cover. Cover NOTICE: Do not apply too much force to the lock arm. Special Tool Raise Up Special Tool Insert Mark Type K (0.64 Type Connector) (1) Special Tool Terminal Retainer Using the special tool, raise the retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (number of terminals, etc.), so check the position before inserting it. Terminal Retainer [Retainer at Full Lock Position] Terminal Retainer Stopper [Retainer at Temporary Lock Position] Wire Harness Repair Manual (RM1022E) 30 B–21 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Good Bad Special Tool Type L (0.64 of Insulation Displacement Connector (IDC) Type) (1) Remove the Lower Housing Using a special tool, release the lock and remove the lower housing. Special Tool Lock Special Tool Lock NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to prevent mistakes when putting them together. (2) Remove the Upper Housing Using a special tool, release the lock and remove the upper housing from the lock housing. NOTICE:
Do not apply too much force to the lock arm.
Mark the upper housing and lower housing to prevent mistakes when putting them together. Special Tool Lock Housing Upper Housing Type M (0.64 of Splash Proof Connector) (1) Release Terminal retainer. Insert Special Tool at the location shown in the figure left. Wire Harness Repair Manual (RM1022E) 31 B–22 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Move Special Tool in the direction of arrow. Terminal Retainer [Retainer at Lock Position] Terminal Retainer [Retainer at Unlock Position] (2) Rear Holder Release Rear holder. Insert Special Tool at the location shown in the figure left. Move Special Tool in the direction of arrow. NOTICE:
Do not remove Rear holder from Connector housing.
If Rear holder completely comes off the housing, replace Connector with a new one. Rear Holder [Rear Holder at Lock Position] Rear Holder [Rear Holder at Unlock Position] Wire Harness Repair Manual (RM1022E) 32 B–23 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Rear Holder 4. Locking Clip Disconnect Terminal from Connector (a) Determine the primary locking system from the charts. 1. Lock Located on terminal 2. Lock Located on connector 3. Method of entry and operation (b) Push the terminal gently into the connector and hold it in this position. (c) Insert the special tool into the connector in the direction shown in the chart. Move the locking clip to the unlock position and hold it there. NOTE: Do not apply excessive force to the terminal. Do not pry on the terminal with the special tool. Pull Out Connector Wire Harness ”Waterproof Type” (d) Terminal Retainer (e) Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTE: Do not use too much force. If the terminal does not come out easily, repeat steps (a) through (e). Special Tool Locking Clip Wire Harness Repair Manual (RM1022E) 33 B–24 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT ”Non–Waterproof Type” Locking Clip Terminal Retainer 4.8 Type (f) 0.64 Type Stopper Portion Insert the SST into the connector in the direction shown in the chart. (g) Insert the SST fully to the tool hole, and push the terminal lance. NOTICE:
The terminal has a lance shape, therefore, the housing may be damaged and the terminal may get stuck if forcibly pried by wires etc.
Insert the SST so that the stopper portion surface is facing up. (h) Tool Hole SST Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTICE: Removal of the terminal from housing cavity will cause damage to the wire seal section, deteriorating waterproofing performance. Replace the connector with a new one. Terminal Lance NOTICE: Do not insert the special tool into the female terminal box. If you do so, replace the terminal with the new one whether the terminal is broken or not. Non–waterproof type TLC housing NOTICE: As for Non–waterproof type TLC housing, insert the special tool into the housing from wire harness side. Insert the tool from wire harness side Wire Harness Repair Manual (RM1022E) 34 B–25 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insulation Displacement Connector Type Tool Hole Special Tool (a) Using a special tool, push the terminal lance from the tool hole. (b) Carefully withdraw the terminal from the connector by pulling the lead toward the rear of the connector. NOTICE:
Do not use too much force. If the terminal does not come out easily, repeat step (a).
Always change the wire with the repair wire, in accordance with page B–27. Special Tool Terminal Lance 0.64 Type Special Tool Tool Hole Special Tool Terminal Lance Wire Harness Repair Manual (RM1022E) 35 B–26 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 5. Terminal Deformation (1) Terminal Bending in Vertical Direction Inspect the terminal and the connector for damage. NOTE:
The locking clip is easily damaged.
Do not reuse the damaged part. 1° or less 1° or less (2) Terminal Bending in Horizontal Direction 3° or less Wire Harness Repair Manual (RM1022E) 36 B–27 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 1. Step 3. Replace the terminal. Cut the Old Terminal from the Harness. (a) Existing terminal Use the new wire lead as a guide for proper length. NOTE: If the length of wire removed is not approximately the same length as the new piece, the following problems may develop:
Too short –– tension on the terminal, splice, or the connector, causing and open circuit.
Too long –– excessive wire near the connector, may get pinched or abraded, causing a short circuit. Cut New Terminal with lead HINT: When connecting a wire harness at there or more spots to the same connector, cut the wire harness as shown on the left. 2. Select the correct replacement terminal with lead, from the supply parts. 3. Strip insulation from wire on the harness and replacement terminal lead. 82998–12200 Stripped insulation length (A) approximately 8 to 11 mm A Existing Harness A Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.) away from the end of the existing harness at vehicle side and also from the end of the repair wire. Supplied lead with New Terminal Wire Harness Repair Manual (RM1022E) 37 B–28 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE: Take care not to damage the wire when stripping the wire harness lead. After finishing the operation, visually inspect the wire. If there is any damage, perform the operation again. Good Example: HINT: If the wire size is not known, start with largest stripper hole and work down until a clean strip of the insulation is removed without nicking or cutting the wire lead. Bad Example: (Wire insulation is Stripped at a Slant) (Wire Lead is Cut) (Insulation Remains on the Lead) 4. Wire Harness Outside Diameter Select Correct Size of Sleeve from the Supply Parts. (a) Insulation Calipers Nominal Size of the Wire Wire Lead Diameter Calipers Measure the diameter of wire by using the measuring device as following:
When size is based on the outside diameter of the wire harness Measure the outside diameter of the wire harness by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the insulation on the lead and taking a reading.
When size is based on the nominal size of the wire lead. Measure the diameter of the wire lead by placing a measuring device, such as a micrometer or Vernier Caliper, across the diameter of the wire lead and taking a reading. HINT: To calculate the ”nominal size” of wire Twist Evenly Nominal size= 3.14 x (Diameter of wire lead)2 4 Wire Harness Repair Manual (RM1022E) 38 B–29 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Small (Red) Use the table to determine proper sleeve size Part Number Medium (Blue) Nominal size of wire (Outside Diameter of wire) Small 82999–12010 0.3 or less (1.0 – 0.2 mm) Medium 82999–12020 0.5 – 1.25 (2.0 – 1.0 mm) Large 82999–12030 2 or more (5.0 – 3.0 mm) Large (Yellow) NOTE: For details, refer to sleeve size table on item 4 of STEP 1 5. Good Example Two Stripped Wires Sleeve (Blue) Crimp the Replacement Terminal Lead to the Harness Lead. (a) Overlap the two stripped wire ends inside the sleeve as illustrated on the left. Pressure–Contact Section Bad Example Wire in Short Position Wire Bend HINT: You might find it easier if you use a miniature special tool as a guide as you insert wires into the sleeve. Special Tool Wire Harness Repair Manual (RM1022E) 39 B–30 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Crimping Tool The crimping tool (AMP Part No. 169060) has color marks on it. Place the sleeve in the correct section of the tool according to the color of the sleeve itself. HINT: For the crimping tool, AMP ”Part No. 169060” is convenient to use. Sleeve Color Marks (c) ”CLOSE HERE” With the center of the sleeve correctly placed between the crimping jaws, squeeze the crimping tool until either end comes into contact at the section marked by ”CLOSE HERE”. Contact HINT: Check to see that the sleeve and wires are still in the correct position before closing the crimping tool ends with steady pressure. (d) Pull the joined wires to either end. Make sure that they are joined firmly by the sleeve. NOTICE: If the joined wires come loose the splice is defective, so replace the sleeve and repeat the procedure. (e) ”INS” Position 6. 10 mm (0.39 in.) Crimp both ends of the sleeve with the crimping tool at the ”INS” position. Protect Joined Section Wrap silicon tape around the joins to protect them from moisture. NOTE: This job is required in repairs of the engine compartment, under the floor and other moisture entry positions. Three or More Times Wire Harness Repair Manual (RM1022E) 40 B–31 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Three or More Times 10 mm (0.39 in.) HINT:
Before starting the operation, thoroughly wipe dirt and grease off the sections to be joined.
If the adhesive surfaces of two tapes come in contact they will stick together and will not come apart, so do not remove the backing film except when using the tape.
Do not let oil and dust, etc. get on the tape surface. (a) (b) (c) (d) Wrap the remaining part of the sleeve with half of the tape overlapping at each turn. (e) Firmly wrap the tape two times or more about 10 mm (0.39 in.) from the other end of the sleeve, then wrap the tape back towards the start again and firmly finish winding the tape around the center of the sleeve. Tape overlapping 10 mm (0.39 in.) Ready about 100 mm (3.94 in.) of silicon tape (Part No. 08231–00045) and peel off the film. Stretch the silicon tape until its width is reduced by half. About 10 mm (0.39 in.) from the end of the sleeve, wrap the silicon tape around the sleeve three or more times while stretching the tape. Two or More Times Finish Wire Harness Repair Manual (RM1022E) 41 B–32 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Step 4. Install the terminal into the connector. HINT: (a) Make sure the terminal is positioned correctly. (b) Insert the terminal until the locking clip locks firmly. (c) Insert the terminal with terminal retainer in the temporary lock position, if equipped. NOTE: If reusing a terminal, check that the locking clip is still in good condition and in the proper position. Locking clip (a) Special Tool (b) If it is on the terminal and not in the proper position, use the special tool to gently bend the locking clip back to the original shape. Check that the other parts of the terminal are in their original shape. NOTICE: Do not readjust or reuse the terminal lance of the insulation displacement connector type terminal. Always change the wire with the repair wire. ”Insulation Displacement Connector” Terminal Lance Special Tool NOTICE: As for 0.64 type terminal, do not adjust the terminal lance with the special tool. ”0.64 Type” Terminal Lance Splash Proof Type Connector Special Tool NOTICE:
Removal of the terminal from housing cavity will cause damage to rubber plug material (the wire seal), deteriorating waterproofing performance. Be sure to replace the housing with a new one.
Check the withdrawn terminal for the following if trying to use it again.
It is free of deformation and damage
It is free of adherents such as rubber plug material (wire seal)
Replace any deformed terminal. Wire Harness Repair Manual (RM1022E) 42 B–33 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 1. Wire Push the Terminal into the Connector until you hear a ”click”. NOTE: Not all terminals will give and audible ”click”. ”Click” ”0.64 IDC Type” ”Click” ”Insulation Displacement Connector” ”Click” Good Example: Bad Example: NOTICE:
After repairing, never let only one harness stretch.
In cese that it becomes short, do over again using the repair wire. Wire Harness Repair Manual (RM1022E) 43 B–34 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT 2. Double Locking Type Connector (with terminal retainer or double locking device) The connector is fitted with a terminal retainer, or a double locking device, it is in the temporary lock position at insert the terminal. Type A (For 1.0, 1.0II, 1.3, 1.8, 2.3II 4.8 and 8.0 of Non–Waterproof Type Connector) Terminal Retainer (a) Example: Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. Double Locking Device Good (b) Insert the terminal until the locking clip locks firmly. Bad ∗ Terminal In Short Position HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. [Female] NOTE: If the terminal to locking clip does not lock firmly, the double locking device cannot lock or terminal retainer does not lock at full lock position so the terminal backs out from connector. Good Bad [Male] ∗ Terminal In Short Position (c) Close terminal retainer or double locking device. The connector is fitted with a terminal retainer, or a double locking device, return it to the full lock position. Wire Harness Repair Manual (RM1022E) 44 B–35 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Full Lock Position [Female] Full Lock Position [Female] Full Lock Position [Male] Terminal Retainer at Temporary Lock Position Type B (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof Type) (For Male Connector) (a) Terminal Locking Clip Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. (b) Insert the terminal until the locking clip locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. Wire Harness Repair Manual (RM1022E) 45 B–36 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTE: If the terminal to locking clip does not lock firmly, terminal retainer can not lock at full lock position so the terminal backs out from connector. Bad Example: Terminal in Short Position Terminal Locking Clip Terminal Retainer (c) [Case 1] ”For Case 1” Push the terminal retainer in to the full lock position. Full Lock Position ”For Case 2” Raise the terminal retainer up to the full lock position. [Case 2] Full Lock Position Terminal Retainer at Temporary Lock Position (For Female Connector) (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. Terminal Locking Clip Wire Harness Repair Manual (RM1022E) 46 B–37 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Insert the terminal until the locking clip locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. Bad Example: Terminal in Short Position NOTE: If the terminal to locking clip does not lock firmly, terminal retainer can not lock at full lock position so the terminal backs out from connector. Terminal Locking Clip (c) [Case 1] ”For Case 1” Push the terminal retainer in to the full lock position. Full Lock Position ”For Case 2” Raise the terminal retainer up to the full lock position. [Case 2] Full Lock Position Wire Harness Repair Manual (RM1022E) 47 B–38 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Type C (For 0.64 Type Connector) (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal with terminal retainer in the temporary lock position. Temporary Lock Position (b) Insert the terminal until the terminal lance locks firmly. HINT: 1. Pull the terminal back gently to check whether it is locked correctly. 2. If it cannot be inserted easily, check the terminal and the connector for damage. NOTE: If the terminal to terminal lance does not lock firmly, the double locking device cannot lock or terminal retainer does not lock at full lock position so the terminal backs out from connector. (c) Close terminal retainer. The connector is fitted with a terminal retainer, return it to the full lock position. Full Lock Position Type D (For 0.64 Splash Proof Type Connector) (a) Verify that the terminal retainer is at unlocked position. Terminal Retainer Wire Harness Repair Manual (RM1022E) 48 B–39 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (b) Verify that Rear Holder is at unlocked position. Upper lock NOTICE: If Rear holder or wire seal has been removed, replace it with new one. Lower lock (c) Insert the terminal fully into the housing until it is locked. HINT: The terminal has a longer insertion stroke than conventional ones. (d) Set Rear holder to locked position. Push Rear holder in the direction of arrow until it is locked. (e) Verify that Rear holder is at the specified position. The rear end of Rear holder is flush with the rear end of Housing. Rear Holder Rear Holder Housing rear end Wire Harness Repair Manual (RM1022E) 49 B–40 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Verify that the lock (upper side) is at the specified position under locked status. Lock check position, upper Lock normal engagement position Incomplete lock engagement Wire Harness Repair Manual (RM1022E) 50 B–41 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Verify that the lock (lower side) is at the specified position under the locked status. Lock check position, lower Lock normal engagement position Incomplete lock engagement (f) Set Terminal retainer to Lock position. Insert Special tool into the hole specified in the left and push Terminal retainer. Insert Special Tool Special Tool hole (U shaped) Wire Harness Repair Manual (RM1022E) 51 B–42 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT (g) Verify that Terminal retainer is inserted to the specified position. NOTICE: If Terminal retainer is stopped at its middle of insertion, holding wire, push Terminal to help it for full insertion. Wire Harness Repair Manual (RM1022E) 52 B–43 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT SPECIAL EXAMPLE
First fit the section A. A
Install the lock of the section A first. A
Install the lock of the retainer and pull the white cover until you hear a click sound. B
Install the convex part (A) of the outer part correctly to the section B of the inner part. A Wire Harness Repair Manual (RM1022E) 53 B–44 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Cover Insulation Displacement Connector w/ Cover : CLOSE COVER NOTICE: Securely lock it HINT: When replacing it to a new connector, cut off the fixing band without leaving it. Fix Band UNITE CONNECTOR Make the projection of the front lock of the upper housing meet the ditch of the front lock of the lower housing and fix the rear lock. NOTICE:
After uniting, securely lock it for not leaving the rear lock arm deformed.
Make sure that the terminals will not become loose by pulling the wires lightly. Wire Harness Repair Manual (RM1022E) 54 B–45 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT Insulation Displacement Connector (0.64 Type) Lock Housing (a) Install the upper housing to the lock housing. NOTICE:
Securely Lock it.
Be careful not to mistake the upper housing and lower housing when putting together. Upper Housing (b) Upper Housing Attached Lock Housing Make the projection of the front lock of the upper housing attached lock housing meet the ditch of the front lock of the lower housing and fix the rear lock. NOTICE:
Afteruniting, securely lock it for not leaving the rear lock arm deformed.
Make sure that the terminals will not become loose by pulling the wires lightily.
Be careful not to mistake the upper housing and lower housing when putting together. Lower Housing 3. When properly installed, pulling gently on the wire lead will prove the terminal is locked in the connector. Wire Pull Wire Harness Repair Manual (RM1022E) 55 B–46 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT NOTICE: If you working on the waterproof type, make sure that a rubber plug or a terminal gasket is inserted into the housing securely. 4. Secure the Repaired Wire to the Harness If the wire is not in the conduit, or secured by other means, wrap vinyl tape around the bundle to keep it together with the other wires. 5. Connect Connector
Fit the male connector to the female terminal. NOTICE:
Do not twist the connector when fitting.
Insert it until fully locked. Wire Harness Repair Manual (RM1022E) 56 B–47 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Low Fit and Lever Type Connector [Case 1] Lever 1. Cut the connection of the connector (1) (2) Push the place indicated by the arrow. The lock is released and lever is lifted up. (3) Lift the lever up until it stops. an (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. Lever 2. Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. HINT: If the lever is locked at the lower position, follow the procedure [Case 1]. (1) to (3) and lift the lever up fully. Wire Harness Repair Manual (RM1022E) 57 B–48 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely locked. Lever Lever is not locked [Case 2] Lever 1. Cut the connection of the connector (1) (2) Hold the area indicated by the arrow in the illustration The lock is released and the lever is lifted up. (3) Lift the lever up fully. (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. Wire Harness Repair Manual (RM1022E) 58 B–49 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS 2. Lever Lever is not locked Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely locked. [Case 3] 1. Cut the connection of the connector (1) (2) Pick the part indicated in the illustration by fingers. The lock is released and the lever is lifted up. (3) Lift the lever up fully. Lever Wire Harness Repair Manual (RM1022E) 59 B–50 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS (4) Cut the connection of the connector. NOTICE: Do not hold the wire harness to pull it. 2. Lever Connect the connector (1) Connect the connector in the condition that the lever is fully lifted up. HINT: If the lever is locked at the lower position, follow the procedure [Case 3]. (1) to (3) and lift the lever up fully. (2) Hold the connector to prevent it from slip off and push it down until you hear a click to lock it. (3) Confirm that the lever is securely fitted Lever is not locked Wire Harness Repair Manual (RM1022E) 60 B–51 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Double locking device pin Coil spring The connector with secondary locking device 1. Area used
Wire harness for SRS airbag deployment Pin Convex part Primary locking device Lock 2. Cut the connection of the connector. (1) Release the double locking. (2) Release the primary locking and separate the connector. NOTICE: Do not hold the wire harness to pull it. 3. Connect the connector (1) Lock Install the primary locking device and connect the connector. (2) Install the double locking device. NOTICE: The double locking device can not be installed unless the primary locking device is installed. Wire Harness Repair Manual (RM1022E) 61 B–52 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS Connector fixed by bolts 1. Area used
Engine control computer harness 2. Connector A (1) Remove the connector A. (2) Loose the bolt using a tool like driver until the connector B can be removed by hand and separate the connector. HINT: If the bolt can not be removed, roll it while pulling forward. Connector B 3. Lass than 1mm Cut the connection of the connector. (1) Connector B Connector A Bolt Connection of the connector Temporarily fit the connector B. (2) Tighten the bolt by using tool like driver and fit the connector B completely. NOTICE:
Tighten the bolt until feeling it lighter. Then confirm that the width of chink of the connector B is less than 1mm.
The bolt can be rolled after it is fitted.
If the impact wrench is used, do not let it rolling more than three seconds. (The housing may be deformed by generated heat)
Be sure and connect the connector B straight. Do not incline it while connecting. (3) Connect the connector A. Cross–section of the bolt Wire Harness Repair Manual (RM1022E) 62 B–53 TERMINAL AND CONNECTOR REPAIR–HOW TO INSTALL AND REMOVE SPECIAL CONNECTORS 1. Cut the connection of the connector (1) Push down on locking arm to unlock. Then hold the back ribs of connector to remove connector. (2) Cut the Connection of the connector. Hold back rib to pull connector Locking Arm NOTICE: Do not hold the wire harness to pull it. 2. back ribs Connect the Connector (1) (2) Align the direction of locking feature in same direction and mate the connector holding the back ribs in straight direction. Insert it until a lock securely locks, and pull the connector lightly after the insertion, and confirm that a lock is enabled. Wire Harness Repair Manual (RM1022E) 63 B–3 TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT TERMINAL REPLACEMENT These steps must be followed when replacing a terminal. Step 1. Identify the connector and the terminal type. B Step 2. Disconnect the terminal from the connector. Step 3. Replace the terminal. Step 4. Install the terminal into the connector. Wire Harness Repair Manual (RM1022E) 13 C–1 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female 0.64 (Double Lock Type) [Terminal Lance] CC 0.64 IDC [Terminal Lance] 1.0 (Double Lock Type) [Housing Lance] 1.0II Non– waterproof Type 90980–11223 (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 64 (Double Lock Type) [Housing Lance] C–2 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female 1.0II 90980–11566 Waterproof Type [Housing Lance] C 1.0III 1.0IV Non– waterproof Type 1.0III IDC 1.0III Waterproof Type 90980–11889 90980–11987 (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 90980–12004 90980–11919 [Terminal Lance] [Terminal Lance] 90980–11863 90980–11856 (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 65 C–3 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 1.3 Non– waterproof Type C 1.3 Non– waterproof Type 1.3 Non– waterproof Type (Double Lock Type) [Housing Lance] 1.3 Waterproof Type 90980–11188 90980–11189 (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 66 C–4 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 1.8 Non– waterproof Type C 1.8 90980–11062 Waterproof Type (Double Lock Type) [Housing Lance] 1.8II (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 90980–10384 90980–10638 [Housing Lance] [Housing Lance] 2.3 Non– waterproof Type Wire Harness Repair Manual (RM1022E) 67 C–5 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female [Housing Lance] [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 2.3 Waterproof Type C 2.3II Non– waterproof Type 2.3II 90980–12026 IDC [Terminal Lance] 2.3II Waterproof Type (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 68 (Double Lock Type) [Housing Lance] C–6 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 4.8 Non– waterproof Type CC 4.8 Waterproof Type (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] [Housing Lance] [Housing Lance] 6.3 Non– waterproof Type 6.3 Single Terminal [Terminal Lance] Wire Harness Repair Manual (RM1022E) 69 C–7 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] 8.0 Non– waterproof Type 8.0 Waterproof Type BLADE FUSE [Housing Lance] C–Type (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 70 (Double Lock Type) [Housing Lance] C–8 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female 6.3 Waterproof Type [Housing Lance] C 6.3 Waterproof Type [Housing Lance] 7.7 [Terminal Lance] [Terminal Lance] [Housing Lance] [Housing Lance] 7.7 Wire Harness Repair Manual (RM1022E) 71 C–9 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female FOG– LP 90980–10481 (Double Lock Type) [Housing Lance] C FTC (Double Lock Type) [Housing Lance] HEAD LAMP 90980–10579 Waterproof Type [Housing Lance] HB3 HB4 90980–11095 [Housing Lance] Wire Harness Repair Manual (RM1022E) 72 C–10 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female [Housing Lance] [Housing Lance] LAC MFPC [Housing Lance] MIC [Terminal Lance] PULSE LOCK [Housing Lance] Wire Harness Repair Manual (RM1022E) 73 C–11 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female SFPC [Housing Lance] SL [Terminal Lance] SP [Housing Lance] TLC Non– waterproof Type (Double Lock Type) [Housing Lance] Wire Harness Repair Manual (RM1022E) 74 (Double Lock Type) [Housing Lance] C–12 TABLE OF HOUSING CROSS SECTION : Position of the lance : Direction of lock released : Direction of the special tool inserted Type Male Female [Housing Lance] [Housing Lance] (Double Lock Type) [Housing Lance] (Double Lock Type) [Housing Lance] [Housing Lance] (Double Lock Type) [Housing Lance] TLC Waterproof Type TNS TODC Wire Harness Repair Manual (RM1022E) 75 E–1 HOUSING PART NUMBER LIST List of equivalent for the gold and tin–plated repair wire Repair Wire Part No. Tin–plated (Sn) Gold–plated (Au) 82998–12160 (2.3.M.U) 82998–24050 –12190 (1.8.F.U) –12300 –12260 (2.3.M.S) –24070 –12270 (2.3.F.S) –24080 –12310 (1.0.F.U) –12320 –12330 (2.3II.M.U) –12350 –12340 (2.3II.F.U) –12360 –12430 (2.3II.M.S) –12450 –12440 (2.3II.F.S) –12460 –12790 (2.3II.F.S) –12780 –12670 (1.0III.M.U) –12680 –12690 (1.0III.F.U) –12700 –12720 (1.0III.F.S) –12730 –24020 (1.0II.F.U) –24110 –24090 (1.8II.M.U) –24130 E Wire Harness Repair Manual (RM1022E) 315 E–2 HOUSING PART NUMBER LIST * Example : 82998–24050 indicates the gold–plated 82998–12160. Part No. of Connector Body Supply Part No. of Repair Wire Male Sealing Terminal Cav. No. 500 mm Female Ability 160 mm Type Type 90980– E 82998– Sleeve Color 82998– 10001 X BHC M 4 U – – – 10002 X BHC F 4 U – – – 10003 X BHC M 6 U – – – 10004 X BHC F 6 U – – – 10006 X BHC F 12 U – – – 10008 X BHC F 16 U – – – 10010 X BHC F 22 U – – – 10011 X BHC M 2 U – – – 10012 X BHC F 2 U – – – 10018 X BHC M 8 U – – – 10019 X BHC F 8 U – – – 10026 X TODC M 16 U 12080 – L,Y 10027 X – – – 12010 – Y 10028 X 12090 – L,Y 10029 X – – – 12020 – Y 10030 X TODC M 17 U 12080 – L,Y 10031 X TODC F 17 U 12090 – L,Y 10032 X TODC M 13 U 12080 – L,Y 10033 X TODC F 13 U 12090 – L,Y 10037 O MIC F 17 U 12120 – L,Y 10038 X TODC M 2 U 12080 – L,Y 10039 X TODC F 2 U 12090 – L,Y 10040 O TODC M 5 U 12080 – L,Y 10041 X TODC F 5 U 12090 – L,Y 10042 X TODC M 7 U 12080 – L,Y 10043 X TODC F 7 U 12090 – L,Y 10044 O TODC M 9 U 12080 – L,Y 10045 O TODC F 9 U 12090 – L,Y 10055 X TODC M 3 U 12080 – L,Y 10056 X TODC F 3 U 12090 – L,Y 10057 X – – – – – – – 10061 X MIC M 13 U – – – 10062 O MIC F 13 U 12120 – L,Y 10063 X MIC M 21 U – – – 10064 X MIC F 21 U 12120 – L,Y 6.3 7.7 TODC 6.3 7.7 M F F 6 6 16 6 6 U U U Wire Harness Repair Manual (RM1022E) 316 Memo PCB PCB E–3 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10065 X TODC M 15 U 12080 – L,Y 10066 X TODC F 15 U 12090 – L,Y 10068 X TODC M 9 U – – – 10069 X SL F 2 U 12130 – L,Y 10070 O SL F 3 U 12130 – L,Y 10071 O SL F 7 U 12130 – L,Y 10072 X 6.3 F 3 U 12060 12580 Y 10087 X TODC M 9 U 12080 – L,Y 10088 X 6.3 F 3 S – – – 10090 X 6.3 F 1 S – – – 10091 X 6.3 M 2 S – – – 10092 X 6.3 F 2 S – – – 10093 X 6.3 M 3 S – – – 10094 X 6.3 M 4 S – – – 10095 X 6.3 F 4 S – – – 10096 X TODC M 6 S – – – 10097 X TODC F 6 S – – – 10100 X TODC M 16 S – – – 10101 X TODC F 16 S – – – 10106 X TODC M 9 U – – – 10108 X SL F 2 U 12130 – L,Y 10109 X SL F 2 U 12130 – L,Y 10110 X 6.3 F 3 S – – – 10111 X FPC F 3 U – – – 10112 X FPC F 8 U – – – 10113 X FPC F 8 U – – – 10114 O 7.7 M 1 S – – – 10115 O 7.7 F 1 S – – – 10116 X 6.3 F 2 S – – – 10117 X TODC M 5 U 12080 – L,Y 10119 X FPC F 8 U – – – 10121 X TODC F 2 U 12090 – L,Y 10122 X 7.7 M 2 S – – – 10123 X 7.7 F 2 S – – – 10124 X 6.3 F 2 U – – – 10125 X TODC M 1 S – – – 10126 X TODC M 4 U 12080 – L,Y 10127 X TODC F 4 U 12090 – L,Y 10130 X TODC M 5 U – – – PCB E PCB PCB Wire Harness Repair Manual (RM1022E) 317 E–4 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– E 82998– Sleeve Color 82998– 10131 X LAC M 22 U 12100 – L,Y 10132 O LAC F 13 U 12110 – L,Y 10133 X LAC F 9 U 12110 – L,Y 10138 X MIC M 13 U – – – 10139 X 6.3 M 4 S – – – 10140 X 6.3 F 4 S – – – 10141 X SL F 2 U 12130 – L,Y 10142 X 6.3 F 4 U – – – 10143 X FPC F 3 U – – – 10144 X 6.3 M 4 U – – – 10145 X – – – 12010 – Y 10146 X – – – 12040 – Y 10147 X TODC M 8 U 12080 – L,Y 10148 X TODC F 8 U 12090 – L,Y 10149 X TODC M 12 U 12080 – L,Y 10150 X TODC F 12 U 12090 – L,Y 10151 X MIC M 22 U – – – 10152 O MIC F 9 U 12120 – L,Y 10153 X 2.3 F 12 U 12170 – L 10154 X – – – – – – 10156 O 6.3 M 2 S – – – 10157 O 6.3 F 2 S – – – 10158 X FPC F 10 U – – – 10159 X FPC F 10 U – – – 10160 X 7.7 M 1 U 12010 – Y 10161 X 6.3 M 5 S – – – 10162 O 6.3 F 5 S – – – 10163 X TODC M 3 U 12080 – L,Y 10164 X TODC F 3 U 12090 – L,Y 10165 X 7.7 F 1 U 12020 – Y 10170 X 6.3 M 4 U 12050 – Y 10171 O 6.3 F 4 U 12060 12580 Y 10172 O 6.3 M 6 U 12050 – Y 10173 O 6.3 F 6 U 12060 12580 Y 10174 O 6.3 M 8 U 12050 – Y 10175 O 6.3 F 8 U 12060 12580 Y 6.3 7.7 6.3 7.7 6.3 7.7 M F M 3 3 2 1 3 3 U U U Wire Harness Repair Manual (RM1022E) 318 Memo PCB PCB w/o Clamp w/o Clamp w/o Clamp E–5 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10176 O 6.3 M 10 U 12050 – Y 10177 O 6.3 F 10 U 12060 12580 Y 10178 O 6.3 M 1 U 12050 – Y 10179 O 6.3 F 1 U 12060 12580 Y 10182 O TODC M 1 U 12080 – L,Y 10183 O TODC F 1 U 12090 – L,Y 10184 X TODC F 2 S – – – 10185 X 7.7 F 2 U 12040 – Y 10186 X 12050 – Y 12030 – Y 10187 X 12050 – Y 12030 – Y 10188 X 12050 – Y 12030 – Y 10189 X 12060 12580 Y 12040 – Y 10190 X EJ M 3 S – – – 10191 X EJ F 3 S – – – 10192 X EJ M 2 S – – – 10193 X EJ F 2 S – – – 10194 X TODC M 6 S – – – 10195 X TODC F 6 S – – – 10196 X 6.3 F 4 U 12060 12580 Y 10197 X TODC F 1 S – – – 10198 X – – – – – – 10199 X – – – – – – 10200 X EJ M 1 S – – – 10201 X EJ F 1 S – – – 10202 X EJ M 4 S – – – 10203 X EJ F 4 S – – – 10204 X EJ M 8 S – – – 10205 X EJ F 8 S – – – 10206 X TODC M 13 U – – – 10207 X TODC F 21 U 12090 – L,Y 10208 X – – – 12080 – L,Y 6.3 7.7 6.3 7.7 6.3 7.7 6.3 7.7 6.3 7.7 6.3 7.7 6.3 TODC M M M F M F M 2 1 2 1 2 1 2 1 2 1 2 1 8 8 U U U U S S U Memo E PCB w/ Flange Wire Harness Repair Manual (RM1022E) 319 E–6 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– E 82998– 6.3 12580 Y 12090 – L,Y 12050 – Y 12080 – L,Y U 12080 – L,Y 13 U 12080 – L,Y M 2 U 12050 – Y 6.3 F 2 U 12060 12580 Y X 6.3 M 3 U 12050 – Y 10216 O 6.3 F 3 U 12060 12580 Y 10217 X TODC M 4 S – – – 10218 X TODC F 4 S – – – 10219 X 6.3 M 4 U 12050 – Y 10220 X 6.3 F 4 S – – – 10221 X 6.3 F 4 U 12060 12580 Y 10222 X 6.3 F 3 U 12060 12580 Y 10223 X 6.3 M 6 U 12050 – Y 10224 X 6.3 F 6 U 12060 12580 Y 10225 X 6.3 M 8 U 12050 – Y 10228 X HEADLAMP F 3 U 24140 24200 L,Y 10229 X 6.3 F 1 U 12060 12580 Y 10231 X 6.3 M 3 U 12050 – Y 10232 X 6.3 F 3 U 12060 12580 Y 10233 X 12050 – Y 12080 – L,Y 10234 X – – – 10235 X – – – – – – 10236 X – – – – – – 10237 X 6.3 M 4 U 12050 – Y 10238 X 7.7 F 2 U 12020 – Y 10239 X 6.3 F 3 S – – – 10240 O TODC M 1 S – – – 10241 O TODC F 1 S – – – 10242 X TODC M 2 S – – – 10243 X TODC F 2 S – – – 10244 O TODC M 3 S – – – 10209 X 10210 X 10211 X TODC M 7 10212 X TODC M 10213 O 6.3 10214 O 10215 TODC 6.3 TODC 6.3 TODC 6.3 6.3 7.7 6.3 7.7 M M F M F 6 2 6 25 25 3 2 1 2 1 U U U U S S Wire Harness Repair Manual (RM1022E) 320 Memo 82998– 12060 F 2 Sleeve Color w/o Clamp w/o Clamp w/o Clamp E–7 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10245 X TODC F 3 S – – – 10246 O 6.3 M 1 S – – – 10247 O 6.3 F 1 S – – – 10248 X 6.3 M 3 S – – – 10249 O 6.3 F 3 S – – – 10250 X 6.3 F 1 U 12060 12580 Y 10251 X 6.3 M 1 U 12050 – Y 10252 X 6.3 F 1 U 12060 12580 Y 10253 X 6.3 M 1 U 12050 – Y 10254 X 6.3 F 1 U 12060 12580 Y 10255 X 6.3 M 2 U 12050 – Y 10256 X 6.3 F 2 U 12060 12580 Y 10257 X 6.3 M 3 U 12050 – Y 10258 X 6.3 F 3 U 12060 12580 Y 10259 X 6.3 M 4 U 12050 – Y 10260 X 6.3 F 4 U 12060 12580 Y 10261 X 6.3 M 5 U 12050 – Y 10262 X 6.3 F 5 U 12060 12580 Y 10263 X 6.3 M 7 U 12050 – Y 10264 X 6.3 F 7 U 12060 12580 Y 10265 X 6.3 M 9 U 12050 – Y 10266 X 6.3 F 9 U 12060 12580 Y 10267 X MIC M 9 U – – – 10272 X LC M 8 U – – – 10273 X LC F 8 U – – – 10274 O TODC F 5 U 12090 – L,Y 10275 X TODC M 7 U 12080 – L,Y 10276 X 6.3 M 5 U 12050 – Y 10277 X 6.3 M 7 U 12050 – Y 10278 X 6.3 M 9 U 12050 – Y 10279 X TODC M 8 U 12080 – L,Y 10280 X TODC F 8 U 12090 – L,Y 10281 X 12050 – Y 12080 – L,Y 10282 X 12060 12580 Y 12090 – L,Y 10283 O 6.3 M 3 U 12050 – Y 10284 X TODC M 18 U 12080 – L,Y 10285 X TODC F 18 U 12090 – L,Y 6.3 TODC 6.3 TODC M F 3 7 3 7 U U Memo w/o Clamp w/o Clamp w/o Clamp E PCB w/ Clamp Wire Harness Repair Manual (RM1022E) 321 E–8 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– E 82998– Sleeve Color 82998– 10286 X TODC M 2 U 12080 – L,Y 10287 X TODC M 16 S – – – 10288 X TODC F 16 S – – – 10289 X LC M 6 U – – – 10290 X LC F 6 U – – – 10291 X LC M 14 U – – – 10292 X LC F 14 U – – – 10293 X PULSE LOCK M 52 U – – – 10294 O PULSE LOCK F 10 U 12200 – L,Y 10295 O PULSE LOCK F 18 U 12210 – L 10296 O PULSE LOCK F 24 U 12210 – L 10297 X TODC M 2 U 12080 – L,Y 10298 X TODC F 2 U 12090 – L,Y 10299 X 6.3 M 3 U 12050 – Y 10300 X 6.3 M 3 U 12050 – Y 10301 X MFPC F 8 U 12150 – L 10302 O MFPC F 10 U 12150 – L 10303 O MFPC F 12 U 12150 – L 10304 X MFPC F 10 U 12150 – L 10305 X 6.3 M 2 U 12050 – Y 10306 X 12050 – Y 12080 – L,Y 10307 X 12060 12580 Y 12090 – L,Y 10308 X MIC M 5 U – – – 10309 X MIC F 5 U 12120 – L,Y 10310 X MIC M 7 U – – – 10311 X MIC F 7 U 12120 – L,Y 10312 X TODC M 6 U 12080 – L,Y 10313 X TODC F 6 U 12090 – L,Y 10314 X TODC M 5 U 12080 – L,Y 10315 X MODU M 26 U – – – 10316 X MODU F 26 U – – – 10317 X 12050 – Y 12080 – L,Y 6.3 TODC 6.3 TODC 6.3 TODC M F M 2 2 2 2 1 8 U U U Wire Harness Repair Manual (RM1022E) 322 Memo PCB w/ Flange w/ Clamp PCB PCB E–9 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 6.3 Memo 82998– 12060 12580 Y 12090 – L,Y 12060 12580 Y 12090 – L,Y U 12170 – L 8 U 12170 – L F 10 U 12170 – L 2.3 M 13 U 12160* – L X 2.3 F 13 U 12170 – L 10325 O 2.3 M 18 U 12160* – L 10326 O 2.3 F 18 U 12170 – L 10327 X 2.3 F 20 U 12170 – L 10328 X 2.3 F 22 U 12170 – L 10329 X 12160* – L 12050 – Y 10330 X 12170 – L 12060 12580 Y 10331 X 12170 – L 12060 12580 Y 10332 X 7.7 F 1 U 12040 – Y 10333 X 6.3 F 2 U 12060 12580 Y 10334 X 6.3 F 6 U 12060 12580 Y 10335 X 6.3 F 6 U 12060 12580 Y 10336 X 6.3 F 8 U 12060 12580 Y 10337 X 6.3 F 11 U 12060 12580 Y 10338 X 6.3 F 11 U 12060 12580 Y 10339 X 12060 12580 Y 12040 – Y 10340 X 12060 12580 Y 12040 – Y 10341 X 6.3 F 3 S 12540 – Y 10342 X 7.7 M 1 U 12030 – Y 10343 X 7.7 F 1 U 12040 – Y 10344 X 6.3 M 2 U 12050 – Y 10345 X 6.3 F 2 U 12060 12580 Y 10346 X 6.3 M 2 U 12050 – Y w/ Clamp 10347 O 6.3 M 3 S 12050 – Y w/ Clamp 10348 X 6.3 F 2 U 12060 12580 Y 10318 X 10319 X 10320 X 2.3 F 2 10321 X 2.3 F 10322 O 2.3 10323 X 10324 TODC 6.3 TODC 2.3 6.3 2.3 6.3 2.3 6.3 6.3 7.7 6.3 7.7 F 1 Sleeve Color F M F F F F 8 1 10 12 2 12 2 14 1 4 1 2 3 U U U U U U U E w/o Clamp Wire Harness Repair Manual (RM1022E) 323 E–10 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– E 82998– Sleeve Color Memo 82998– 10349 X PULSE LOCK M 30 U – – – 10350 X PULSE LOCK F 18 U 12200 – L,Y 10351 O PULSE LOCK F 12 U 12200 – L,Y 10352 X TODC F 2 S – – – 10353 O TODC F 3 S – – – 10354 X 2.3 M 2 U 12160* – L 10355 O 2.3 F 2 U 12170 – L 10356 O 7.7 M 2 U 12030 – Y 10357 O 7.7 F 2 U 12040 – Y 10358 X 6.3 F 8 U 12060 12580 Y 10359 O 6.3 F 1 U 12060 12580 Y 10360 X 2.3 M 8 U 12160* – L 10361 X 2.3 M 20 U 12160* – L 10362 O SP F 2 U 12530 – L,Y 10363 X 5.2 F 1 U – – – 10364 X 2.3 M 3 U 12160* – L 10365 O 2.3 F 3 U 12170 – L 10366 O 2.3 M 6 U 12160* – L 10367 O 2.3 F 6 U 12170 – L 10368 X MFPC F 14 U 12150 – L 10369 O MFPC F 14 U 12150 – L 10370 X PULSE LOCK M 42 U – – – 10371 O PULSE LOCK F 14 U 12210 – L 10372 X MFPC F 12 U 12150 – L 10373 X – – – – – – 10374 X 7.7 M 2 S – – – 10375 X 2.3 M 10 U 12160* – L 10376 X 12520 – L,Y 12530 – L,Y 10377 X SP F 10 U 12530 – L,Y 10378 O MIC F 4 U 12120 – L,Y 10379 X TODC M 9 S – – – 10380 X TODC F 9 S – – – w/o Clamp 10381 X TODC F 9 S – – – w/ Clamp 7.7 TODC SP SP F F 2 2 5 5 S U Wire Harness Repair Manual (RM1022E) 324 PCB w/o Clamp w/o Clamp w/o Clamp PCB w/o Flange E–11 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 6.3 12580 Y 12040 – Y – – – 12080 – L,Y U 12160* – L 2 U 12040 – Y 9 U 12060 12580 Y 12280 – R – – – 12290 – R – – – S 12280 – R 3 S 12290 – R M 1 U 12220 – L 2.3 F 12 U 12170 – L X TLC F 1 U 12230 – L 10399 O TLC M 4 U 12220 – L 10400 X TLC F 4 U 12230 – L 10401 O TLC M 6 U 12220 – L 10402 O TLC F 6 U 12230 – L 10403 X 12220 – L 12080 – L,Y 10404 X 12230 – L 12090 – L,Y 10405 X 12160* – L 12220 – L 10406 X 12170 – L 12230 – L 10407 X TLC M 12 U 12220 – L 10408 X TLC F 12 U 12230 – L 10410 X 6.3 M 3 U 12050 – Y 10411 X 12050 – Y 12080 – L,Y 10412 X 6.3 M 2 S – – – 10413 X 2.3 M 18 U 12160* – L 10414 O 2.3 F 6 U 12170 – L 10415 X 12160* – L 12050 – Y 10416 X – – – 10382 X 10383 X 10384 O 2.3 M 6 10385 X 7.7 F 10386 X 6.3 F 10392 X 10393 X 10394 X TLC M 3 10395 X TLC F 10396 X TLC 10397 X 10398 7.7 6.3 TODC TLC TODC TLC TODC TLC TODC TLC TODC 2.3 TLC 2.3 TLC 6.3 TODC 2.3 6.3 2.3 M M F M F M F M M M 2 2 6 3 2 3 2 6 2 6 2 6 6 6 6 2 6 10 2 6 U U S S U U U U U U U Memo 82998– 12060 F 4 Sleeve Color w/ Flange w/o Flange w/ Clamp w/ Clamp w/ Clamp w/ Clamp PCB Wire Harness Repair Manual (RM1022E) 325 E–12 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 10417 X 2.3 10418 X – 12160* – L 12080 – L,Y 10419 X 12170 – L 12090 – L,Y 10420 X 12170 – L 10421 X 12170 – L 12060 12580 Y 10422 X 12160* – L 12050 – Y 10423 X MIC F 2 U 12120 – L,Y 10424 X 6.3 M 2 U 12050 – Y 10425 X 6.3 F 2 U 12060 12580 Y 10426 X MIC F 2 U 12120 – L,Y 10427 X 2.3 M 10 U 12160* – L 10428 O HEADLAMP F 3 U 24140 24200 L,Y 10429 X PULSE LOCK M 24 U – – – 10430 X TLC M 8 U 12220 – L 10431 X TLC F 8 U 12230 – L 10432 O 2.3 F 12 U 12170 – L 10433 X 2.3 M 1 U 12160* – L w/o Clamp 10434 X 2.3 M 1 U 12160* – L w/ Clamp 10435 X 2.3 F 1 U 12170 – L 10436 X 2.3 M 12 U – – – PCB 10437 O 2.3 M 2 U 12160* – L w/ Clamp 10438 X 2.3 M 1 S 12260* – L 10439 X 2.3 F 1 S 12270* 12600 L 10440 X 2.3 M 12 U – – – PCB 10441 X 2.3 M 18 U – – – PCB 10442 X 12180 – L 12050 – Y 10443 X 12190* – L 12060 12580 Y 10444 X TLC M 3 S 12280 – R w/o Clamp 10445 X TODC M 13 U – – – PCB 10446 X 12050 – Y 12030 – Y TODC 2.3 TODC 2.3 2.3 6.3 2.3 6.3 1.8 6.3 1.8 6.3 6.3 7.7 F F F M M F M 6 2 6 2 3 10 2 12 2 12 3 12 3 4 2 U 82998– – M 10 Memo – 2.3 M Sleeve Color U U U U U U U U Wire Harness Repair Manual (RM1022E) 326 PCB w/ Flange PCB E–13 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 6.3 12580 Y 12040 – Y U – – – 8 U 24170 – Y F 11 U 24170 – Y 6.3 M 7 U 12050 – Y 6.3 F 7 U 12060 12580 Y 12160* – L 12050 – Y 12170 – L 12060 12580 Y U 12220 – L U 12230 – L 12160* – L 12050 – Y 12170 – L 12060 12580 Y U – – – 7 U 12230 – L 15 U 12080 – L,Y 12160* – L 12050 – Y 12170 – L 12060 12580 Y U 12090 – L,Y 2 U 12170 – L M 4 U 12240 – L TNS F 4 U 12250 – L X TNS M 10 U 12240 – L 10469 X TNS F 10 U 12250 – L 10470 O TNS M 14 U 12240 – L 10471 O TNS F 14 U 12250 – L 10472 X 12160* – L 12240 – L 10473 X 12170 – L 12250 – L 10474 O 2.3 F 2 S 12270* 12600 L 10475 O 2.3 M 4 S 12260* – L 10476 O 2.3 F 4 S 12270* 12600 L 10447 O 10448 X 6.3 II M 4 10449 X 6.3 II F 10450 X 6.3 II 10451 X 10452 X 10453 X 10454 X 10455 X TLC M 22 10456 X TLC F 22 10457 X 10458 X 10459 X TLC M 7 10460 X TLC F 10461 X TODC M 10462 X 10463 O 10464 X TODC F 3 10465 X 2.3 F 10466 X TNS 10467 O 10468 7.7 2.3 6.3 2.3 6.3 2.3 6.3 2.3 6.3 2.3 6.3 2.3 6.3 2.3 TNS 2.3 TNS M F M F M F M F 2 12 4 12 4 19 3 19 3 5 3 5 3 12 9 12 9 U U U U U U U U U Memo 82998– 12060 F 4 Sleeve Color PCB Wire Harness Repair Manual (RM1022E) 327 E–14 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10477 X 2.3 M 6 S 12260* – L 10478 X 2.3 F 6 S 12270* 12600 L 10479 X 12160* – L 12050 – Y 10480 X 12170 – L 12060 12580 Y 10481 O 6.3 F 2 U 12060 12580 Y 10482 X 2.3 F 2 U 12170 – L 10483 X 2.3 F 3 U 12170 – L 10484 X 2.3 F 4 U 12170 – L 10485 X 12160* – L 12080 – L,Y 10486 X 12170 – L 12090 – L,Y 10487 O FTC F 5 U 12510 – L,Y 10488 O FTC F 5 U 12510 – L,Y 10489 O FTC F 3 U 12510 – L,Y 10490 O FTC F 3 U 12510 – L,Y 10491 X MIC F 2 U 12120 – L,Y 10492 X 2.3 M 3 S 12260* – L w/o Clamp 10493 X 2.3 M 3 S 12260* – L w/ Clamp 10494 X 2.3 F 3 S 12270* 12600 L 10495 O 2.3 M 2 S 12260* – L 10496 O 2.3 F 2 S 12270* 12600 L 10497 X 2.3 M 2 S 12260* – L 10498 O 2.3 F 2 S 12270* 12600 L 10499 X 6.3 M 1 U 12050 – Y 10500 X 2.3 M 3 S 12260* – L 10501 X 2.3 F 3 S 12270* 12600 L 10502 X 2.3 M 4 U 12160* – L 10503 X 2.3 M 4 U 12160* – L 10504 O 2.3 F 4 U 12170 – L 10505 X 2.3 M 6 U 12160* – L w/ Clamp 10506 X 2.3 M 14 U – – – PCB 10507 X 2.3 F 14 U 12170 – L 10508 X 2.3 M 20 U – – – 10509 X TODC F 5 U 12090 – L,Y 10510 X TNS M 4 S – – – 10511 X TNS F 2 U 12250 – L 2.3 6.3 2.3 6.3 2.3 TODC 2.3 TODC M F M F 12 1 12 1 10 6 10 6 U U U U Wire Harness Repair Manual (RM1022E) 328 w/ Clamp PCB w/o Clamp E–15 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10512 X TNS F 2 U 12250 – L 10513 O 2.3 M 12 U 12160* – L 10514 X 12170 – L 12060 12580 Y 10515 X 2.3 F 4 U 12170 – L 10516 X 2.3 M 10 U – – – 12170 – L 12060 12580 Y 12040 – Y 12160* – L 12050 – Y 12160* – L 12050 – Y 12170 – L 12060 12580 Y 12160* – L 12030 – Y 12170 – L 12040 – Y 2.3 6.3 F 2.3 10517 X 6.3 2 U 4 F 7.7 2.3 2 2 U 2 4 10518 X 10519 X 10520 X 10521 X 10522 X 10523 X TNS F 8 U 12250 – L 10524 X TNS F 12 U 12250 – L 10525 X TNS F 16 U 12250 – L 10526 O TNS F 22 U 12250 – L 10527 X TLC M 10 U – – – 10528 O TLC F 10 U 12230 – L 10529 X TLC M 12 U – – – 10530 X 12170 – L 12060 12580 Y 10531 X 2.3 M 11 U 12160* – L 10532 O 2.3 F 2 S 12270* 12600 L 10533 X 2.3 M 2 S 12260* – L 10534 X 2.3 F 2 S 12270* 12600 L 10535 X 2.3 M 3 U – – – 10536 X 12170 – L 12060 12580 Y 10537 X 12170 – L 12060 12580 Y 10538 X 2.3 F 14 U 12170 – L 10539 X 2.3 F 16 U 12170 – L 6.3 2.3 6.3 2.3 6.3 2.3 7.7 2.3 7.7 2.3 6.3 2.3 6.3 2.3 6.3 M M F M F F F F 1 4 1 4 1 15 1 15 1 17 1 8 1 10 1 U U U U U U U U Memo PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 329 E–16 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10542 X 2.3 M 16 U 12160* – L 10543 X 2.3 F 16 U 12170 – L 10544 X 2.3 M 3 U 12160* – L 10545 X 12160* – L 12050 – Y 10546 X 12220 – L 12260* – L – – – – – – 12270* 12600 L – – – – – – 12270* 12600 L – – – 2.3 6.3 TLC M M 2.3 10547 X 6.3 2 8 U U 12 M 7.7 2.3 12 2 S 2 10548 X 10549 X 10550 X 10551 X 6.3 F 4 S – – – 10552 O TNS M 22 U 12240 – L 10553 X TLC M 3 S 12280 – R 10554 O TLC F 3 S 12290 – R 10555 X 2.3 M 2 S 12260* – L 10556 X 2.3 F 2 S 12270* 12600 L 10557 X TLC M 5 S 12280 – R 10558 X TLC F 5 S 12290 – R 10559 X 7.7 F 2 U 12040 – Y 10560 X 2.3 M 16 U 12160* – L 10561 X 2.3 F 16 U 12170 – L 12160* – L 12050 – Y 6.3 7.7 2.3 6.3 F F F 2.3 10562 10563 X X 6.3 12 2 2 3 2 S S S 12 M 2 U 7.7 1 12030 – Y 2.3 12 12170 – L 12060 12580 Y 12040 – Y 6.3 F 7.7 2 U 1 10564 X 1.8 M 12 U 12180 – L 10565 X 1.8 F 12 U 12190* – L 10566 X 6.3 M 2 S – – – 10567 X 6.3 F 2 S 12540 – Y 10568 X TODC M 12 S – – – 10569 X TODC F 12 S – – – 10570 X TLC M 5 S 12280 – R 10571 X 2.3 M 2 S 12260* – L Wire Harness Repair Manual (RM1022E) 330 Memo w/ Clamp w/ Clamp w/o Clamp E–17 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10572 O 2.3 F 2 S 12270* 12600 L 10573 O 2.3 M 3 U 12160* – L 10574 X HEADLAMP F 3 S 24150 24190 L,Y 10575 O 2.3 M 2 S 12260* – L 10576 X 2.3 F 2 S 12270* 12600 L 10577 O TLC M 3 S 12280 – R 10578 X 2.3 F 2 S 12270* 12600 L 10579 X HEADLAMP F 3 S 24150 24190 L,Y 10580 O 2.3 M 2 S 12260* – L 10581 X 2.3 F 2 S 12270* 12600 L 10582 X 2.3 M 2 S 12260* – L 10583 X 2.3 F 2 S 12270* 12600 L 10584 X TNS M 38 U – – – 10585 X TNS F 24 U 12250 – L 10586 X TNS M 26 U – – – 10587 O TNS F 26 U 12250 – L 10588 X TNS M 20 U – – – 10589 X TNS F 20 U 12250 – L 10590 O 2.3 M 4 S 12260* – L 10591 X 2.3 F 4 S 12270* 12600 L 10592 O 2.3 M 2 S 12260* – L 10593 X 2.3 F 2 S 12270* 12600 L 10594 X 2.3 M 2 S 12260* – L 10595 X 2.3 F 2 S 12270* 12600 L 10596 X 2.3 M 6 S 12260* – L 10597 X 2.3 F 6 S 12270* 12600 L 10598 O 2.3 F 2 S 12270* 12600 L 10599 O TNS M 26 U 12240 – L 10600 X 2.3 M 4 U 12160* – L 10601 O 2.3 F 4 U 12170 – L 10602 X 2.3 M 6 U 12160* – L 10603 X 2.3 M 6 U 12160* – L 10604 X 2.3 F 6 U 12170 – L 10605 X 2.3 F 6 U 12170 – L 10606 X 1.8 M 34 U 12180 – L 10607 X 1.8 F 20 U 12190* – L 10608 X 1.8 F 14 U 12190* – L 10609 O 2.3 F 2 S 12270* 12600 L w/ Clamp w/ Clamp PCB PCB PCB Wire Harness Repair Manual (RM1022E) 331 E–18 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 2.3 Memo 82998– 12170 – L 12250 – L 12170 – L 12250 – L 12170 – L 12250 – L U 12250 – L 16 U 12250 – L M 7 U – – – 6.3 F 4 S 12540 – Y 2.3 F 2 S 12270* 12600 L 12060 12580 Y 12040 – Y U 12060 12580 Y 2 U 12220 – L F 2 U 12230 – L 2.3 F 2 S 12270* 12600 L X 2.3 F 2 S 12270* 12600 L 10624 X 2.3 F 5 S 12270* 12600 L 10625 X 2.3 M 2 S 12260* – L 10626 X 2.3 F 2 S 12270* 12600 L 10627 X TLC M 7 S 12280 – R 10628 X TLC F 7 S 12290 – R 10629 X 2.3 F 3 S 12270* 12600 L 10630 X 2.3 M 18 U – – – 10631 X 2.3 F 5 U 12170 – L 10632 X 2.3 F 12 U 12170 – L 10633 X TLC F 14 U 12230 – L 10634 X TLC F 14 U 12230 – L 10635 X TLC F 16 U 12230 – L 10636 X TLC F 16 U 12230 – L 10637 X 2.3 F 2 U 12170 – L 10638 X 2.3 F 3 U 12170 – L 10639 X 2.3 M 20 U 12160* – L 10640 X 2.3 F 20 U 12170 – L 10641 X 2.3 M 6 U 12160* – L w/ Flange 10642 X 2.3 M 5 S – – – PCB 10643 X 2.3 F 6 S 12270* 12600 L 10644 X 2.3 F 5 U 12170 – L 10610 X 10611 X 10612 X 10613 X TNS F 16 10614 X TNS F 10615 X TODC 10616 X 10617 X 10618 X 10619 O 6.3 F 1 10620 X TLC M 10621 X TLC 10622 X 10623 TNS 2.3 TNS 2.3 TNS 6.3 7.7 F 1 Sleeve Color F F F 4 8 8 10 10 2 1 U U U U Wire Harness Repair Manual (RM1022E) 332 PCB w/ Clamp PCB E–19 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10645 O MFPC F 4 U 12150 – L 10646 X 6.3 M 4 S – – – 10647 X 6.3 M 5 S – – – 10648 O 2.3 M 4 S 12260* – L 10649 X 2.3 F 4 S 12270* 12600 L 10650 O 2.3 M 6 S 12260* – L 10651 X 2.3 F 6 S 12270* 12600 L 10652 X 7.7 F 1 U 12040 – Y 10653 X 1.8 M 13 S – – – 10654 X 1.8 F 13 S 12620 – L 10655 X 1.8 M 18 U – – – 10656 X 1.8 F 18 U 12190* – L 10657 X 1.8 M 30 U – – – 10658 O 1.8 F 12 U 12190* – L 10659 X FTC F 5 U 12510 – L,Y 10660 X 2.3 F 3 U 12170 – L 10661 X TNS M 14 U – – – 10662 X TNS M 4 S – – – 10663 X TNS F 4 S – – – Outer 10664 X TNS F 4 S – – – Inner 10665 X 2.3 M 2 S 12260* – L 10666 X 2.3 M 10 U – – – PCB 10667 X 2.3 M 10 U – – – PCB 10668 X 2.3 M 10 U – – – PCB 10669 O 2.3 F 10 U 12170 – L 10670 X 2.3 M 6 U – – – PCB 10671 X 2.3 M 6 U – – – PCB 10672 O 2.3 F 6 U 12170 – L 10673 X 12060 12580 Y 12040 – Y 10674 X 12160* – L 12050 – Y 10675 X 12170 – L 12060 12580 Y 10676 X TLC M 7 S 12280 – R 10677 X TLC M 9 S 12280 – R 10678 X TLC F 9 S 12290 – R 10679 O 2.3 F 2 U 12170 – L 10680 X TLC M 10 U – – – 6.3 7.7 2.3 6.3 2.3 6.3 F M F 4 2 18 1 18 1 U U U w/ Clamp w/ Clamp PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 333 E–20 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10681 X TNS M 20 U – – – 10682 X TNS M 3 S – – – 10683 X TNS F 3 S – – – 10684 X TNS F 3 S – – – 10685 X 12270* 12600 L 12540 – Y 10686 O 12270* 12600 L 12540 – Y 10687 X 2.3 M 2 U 12160* – L 10688 X 5.2 F 1 U – – – 10689 X 2.3 M 3 S 12260* – L 10690 X 2.3 F 3 S 12270* 12600 L 10691 X TNS M 4 U – – – 10692 X TNS F 4 U 12250 – L 10693 X 2.3 M 10 U 12160* – L 10694 X 2.3 M 6 U 12160* – L 10695 X 2.3 F 3 S 12270* 12600 L 10696 O 1.8 F 20 U 12190* – L 10697 O 1.8 F 14 U 12190* – L 10698 X TLC M 3 S 12280 – R 10699 X TLC M 10 U – – – 10700 X 6.3 M 2 U 12050 – Y 10701 X 6.3 F 4 S 12540 – Y 10702 O 2.3 F 2 S 12270* 12600 L 10703 X 6.3 F 1 U 12060 12580 Y 10704 X 6.3 F 3 U 12060 12580 Y 10705 X 6.3 F 1 S – – – 10706 O 2.3 F 2 S 12270* 12600 L 10707 X 2.3 M 2 S 12260* – L 10708 X 6.3 F 3 S – – – 10709 X 12260* – L 12280 – R 10710 X 12270* 12600 L 12290 – R 10711 O 1.8 F 4 S 12620 – L 10712 X 2.3 F 5 S 12270* 12600 L 10713 X 12060 12580 Y 12040 – Y 2.3 6.3 2.3 6.3 2.3 TLC 2.3 TLC 6.3 7.7 F F M F F 2 2 7 2 2 3 2 3 3 2 S S S S U Wire Harness Repair Manual (RM1022E) 334 Memo PCB PCB PCB E–21 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 2.3 Memo 82998– 12170 – L 12060 12580 Y U 12160* – L 4 U 12170 – L F 4 U 12170 – L 6.3 F 5 U 12060 12580 Y O TLC M 10 U 12220 – L 10720 O 2.3 F 2 S 12270* 12600 L 10721 X 2.3 F 10 U 12170 – L 10722 X 1.8 M 34 U 12180 – L 10723 X 2.3 F 11 U 12170 – L 10724 X 2.3 F 12 U 12170 – L 10725 X 2.3 F 12 U 12170 – L 10726 X PULSE LOCK M 30 U – – – 10727 X 12170 – L 12060 12580 Y 10728 X – – – – – – 10729 X 12170 – L 12060 12580 Y 10730 X 2.3 M 17 U 12160* – L 10731 X 2.3 F 17 U 12170 – L 10732 X TNS M 14 U – – – PCB 10733 X TNS M 20 U – – – PCB 10734 X 1.8 F 2 S 12620 – L 10735 X 1.8 F 2 S 12620 – L 10736 X 1.8 F 2 S 12620 – L 10737 O 1.8 F 2 S 12620 – L 10738 X – – – – – – 10739 X 12190* – L 12310* – L 10740 X 12310* – L 10741 X 12190* – L 12310* – L 10742 X 1.8 M 42 U – – – 10743 O 1.8 F 12 U 12190* – L 10744 X 2.3 M 16 U – – – 10714 X 10715 X 2.3 M 14 10716 X 2.3 F 10717 X 2.3 10718 X 10719 6.3 2.3 6.3 2.3 6.3 2.3 6.3 1.8 1.0 1.8 1.0 1.0 1.8 1.0 F 9 Sleeve Color F M F M F F F 3 9 2 5 2 5 2 16 48 10 16 16 6 16 U U U U U U U U PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 335 E–22 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10745 X 2.3 M 6 U – – – 10747 X 8.0 F 3 U 12400 – Y 10748 X 2.3 F 2 S 12270* 12600 L 10749 O 12470 – Y 12430* – L,Y 10750 X TNS M 26 U 12240 – L 10751 X 2.3 M 4 S 12260* – L w/ Clamp 10752 X 1.8 M 30 U – – – PCB 10753 X 2.3 M 16 U – – – PCB 10758 X 6.3 M 4 U 12050 – Y w/ Clamp 10759 X 12060 12580 Y 12040 – Y 10760 X – – – 12060 12580 Y 10761 X – – – – – – 10762 X 12160* – L 10763 O 12190* – L 12310* – L 10764 O 12310* – L 10765 O 12190* – L 12310* – L 10766 X 12060 12580 Y 12040 – Y 10767 X 2.3 II M 14 U – – – PCB 10768 X 2.3 M 4 S 12260* – L w/o Clamp 10769 X 2.3 M 8 U – – – PCB 10770 X PULSE LOCK M 24 U – – – PCB 10771 X – – – – – – 10772 X 12170 – L 12060 12580 Y 10773 X – – – – – – 10774 X 2.3 M 3 S 12260* – L 10775 X TODC M 9 S – – – 10776 X TODC F 9 S – – – 10777 X TLC M 3 S 12280 – R 4.8 2.3 II 6.3 7.7 5.2 6.3 1.8 1.0 2.3 1.8 1.0 1.0 1.8 1.0 6.3 7.7 2.3 6.3 2.3 6.3 1.8 1.0 M F F M M F F F F M F M 2 2 2 2 1 1 16 48 5 10 16 16 6 16 4 2 5 2 5 2 16 48 S U U U U U U U U U U U Wire Harness Repair Manual (RM1022E) 336 PCB PCB PCB PCB w/ Clamp w/ Clamp E–23 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 2.3 10778 X 2.3 2 F 6.3 TNS 15 1 12270* 12600 L 12170 – L 12060 12580 Y 12240 – L – – – – – – 10780 X 10781 X MIC F 11 U 12120 – L,Y 10782 X 7.7 F 1 U 12040 – Y 10783 X 7.7 F 2 U 12040 – Y 10784 X 12060 12580 Y 12040 – Y 10785 X 2.3 F 6 U 12170 – L 10786 O 6.3 F 1 U 12070 – Y 10787 X 2.3 M 3 S 12260* – L w/ Clamp 10788 X 2.3 M 2 S 12260* – L w/ Clamp 10789 O 2.3 II F 5 U 12340* – L,Y 10790 X 2.3 II M 5 U – – – 10791 X 12160* – L 12050 – Y 10792 O 6.3 F 1 U 12060 12580 Y 10793 X 2.3 II M 6 U – – – 10794 O 2.3 II M 4 U 12330* – L,Y 10795 O 2.3 II F 4 U 12340* – L,Y 10796 O 2.3 II M 6 U 12330* – L,Y 10797 O 2.3 II F 6 U 12340* – L,Y 10798 O 2.3 II M 8 U 12330* – L,Y 10799 O 2.3 II F 8 U 12340* – L,Y 10800 O 2.3 II M 10 U 12330* – L,Y 10801 O 2.3 II F 10 U 12340* – L,Y 10802 O 2.3 II M 12 U 12330* – L,Y 10803 O 2.3 II F 12 U 12340* – L,Y 10804 O 2.3 II M 13 U 12330* – L,Y 10805 O 2.3 II F 13 U 12340* – L,Y 10806 O 2.3 II M 14 U 12330* – L,Y 10807 O 2.3 II F 14 U 12340* – L,Y 10808 O 2.3 II M 16 U 12330* – L,Y 10809 O 2.3 II F 16 U 12340* – L,Y 10810 O 2.3 II M 20 U 12330* – L,Y 10811 O 2.3 II F 20 U 12340* – L,Y 1.0 6.3 7.7 2.3 6.3 F M 16 48 2 1 2 2 U 82998– X M 24 U Memo 10779 1.8 M S Sleeve Color U U U PCB PCB PCB Wire Harness Repair Manual (RM1022E) 337 E–24 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y U 12330* – L,Y 18 U 12340* – L,Y M 20 U 12330* – L,Y 2.3 II F 20 U 12340* – L,Y O 2.3 II F 10 U 12340* – L,Y 10823 O 2.3 II F 2 U 12340* – L,Y 10824 O 2.3 II M 2 U 12330* – L,Y 10825 O 2.3 II F 2 U 12340* – L,Y 10826 X TLC M 9 S 12280 – R 10827 O 2.3 II M 15 U 12330* – L,Y 10828 O 2.3 II F 15 U 12340* – L,Y 10829 O 2.3 II M 11 U 12330* – L,Y 10830 O 2.3 II F 11 U 12340* – L,Y 10831 X 2.3 F 4 S 12270* 12600 L 10833 O 2.3 II M 2 U 12330* – L,Y 10834 O 2.3 II F 3 S 12440* 12590 L,Y 10835 O 2.3 II F 2 U 12340* – L,Y 10836 O 8.0 M 1 S 12490 – Y 10837 O 8.0 F 1 S 12500 – Y 10838 O 8.0 M 2 S 12490 – Y 10839 O 8.0 F 2 S 12500 – Y 10840 O 4.8 M 3 S 12470 – Y 10841 O 4.8 F 3 S 12480 – Y 10842 O 2.3 II M 2 S 12430* – L,Y 10843 O 2.3 II F 2 S 12440* 12590 L,Y 10844 O 12480 – Y 12440* 12590 L,Y 10812 O 10813 O 10814 O 10815 O 10816 O 10817 O 10818 O 2.3 II M 18 10819 O 2.3 II F 10820 O 2.3 II 10821 O 10822 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II F M F M F F 12 2 12 3 12 3 12 2 18 2 18 2 2 U U U U U U S Wire Harness Repair Manual (RM1022E) 338 Memo 82998– 12370 M 2 Sleeve Color w/ Clamp E–25 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10845 O 2.3 II F 3 S 12440* 12590 L,Y 10846 X 2.3 F 2 S 12270* 12600 L 10847 X 2.3 F 2 S 12270* 12600 L 10848 O 2.3 II F 16 U 12340* – L,Y 10849 X 2.3 II M 2 U 12330* – L,Y 10850 O 2.3 II F 2 U 12340* – L,Y 10851 X 2.3 II M 14 U – – – 10852 O 2.3 II F 14 U 12340* – L,Y 10853 X 2.3 II F 2 S 12440* 12590 L,Y 10854 O 2.3 II F 6 S 12440* 12590 L,Y 10855 O 2.3 II F 2 U 12340* – L,Y 10856 O 12330* – L,Y 12390 – Y 10857 O 12340* – L,Y 12400 – Y 10858 O 2.3 II M 4 U 12330* – L,Y 10859 O 2.3 II M 2 U 12330* – L,Y 10860 O 2.3 II F 2 U 12340* – L,Y 10861 O 4.8 M 10 U 12370 – Y 10862 O 4.8 F 10 U 12380 – Y 10863 X 2.3 II M 18 U – – – PCB 10864 O 2.3 II M 12 U – – – PCB 10865 X 2.3 II M 10 U – – – PCB 10866 O 8.0 M 4 U 12390 – Y 10867 O 8.0 F 4 U 12400 – Y 10868 O 2.3 II M 4 S 12430* – L,Y 10869 O 2.3 II F 4 S 12440* 12590 L,Y 10870 O 2.3 II M 1 U 12330* – L,Y 10871 O 2.3 II F 1 U 12340* – L,Y 10872 O 12370 – Y 12330* – L,Y 10873 O 12380 – Y 12340* – L,Y 10874 O 2.3 II M 16 U – – – 10875 O 2.3 II F 22 U 12340* – L,Y 10876 O 12370 – Y 12330* – L,Y 10877 O 12380 – Y 12340* – L,Y 2.3 II 8.0 2.3 II 8.0 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II M F M F M F 18 1 18 1 7 4 7 4 3 5 3 5 U U U U U U PCB w/o Clamp PCB Wire Harness Repair Manual (RM1022E) 339 E–26 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 82998– 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y S 12430* – L,Y S 12440* 12590 L,Y 12380 – Y 12400 – Y 12380 – Y 12400 – Y S 12430* – L,Y 8 S 12440* 12590 L,Y M 1 S 12430* – L,Y F 1 S 12440* 12590 L,Y 12470 – Y 12430* – L,Y 12480 – Y 12440* 12590 L,Y S 12430* – L,Y 8 S 12440* 12590 L,Y M 2 S 12430* – L,Y 2.3 II F 2 S 12440* 12590 L,Y O 2.3 II M 2 S 12430* – L,Y 10901 O 2.3 II F 2 S 12440* 12590 L,Y 10902 O 2.3 II F 3 S 12440* 12590 L,Y 10903 O 8.0 F 2 U 12400 – Y 10904 O 2.3 II F 4 U 12340* – L,Y 10878 O 10879 O 10880 O 10881 O 10882 O 10883 O 10884 O 10885 O 10886 O 2.3 II M 2 10887 O 2.3 II F 2 10888 O 10889 O 10890 O 2.3 II M 8 10891 O 2.3 II F 10892 O 2.3 II 10893 O 2.3 II 10894 O 10895 O 10896 O 2.3 II M 8 10897 O 2.3 II F 10898 O 2.3 II 10899 O 10900 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 8.0 4.8 8.0 4.8 2.3 II 4.8 2.3 II M 2 Sleeve Color F M F M F M F F F M F 10 2 10 4 20 4 20 1 18 1 18 4 12 4 12 2 3 4 2 2 6 2 6 U U U U U U U U U U S S Wire Harness Repair Manual (RM1022E) 340 Memo E–27 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10905 O 2.3 II M 2 U 12330* – L,Y 10906 O 2.3 II F 2 U 12340* – L,Y 10907 O 2.3 II M 3 U 12330* – L,Y 10908 O 2.3 II F 3 U 12340* – L,Y 10909 O 12330* – L,Y 12390 – Y 10910 O 12340* – L,Y 12400 – Y 10911 O 4.8 F 1 U 12380 – Y 10912 O 4.8 F 1 U 12380 – Y 10913 X 6.3 F 1 U 12060 12580 Y 10914 X 6.3 F 1 U 12060 12580 Y 10915 O 4.8 M 2 U 12370 – Y 10916 O 4.8 F 2 U 12380 – Y 10917 X – – – – – – 10918 X 12190* – L 12310* – L 10919 O 12440* 12590 L,Y 10920 O 12410 – L 12330* – L,Y 10921 O 12420 – L 12340* – L,Y 10923 O 12440* 12590 L,Y 10924 X – – – – – – 10925 O 12190* – L 12310* – L 10926 O 4.8 F 8 U 12380 – Y 10927 O 4.8 M 2 S 12470 – Y 10928 O 4.8 F 2 S 12480 – Y 10929 X 1.8 F 4 S 12620 – L 10930 O 2.3 II M 7 S 12430* – L,Y 10931 O 2.3 II F 7 S 12440* 12590 L,Y 10932 O 12380 – Y 12340* – L,Y 10933 O 2.3 II F 6 U 12340* – L,Y 10934 O 2.3 II M 2 U 12330* – L,Y 10935 O 2.3 II F 2 U 12340* – L,Y 2.3 II 8.0 2.3 II 8.0 1.8 1.0 1.8 1.0 2.3 II 1.3 2.3 II 1.3 2.3 II 2.3 II 1.8 1.0 1.8 1.0 4.8 2.3 II M F M F F M F F M F F 4 2 4 2 8 18 8 18 3 19 4 19 4 2 16 10 10 16 2 10 U U U U S U U S U U U Memo PCB PCB Wire Harness Repair Manual (RM1022E) 341 E–28 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10936 X 2.3 II M 20 U – – – PCB 10937 X 2.3 II M 18 U – – – PCB 10938 X 2.3 II M 12 U – – – PCB 10939 O 12480 – Y 12440* 12590 L,Y 10940 O 12480 – Y 12440* 12590 L,Y 10941 O 2.3 II M 4 S 12430* – L,Y 10942 O 2.3 II F 4 S 12440* 12590 L,Y 10943 O 2.3 II F 4 S 12440* 12590 L,Y 10944 O 4.8 M 3 S 12470 – Y 10945 O 12470 – Y 12430* – L,Y 10946 O 12480 – Y 12440* 12590 L,Y 10947 O 2.3 II F 2 S 12440* 12590 L,Y 10948 O 2.3 II M 2 S 12430* – L,Y 10949 O 2.3 II F 2 S 12440* 12590 L,Y 10950 X 2.3 II F 88 U 12340* – L,Y 10951 X 2.3 II M 52 U 12330* – L,Y 10952 X 12380 – Y 12400 – Y 10953 X 12380 – Y 12400 – Y 10954 X 12370 – Y 12390 – Y 10955 X 12380 – Y 12400 – Y 10956 O 8.0 F 3 U 12400 – Y 10957 O 2.3 II F 6 U 12340* – L,Y 10958 O 8.0 M 2 U 12390 – Y 10959 O 2.3 II M 2 S 12430* – L,Y 10960 X MIRROR F 2 U – – – 10961 X 2.3 II M 10 U – – – 10962 O 2.3 II F 2 U 12340* – L,Y 10963 O 4.8 M 8 U 12370 – Y 10964 O 2.3 II F 6 U 12340* – L,Y 10965 O 2.3 II F 10 U 12340* – L,Y 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 2.3 II 4.8 8.0 4.8 8.0 4.8 8.0 4.8 8.0 F F M F F F M F 2 4 2 2 2 3 2 3 12 8 18 4 18 6 18 6 S S S S U U U U Wire Harness Repair Manual (RM1022E) 342 PCB E–29 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 10966 O 2.3 II F 11 U 12340* – L,Y 10967 O 2.3 II F 12 U 12340* – L,Y 10968 O 2.3 II F 12 U 12340* – L,Y 10969 X – – – – – – 10970 X 7.7 M 2 S – – – 10971 X 2.3 II M 14 U – – – 10972 X – – – – – – 10973 O 1.8 F 12 U 12190* – L 10974 O 2.3 II F 2 S 12440* 12590 L,Y 10975 O 4.8 M 6 U 12370 – Y 10976 O 4.8 F 6 U 12380 – Y 10977 O 2.3 II M 22 U 12330* – L,Y 10978 O – – – – – – 10979 X 4.8 M 3 U 12370 – Y 10980 O 4.8 F 3 U 12380 – Y 10981 O 2.3 II F 3 S 12440* 12590 L,Y 10982 O 4.8 M 1 S 12470 – Y 10983 O 4.8 F 1 S 12480 – Y 10984 X 2.3 M 6 S 12260* – L 10985 O 12370 – Y 12330* – L,Y 10986 O 12380 – Y 12340* – L,Y 10987 O 2.3 II M 6 S 12430* – L,Y 10988 O 2.3 II F 6 S 12440* 12590 L,Y 10989 O 4.8 M 4 S 12470 – Y 10990 O 4.8 F 4 S 12480 – Y 10991 X – – – – – – 10992 X – – – – – – 10993 O 12380 – Y 12340* – L,Y 10994 O 8.0 M 1 U 12390 – Y 10995 O 8.0 F 1 U 12400 – Y 10996 O 2.3 II F 6 U 12340* – L,Y 1.8 1.0 1.8 1.0 1.8 1.0 4.8 2.3 II 4.8 2.3 II 1.8 1.0 4.8 2.3 II 4.8 2.3 II M M M M F M M F 10 32 22 32 16 10 1 4 1 4 18 16 4 6 4 6 U U U U U U U U Memo PCB PCB PCB PCB w/o Clamp PCB PCB Wire Harness Repair Manual (RM1022E) 343 E–30 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 10997 O 2.3 II F 10 U 12340* – L,Y 10998 O 2.3 II M 6 U 12330* – L,Y 11001 O 2.3 II F 6 U 12340* – L,Y 11002 O 2.3 II M 2 S 12430* – L,Y 11003 O 2.3 II F 2 S 12440* 12590 L,Y 11004 O 2.3 II M 2 S 12430* – L,Y 11005 O 2.3 II F 2 S 12440* 12590 L,Y 11006 O 2.3 II M 1 S 12430* – L,Y 11007 O 2.3 II F 1 S 12440* 12590 L,Y 11008 O 2.3 II M 2 S 12430* – L,Y 11009 O 2.3 II F 2 S 12440* 12590 L,Y 11010 O 2.3 II M 6 U 12330* – L,Y 11011 O 2.3 II F 6 U 12340* – L,Y 11012 O 2.3 II M 4 U 12330* – L,Y 11013 O 2.3 II F 4 U 12340* – L,Y 11014 X 6.3 M 2 U 12050 – Y 11015 O 2.3 II M 3 S 12430* – L,Y 11016 O 2.3 II F 3 S 12440* 12590 L,Y 11017 X 1.8 M 18 U – – – PCB 11018 X 1.8 M 42 U – – – PCB 11019 O 2.3 II F 2 S 12440* 12590 L,Y 11020 O 2.3 II F 3 S 12440* 12590 L,Y 11021 O 12470 – Y 12430* – L,Y 11022 O 12480 – Y 12440* 12590 L,Y 11023 O 2.3 II M 4 U 12330* – L,Y 11024 O 2.3 II F 5 S 12440* 12590 L,Y 11025 O 2.3 II F 2 S 12440* 12590 L,Y 11026 O 2.3 II M 1 U 12330* – L,Y 11027 O 2.3 II M 4 S 12430* – L,Y 11028 O 2.3 II F 4 S 12440* 12590 L,Y 11029 O 2.3 II M 2 S 12430* – L,Y 11030 O 2.3 II F 2 S 12440* 12590 L,Y 11031 O 8.0 M 2 S 12490 – Y 11032 O 8.0 F 2 S 12500 – Y 11033 O 2.3 II M 6 S 12430* – L,Y 11034 O 2.3 II F 6 S 12440* 12590 L,Y 11035 O 4.8 M 4 S 12470 – Y 4.8 2.3 II 4.8 2.3 II M F 2 3 2 3 S S Wire Harness Repair Manual (RM1022E) 344 w/ Clamp E–31 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 11036 O 4.8 F 4 S 12480 – Y 11037 O 2.3 II F 4 S 12440* 12590 L,Y 11038 O 2.3 II F 2 S 12440* 12590 L,Y 11039 X – – – – – – 11040 X – – – – – – 11041 O 12420 – L 11042 O 12420 – L 12340* – L,Y 11043 O 12420 – L 11044 O 12470 – Y 12490 – Y 11045 O 12480 – Y 12500 – Y 11046 X 2.3 II M 17 U 12330* – L,Y 11049 O 2.3 II F 5 S 12440* 12590 L,Y 11050 O 2.3 II M 2 S 12430* – L,Y 11051 O 2.3 II F 2 S 12440* 12590 L,Y 11052 O 1.3 M 3 U 12410 – L 11053 O 1.3 F 3 U 12420 – L 11054 X – – – – – – 11055 O 12420 – L 11056 O 12420 – L 12340* – L,Y 11057 X – – – – – – 11058 O 12420 – L 12340* – L,Y 11059 X – – – – – – 11060 O 2.3 II M 2 U 12330* – L,Y 11061 X 1.8 F 2 S 12620 – L 11062 O 1.8 F 2 S 12620 – L 11063 O 1.3 M 4 S 12630 – L Outer 11064 O 1.3 M 4 S 12630 – L Inner 11065 O 1.3 F 4 S 12650 – L Outer 11066 O 1.3 F 4 S 12650 – L Inner 1.8 1.0 1.3 2.3 II 1.3 1.3 2.3 II 1.3 4.8 8.0 4.8 8.0 1.3 2.3 II 1.3 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.8 1.0 M M F F F M F M F F M F M 16 18 47 4 11 11 4 25 2 1 2 1 55 8 25 11 4 21 4 21 4 18 16 U U U U U S S U U U U U U PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 345 E–32 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 11067 X 2.3 II M 6 U – – – 11068 O 2.3 II F 2 S 12440* 12590 L,Y 11069 O 2.3 II M 2 S 12430* – L,Y 11070 O 2.3 II F 2 S 12440* 12590 L,Y 11071 O 2.3 II F 3 U 12340* – L,Y 11072 O 2.3 II M 2 S 12430* – L,Y 11073 O 2.3 II M 2 S 12430* – L,Y w/o Clamp 11074 O 2.3 II M 2 S 12430* – L,Y w/ Clamp 11075 O 2.3 II F 2 S 12440* 12590 L,Y 11076 X TNS M 4 S – – – 11077 O 2.3 II F 5 S 12440* 12590 L,Y 11078 O 2.3 II M 5 S 12430* – L,Y 11079 O 2.3 II F 3 U 12340* – L,Y 11080 O 2.3 II F 2 U 12340* – L,Y 11081 X – – – – – – 11082 X 1.0 F 16 U 12310* – L 11083 O 1.3 F 11 U 12420 – L 11084 X – – – – – – 11085 O 2.3 II M 5 U 12330* – L,Y 11086 O 2.3 II M 12 S 12430* – L,Y 11087 O 2.3 II F 12 S 12440* 12590 L,Y 11088 O 1.3 M 15 S 12630 – L 11089 O 1.3 F 15 S 12650 – L 11090 O 2.3 II F 4 U 12340* – L,Y 11091 O 4.8 F 6 U 12380 – Y 11092 O 4.8 F 8 U 12380 – Y 11093 O 4.8 M 2 U 12370 – Y 11094 O 4.8 F 2 U 12380 – Y 11095 O HEADLAMP F 2 S 24150 24190 L,Y 11096 O HEADLAMP F 2 S 24150 24190 L,Y 11097 O 2.3 II M 1 U 12330* – L,Y 11098 O 2.3 II F 2 U 12340* – L,Y 11099 O 2.3 II M 6 U 12330* – L,Y 11100 O 2.3 II M 4 U 12330* – L,Y 11101 O 2.3 II M 6 U 12330* – L,Y 11102 O 2.3 II M 10 U 12330* – L,Y 1.8 1.0 1.3 2.3 II M M 10 32 30 4 U U Wire Harness Repair Manual (RM1022E) 346 PCB w/ Clamp PCB PCB w/ Clamp E–33 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.8 Memo 82998– – – – – – – U – – – PCB 12 U – – – PCB M 4 U – – – PCB 1.3 F 4 U 12420 – L X HEADLAMP F 3 S 24150 24190 L,Y 11110 O 2.3 II M 6 U 12330* – L,Y 11111 O – – – – – – – 11113 O SFPC F 16 U 24180 – L 11114 O SFPC F 13 U 24180 – L 11115 O SFPC F 13 U 24180 – L 11116 O SFPC F 10 U 24180 – L 11117 X 2.3 II M 20 U – – – 11118 O 12380 – Y 12340* – L,Y 11119 X – – – 11120 X – – – – – – 11121 O 2.3 II F 12 U 12340* – L,Y 11122 O 2.3 II M 4 S 12430* – L,Y 11123 X 2.3 II M 8 U – – – PCB 11124 X 1.8 M 30 U – – – PCB 11125 O 1.3 F 21 U 12420 – L 11126 O 12370 – Y 12330* – L,Y 11127 O – – – 11128 X – – – – – – 11129 O 12310* – L 11130 O 12380 – Y 12340* – L,Y 11131 O 2.3 II M 3 S 12430* – L,Y 11132 O 2.3 II F 3 S 12440* 12590 L,Y 11133 O 1.3 M 25 U 12410 – L 11134 O 2.3 II M 8 U – – – 11135 O 4.8 M 4 U 12370 – Y 11136 O 4.8 F 4 U 12380 – Y 11103 X 11104 X 2.3 II M 20 11105 X 2.3 II M 11106 X 1.3 11107 O 11108 1.0 4.8 2.3 II 1.3 1.3 2.3 II 4.8 2.3 II 2.3 II 1.8 1.0 1.0 4.8 2.3 II M 8 Sleeve Color F M M M M M F F 18 2 2 21 19 4 2 2 18 16 60 12 2 6 U U U U U U U U U PCB PCB PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 347 E–34 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 11137 O 2.3 II – L,Y 11138 O 12470 – Y 12490 – Y 11139 O 12480 – Y 12500 – Y 11140 O 2.3 II F 2 S 12440* 12590 L,Y 11141 O 2.3 II M 2 S 12430* – L,Y 11142 O 2.3 II F 2 S 12440* 12590 L,Y 11143 O 2.3 II F 3 S 12440* 12590 L,Y 11144 O 2.3 II F 6 S 12440* 12590 L,Y 11145 O 2.3 II F 3 S 12440* 12590 L,Y 11146 O 2.3 II M 1 U 12330* – L,Y 11147 O 2.3 II F 1 U 12340* – L,Y 11148 O 2.3 II F 2 U 12340* – L,Y 11149 O 2.3 II F 2 S 12440* 12590 L,Y 11150 O 2.3 II F 4 S 12440* 12590 L,Y 11151 O 2.3 II F 12 S 12440* 12590 L,Y 11152 O 2.3 II F 4 S 12440* 12590 L,Y 11153 O 2.3 II F 2 S – 12790* L,Y 11154 O 2.3 II F 2 S – 12790* L,Y 11155 O 2.3 II M 2 S 12430* – L,Y 11156 O 2.3 II F 2 S 12440* 12590 L,Y 11157 X 2.3 II F 3 S 12440* 12590 L,Y 11158 O 12410 – L 12330* – L,Y 11159 O 12330* – L,Y 11160 O 12470 – Y 12430* – L,Y 11161 O 12480 – Y 12440* 12590 L,Y 11162 O 2.3 II F 2 S 12440* 12590 L,Y 11163 O 2.3 II F 2 S 12440* 12590 L,Y 11164 X 1.3 M 7 U – – – 11165 O 1.3 F 7 U 12420 – L 11166 O 2.3 II F 1 S 12440* 12590 L,Y 11167 O 2.3 II M 16 U 12330* – L,Y 11168 O 2.3 II M 2 S 12430* – L,Y 11169 O 1.3 M 3 S 12630 – L 11170 O 1.3 F 3 S 12650 – L 8.0 4.8 8.0 1.3 2.3 II 2.3 II 4.8 2.3 II 4.8 2.3 II M F M M M F 2 2 2 2 2 21 4 2 1 2 1 2 S S S U U S S Wire Harness Repair Manual (RM1022E) 348 Memo 82998– 12430* 4.8 M Sleeve Color PCB E–35 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11171 O 1.3 M 7 S 12630 – L 11172 O 1.3 F 7 S 12650 – L 11173 O 1.3 M 11 S 12630 – L 11174 O 1.3 F 11 S 12650 – L 11175 O 2.3 II M 2 S 12430* – L,Y 11176 O 2.3 II F 2 S 12440* 12590 L,Y 11177 O 2.3 II M 4 S 12430* – L,Y 11178 O 2.3 II F 4 S 12440* 12590 L,Y 11179 O 1.3 F 15 U 12420 – L 11180 X 1.3 M 15 U – – – 11181 O 1.3 M 5 S 12630 – L 11182 O 1.3 F 5 S 12650 – L 11183 O 8.0 M 1 S 12490 – Y 11184 O 8.0 F 1 S 12500 – Y 11186 O 1.3 M 4 U 12410 – L 11187 O 1.3 F 4 U 12420 – L 11188 O 1.3 M 2 S 12630 – L 11189 O 1.3 F 2 S 12650 – L 11190 O 2.3 II F 8 S 12440* 12590 L,Y 11191 O 1.3 M 9 S 12630 – L 11192 O 1.3 F 9 S 12650 – L 11193 O 2.3 II M 6 S 12430* – L,Y 11194 O 2.3 II F 6 S 12440* 12590 L,Y 22 S 12440* 12590 L,Y 22 U 12340* – L,Y 1 S 24160 – L 2.3 II 11195 O 2.3 II F 6.3 II 11196 O 2.3 II M 6 S 12430* – L,Y 11197 O 2.3 II F 6 S 12440* 12590 L,Y 11198 X 1.3 M 13 U – – – 11199 X 1.3 F 13 U 12420 – L 11200 X 1.3 M 11 U 12410 – L 11201 X 1.3 M 15 U 12410 – L 11202 X 1.3 M 17 U 12410 – L 11203 X 1.3 F 17 U 12420 – L 11204 X 12410 – L 12330* – L,Y 11205 X 12420 – L 12340* – L,Y 11206 X 12410 – L 1.3 2.3 II 1.3 2.3 II 1.3 M F M 15 4 15 4 21 U U U Memo PCB PCB Wire Harness Repair Manual (RM1022E) 349 E–36 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 11207 O 2.3 II 12590 L,Y 11208 O 12410 – L 12330* – L,Y 11211 O 1.3 M 2 U 12410 – L 11212 O 1.3 F 2 U 12420 – L 11213 X 1.0 M 120 S – – – 11214 O 1.0 F 80 S – – – 11215 O 1.0 F 40 S – – – 11216 O – – – – – – – 11217 X 1.0 II M 100 U – – – 11218 O 1.0 II F 28 U 24020* – L 11219 O 1.0 II F 16 U 24020* – L 11220 O 1.0 II F 22 U 24020* – L 11221 O 1.0 II F 34 U 24020* – L 24010 – L 24030 – L,Y 2.3 II M 1.0 II 11222 11223 11224 11225 11226 O O O O O 1.8 II 2 19 4 S U 18 M 14 U 1.8 II 14 24090 – L,Y 1.0 II 12 24010 – L 24030 – L,Y 1.8 II M 6 U 1.8 II 6 24090 – L,Y 1.0 II 12 24020* – L 24040 – L,Y 1.8 II F 6 U 1.8 II 6 24100* – L,Y 1.0 II 6 24020* – L 24040 – L,Y 1.8 II F 8 U 1.8 II 8 24100* – L,Y 1.0 II 12 24020* – L 24040 – L,Y 24100* – L,Y 12340* – L,Y – – – – – – 1.8 II F 1.8 II 2.3 II 6 U 6 11228 O 11229 X 2.3 II M 3 U – – – PCB 11230 X 2.3 II M 5 U – – – PCB 11231 O 2.3 II F 10 S 12440* 12590 L,Y 11232 O 2.3 II F 5 S 12440* 12590 L,Y 11233 X – – – – – – 1.0 1.8 1.0 M 18 16 4 22 U PCB O M 2 PCB 11227 1.8 F Memo 82998– 12440* 1.3 F Sleeve Color U U Wire Harness Repair Manual (RM1022E) 350 PCB PCB E–37 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.8 Memo 82998– 12190* – L 12310* – L S 12440* 12590 L,Y 2 S 12470 – Y F 2 S 12480 – Y F 22 U 12340* – L,Y 12470 – Y 12430* – L,Y 12480 – Y 12440* 12590 L,Y 12430* – L,Y 12490 – Y 12440* 12590 L,Y 12500 – Y S 12440* 12590 L,Y 3 S 12430* – L,Y F 3 S 12440* 12590 L,Y 2.3 II F 2 S 12440* 12590 L,Y O 2.3 II M 2 S 12430* – L,Y 11248 O 2.3 II F 2 S 12440* 12590 L,Y 11249 X 2.3 II M 2 S 12430* – L,Y 11250 O 2.3 II F 2 S 12440* 12590 L,Y 11251 X 2.3 II F 3 U 12340* – L,Y 11252 O 2.3 II F 1 S 12440* 12590 L,Y 11253 X – – – – – – 11254 X 2.3 II M 2 S 12430* – L,Y 11255 O 2.3 II F 2 S 12440* 12590 L,Y 11256 X 1.3 M 11 S 12630 – L 11257 X 1.3 F 11 S 12650 – L 11258 O 4.8 M 1 U 12370 – Y 11259 O 4.8 F 1 U 12380 – Y 11260 X 2.3 II F 20 U 12340* – L,Y 11261 O 2.3 II F 3 S 12440* 12590 L,Y 11262 X 1.3 M 4 S 12630 – L Outer 11263 X 1.3 M 15 U – – – PCB 11264 O 1.3 F 15 U 12420 – L 11265 X 2.3 II M 14 U – – – 11234 X 11235 O 2.3 II F 2 11236 X 4.8 M 11237 O 4.8 11238 X 2.3 II 11239 O 11240 O 11241 O 11242 O 11243 O 2.3 II F 1 11244 O 2.3 II M 11245 O 2.3 II 11246 O 11247 1.0 4.8 2.3 II 4.8 2.3 II 2.3 II 8.0 2.3 II 8.0 1.0 III 1.0 III F 4 Sleeve Color M F M F M 22 3 8 3 8 6 2 6 2 5 52 U S S S S U w/ Clamp PCB PCB Wire Harness Repair Manual (RM1022E) 351 E–38 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.8 – – – – – 12470 – Y 12430* – L,Y S 12430* – L,Y 4 S 12440* 12590 L,Y M 1 S 12430* – L,Y 2.3 II F 1 S 12440* 12590 L,Y O 2.3 II M 2 S 12430* – L,Y 11273 O 2.3 II F 2 S 12440* 12590 L,Y 11274 O – – – – – – – 11276 X 4.8 F 10 U 12380 – Y 11277 X 12380 – Y 12340* – L,Y 11278 O 12340* – L,Y 11279 O 12380 – Y 12340* – L,Y 11280 O 12340* – L,Y 11281 X – – – – – – 11282 X 12440* 12590 L,Y 11283 X 12480 – Y 12440* 12590 L,Y 11284 O 2.3 II F 2 S – 12790* L,Y 11285 O 2.3 II F 2 S – 12790* L,Y 11286 X 2.3 II F 2 S 12440* 12590 L,Y 11287 X 12430* – L,Y 12490 – Y 11288 X 12440* 12590 L,Y 12500 – Y 11289 O 2.3 II M 6 S 12430* – L,Y 11290 O 2.3 II F 6 S 12440* 12590 L,Y 11291 O 2.3 II M 4 S 12430* – L,Y 11292 O 2.3 II F 4 S 12440* 12590 L,Y 11293 X 2.3 II M 3 S 12430* – L,Y 11294 O 2.3 II F 3 S 12440* 12590 L,Y 11295 O 2.3 II M 3 S 12430* – L,Y 11296 X 2.3 II F 3 U 12340* – L,Y 11297 X 4.8 F 6 U 12380 – Y 11266 X 11267 X 11268 X 2.3 II M 4 11269 X 2.3 II F 11270 O 2.3 II 11271 O 11272 1.0 4.8 2.3 II 4.8 2.3 II 2.3 II 4.8 2.3 II 2.3 II 1.0 III 1.0 IV 2.3 II 4.8 2.3 II 2.3 II 8.0 2.3 II 8.0 M F F F 32 2 4 1 8 2 2 6 U S U U U F 6 U M 98 24 U F 1 S F M F 2 2 2 2 2 2 S S S Wire Harness Repair Manual (RM1022E) 352 Memo 82998– – M 10 Sleeve Color PCB PCB w/ Clamp E–39 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11298 X 2.3 II M 3 U 12330* – L,Y 11299 O 2.3 II M 2 U 12330* – L,Y 11300 O 2.3 II M 2 U 12330* – L,Y 11301 X 2.3 II M 4 U 12330* – L,Y 11302 X 4.8 F 9 U 12380 – Y 11303 X 2.3 II M 2 S 12430* – L,Y 11304 O 12480 – Y 12440* 12590 L,Y 11305 X 1.3 M 2 U 12410 – L 11306 X 1.3 F 2 U 12420 – L 11307 X 12410 – L 12330* – L,Y 11308 X 12420 – L 12340* – L,Y 11309 X 12410 – L 12330* – L,Y 11310 X 12420 – L 12340* – L,Y 11311 O 2.3 II F 12 U 12340* – L,Y 11312 X 2.3 II M 14 U – – – 11313 X 2.3 II F 4 U 12340* – L,Y 11314 O HEADLAMP F 3 U 24140 24200 L,Y 11315 X 2.3 II F 1 U 12340* – L,Y 11316 X 12330* – L,Y – – – 11317 O 2.3 II F 5 S 12440* 12590 L,Y 11318 X 1.3 M 5 U – – – 11319 O 1.3 F 5 U 12420 – L 11320 X 1.3 M 8 U – – – 11321 X 1.3 F 8 U 12420 – L 11322 X 2.3 II M 2 S 12430* – L,Y 22 S 12440* 12590 L,Y 22 U 12340* – L,Y 1 S 24160 – L 4.8 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 2.3 II 6.3 II F M F M F M 2.3 II 11323 O 2.3 II F 6.3 II 2 2 15 4 15 4 13 4 13 4 20 1 S U U U U U Memo w/ Clamp PCB PCB PCB 11324 X 2.3 II M 16 U – – – PCB 11325 X 2.3 II M 10 U – – – PCB 11326 X 2.3 II F 6 U 12340* – L,Y 11327 X 2.3 II M 5 U 12330* – L,Y Wire Harness Repair Manual (RM1022E) 353 E–40 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 11328 X 1.3 M 4 S 12630 – L Inner 11329 X 1.3 F 4 S 12650 – L Outer 11330 X 1.3 F 4 S 12650 – L Inner 11331 X 2.3 II M 10 U – – – PCB 11332 O 12480 – Y 12440* 12590 L,Y 11333 X 12180 – L – – – 11334 X 1.3 M 17 U 12410 – L 11335 X 1.3 F 17 U 12420 – L 11336 X 1.3 F 3 U 12420 – L 11337 X 2.3 II M 14 U – – – 11338 X 1.0 M 80 S – – – 11339 X 1.3 M 7 U – – – 11340 X 1.3 F 7 U 12420 – L 11341 X 2.3 II M 3 S 12430* – L,Y 11342 X 1.0 M 40 U – – – 11343 X 1.0 M 28 U – – – 11344 X 1.0 M 16 U – – – 11345 X 1.0 M 22 U – – – 11346 X 1.0 M 34 U – – – 11347 X LA F 40 U – – – 11348 O 2.3 II M 3 S 12430* – L,Y 11349 O 2.3 II F 3 S 12440* 12590 L,Y 11350 X 1.3 F 13 U 12420 – L 11351 X 2.3 II M 16 U – – – 11352 X – – – – – – 11353 X 2.3 II M 8 U 12330* – L,Y 11354 X 2.3 II F 8 U 12340* – L,Y 12370 – Y 12330* – L,Y 12390 – Y 12370 – Y 12330* – L,Y 12330* – L,Y 12380 – Y 12340* – L,Y 4.8 2.3 II 1.8 1.0 1.0 II 1.8 II F M M 4.8 11355 X 2.3 II X 11357 X 11359 X 4.8 2.3 II 2.3 II 4.8 2.3 II 8 4 22 60 16 S U U 4 M 8.0 11356 2 38 U 1 M M F 4 24 27 4 51 U U U Wire Harness Repair Manual (RM1022E) 354 PCB PCB PCB PCB PCB E–41 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 11360 X 2.3 II 4 F 8.0 4.8 38 U 1 4 12380 – Y 12340* – L,Y 12400 – Y – – – – – – 12380 – Y 12340* – L,Y 12440* 12590 L,Y – – – – – – – – – – – – 12380 – Y 12340* – L,Y X 11362 X 11363 O 11364 O 11365 X 11366 X 11367 X 1.3 M 2 U 12410 – L 11368 O 1.3 M 2 U 12410 – L 11369 O 1.3 F 2 U 12420 – L 11370 X 2.3 II M 15 U 12330* – L,Y 11371 X 2.3 II M 15 U 12330* – L,Y 11372 X 2.3 II F 15 U 12340* – L,Y 11373 X 2.3 II M 25 U 12330* – L,Y 11374 X 2.3 II M 25 U 12330* – L,Y 11375 X 2.3 II F 25 U 12340* – L,Y 11376 X 1.3 M 19 U 12410 – L 11377 X 1.3 F 19 U 12420 – L 11378 X 1.3 M 21 U 12410 – L 11379 X 1.3 F 21 U 12420 – L 11380 X 1.3 M 23 U 12410 – L 11381 X 1.3 F 23 U 12420 – L 11382 X 2.3 II M 14 U – – – 11383 X 2.3 II F 14 U 12340* – L,Y 11384 X 1.3 M 13 U – – – 11385 X 8.0 M 3 U 12390 – Y 11386 X 8.0 F 2 U 12400 – Y 11387 X 12380 – Y 12400 – Y 11388 X 2.3 II F 2 U 12340* – L,Y 11389 X 1.3 M 8 U – – – 4.8 2.3 II 2.3 II 1.0 III 1.0 IV 4.8 2.3 II 4.8 2.3 II 4.8 8.0 F F M M F F 4 4 4 1 81 24 2 8 2 8 1 2 U U S U U U U Memo 82998– 11361 2.3 II M Sleeve Color PCB PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 355 E–42 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.0 II – L 24100* – L,Y 24020* – L 24020* – L 24100* – L,Y U 12410 – L 13 U 12420 – L M 2 U 12330* – L,Y 2.3 II F 2 U 12340* – L,Y X 2.3 II F 8 U 12340* – L,Y 11398 X 2.3 II F 4 U 12340* – L,Y 11399 O 2.3 II M 4 U 12330* – L,Y 11400 O 4.8 F 1 S 12480 – Y 11401 X 2.3 II F 2 S 12440* 12590 L,Y 11402 X 1.3 M 7 U – – – 11403 X 1.3 M 25 U 12410 – L 11404 X 1.3 F 25 U 12420 – L – – – – – – – – – 24020* – L 24100* – L,Y 11390 O 11391 O 11392 O 11393 X 1.3 M 13 11394 X 1.3 F 11395 X 2.3 II 11396 X 11397 1.8 II 1.0 II 1.0 II 1.8 II F F 1.8 11405 X 1.0 II 16 16 6 U U 12 M 1.8 II 1.0 II 10 U 32 U 10 22 11406 X 11407 X 2.3 II M 3 S 12430* – L,Y 11408 O 1.0 II F 12 U 24020* – L 11409 X 4.8 M 2 S 12470 – Y 11410 O 4.8 F 2 S 12480 – Y 11411 X – – – – – – 11412 O 12470 – Y 12430* – L,Y 11413 O 12480 – Y 12440* 12590 L,Y 11414 X SL F 3 S – – – 11415 X 2.3 II M 16 U 12330* – L,Y 11416 X 2.3 II F 16 U 12340* – L,Y 11417 O 2.3 II F 17 U 12340* – L,Y – – – – – – – – – 1.8 II 1.3 2.3 II 4.8 2.3 II 4.8 2.3 II F M M F 1.8 11418 X 1.0 II 1.8 II 4 21 4 3 2 3 2 U U S S 12 M 16 10 U Wire Harness Repair Manual (RM1022E) 356 Memo 82998– 24020* F 16 Sleeve Color PCB PCB w/o Clamp PCB PCB E–43 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11419 X 2.3 II M 10 U – – – 11420 X 2.3 F 17 U 12170 – L 11421 O 12690* – L 12740 – L 11422 X 24020* – L 24100* – L,Y 11423 O 24020* – L 24100* – L,Y 11424 O 1.8 II F 12 U 24100* – L,Y 11425 X 1.0 II F 16 U 24020* – L 11426 X 2.3 II M 4 U – – – 11427 X 2.3 II F 4 U 12340* – L,Y 11428 O 2.3 II F 1 S 12440* 12590 L,Y 11429 X 2.3 II F 2 U 12340* – L,Y 12370 – Y 12330* – L,Y 1.0 III 1.0 IV 1.0 II 1.8 II 1.0 II 1.8 II F F F 4.8 11430 11431 X X 2.3 II 20 11 18 8 16 10 U U U 4 M 40 U 8.0 5 12390 – Y 4.8 4 12380 – Y 12340* – L,Y 12400 – Y 24100* – L,Y 24040 – L,Y 24100* – L,Y 2.3 II F 8.0 1.8 II 40 U 5 11432 X 11433 O 11434 X C–TYPE M 16 U 12560 – L 11435 X C–TYPE F 16 U 12570 – L 11436 O 1.3 F 2 U 12420 – L 11437 X 2.3 II F 14 U 12340* – L,Y 11438 X 12370 – Y 12330* – L,Y 11439 X 12380 – Y 12340* – L,Y 11440 X 2.3 II M 20 U 12330* – L,Y 11441 X 2.3 II F 20 U 12340* – L,Y 11442 X 2.3 II M 20 U 12330* – L,Y 11443 X 2.3 II F 20 U 12340* – L,Y 11444 O 2.3 II M 16 U 12330* – L,Y 11445 X 2.3 II F 16 U 12340* – L,Y 11447 X 2.3 II M 2 S 12430* – L,Y 11448 X 2.3 II F 2 S 12440* 12590 L,Y 1.8 II 1.8 II 4.8 2.3 II 4.8 2.3 II F F M F 20 14 14 3 5 3 5 U U U U Memo PCB PCB Wire Harness Repair Manual (RM1022E) 357 E–44 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11449 X 1.3 M 10 U – – – 11450 O 1.3 F 10 U 12420 – L 11451 O 2.3 II F 3 S – 12790* L,Y 11452 X 2.3 II M 6 U 12330* – L,Y 11453 X 2.3 II F 12 U 12340* – L,Y 11459 X 2.3 II F 8 U 12340* – L,Y 11460 X 12470 – Y 12430* – L,Y 11461 X 12480 – Y 12440* 12590 L,Y 11462 X 1.3 M 16 S 12630 – L 11463 X 1.3 F 16 S 12650 – L 11464 X 2.3 II M 14 U – – – 11465 X 2.3 II F 14 U 12340* – L,Y 11466 X 2.3 II M 2 S 12430* – L,Y 11467 O 2.3 II F 2 S 12440* 12590 L,Y 11468 X 1.3 M 22 U – – – 11469 O 12420 – L 12340* – L,Y 11470 X 1.3 M 3 U 12410 – L 11471 O 1.3 F 3 U 12420 – L 11472 X – – – – – – 11473 X – – – – – – 11474 X 1.3 M 12 U – – – 11475 O 1.3 F 12 U 12420 – L 11476 O 12690* – L 12740 – L 11477 X LAC M 22 U 12100 – L,Y 11478 X LAC F 13 U 12110 – L,Y 11479 X LAC F 9 U 12110 – L,Y 11483 X – – – – – – 11484 X 12330* – L,Y 12390 – Y 11485 X 12340* – L,Y 12400 – Y 11486 O 12430* – L,Y 4.8 2.3 II 4.8 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.0 III 1.0 IV 1.3 2.3 II 2.3 II 8.0 2.3 II 8.0 2.3 II M F F M M F M M F M 2 6 2 6 16 4 30 4 21 4 17 7 21 4 1 2 1 2 2 S S U U U U U U U S Wire Harness Repair Manual (RM1022E) 358 Memo PCB PCB PCB PCB PCB PCB PCB E–45 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11487 X 1.3 M 6 U 12410 – L 11488 X 1.3 F 6 U 12420 – L 11489 X 1.3 M 3 U 12410 – L 11490 O 1.3 F 3 U 12420 – L 11491 X 6.3 F 3 S 12540 – Y 11492 X 12410 – L 12330* – L,Y 11493 X 12420 – L 12340* – L,Y 11494 O 1.3 F 4 U 12420 – L 11495 X 1.3 F 4 U 12420 – L 11496 X 1.3 M 18 U – – – 11497 X 1.3 F 18 U 12420 – L 11498 X 1.3 M 20 U 12410 – L 11499 X 1.3 F 20 U 12420 – L 11500 X 1.3 M 12 U 12410 – L 11501 O – – – – – – 11502 O 1.3 F 22 U 12420 – L 11503 O 1.3 M 22 U 12410 – L 11504 O 12410 – L 12330* – L,Y 11505 X 1.3 M 17 U 12410 – L 11506 X 1.3 F 17 U 12420 – L 11507 X 1.3 M 64 U – – – 11508 X 1.3 F 40 U 12420 – L 11509 X 1.3 F 24 U 12420 – L 11510 X 1.3 M 14 U – – – 11511 X 1.3 F 14 U 12420 – L 11512 X ABS F 2 U – – – 11514 X ABS F 32 U – – – 11517 X ABS F 6 S – – – 11519 X ABS F 2 S – – – 11520 X ABS F 2 S – – – 11522 X ABS F 4 S – – – 11524 X ABS F 12 U – – – 11526 X – – – – – – 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 4.8 2.3 II M F M M M 4 2 4 2 16 4 16 4 2 8 U U U U U Memo PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 359 E–46 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 Memo 82998– 12380 – Y 12340* – L,Y U 12330* – L,Y 7 U 12340* – L,Y M 12 U 12330* – L,Y 2.3 II F 12 U 12340* – L,Y O 1.3 M 8 U 12410 – L 11533 O 1.3 F 8 U 12420 – L 11534 O 2.3 II M 9 U 12330* – L,Y 11535 O 2.3 II F 9 U 12340* – L,Y 11536 O 2.3 II M 10 U 12330* – L,Y 11537 O 2.3 II F 10 U 12340* – L,Y 11538 O 2.3 II M 11 U 12330* – L,Y 11539 O 2.3 II F 11 U 12340* – L,Y 11540 X 2.3 II F 2 S 12440* 12590 L,Y 11541 O 2.3 II M 13 U 12330* – L,Y 11542 O 2.3 II F 13 U 12340* – L,Y 11543 X 2.3 II M 9 U – – – PCB 11544 O 1.3 M 10 U – – – PCB 11545 X 2.3 II M 2 U 12330* – L,Y 11546 X 12370 – Y 12330* – L,Y 11547 X 12380 – Y 12340* – L,Y 11548 X – – – – – – 11549 X 24030 – L,Y 24090 – L,Y 11550 X 1.8 M 12 U – – – 11551 X 4.8 M 8 U 12370 – Y 11552 O 12420 – L 12340* – L,Y 11553 X – – – 11554 X 12410 – L 12330* – L,Y 11555 X 12420 – L 12340* – L,Y 11556 O 1.3 F 14 U 12420 – L 11557 X 1.3 M 60 U – – – 11527 O 11528 O 2.3 II M 7 11529 O 2.3 II F 11530 O 2.3 II 11531 O 11532 2.3 II 4.8 2.3 II 4.8 2.3 II 1.8 1.0 1.8 II 1.8 II 1.3 2.3 II 1.3 1.3 2.3 II 1.3 2.3 II F 2 Sleeve Color M F M M F M M F 8 4 12 4 12 8 18 34 34 16 22 5 16 22 16 22 U U U U U U U U U Wire Harness Repair Manual (RM1022E) 360 PCB PCB PCB PCB E–47 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 11558 X 1.3 11559 X L 12410 – L 12330* – L,Y 11560 X 12420 – L 12340* – L,Y 11561 X 12410 – L 12330* – L,Y 11562 X 12420 – L 12340* – L,Y 11563 O – – – – – – 11564 O – – – – – – 11565 O 24020* – L 24100* – L,Y 11566 X 1.0 II F 40 S 24060 – L 11567 X 1.0 II M 40 S – – – 11568 X 2.3 II M 13 U 12330* – L,Y 11569 X 12440* 12590 L,Y 12500 – Y 11570 O 1.3 M 19 U 12410 – L 11571 O 1.3 F 19 U 12420 – L 11572 O 1.3 M 52 U – – – 11573 O 1.3 M 16 U 12410 – L 11574 O 1.3 F 16 U 12420 – L 11575 O – – – – – – 11576 O – – – – – – 11577 O – – – – – – 11578 O 1.0 M 100 U – – – 11579 O 8.0 F 2 U 12400 – Y 11580 X 1.3 M 10 U 12410 – L 11581 X 1.3 F 10 U 12420 – L 11582 X 1.3 M 8 U 12410 – L 11583 O 4.8 F 6 U 12380 – Y 11585 X 2.3 II M 16 U – – – PCB 11586 X 1.0 III F 17 U 12640 – L IDC 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.8 1.0 1.0 II 1.8 II 1.0 II 1.8 II 2.3 II 8.0 1.8 1.0 1.8 1.0 1.8 1.0 F M F M M F F M M M 8 9 8 9 6 10 6 10 10 32 26 16 10 6 2 2 22 32 16 48 16 60 U 82998– – M 20 Memo 12420 1.3 F Sleeve Color U U U U U U U S U U U PCB PCB PCB PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 361 E–48 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11587 O 2.3 II M 6 U 12330* – L,Y 11588 X 1.3 M 8 U 12410 – L 11589 X 1.3 M 2 U – – – 11590 X 12410 – L 12330* – L,Y 11591 X 12420 – L 12340* – L,Y 11592 O 2.3 II F 8 S 12440* 12590 L,Y 11593 X 2.3 II F 8 S 12440* 12590 L,Y 11594 O 12420 – L 12340* – L,Y 11595 O 12420 – L 12340* – L,Y 11596 O 12370 – Y 12330* – L,Y 11597 X – – – – – – 11598 O 2.3 II M 5 S 12430* – L,Y 11599 O 2.3 II F 5 S 12440* 12590 L,Y 12470 – Y 12430* – L,Y 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 4.8 2.3 II 1.8 1.0 M F F F M M 4.8 11600 11601 O X 2.3 II 8 6 8 6 10 8 10 8 2 8 10 32 U U U U U U 3 M 12 S 8.0 2 12490 – Y 4.8 3 12480 – Y 12440* 12590 L,Y 12500 – Y 12370 – Y 12330* – L,Y 12380 – Y 12340* – L,Y 12340* – L,Y 12410 – L 12330* – L,Y 12420 – L 12340* – L,Y 2.3 II F 8.0 4.8 12 S 2 2 11602 X 11603 X 11604 O 11605 X 11606 X 11607 X 2.3 II M 3 S 12430* – L,Y 11608 O 2.3 II F 2 U 12340* – L,Y 11609 X 12470 – Y 12430* – L,Y 2.3 II 4.8 2.3 II 2.3 II 1.3 2.3 II 1.3 2.3 II 4.8 2.3 II M F F M F M 3 2 3 13 2 2 2 2 3 8 U U U U U S Wire Harness Repair Manual (RM1022E) 362 Memo PCB PCB E–49 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 Y 12330* – L,Y 12380 – Y 12340* – L,Y 12480 – Y 12440* 12590 L,Y 12410 – L 12330* – L,Y 12420 – L 12340* – L,Y U 12380 – Y 6 U 12420 – L F 6 U 12340* – L,Y F 40 U 12420 – L – – – – – – U – – – PCB 22 U – – – PCB M 3 S 12430* – L,Y M 8 U 12410 – L – – – – – – – – – – – – – – – X 11611 X 11612 X 11613 O 11614 X 11615 O 4.8 F 8 11616 O 1.3 F 11617 X 2.3 II 11618 X 1.3 11619 X 11620 X 1.3 M 3 11621 X 1.3 M 11622 O 2.3 II 11623 O 1.3 11624 X 4.8 2.3 II 4.8 2.3 II 1.3 2.3 II 1.3 2.3 II 1.0 II 1.8 II 1.3 2.3 II F F M F M M 1.3 11625 X 4.8 82998– – 11610 2.3 II Memo 12370 M 4 Sleeve Color 22 4 22 3 8 8 2 8 2 16 18 6 10 U U S U U U U 5 M 2.3 II 2 U 17 PCB PCB PCB 11626 X 2.3 II F 12 U 12340* – L,Y 11627 X 1.3 M 20 U 12410 – L 11628 O 1.3 F 22 U 12420 – L 11629 O 1.3 M 8 U – – – 11630 O 1.3 F 8 U 12420 – L 11631 O 12370 – Y 12330* – L,Y 11632 X 12380 – Y 12340* – L,Y 11633 X 1.3 F 8 U 12420 – L 11634 X 1.3 M 12 U – – – PCB 11635 X 1.3 M 13 U – – – PCB 11636 X 1.3 M 8 U – – – PCB 11637 O 1.0 III F 28 U 12690* – L 4.8 2.3 II 4.8 2.3 II M F 6 20 6 20 U U PCB Wire Harness Repair Manual (RM1022E) 363 E–50 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.0 III – L 12740 – L – – – – 4 S 24160 – L M 10 U – – – F 10 U 12420 – L 12480 – Y 12440* 12590 L,Y – – – – – – – – – – – – – – – – – – – – – U 12420 – L U 12340* – L,Y – – – – – – – – – – – – 12420 – L 12340* – L,Y S 12440* 12590 L,Y 14 U 12410 – L M 2 U 12390 – Y 2.3 II F 12 U 12340* – L,Y O 1.3 F 10 U 12420 – L 11658 O 2.3 II F 10 S 12440* 12590 L,Y 11659 O HEADLAMP F 2 S 24150 24190 L,Y 11660 O HEADLAMP F 2 S 24150 24190 L,Y 11661 O 2.3 II F 12 U 12340* – L,Y 11662 X 8.0 F 4 U 12400 – Y 11663 X 2.3 II F 6 S 12440* 12590 L,Y 11664 X 2.3 II F 12 S 12440* 12590 L,Y 11665 O OBD II F 16 U – – – 11666 X – – – – – – – 11638 O 11639 X – – – 11640 X 6.3 II F 11641 O 1.3 11642 O 1.3 11643 O 11644 X 11645 X 11646 X 11647 X 11648 X 1.3 F 16 11649 O 2.3 II F 12 11650 X 11651 X 11652 X 11653 O 2.3 II F 10 11654 O 1.3 M 11655 O 8.0 11656 O 11657 1.0 IV 4.8 2.3 II 1.3 1.3 2.3 II 1.3 2.3 II 1.3 2.3 II 1.8 1.0 1.3 2.3 II 1.3 2.3 II F M M M M M M F 6 2 7 14 60 10 36 16 20 16 22 32 8 6 10 6 U S U U U U U U U Wire Harness Repair Manual (RM1022E) 364 Memo 82998– 12690* F 16 Sleeve Color PCB PCB PCB PCB PCB PCB PCB E–51 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 Memo 82998– 12380 – Y 12400 – Y U 12330* – L,Y U 12340* – L,Y 12420 – L 12340* – L,Y 12420 – L 12340* – L,Y U 12400 – Y 15 S 12440* 12590 L,Y M 16 U 12410 – L 1.3 F 16 U 12420 – L X 1.3 M 16 U 12410 – L 11683 X 1.3 F 16 U 12420 – L 11684 O 8.0 F 2 U 12400 – Y 11685 O 8.0 F 3 U 12400 – Y 11686 O 4.8 F 8 U 12380 – Y 11687 X 6.3 F 2 U 12060 12580 Y 11688 X 1.3 M 5 S 12630 – L 11689 X 1.3 M 5 S 12630 – L 11690 X 1.3 F 5 S 12650 – L Outer 11691 X 1.3 F 5 S 12650 – L Inner 11693 X 2.3 II F 12 U 12340* – L,Y 11694 X 2.3 II M 13 U 12330* – L,Y 11695 X 2.3 II F 13 U 12340* – L,Y 11696 X 1.5 M 6 U – – – 11697 X 1.5 F 6 U – – – 11698 O 1.3 F 12 S 12650 – L 11700 X – – – – – – 11701 O 12380 – Y 12340* – L,Y 11703 X 2.3 II F 1 U 12340* – L,Y 11709 X 2.3 II M 9 U 12330* – L,Y 11710 X 2.3 II F 9 U 12340* – L,Y 11714 X 2.3 II F 13 U 12340* – L,Y 11716 X 12420 – L 12340* – L,Y 11720 X 12340* – L,Y 11667 X 11669 X 2.3 II M 27 11670 X 2.3 II F 27 11671 O 11672 X 11676 X 8.0 F 4 11677 X 2.3 II F 11680 X 1.3 11681 X 11682 8.0 1.3 2.3 II 1.3 2.3 II 1.0 II 1.8 II 4.8 2.3 II 1.3 2.3 II 2.3 II F 1 Sleeve Color F F M F F F 2 8 9 8 9 32 10 4 4 10 8 12 U U U U U U U PCB PCB Wire Harness Repair Manual (RM1022E) 365 E–52 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11724 X 2.3 II M 2 U 12350* – L,Y 11731 X HEADLAMP F 3 U 24140 24200 L,Y – – – – – – – – – – – – 1.8 11733 O 1.0 1.0 II 22 M 1.8 II 16 16 U 22 Memo PCB 11735 X 2.3 II M 2 U 12330* – L,Y 11736 O 2.3 II F 2 U 12340* – L,Y 11737 X 2.3 II M 1 U 12330* – L,Y 11738 X 2.3 II F 1 U 12340* – L,Y 11739 X 2.3 II M 7 U 12330* – L,Y 11740 X 2.3 II F 7 U 12340* – L,Y 11742 O 4.8 F 4 U 12380 – Y 11743 X 1.3 M 14 U – – – PCB 11744 X 1.3 M 14 U – – – PCB 11745 X 1.3 M 18 U – – – PCB 11746 X 1.3 M 22 U – – – PCB 11747 X 2.3 II M 12 U – – – PCB 11748 X 2.3 II M 18 U – – – PCB 11749 X 2.3 II M 20 U – – – PCB 11750 X 2.3 II M 20 U – – – PCB 11751 X 2.3 II M 18 U – – – PCB 11752 X 2.3 II M 10 U – – – PCB 11753 X 2.3 II M 14 U – – – PCB 11757 X 2.3 II M 10 U 12330* – L,Y 11763 X 2.3 II M 3 U 12330* – L,Y 11764 O 2.3 II F 3 U 12340* – L,Y 11765 X 2.3 II M 4 U 12330* – L,Y 11766 X 2.3 II F 4 U 12340* – L,Y 11767 X 2.3 II M 1 U 12330* – L,Y 11769 X 2.3 II F 2 U 12340* – L,Y 11771 X 12380 – Y 12340* – L,Y 11772 X 2.3 II F 5 U 12340* – L,Y 11773 X 2.3 II F 2 S 12440* 12590 L,Y 11774 X 9.5 M 1 U – – – 11775 X 9.5 F 1 U – – – 11777 X 1.3 F 3 U 12420 – L 4.8 2.3 II F 2 2 U Wire Harness Repair Manual (RM1022E) 366 E–53 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color 82998– 11778 O 4.8 F 6 U 12380 – Y 11779 O 2.3 II M 4 U 12330* – L,Y 11780 O 2.3 II F 6 U 12340* – L,Y 11781 X 2.3 II F 10 U 12340* – L,Y 11782 X 2.3 II F 12 U 12340* – L,Y 11784 O 12480 – Y 12440* 12590 L,Y 11785 X – – – – – – 11786 X – – – – – – 11787 X – – – 11788 X – – – – – – 11789 X 1.0 III M 2 S 12710 – L 11790 X 1.0 III F 2 S 12720* – L 11791 X 2.3 II F 14 U 12340* – L,Y 11792 X 2.3 II F 4 U 12340* – L,Y 11794 X VH F 7 U – – – 11797 X 2.3 II F 5 U 12340* – L,Y 11799 X 4.8 F 4 U 12380 – Y 11800 X 2.3 II F 10 U 12340* – L,Y 11805 X 2.3 II F 14 U 12340* – L,Y 11809 X 4.8 M 4 U 12370 – Y 11812 X 2.3 II M 4 U 12330* – L,Y 11814 X 2.3 II M 6 U 12330* – L,Y 11817 X 2.3 II F 10 U 12340* – L,Y 11820 X 2.3 II F 6 U 12340* – L,Y 11823 X 2.3 II M 10 U 12330* – L,Y 11824 X 8.0 F 2 U 12400 – Y 11827 X 2.3 II F 13 U 12340* – L,Y 11839 X 2.3 II F 2 U 12340* – L,Y 11840 X 2.3 II F 2 U 12340* – L,Y 11841 X 2.3 II F 4 U 12340* – L,Y 11842 X 2.3 II F 4 U 12340* – L,Y 11843 X 2.3 II M 5 U 12330* – L,Y 11847 X 2.3 II F 12 U 12340* – L,Y 11848 X 2.3 II F 13 U 12340* – L,Y 4.8 2.3 II 1.0 J 1.8 J 1.0 J 1.8 J 1.0 J 1.0 J 1.8 J F M F F F 2 7 48 16 16 10 16 16 6 S U U U U Memo PCB Wire Harness Repair Manual (RM1022E) 367 E–54 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 4.8 – Y – 12790* L,Y U 12060 12580 Y 2 S 12710 – L F 2 S 12720* – L 1.0 III F 4 S 12720* – L O 2.3 II F 6 S 12440* 12590 L,Y 11859 X 2.3 II F 2 S 12440* 12590 L,Y 11860 X 2.3 II F 3 S 12440* 12590 L,Y 11861 X 12480 – Y – – – 11862 O PAI 1 F 2 U – – – 11863 X 1.0 III M 2 S 12710 – L 11864 X 1.0 III F 2 S 12720* – L 11865 X 1.0 III M 2 S 12710 – L 11866 X 1.0 III M 44 U – – – 11867 X 1.0 III F 12 U 12690* – L 11868 X 1.0 III F 20 U 12690* – L 11869 X 1.0 III F 12 U 12690* – L 11870 X 1.0 III M 52 U – – – 11871 X 1.0 III F 12 U 12690* – L 11872 X 1.0 III F 28 U 12690* – L 11873 X 1.0 III F 12 U 12690* – L 11874 X 2.3 II M 3 U – – – 11875 O 2.3 II F 2 S – 12790* L,Y 11876 X – – – – – – 11877 O 12690* – L 12340* – L,Y 11878 O 4.8 M 4 U 12370 – Y 11879 X 4.8 F 6 U 12380 – Y 11880 X 8.0 F 3 U 12400 – Y 11881 X 9.5 F 1 U – – – 11882 X 12480 – Y – 12790* L,Y 11883 X 1.0 III M 2 U 12670* – L 11884 X 1.0 III F 2 U 12690* – L 11885 O 2.3 II F 4 S – 12790* L,Y 11886 O 1.0 III F 2 U 12690* – L 11851 X 11853 X 6.3 F 1 11854 X 1.0 III M 11856 O 1.0 III 11857 X 11858 2.3 II 4.8 1.5 1.0 III 2.3 II 1.0 III 2.3 II 4.8 2.3 II F M F F 20 25 25 19 6 19 6 4 20 S S U U S Wire Harness Repair Manual (RM1022E) 368 Memo 82998– 12480 F 4 Sleeve Color PCB PCB PCB PCB E–55 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 11889 X 1.0 III M 2 U 12670* – L 11890 X 1.0 III F 2 U 12690* – L 11891 X 1.0 III M 4 U 12670* – L 11892 X 1.0 III F 4 U 12690* – L 11893 X 12480 – Y – 12790* L,Y 11898 X 12720* – L 11899 X – – – – – – 11900 X 2.3 II F 2 S – 12790* L,Y 11901 X 2.3 II M 2 S 12430* – L,Y 11902 O – – – – – – 11903 X – – – – – – 11904 X 12710 – L 11905 X – – – – – – 11906 X SL F 83 U 12130 – L,Y 11907 X SL F 3 S – – – 11908 X SL F 5 U 12130 – L,Y 11909 O 1.0 III F 5 U 12690* – L 11910 X 1.0 III M 14 U 12670* – L 11911 O 1.0 III F 14 U 12690* – L 11912 X 1.0 III M 18 U 12670* – L 11913 O 1.0 III F 18 U 12690* – L 11914 O 1.0 III F 18 U 12640 – L 11915 O 1.0 III F 22 U 12690* – L 11916 X 1.0 III M 40 U – – – 11917 X 1.0 III M 2 U 12670* – L 11918 O 1.0 III F 2 U 12690* – L 11919 O 1.0 III F 2 U 12640 – L 11920 O 1.0 III M 5 U 12670* – L 11921 O 1.0 III F 5 U 12640 – L 11922 X 1.0 III M 10 U 12670* – L 11923 O 1.0 III F 10 U 12690* – L 11924 O 1.0 III F 10 U 12640 – L IDC 11925 O 1.0 III F 14 U 12640 – L IDC 11926 O 1.0 III M 22 U 12670* – L 4.8 2.3 II 1.0 III 1.8 1.0 1.8 1.0 1.0 III 1.0 III 1.0 III 1.3 2.3 II F F M M M M M 4 20 2 8 18 6 32 5 44 5 16 4 S S U U U S U PCB PCB PCB PCB IDC PCB IDC IDC Wire Harness Repair Manual (RM1022E) 369 E–56 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 11927 O 1.0 III F 22 U 12640 – L IDC 11928 X 1.0 III M 54 U – – – PCB 11929 X 2.3 II M 4 S 12430* – L,Y 11930 X 2.3 II F 4 S 12440* 12590 L,Y 11933 X 1.0 III M 2 U 12670* – L 11934 X – – – – – – 11935 X 12690* – L 12740 – L 11936 X 8.0 M 3 U 12390 – Y 11937 X INVERTER M 3 U – – – 11938 X INVERTER F 3 U – – – 11939 O – – – – – – – 11940 X PIN M 2 S – – – 11941 X LA F 1 S – – – 11942 O LA F 1 S – – – 11943 X SOCKET F 1 S – – – 11944 O SOCKET F 1 S – – – 11945 O PIN M 2 S – – – 11946 X 1.0 III M 5 U – – – 11947 X 12690* – L 12340* – L,Y 11948 O 1.0 III F 10 U 12640 – L IDC 11949 X 1.0 III M 18 U – – – PCB 11950 X 1.0 III F 4 U 12690* – L 11951 X 1.0 III M 13 U – – – 11952 X 1.0 III F 13 U 12690* – L 11953 X – – – – – – 11954 X 12690* – L 12340* – L,Y 11955 X 1.0 III F 19 U 12690* – L 11956 X 1.0 III F 21 U 12690* – L 11957 X 12690* – L 12340* – L,Y 11960 X 12440* 12590 L,Y 1.0 III 1.0 IV 1.0 III 1.0 IV 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 2.3 II M F F M F F F 81 24 20 11 8 4 64 14 8 9 16 5 5 U U U U U U S Wire Harness Repair Manual (RM1022E) 370 PCB PCB PCB PCB E–57 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.0 III Memo 82998– – – – – – – S – – – 1 S – – – F 4 S 12440* 12590 L,Y 8.0 M 4 U – – – PCB X 1.0 II M 22 U – – – PCB 11967 O 1.0 III M 2 U 12670* – L 11968 X 1.0 III M 5 U – – – PCB 11969 X 1.0 III M 14 U – – – PCB 11970 X – – – – – – 11971 X 12690* – L 12340* – L,Y 11972 X – – – – – – 11973 O 12690* – L 12340* – L,Y 11974 X 1.0 III F 20 U 12690* – L 11976 O – – – – – – – 11978 X OBD II F 16 U – – – 11985 X 1.0 III M 4 U – – – 11986 O 1.0 III F 6 U 12690* – L 11987 X 1.0 III F 3 U 12690* – L 11988 O 1.0 III F 4 U 12640 – L 11989 X 1.0 III F 8 U 12690* – L 11990 X – – – – – – 11992 X 1.0 III M 2 U 12670* – L 11993 X 1.0 III M 10 U – – – PCB 11994 X 2.3 II M 3 U – – – PCB 11995 O – – – – – – – 11996 X 9.5 F 2 U – – – 12002 X 12670* – L 12330* – L,Y 12003 X 12690* – L 12340* – L,Y 12004 X 1.0 M 6 U – – – 12005 X 2.3 II F 4 S – 12790* L,Y 11961 X 11962 X 9.5 M 1 11963 X 9.5 F 11964 O 2.3 II 11965 X 11966 1.0 III 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II M 5 Sleeve Color M F M F M M F 28 16 4 16 4 49 14 10 8 37 18 6 5 6 5 U U U U U U U U PCB PCB PCB PCB IDC PCB IDC Wire Harness Repair Manual (RM1022E) 371 E–58 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 12006 O – 12007 X – 12690* – L 12340* – L,Y 12008 O 12690* – L 12340* – L,Y 12009 X – – – 12010 X – – – – – – 12011 X 1.0 III M 18 U – – – 12012 X 1.0 III F 6 U 12690* – L 12013 X 1.0 III M 6 U – – – 12014 X 2.3 II F 2 U 12340* – L,Y 12015 X 1.0 III M 14 U – – – 12016 X 1.0 III M 4 U 12670* – L 12017 X 1.0 III F 4 U 12690* – L 12018 X 2.3 II F 4 U 12340* – L,Y 12019 X 1.0 III F 4 U 12640 – L 12020 O 12480 – Y 12720* – L 12021 O 12480 – Y 12720* – L 12022 X 12480 – Y 12720* – L 12023 X 1.0 III M 10 U 12660 – L 12024 X 1.0 III M 22 U 12670* – L 12025 X 12670* – L 12330* – L,Y 12026 X 2.3 II F 9 U 24220 – L IDC 12027 X 2.3 II F 13 U 24220 – L IDC 12028 O 2.3 II F 2 S 12440* 12590 L,Y 12029 X 1.0 M 2 U – – – 12030 X 1.0 III M 22 U – – – 12031 X – – – – – – 12032 X – – – 12033 X – – – – – – 12034 X 12380 – Y 12690* – L 2.3 II 1.0 III 2.3 II 1.0 III 1.0 III 2.3 II 4.8 1.0 III 4.8 1.0 III 4.8 1.0 III 1.0 III 2.3 II 1.0 J 1.8 J 1.0 J 4.8 1.0 III 4.8 1.0 III F M M F F F M M F M F 4 9 2 8 10 10 8 4 30 4 23 4 16 16 4 60 16 12 2 18 2 18 – 82998– – F – Memo – 1.0 III – Sleeve Color U U U U S S S U U U U U Wire Harness Repair Manual (RM1022E) 372 PCB PCB PCB PCB PCB IDC IDC PCB PCB PCB E–59 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 1.0 III – – – – – – – – – – – – – – 12690* – L 12340* – L,Y U – – – 1 U – – – 5 U – – – – – – – – – U – – – S 12440* 12590 L,Y 12480 – Y 12500 – Y U 12670* – L 7 U 12690* – L M 8 U – – – 1.0 III M 2 U 12670* – L X 1.0 III F 2 U 12690* – L 12064 X 1.0 III M 6 U – – – 12067 X 1.0 III F 6 U 12690* – L 12068 X 8.0 F 2 S 12500 – Y 12070 X 2.3 II F 24 U 12340* – L,Y 12071 X 2.3 II F 32 U 12340* – L,Y 12079 X B TO J F 24 U – – – 12080 X 1.0 III F 8 S 12720* – L 12081 X 1.0 III M 29 U 12670* – L 12082 X 1.0 III F 14 U 12690* – L 12087 X 1.0 III M 20 U – – – 12088 O 2.3 II F 2 U 12340* – L,Y 12089 X 2.3 II F 2 U 12340* – L,Y 12090 X 2.3 II F 12 U 12340* – L,Y 12091 X 1.0 III F 8 U 12690* – L 12092 O – – – 12740 – L 12093 X 1.0 III M 16 U – – – 12094 X 1.0 III F 16 U 12690* – L 12035 X 12036 X 12037 X 12038 O 12039 X VH F 2 12041 X HFC M 12050 X 1.0 III M 12055 X 12056 X 0.64 F 6 12057 X 2.3 II F 4 12058 X 12059 X 1.0 III M 7 12060 X 1.0 III F 12061 X 1.0 III 12062 X 12063 2.3 II 1.0 III 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 1.0 IV 4.8 8.0 0.64 1.0 IV M M F M F F 6 5 16 4 16 4 100 22 1 2 5 2 U U U U U S U Memo 82998– – M 41 Sleeve Color PCB PCB PCB PCB PCB PCB PCB PCB PCB Wire Harness Repair Manual (RM1022E) 373 E–60 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 12095 X M6 NUT 12096 X – 12690* – L 12340* – L,Y 12101 X 2.3 II F 16 U 12340* – L,Y 12102 X 2.3 II F 28 U 12340* – L,Y 12104 X 2.3 II F 16 U 12340* – L,Y 12105 X 2.3 II M 16 U 12330* – L,Y 12106 X 2.3 II F 20 U 12340* – L,Y 12108 X 2.3 II M 18 U – – – 12109 X PAI 1 F 2 U – – – 12110 X VALVE F 2 U – – – 12111 X VALVE F 2 U – – – 12112 X 1.0 III M 8 U – – – 12113 X 1.0 III F 8 U 12690* – L 12114 X 12690* – L 12340* – L,Y 12116 O 12480 – Y 12720* – L 12117 X 2.3 II F 2 S – 12790* L,Y 12118 X 8.0 M 2 U – – – PCB 12119 X 8.0 M 2 U – – – PCB 12120 X 8.0 F 2 U 12400 – Y 12122 X 12690* – L 12340* – L,Y 12123 X 1.0 III M 4 U 12670* – L 12125 X LA F 1 S – – – 12129 X LA F 1 S – – – 12131 X BUS– BAR M 3 S – – – 12134 X 1.0 III M 10 U – – – 12135 X 1.0 III F 10 U 12690* – L 12136 X LA F 1 S – – – 12137 X – – – – – – 12138 O – – – 12140 X – – – – – – 12141 X – – – – – – 2.3 II 1.0 III 2.3 II 4.8 1.0 III 1.0 III 2.3 II 1.0 III 2.3 II PAI 1 1.0 II 1.8 II 0.64 1.0 IV F F F M F M M 12 20 6 28 4 20 6 12 14 6 2 48 16 133 34 S 82998– – F 3 Memo – 1.0 III F Sleeve Color U U S U U U U U Wire Harness Repair Manual (RM1022E) 374 PCB PCB PCB PCB PCB PCB E–61 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 0.64 Memo 82998– 12750* – L 12740 – L 12750* – L 12740 – L 12750* – L 12740 – L 12750* – L 12740 – L 12750* – L 12740 – L – – – – – – – – – – – – 12750* – L 12340* – L,Y 12750* – L 12340* – L,Y 12750* – L 12340* – L,Y U – – – 32 U 12750* – L F 16 U 12750* – L 0.64 F 16 U 12770 – L IDC X 0.64 M 16 U – – – PCB 12159 X 1.0 III M 4 U 12670* – L 12160 X 1.0 III F 4 U 12690* – L 12161 X 12670* – L 12330* – L,Y 12162 X 1.0 III F 10 U 12690* – L 12163 X 2.3 II M 8 S 12430* – L,Y 12164 X 2.3 II F 8 S 12440* 12590 L,Y 12165 O – – – – – – – 12166 X 12690* – L 12340* – L,Y 12167 X 1.0 III M 8 U – – – 12168 X 1.0 III F 3 S 12720* – L 12169 X 0.64 F 40 U 12750* – L 12170 X 0.64 F 40 U 12770 – L 12142 X 12143 X 12144 X 12145 X 12146 X 12147 X 12148 X 12149 X 12150 X 12151 X 12152 X 0.64 M 32 12153 X 0.64 F 12155 X 0.64 12156 X 12157 1.0 IV 0.64 1.0 IV 0.64 1.0 IV 0.64 1.0 IV 0.64 1.0 IV 0.64 2.3 II 0.64 2.3 II 0.64 2.3 II 0.64 2.3 II 0.64 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II F 24 Sleeve Color F F F F M M F F F M F 7 25 7 27 7 28 7 29 6 68 12 40 10 20 4 20 6 28 2 8 9 14 6 U U U U U U U U U U U U PCB PCB PCB PCB IDC Wire Harness Repair Manual (RM1022E) 375 E–62 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 12171 X 0.64 M 40 U – – – PCB 12174 X 1.0 II F 18 U 24020* – L IDC 12176 O 2.3 II F 4 S – 12790* L,Y 12177 X 2.3 II M 4 S – – L,Y 12179 X 12690* – L 12340* – L,Y 12182 X 0.64 M 12 U – – – 12183 X 0.64 F 12 U 12750* – L 12184 X 12690* – L 12340* – L,Y 12188 X 2.3 II F 2 S 12440* 12590 L,Y 12189 X 1.0 III M 5 U 12670* – L 12190 X 1.0 III F 5 U 12690* – L 12191 X PAI 1 F 2 U – – – 12192 X 0.64 M 16 U – – – 12193 X 0.64 M 24 U – – – 12194 X 1.0 III M 2 S 12710 – L 12195 X 1.0 III F 2 S 12720* – L 12196 X D–3 M 3 U – – – 12197 X D–3 F 3 U – – – 12198 X D–3 M 6 U – – – 12199 X D–3 F 6 U – – – 12200 X 0.64 F 24 U 12750* – L 12202 X – – – – – – 12203 X 12750* – L 12340* – L,Y 12204 X 1.0 III M 6 U 12670* – L 12205 X 2.3 II M 12 U – – – PCB 12206 X 2.3 II M 16 U – – – PCB 12207 X – – – – – – 12208 X 1.0 III M 6 U – – – 12209 O 1.0 III F 6 U 12690* – L 12210 X 1.0 III M 4 U – – – 12211 O 1.0 III F 4 U 12690* – L 12212 X 1.0 III M 4 U 12670* – L 12213 X 0.64 M 40 U – – – PCB 12214 X 0.64 M 24 U – – – PCB 1.0 III 2.3 II 1.0 III 2.3 II 0.64 2.3 II 0.64 2.3 II 1.0 III 2.3 II F F M F M 42 4 30 12 20 6 20 6 26 8 U U U U U Wire Harness Repair Manual (RM1022E) 376 PCB PCB PCB PCB PCB E–63 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– Sleeve Color Memo 82998– 12215 X 0.64 M 24 U – – – PCB 12216 X 0.64 M 8 U – – – PCB 12217 X 0.64 F 8 U 12750* – L 12218 X PAI 1 M 2 U – – – 12219 X PAI 1 F 2 U – – – 12220 X 0.64 M 8 U – – – 12221 X 0.64 F 8 U 12750* – L 12222 X 0.64 F 12 U 12750* – L 12223 X PAI 1 M 2 U – – – 12224 X PAI 1 F 2 U – – – 12225 X 0.64 F 4 U 12750* – L 12226 X 12690* – L 12340* – L,Y 12227 X 9.5 M 3 S – – – 12228 X 9.5 F 3 S – – – 12230 X LA F 1 S – – – 12231 X LA F 1 S – – – 12232 X – – – – – – 12233 X – – – – – – 12234 X 4.8 M 3 S 12470 – Y 12237 X 4.8 F 3 S 12480 – Y 12241 X 0.64 F 2 U 12750* – L 12242 X PAI 1 F 2 U – – – 12243 X PAI 1 F 2 U – – – 12249 X 2.3 II M 10 U 12330* – L,Y 12250 X 0.64 M 11 U – – – 12251 X 0.64 F 11 U 12750* – L 12252 X 0.64 M 16 U – – – 12253 O PAI 1 F 2 U – – – 12258 X 0.64 M 20 U – – – 12259 X 0.64 F 20 U 12750* – L 12260 X 0.64 M 24 U – – – PCB 12269 X 0.64 M 12 U – – – PCB 12270 X 0.64 M 24 U – – – PCB 12271 X 12690* – L 12340* – L,Y 12272 X 12690* – L 1.0 III 2.3 II 0.64 1.0 IV 0.64 2.3 II 1.0 III 2.3 II 1.0 III F M M F F 6 4 108 27 20 6 20 6 10 U U U U U PCB Splash Proof PCB PCB Splash Proof PCB Wire Harness Repair Manual (RM1022E) 377 E–64 HOUSING PART NUMBER LIST Part No. of Connector Body Supply Terminal Part No. of Repair Wire Male Sealing Cav. No. 500 mm Female Ability 160 mm Type Type 90980– 82998– 12273 X 12274 X 12275 X 12276 X 12277 X 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II 1.0 III 2.3 II F F F F F 4.8 12278 X 1.0 III 6 6 18 18 8 24 24 14 10 20 U U U U U 1 F 2.3 II 6 U 18 Sleeve Color 82998– 12690* – L 12340* – L,Y 12690* – L 12340* – L,Y 12690* – L 12340* – L,Y 12690* – L 12340* – L,Y 12690* – L 12340* – L,Y 12380 – Y 12690* – L 12340* – L,Y 12291 X 1.0 III M 39 U – – – 12296 X 0.64 F 3 U 12750* – L Wire Harness Repair Manual (RM1022E) 378 Memo PCB D–1 TABLE OF HOUSING SHAPE 1P Waterproof Type D 1 1 1 1 90980–10090 90980–10115 90980–10197 90980–10201 1 1 1 1 90980–10241 90980–10247 90980–10705 90980–10439 90980–10837 1 1 1 1 90980–10893 90980–10983 90980–11007 90980–11166 1 1 1 1 90980–11184 90980–11243 90980–11252 90980–11271 1 1 1 90980–11282 90980–11363 90980–11400 Wire Harness Repair Manual (RM1022E) 76 1 90980–11428 D–2 TABLE OF HOUSING SHAPE 1P Waterproof Type 1 1 1 1 90980–11941 90980–11942 90980–11943 90980–11944 1 1 90980–12125 90980–12129 90980–12136 1 90980–11963 D Wire Harness Repair Manual (RM1022E) 77 D–3 TABLE OF HOUSING SHAPE 2P Waterproof Type 1 90980–10092 1 2 D 1 1 2 2 1 2 90980–10123 90980–10157 90980–10184 2 1 2 90980–10193 90980–10243 1 2 1 2 90980–10498 90980–10706 90980–10532 1 90980–10567 1 12 2 2 90980–10581 2 90980–10583 2 90980–10474 1 2 90980–10534 1 90980–10572 1 1 2 90980–10576 1 2 90980–10593 Wire Harness Repair Manual (RM1022E) 78 1 2 90980–10496 1 2 90980–10556 1 2 90980–10578 1 2 90980–10595 D–4 TABLE OF HOUSING SHAPE 2P Waterproof Type 1 2 1 2 90980–10598 90980–10609 1 2 1 2 1 2 1 2 90980–10617 90980–10622 1 2 1 2 90980–10623 90980–10626 90980–10702 90980–10720 1 2 1 2 1 2 1 2 90980–10734 90980–10735 90980–10736 90980–10737 1 2 1 2 90980–10839 90980–10843 90980–10847 1 2 1 2 1 2 90980–10887 90980–10899 90980–10901 12 1 90980–10748 90980–10846 1 2 90980–10853 2 D Wire Harness Repair Manual (RM1022E) 79 D–5 TABLE OF HOUSING SHAPE 2P Waterproof Type 1 2 90980–10923 90980–10974 1 2 90980–11019 1 2 90980–11038 1 2 90980–11068 2 90980–10928 1 1 2 D 1 2 90980–11003 1 2 90980–11025 90980–11401 1 2 90980–11051 1 2 90980–11070 1 2 1 2 90980–10947 90980–10949 1 2 1 2 90980–11005 90980–11009 1 2 2 90980–11030 90980–11032 1 2 1 2 90980–11061 90980–11062 1 2 90980–11075 Wire Harness Repair Manual (RM1022E) 80 1 1 2 90980–11095 D–6 TABLE OF HOUSING SHAPE 2P Waterproof Type 1 2 1 2 90980–11096 90980–11140 12 12 90980–11153 90980–11154 90980–11284 1 1 2 90980–11235 1 2 90980–11250 2 1 90980–11142 1 2 90980–11149 1 2 90980–11156 90980–11162 1 1 2 90980–11176 1 2 D 2 1 2 90980–11163 1 2 90980–11189 1 2 2 90980–11207 1 2 90980–11237 90980–11246 90980–11248 1 2 1 2 12 90980–11255 90980–11273 90980–11285 Wire Harness Repair Manual (RM1022E) 81 D–7 TABLE OF HOUSING SHAPE 2P Waterproof Type 1 2 90980–11286 1 2 1 2 90980–11410 1 1 90980–11659 1 2 90980–11856 1 2 90980–11898 1 2 90980–12117 90980–11467 1 2 90980–11900 1 2 90980–12188 1 2 90980–11773 2 90980–11859 2 90980–11790 1 2 1 2 90980–11864 1 2 90980–12028 1 2 90980–12195 Wire Harness Repair Manual (RM1022E) 82 2 2 90980–11660 1 1 90980–11448 1 D 2 90980–11875 1 2 90980–12068 D–8 TABLE OF HOUSING SHAPE 3P Waterproof Type 1 2 1 3 90980–10088 2 3 90980–10239 1 2 3 3 3 90980–10110 90980–10191 90980–10199 1 1 1 1 2 1 2 2 3 90980–10245 2 3 90980–10249 2 3 90980–10341 90980–11491 D 1 2 3 1 2 3 1 2 1 2 3 3 90980–10353 1 2 3 90980–10554 1 2 90980–10395 90980–10494 90980–10501 1 2 3 1 2 3 1 2 3 90980–10574 90980–10579 90980–10629 1 2 3 3 90980–10683 90980–10690 90980–11157 1 2 3 1 2 3 90980–10695 90980–10834 Wire Harness Repair Manual (RM1022E) 83 D–9 TABLE OF HOUSING SHAPE 3P Waterproof Type 1 2 3 90980–10841 1 2 3 90980–10845 1 3 90980–10902 90980–10919 1 2 3 3 1 2 3 1 2 3 90980–10981 90980–11016 90980–11020 90980–11045 1 2 3 1 2 3 1 2 3 1 2 3 90980–11108 90980–11132 90980–11143 90980–11145 2 3 2 2 1 2 3 1 2 3 3 90980–11161 1 2 1 1 3 90980–11294 90980–11170 1 2 3 90980–11349 90980–11245 1 2 3 90980–11451 Wire Harness Repair Manual (RM1022E) 84 2 3 1 D 1 2 90980–11261 1 2 3 90980–11860 D–10 TABLE OF HOUSING SHAPE 3P Waterproof Type 1 1 2 3 1 90980–11907 1 2 2 3 90980–12058 2 3 90980–12095 1 2 3 90980–12168 3 90980–12228 D Wire Harness Repair Manual (RM1022E) 85 D–11 TABLE OF HOUSING SHAPE 4P Waterproof Type 1 2 3 4 1 2 3 90980–10095 3 4 4 90980–10140 90980–10220 1 1 2 2 3 4 90980–10373 1 2 3 4 90980–10476 1 3 90980–10203 1 3 2 4 90980–10549 2 1 2 4 3 4 90980–10649 90980–10663 90980–10664 1234 1 2 3 4 90980–10701 90980–10711 90980–10831 1 2 3 4 1 2 3 4 90980–10869 90980–10929 90980–10591 1 3 2 2 4 90980–10218 1 3 2 4 90980–10551 1 3 2 4 90980–10685 1 2 4 1 2 3 4 90980–10940 Wire Harness Repair Manual (RM1022E) 86 1 3 1 2 3 4 3 4 90980–10844 1 2 3 4 90980–10942 D–12 TABLE OF HOUSING SHAPE 4P Waterproof Type 1 2 1 3 4 90980–10943 1 2 3 4 90980–11037 3 1 3 1 3 2 4 90980–11065 90980–11066 1 2 3 4 1 2 3 4 1 2 3 4 2 4 90980–11036 1 2 3 4 1 2 3 4 90980–11139 90980–11150 90980–11269 1 2 3 90980–11292 1 3 90980–11028 1 2 3 4 90980–11178 2 4 90980–11288 4 90980–10990 1 2 3 4 90980–11152 2 4 90980–11304 1 3 2 4 90980–11283 1 2 3 4 90980–11329 90980–11330 3 1 2 3 4 1 2 1 2 3 4 1 2 3 4 90980–11857 90980–11885 5 90980–11569 90980–11640 Wire Harness Repair Manual (RM1022E) 87 D–13 TABLE OF HOUSING SHAPE 4P Waterproof Type 1 3 2 4 90980–11930 1 2 1 2 3 4 3 4 90980–11964 90980–12005 Wire Harness Repair Manual (RM1022E) 88 1 2 3 4 90980–12057 D–14 TABLE OF HOUSING SHAPE 5P Waterproof Type 1 2 4 1 3 5 2 3 4 5 90980–10162 90980–10393 12345 1 2 3 4 90980–10624 1 2 3 4 5 90980–10550 90980–10558 1 1 2 3 4 5 5 90980–10710 90980–10712 1 2 3 4 5 1 2 3 4 5 90980–10946 1 2 4 5 90980–11022 90980–11024 90980–11049 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 90980–11182 90980–11232 1 2 3 1 2 3 4 5 90980–11317 3 5 90980–11077 1 3 2 4 5 90980–11413 1 2 3 4 5 4 5 90980–11599 2 3 4 5 1 2 3 4 12345 90980–11904 90980–11960 Wire Harness Repair Manual (RM1022E) 89 D–15 TABLE OF HOUSING SHAPE 6P Waterproof Type 1 4 2 5 3 6 90980–10097 1 2 3 4 5 6 90980–10195 1 1 2 3 4 5 6 4 2 5 1 2 3 4 5 6 1 2 3 4 5 6 90980–10988 90980–11034 4 5 3 5 6 90980–10478 1 2 3 4 5 6 6 90980–10651 2 2 4 3 90980–10643 1 1 90980–10854 1 4 2 5 90980–11144 3 1 2 3 1 2 3 6 4 5 6 4 5 6 90980–11197 90980–11290 2 3 4 5 6 90980–10597 1 2 3 4 5 6 90980–10939 1 2 3 4 5 6 90980–11194 1 2 3 4 5 6 90980–11663 Wire Harness Repair Manual (RM1022E) 90 3 6 1 90980–11858 D–16 TABLE OF HOUSING SHAPE 7P, 8P Waterproof Type 1 1 2 2 1 2 3 3 4 6 7 8 5 1 2 3 4 5 6 7 3 4 5 6 7 4 5 6 7 90980–10628 90980–10931 90980–11172 90980–10205 1 2 3 4 1 2 3 4 5 6 7 8 5 6 7 8 90980–10897 90980–11190 1 4 1 2 3 4 5 6 7 8 1 5 2 6 3 7 6 7 90980–10891 1 2 3 4 5 6 7 8 90980–12080 8 90980–10895 1 4 7 4 8 90980–11242 2 5 3 2 5 8 3 6 1 90980–11461 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 90980–11592 1 2 3 4 5 6 7 8 90980–11593 90980–12164 Wire Harness Repair Manual (RM1022E) 91 D–17 TABLE OF HOUSING SHAPE 9P Waterproof Type 1 2 3 4 5 6 7 8 9 90980–10380 90980–10381 1 2 3 4 5 6 7 8 9 6 2 3 7 4 8 1 2 3 4 5 678 9 90980–10678 90980–10686 1 2 3 4 5 6 7 8 9 90980–11192 5 9 90980–11784 Wire Harness Repair Manual (RM1022E) 92 1 5 90980–10776 1 12 34 56 78 9 2 6 3 7 8 4 9 90980–11643 D–18 TABLE OF HOUSING SHAPE 10P Waterproof Type 1 2 1 7 3 4 5 6 7 8 9 10 90980–11231 1 2 3 4 5 6 7 5 2 8 6 3 4 9 10 90980–11332 8 9 10 90980–11653 1 2 3 4 6 7 8 9 10 5 90980–11658 Wire Harness Repair Manual (RM1022E) 93 D–19 TABLE OF HOUSING SHAPE 11P Waterproof Type 1 4 7 9 1 2 3 4 5 6 7 8 9 1011 90980–11174 90980–11240 1 4 7 9 1 2 3 4 5 6 7 8 9 1011 90980–11257 3 6 5 8 10 11 2 90980–11612 Wire Harness Repair Manual (RM1022E) 94 3 5 6 8 10 11 2 D–20 TABLE OF HOUSING SHAPE 12P Waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–10548 90980–10569 1 2 3 4 1 7 5 6 7 8 9 10 11 12 90980–11087 1 7 2 8 3 9 4 5 2 3 4 5 6 8 9 10 11 12 90980–11151 6 1 2 3 4 10 11 12 7 8 9 10 11 12 90980–11664 5 6 90980–11698 Wire Harness Repair Manual (RM1022E) 95 D–21 TABLE OF HOUSING SHAPE 13P, 15P Waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 7 8 9 10 11 12 13 14 15 90980–10654 90980–11089 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 90980–11677 Wire Harness Repair Manual (RM1022E) 96 4 5 6 D–22 TABLE OF HOUSING SHAPE 16P, 17P, 23P Waterproof Type 1 2 3 4 5 6 7 8 1 2 4 5 6 9 10 11 14 15 9 10 11 12 13 14 15 16 90980–10101 90980–10288 5 6 7 1 2 8 9 10 11 12 13 14 15 16 8 9 1 2 3 4 3 7 8 12 13 16 12 13 90980–11463 3 4 6 5 7 10 11 14 15 16 17 90980–11601 1 2 3 4 5 6 18 19 1 2 3 4 5 6 7 8 9 18 19 7 8 9 12 13 14 10 11 20 15 12 13 14 10 11 20 15 16 17 21 22 23 16 17 21 22 23 90980–11195 90980–11323 Wire Harness Repair Manual (RM1022E) 97 D–23 TABLE OF HOUSING SHAPE 24P, 25P Waterproof Type 1 1 2 3 10 11 12 4 5 6 7 2 3 4 5 6 7 8 9 10 11 12 13 14 15 23 24 16 17 18 19 20 21 22 13 14 15 8 9 23 24 16 17 18 19 20 21 22 90980–11851 1 2 16 17 90980–11882 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 18 19 20 21 22 23 24 16 17 10 11 12 13 14 15 18 19 20 21 22 23 24 90980–11893 1 2 17 18 90980–12116 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 24 25 90980–11861 Wire Harness Repair Manual (RM1022E) 98 D–24 TABLE OF HOUSING SHAPE 34P, 40P Waterproof Type 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3 1 2 23 24 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 90980–12021 90980–12022 90980–12020 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 31 32 33 34 35 36 37 38 39 40 90980–11215 90980–11566 Wire Harness Repair Manual (RM1022E) 99 D–25 TABLE OF HOUSING SHAPE 80P Waterproof Type 1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 29 30 41 42 43 44 45 46 47 48 49 50 61 62 63 64 65 66 67 68 69 70 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40 51 52 53 54 55 56 57 58 59 60 71 72 73 74 75 76 77 78 79 80 90980–11214 Wire Harness Repair Manual (RM1022E) 100 D–26 TABLE OF HOUSING SHAPE 1P Non–waterproof Type 1 1 1 1 90980–10165 90980–10179 90980–10183 90980–10229 1 1 1 1 90980–10254 90980–10332 90980–10250 90980–10252 1 1 90980–10343 90980–10359 1 1 1 90980–10363 1 90980–10435 90980–10619 90980–10652 1 1 1 90980–10703 90980–10782 90980–10786 1 90980–10398 1 90980–10688 1 90980–10792 Wire Harness Repair Manual (RM1022E) 101 D–27 TABLE OF HOUSING SHAPE 1P Non–waterproof Type 1 90980–10871 1 90980–10911 1 1 90980–10912 1 1 90980–10913 1 90980–10914 90980–10995 90980–11147 90980–11259 1 1 1 1 90980–11315 90980–11703 90980–11738 90980–11775 1 1 90980–11853 90980–11881 Wire Harness Repair Manual (RM1022E) 102 1 D–28 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 2 1 2 90980–10012 90980–10039 1 2 1 2 90980–10109 90980–10121 1 2 90980–10069 1 2 90980–10108 1 1 2 2 90980–10124 90980–10141 1 1 1 2 1 2 90980–10185 90980–10214 90980–10256 12 12 1 2 90980–10320 90980–10333 90980–10345 12 1 2 90980–10355 90980–10357 2 2 1 90980–10298 1 2 90980–10348 2 1 90980–10362 2 90980–10385 Wire Harness Repair Manual (RM1022E) 103 D–29 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 12 90980–10423 1 1 2 1 2 90980–10425 90980–10426 90980–10465 1 2 12 90980–10482 90980–10491 1 2 90980–10481 1 2 90980–10512 2 1 2 90980–10559 1 1 90980–10621 1 2 90980–10679 2 2 90980–10760 A 90980–10511 1 2 2 1 1 2 90980–10637 A B 1 2 90980–10783 90980–10823 B 1 2 1 2 1 2 1 2 90980–10825 90980–10835 90980–10850 Wire Harness Repair Manual (RM1022E) 104 90980–10855 D–30 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 2 1 2 90980–10860 90980–10903 1 1 2 1 2 90980–10906 1 90980–10916 1 1 2 2 2 90980–10935 1 2 2 90980–11094 1 2 90980–10960 1 2 90980–11098 1 2 90980–10962 1 90980–11080 12 2 90980–11148 12 90980–11227 90980–11278 90980–11306 1 2 1 2 1 2 90980–11386 90980–11388 90980–11212 1 2 90980–11369 1 90980–11396 2 90980–11429 Wire Harness Repair Manual (RM1022E) 105 D–31 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 2 1 90980–11436 2 1 2 90980–11579 90980–11608 1 2 1 2 90980–11736 90980–11769 1 2 90980–11684 1 2 90980–11687 1 2 90980–11824 1 2 1 2 90980–11839 1 2 2 90980–11996 1 2 2 90980–11840 1 2 90980–11886 1 1 90980–11862 12 1 2 90980–11890 90980–11918 90980–11919 1 2 1 2 1 2 90980–12014 90980–12039 90980–12063 Wire Harness Repair Manual (RM1022E) 106 90980–11884 D–32 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 1 2 90980–12088 1 1 2 90980–12089 90980–12109 1 1 2 2 90980–12110 2 1 2 1 2 90980–12111 90980–12120 1 2 1 2 90980–12138 90980–12224 90980–12243 90980–12191 1 1 90980–12219 90980–12242 2 2 2 90980–12241 90980–12253 Wire Harness Repair Manual (RM1022E) 107 D–33 TABLE OF HOUSING SHAPE 3P Non–waterproof Type 1 1 2 1 2 3 90980–10056 90980–10070 1 1 2 3 3 2 3 1 2 3 90980–10072 90980–10111 1 1 2 2 3 3 2 3 90980–10143 90980–10189 90980–10216 1 1 1 2 3 90980–10228 90980–10222 1 2 3 2 90980–10232 3 90980–10234 90980–10258 1 1 2 3 1 2 3 90980–10365 123 90980–10483 90980–10420 12 3 2 1 2 3 3 90980–10428 12 3 90980–10464 1 2 3 90980–10489 90980–10490 Wire Harness Repair Manual (RM1022E) 108 3 2 90980–10618 D–34 TABLE OF HOUSING SHAPE 3P Non–waterproof Type 1 1 2 3 90980–10638 90980–10660 2 2 1 1 3 3 90980–10704 90980–10747 90980–10784 1 1 2 3 90980–10908 1 2 3 90980–11071 1 2 3 90980–10956 1 2 90980–11079 123 3 90980–10980 90980–11053 1 2 3 3 1 1 2 3 90980–11251 90980–11296 1 2 3 90980–11314 1 2 2 2 3 3 90980–11485 1 23 90980–11336 1 2 3 90980–11490 2 90980–11387 1 1 2 3 3 2 3 90980–11667 90980–11471 1 2 3 90980–11685 Wire Harness Repair Manual (RM1022E) 109 D–35 TABLE OF HOUSING SHAPE 3P Non–waterproof Type 1 2 3 90980–11731 1 2 3 1 2 3 90980–11764 90980–11777 1 2 3 90980–11938 1 2 3 90980–11987 1 2 90980–12197 Wire Harness Repair Manual (RM1022E) 110 3 1 2 3 90980–11880 D–36 TABLE OF HOUSING SHAPE 4P Non–waterproof Type 90980–10002 1 1 1 2 3 4 1 2 3 4 90980–10127 2 3 1 3 4 90980–10196 1 2 3 4 2 1 3 3 4 2 4 1 2 3 90980–10221 1 2 90980–10142 3 4 4 2 4 90980–10171 1 3 2 4 90980–10260 90980–10307 1 2 3 4 1 2 3 4 90980–10378 90980–10400 90980–10467 90980–10484 12 34 1 2 3 4 1 2 3 4 1 234 90980–10504 90980–10514 90980–10515 90980–10601 1234 1 2 3 4 90980–10716 90980–10717 1234 90980–10645 1 2 3 4 90980–10692 Wire Harness Repair Manual (RM1022E) 111 D–37 TABLE OF HOUSING SHAPE 4P Non–waterproof Type 1 2 3 1 2 3 4 4 1 2 3 4 90980–10759 90980–10795 90980–10867 1 2 3 4 1 2 3 4 1 2 3 4 90980–11013 1 2 3 4 90980–11136 B 1 2 1 2 3 4 90980–10904 1 90980–11090 90980–11107 1 2 3 4 1 2 3 4 90980–11187 90980–11313 1 2 3 4 1 2 3 4 90980–11494 90980–11495 A 2 3 4 90980–11118 1 2 3 4 90980–11398 1 2 3 3 4 4 90980–11427 90980–11606 1 2 3 4 90980–11662 1 2 3 4 90980–11676 1 3 2 4 90980–11742 Wire Harness Repair Manual (RM1022E) 112 1 2 3 4 90980–11766 D–38 TABLE OF HOUSING SHAPE 4P Non–waterproof Type 1 2 3 1 2 3 4 4 1 3 2 4 1 2 3 4 90980–11771 90980–11792 90980–11799 90980–11841 1 2 3 4 1 2 1 2 3 4 1 2 3 4 90980–11892 90980–11950 90980–11988 1 2 3 4 1 2 3 4 1 2 3 4 90980–12017 90980–12018 90980–12019 90980–12160 1 2 1 2 3 4 3 4 90980–11842 1 2 3 4 3 4 90980–12211 90980–12225 Wire Harness Repair Manual (RM1022E) 113 D–39 TABLE OF HOUSING SHAPE 5P Non–waterproof Type 1 3 4 2 5 90980–10041 1 3 4 2 5 90980–10340 1 4 1 2 3 4 5 90980–10644 1 2 3 4 5 90980–10789 5 90980–10262 1 2 3 4 5 90980–10376 1 2 3 4 5 90980–10509 1 3 3 2 1 2 3 4 5 1 2 90980–10274 12 345 90980–10487 1 3 90980–10520 2 5 4 1 2 90980–10659 1 3 4 2 5 90980–10888 90980–10713 1 3 4 2 5 345 90980–10488 12345 90980–10631 2 3 5 90980–10718 2 1 5 2 3 4 5 90980–10986 Wire Harness Repair Manual (RM1022E) 114 12 1 4 345 4 90980–10339 2 5 4 90980–10610 3 4 5 1 3 90980–11319 D–40 TABLE OF HOUSING SHAPE 5P Non–waterproof Type 1 3 2 4 5 90980–11603 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 90980–11772 90980–11908 90980–11909 3 1 2 1 2 3 4 5 4 5 90980–11921 90980–12190 Wire Harness Repair Manual (RM1022E) 115 D–41 TABLE OF HOUSING SHAPE 6P Non–waterproof Type 1 2 3 4 5 6 1 3 4 2 6 5 90980–10004 90980–10029 1 2 3 4 5 6 1 2 3 4 5 6 90980–10313 90980–10334 1 4 2 5 3 6 1 2 3 1 4 2 5 90980–10173 1 4 2 5 1 2 3 4 5 6 90980–10414 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 90980–10604 90980–10605 90980–10672 3 5 1 2 3 4 5 6 1 90980–10367 1 90980–10402 2 3 6 123 456 3 90980–10382 1 4 2 5 90980–10224 3 6 90980–10335 4 5 6 1 4 3 6 2 4 5 6 90980–10447 1 4 3 6 2 5 90980–10673 2 1 3 4 5 6 3 2 4 5 6 6 90980–10766 90980–10785 90980–10797 Wire Harness Repair Manual (RM1022E) 116 90980–10889 D–42 TABLE OF HOUSING SHAPE 6P Non–waterproof Type 1 2 3 4 5 6 90980–10910 1 3 4 5 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 90980–10933 90980–10957 90980–10964 2 1 6 3 4 5 6 90980–10976 1 1 2 3 4 5 6 90980–10996 3 4 4 5 6 5 6 90980–11001 90980–11011 1 2 3 4 5 6 3 4 5 6 90980–11280 1 2 3 4 5 6 1 2 3 90980–11488 90980–11493 4 5 6 4 5 6 90980–11617 1 2 34 5 6 90980–11297 1 1 2 3 90980–11616 1 2 3 2 1 90980–11091 1 2 3 4 5 6 1 2 2 3 2 4 5 6 90980–11552 1 3 4 2 5 6 90980–11697 90980–11326 1 3 2 4 5 6 90980–11583 1 4 2 5 3 6 90980–11778 Wire Harness Repair Manual (RM1022E) 117 D–43 TABLE OF HOUSING SHAPE 6P Non–waterproof Type 1 1 2 3 4 5 6 1 2 3 4 5 6 90980–11780 90980–11820 1 2 3 4 5 6 90980–12012 2 4 6 1 3 5 90980–12056 3 2 4 5 90980–11879 1 2 3 4 5 6 90980–11986 1 2 3 4 5 6 1 2 3 4 5 6 90980–12067 1 2 3 4 5 6 90980–12209 Wire Harness Repair Manual (RM1022E) 118 6 90980–12199 D–44 TABLE OF HOUSING SHAPE 7P Non–waterproof Type 1 2 4 5 6 3 7 90980–10043 12 3 45 6 7 1 1 2 3 4 5 6 7 4 90980–10071 1 2 3 4 5 6 7 2 5 6 3 12 45 3 7 7 90980–10264 1 6 90980–10311 2 3 4 5 6 7 1 2 3 4 5 6 7 90980–10452 90980–10460 90980–10729 90980–10772 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 90980–11340 90980–11529 90980–11740 90980–11794 90980–11165 1 2 4 5 6 7 3 90980–12060 Wire Harness Repair Manual (RM1022E) 119 D–45 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 1 2 3 4 5 6 7 8 1 90980–10019 4 5 2 3 6 7 8 90980–10112 1 2 1 5 3 4 5 6 7 8 2 6 3 7 4 8 1 2 3 4 5 6 7 8 90980–10113 90980–10175 1 2 3 4 5 6 7 8 12 3 456 78 90980–10301 90980–10321 90980–10336 1 23 4 5678 1 2 3 4 5 6 7 8 90980–10419 90980–10431 6 7 2 4 8 90980–10404 1 2 6 3 4 5 7 8 1 3 4 5 2 6 7 2 3 4 90980–10209 1 3 5 7 2 4 6 8 1 2 3 4 5 6 7 8 5 6 7 8 90980–10119 1 5 1 2 3 4 5 6 7 8 90980–10148 1 3 5 1 2 3 4 6 7 8 90980–10280 1 5 2 6 3 7 4 8 90980–10358 1 3 5 7 2 4 6 8 90980–10449 12 3 456 7 8 8 90980–10463 90980–10517 90980–10523 Wire Harness Repair Manual (RM1022E) 120 90980–10799 D–46 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 1 2 3 4 5 1 2 3 4 5 6 7 8 6 7 8 90980–10877 90980–11439 1 2 3 4 5 6 7 8 90980–11397 1 A B 2 5 90980–10926 3 6 7 8 3 4 5 6 7 8 90980–11321 90980–11354 1 2 2 3 4 5 6 90980–11459 1 2 3 4 5 6 7 8 4 5 6 7 4 5 7 8 90980–11130 3 90980–11533 2 3 1 1 2 3 456 78 7 8 2 6 90980–11092 1 2 1 4 1 2 3 4 5 6 7 8 1 1 2 3 4 5 6 7 8 90980–11279 1 3 8 2 4 5 6 7 8 90980–11362 1 2 3 4 5 6 7 8 90980–11615 1 2 3 4 5 6 7 8 3 4 5 6 7 8 90980–11630 90980–11633 90980–11686 90980–11701 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 5 6 7 8 1 2 3 4 5 6 7 8 90980–11989 90980–12091 90980–12113 90980–12217 Wire Harness Repair Manual (RM1022E) 121 D–47 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 1 2 3 4 5 6 7 8 90980–12221 Wire Harness Repair Manual (RM1022E) 122 D–48 TABLE OF HOUSING SHAPE 9P Non–waterproof Type 1 2 5 6 3 4 8 9 7 1 2 5 6 7 3 4 8 9 1 2 5 6 7 3 4 8 9 1 4 8 90980–10045 12 56 34 89 7 90980–10318 1 2 3 4 5 6 7 8 9 1 4 7 2 5 8 3 6 9 90980–10386 1 2 5 6 90980–11302 1 2 90980–10133 7 3 4 8 9 90980–11479 90980–10152 1 2 5 6 7 3 4 8 9 90980–10536 1 2 3 3 2 5 6 7 9 90980–10266 12 34 67 5 89 90980–11277 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 90980–11535 90980–11710 3 4 5 6 7 8 9 90980–12026 Wire Harness Repair Manual (RM1022E) 123 D–49 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 90980–10158 1 2 3 4 5 6 7 8 9 10 90980–10282 1 2 3 4 5 7 8 9 10 90980–10304 1 2 5 6 7 3 4 8 9 10 90980–10469 7 8 2 7 3 8 4 5 9 10 90980–10177 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 90980–10294 90980–10302 5 6 7 3 4 8 9 10 90980–10322 1 2 3 4 6 7 8 9 10 90980–10377 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 90980–10528 90980–10669 1 2 3 4 Wire Harness Repair Manual (RM1022E) 124 1 6 9 10 90980–10159 1 2 1 2 3 4 5 6 6 5 D–50 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 5 6 3 7 8 1 2 4 9 10 90980–10721 1 2 5 6 7 8 3 4 9 10 3 4 5 6 7 8 9 10 90980–10997 1 2 5 6 3 4 7 8 1 2 1 5 2 6 3 7 8 7 A B 9 10 8 90980–10822 4 9 3 4 5 6 90980–10801 90980–10862 1 2 3 4 5 6 7 8 9 10 1 10 90980–10965 1 2 3 4 5 6 7 8 9 10 2 3 4 6 5 7 8 9 10 90980–10993 1 3 7 4 8 2 5 6 9 10 90980–11116 90980–11276 1 2 5 6 7 1 2 3 4 8 9 10 5 6 3 4 7 8 9 10 9 10 90980–11366 90980–11450 90980–11527 Wire Harness Repair Manual (RM1022E) 125 D–51 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 1 2 3 4 6 7 8 9 10 6 7 8 9 10 90980–11537 90980–11581 90980–11614 1 3 5 2 A B 1 2 4 3 4 1 2 3 4 5 6 7 8 9 10 5 6 7 8 9 10 90980–11642 90980–11657 90980–11781 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 6 7 8 9 10 90980–11817 90980–11923 5 6 7 8 9 10 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 90980–12008 Wire Harness Repair Manual (RM1022E) 126 90980–11924 1 2 3 4 5 6 7 8 9 10 6 7 8 9 10 90980–11948 6 7 8 9 10 90980–12135 D–52 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 1 2 3 4 5 6 7 8 9 10 90980–12162 2 3 4 5 6 7 8 9 10 90980–12226 1 2 3 4 5 6 7 8 9 10 90980–12272 Wire Harness Repair Manual (RM1022E) 127 D–53 TABLE OF HOUSING SHAPE 11P Non–waterproof Type 1 2 6 7 8 1 2 3 4 5 6 7 8 9 10 11 3 4 5 9 1011 90980–10319 1 3 6 9 4 7 10 90980–10337 2 5 8 11 1 2 3 6 7 8 90980–10450 1 2 3 4 5 6 7 8 9 2 5 6 7 8 9 10 11 3 4 90980–10873 4 5 10 11 9 10 11 1 2 3 6 7 8 4 9 1 2 6 3 7 8 9 5 1 2 8 9 5 10 3 4 5 6 7 8 9 10 11 1 2 11 90980–10966 Wire Harness Repair Manual (RM1022E) 128 7 4 90980–10830 5 10 3 90980–10723 10 11 4 2 6 90980–10781 1 2 5 8 11 90980–10338 90980–10537 90980–10727 1 1 3 4 6 7 9 10 3 4 5 6 7 8 9 1011 90980–11041 11 D–54 TABLE OF HOUSING SHAPE 11P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 9 1011 90980–11083 90980–11539 1 2 3 4 5 6 7 8 9 1011 90980–12003 Wire Harness Repair Manual (RM1022E) 129 D–55 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 101112 3 7 90980–10006 1 2 3 4 5 6 90980–10150 7 8 9 10 11 12 90980–10303 1 2 3 4 5 6 7 8 9 90980–10397 1 2 3 9 7 8 4 5 6 10 11 12 90980–10421 1 2 4 5 6 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–10351 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 90980–10372 1 2 3 4 5 6 7 8 9 10 11 12 90980–10408 1 2 3 1 2 4 5 10 11 12 90980–10153 90980–10406 3 4 5 6 7 8 9 10 11 12 6 7 8 9 10 11 12 90980–10432 90980–10524 Wire Harness Repair Manual (RM1022E) 130 1 2 3 D–56 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 90980–10565 1 2 3 4 8 90980–10632 5 6 7 9 10 11 12 1 2 7 90980–10714 1 2 6 7 5 6 7 3 4 9 10 11 12 90980–10932 4 9 10 5 6 1 11 12 7 2 7 3 8 4 9 10 4 9 10 5 6 11 12 90980–10725 1 2 3 4 7 8 90980–10803 2 3 8 1 2 3 4 5 6 7 8 9 101112 1 4 5 9 10 11 12 90980–10658 90980–10724 90980–10743 8 3 8 3 4 5 8 9 10 11 12 1 2 1 2 3 6 7 8 10 11 12 9 5 6 10 1112 90980–10879 5 6 1 11 12 7 90980–10967 2 8 3 4 9 10 5 6 11 12 90980–10968 Wire Harness Repair Manual (RM1022E) 131 D–57 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 7 8 9 10 11 12 90980–10973 1 2 3 4 5 6 7 8 9 10 11 12 90980–11311 1 2 3 4 56 7 89 10 1112 7 8 9 10 1112 90980–11121 90980–11129 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 12 90980–11408 90980–11424 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–11475 90980–11531 1 2 10 1112 90980–11453 1 4 5 6 7 8 9 3 4 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 8 9 10 11 12 90980–11626 90980–11649 Wire Harness Repair Manual (RM1022E) 132 90980–11656 101112 D–58 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–11661 90980–11693 1 2 3 4 5 6 1 2 3 90980–11720 A 1 2 3 4 5 1 2 3 4 5 6 6 7 8 9 10 11 12 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12 B 1 2 3 4 5 6 7 8 9 101112 90980–11782 A B 90980–11847 A B 90980–11867 A B 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 101112 7 8 9 101112 7 8 9 101112 90980–11869 90980–11871 90980–11873 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 101112 7 8 9 10 11 12 90980–11947 90980–12032 90980–12090 1 2 3 4 5 6 Wire Harness Repair Manual (RM1022E) 133 D–59 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–12183 90980–12222 Wire Harness Repair Manual (RM1022E) 134 1 2 7 8 9 10 11 12 3 4 5 6 90980–12273 D–60 TABLE OF HOUSING SHAPE 13P Non–waterproof Type 1 2 3 7 8 9 4 5 6 10 11 12 13 90980–10033 1 2 3 7 8 9 90980–10062 90980–10132 4 5 6 10 11 12 13 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 7 8 9 90980–10324 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 7 8 9 10 11 12 13 10 4 5 6 7 8 11 12 13 9 10 11 12 13 90980–10480 1 2 3 4 5 6 3 4 5 6 90980–10805 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–11114 1 2 3 7 8 4 5 6 9 10 11 12 13 90980–11350 90980–11115 1 2 3 4 5 90980–11199 1 2 3 7 8 9 10 4 5 6 11 12 13 6 7 8 9 10111213 90980–11394 90980–11478 Wire Harness Repair Manual (RM1022E) 135 D–61 TABLE OF HOUSING SHAPE 13P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10111213 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10111213 90980–11542 90980–11604 90980–11695 1 2 3 4 5 6 7 8 9 10111213 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–11714 90980–11827 90980–11848 1 2 3 4 5 1 2 6 7 8 9 5 6 7 8 9 10 11 12 13 1011 1213 90980–11952 3 4 90980–12007 Wire Harness Repair Manual (RM1022E) 136 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–12027 D–62 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 90980–10330 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10368 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10369 1 2 3 90980–10371 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14 90980–10471 90980–10507 Wire Harness Repair Manual (RM1022E) 137 D–63 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 7 2 3 4 5 6 8 9 10 11 12 13 14 1 2 3 7 8 9 10 11 12 13 14 90980–10538 90980–10608 1 2 3 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10633 90980–10634 4 5 6 1 2 1 2 3 4 5 6 7 8 9 1011121314 90980–10807 90980–11437 3 4 5 6 7 8 9 10 11 12 13 14 90980–10813 Wire Harness Repair Manual (RM1022E) 138 4 5 6 D–64 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 1 2 8 9 10 11 12 13 14 4 5 6 7 8 9 10 A B 11 12 13 14 90980–10852 3 4 5 6 90980–11225 1 2 3 1 2 5 6 7 A B 3 4 7 8 9 10 11 12 13 14 90980–11433 1 2 4 5 6 8 9 10 11 12 13 14 90980–11383 1 7 A B 3 2 3 4 5 6 7 8 4 9 1011121314 5 6 7 8 9 10 11 12 13 14 90980–11465 90980–11511 Wire Harness Repair Manual (RM1022E) 139 D–65 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–11556 1 2 3 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–11591 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14 90980–11791 90980–11805 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8 9 1011121314 90980–11911 90980–11925 Wire Harness Repair Manual (RM1022E) 140 1 D–66 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 7 6 5 4 3 2 1 14 13 12 11 10 9 8 90980–12082 Wire Harness Repair Manual (RM1022E) 141 D–67 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 8 9 10 11 90980–10066 1 3 5 6 7 8 9 10 11 12 13 14 15 12 13 14 15 90980–10331 2 4 1 2 3 7 8 9 10 90980–10443 1 3 4 5 6 12 13 14 15 90980–10563 1 2 2 5 11 4 3 6 7 4 5 6 7 8 9 8 9 10 11 12 10 11 12 13 14 15 13 14 15 90980–10815 90980–10828 Wire Harness Repair Manual (RM1022E) 142 5 6 7 D–68 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 1 2 3 7 8 9 1011121314 15 4 5 6 1 2 3 90980–11042 1 2 3 90980–11056 1 2 3 4 4 5 6 8 9 7 8 9 101112131415 90980–11179 1 2 3 4 8 9 4 5 6 7 8 9 1011121314 15 10 11 12 13 5 6 7 14 15 90980–11264 5 6 7 10 11 12 13 14 15 90980–11372 Wire Harness Repair Manual (RM1022E) 143 D–69 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 9 10 11 90980–10008 1 2 3 7 8 13 10 16 1 2 3 4 5 6 7 8 9 10 11 12 11 12 13 14 15 16 14 90980–10454 1 5 2 6 7 5 6 7 8 13 14 15 16 90980–10028 4 5 6 9 15 4 12 90980–10486 3 4 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 90980–10522 90980–10525 Wire Harness Repair Manual (RM1022E) 144 D–70 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10539 1 2 90980–10543 3 4 1234 5 6 7 8 9 10 9 10 11 12 13 14 15 16 11 12 13 14 15 16 90980–10561 1 2 3 4 567 8 90980–10611 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 90980–10613 90980–10614 Wire Harness Repair Manual (RM1022E) 145 D–71 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10635 90980–10636 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 90980–10740 90980–10764 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10809 90980–11445 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10848 Wire Harness Repair Manual (RM1022E) 146 1 2 D–72 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 5 6 3 4 7 11 12 13 8 1 2 3 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 14 15 16 90980–10885 90980–11082 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 5 6 7 8 9 10 11 12 13 14 15 16 90980–11113 90980–11219 1 2 3 4 5 6 7 8 1 2 3 4 5 6 9 10 11 12 13 14 15 16 7 8 9 10 11 12 13 14 15 16 90980–11391 90980–11416 Wire Harness Repair Manual (RM1022E) 147 D–73 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 90980–11425 1 2 3 4 9 10 11 12 90980–11435 5 6 7 8 13 14 15 16 90980–11547 1 2 3 7 8 9 10 11 12 13 14 15 16 90980–11562 1 2 3 1 2 3 4 5 6 7 8 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 11 12 13 90980–11565 14 15 16 90980–11574 Wire Harness Repair Manual (RM1022E) 148 4 5 6 D–74 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 1 2 3 4 5 6 7 8 90980–11648 90980–11652 16 15 14 13 12 11 10 9 1 2 3 4 9 10 1112 A 8 7 6 5 4 3 2 1 90980–11665 90980–11978 3 4 A 9 10 1112 6 7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 1 2 4 5 5 6 7 8 1314 1516 B 90980–11681 5 6 7 8 1314 1516 B 90980–11683 1 2 3 4 5 6 7 8 9 10111213141516 90980–11787 Wire Harness Repair Manual (RM1022E) 149 D–75 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 90980–12093 90980–12094 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 90980–12101 7 8 9 10 11 12 13 14 15 16 90980–12104 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 90980–12105 90980–12155 Wire Harness Repair Manual (RM1022E) 150 1 2 3 4 5 6 D–76 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–12156 Wire Harness Repair Manual (RM1022E) 151 D–77 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 1 2 3 4 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 90980–10031 17 16 5 6 7 8 14 15 16 17 90980–10037 15 14 1 2 3 4 13 12 11 10 9 8 7 5 6 7 6 5 4 3 2 1 8 9 1011121314151617 90980–10731 90980–11417 90980–11420 90980–11203 1 2 3 4 1 2 3 5 6 7 4 5 6 7 8 9 10111213141516 17 8 9 10 11 12 13 14 15 16 17 90980–11310 90980–11335 Wire Harness Repair Manual (RM1022E) 152 13 D–78 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 1 2 3 1 2 3 4 4 5 6 7 8 9 10 5 6 7 8 9 10 11 12 11 12 13 14 15 16 17 13 14 15 90980–11506 16 17 90980–11560 1 2 3 4 5 6 1 7 8 9 10 11 12 13 14 15 2 3 4 5 6 7 6 7 8 9 10 1112131415 16 17 16 17 90980–11586 1 2 3 4 5 90980–11671 1 2 6 7 3 4 5 8 9 8 9 10 1112131415 16 17 1011121314151617 90980–11672 90980–11954 Wire Harness Repair Manual (RM1022E) 153 D–79 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 9 10 1 2 3 4 5 6 7 8 9 14 10 11 12 13 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 90980–10285 90980–10295 3 4 11 12 13 14 5 6 7 8 15 16 17 18 90980–10326 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 90980–10350 12 13 14 15 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 16 17 18 90980–10530 90980–10656 Wire Harness Repair Manual (RM1022E) 154 D–80 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 12 13 14 15 11 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 90980–10778 1 2 3 4 5 6 7 8 90980–10819 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 90980–11224 90980–11226 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 8 9 101112131415161718 10 11 12 131415 16 17 18 90980–11497 90980–11594 Wire Harness Repair Manual (RM1022E) 155 D–81 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 1213141516 17 18 10 11 12 13 14 15 16 17 18 90980–11595 90980–11913 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 101112131415161718 90980–11914 1 2 3 4 5 6 90980–11973 1 2 3 4 5 6 7 8 9 7 8 9 1011121314151617 18 10 11 12 13 14 15 16 17 18 90980–12122 90980–12174 Wire Harness Repair Manual (RM1022E) 156 D–82 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 8 9 7 10 11 12 13 14 15 16 17 18 19 18 19 90980–10675 1 3 4 7 8 9 90980–10857 2 5 6 1 2 3 4 10 11 12 13 14 15 16 17 18 19 90980–10883 1 2 3 4 5 6 7 8 9 101112131415161718 19 90980–11205 1 2 3 4 5 6 7 8 5 6 7 8 9 101112131415161718 19 9 10 11 12131415 16 1718 19 90980–11308 90980–11377 Wire Harness Repair Manual (RM1022E) 157 D–83 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 5 6 7 8 9 10 11 12 8 9 10 13 14 15 16 13141516171819 17 18 19 90980–11571 90980–11955 Wire Harness Repair Manual (RM1022E) 158 1112 D–84 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 90980–10327 1 2 3 4 5 10 11 12 90980–10589 6 7 8 9 13 14 15 16 17 18 19 20 1 2 3 4 5 5 6 7 11 12 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10607 1 2 5 6 7 8 9 15 16 17 18 19 20 90980–10612 3 4 1 2 8 9 10 5 6 7 13 14 11 12 15 16 17 18 19 20 3 4 8 9 10 13 14 15 16 17 18 19 20 90980–10811 90980–11441 90980–10640 Wire Harness Repair Manual (RM1022E) 159 D–85 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10817 A 2 1 4 3 7 10 6 9 5 8 10 7 9 6 8 5 90980–10821 4 3 B 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10952 1 2 3 4 5 10 11 12 90980–11260 6 7 8 9 13 14 15 16 17 18 19 20 1 2 3 4 9 10 11 12 13 14 15 16 17 18 19 20 90980–11432 90980–11469 Wire Harness Repair Manual (RM1022E) 160 5 6 7 8 D–86 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 13 14 15 16 17 18 19 20 90980–11499 90980–11558 A B 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 5 6 7 8 9 101112 13 1415 16 171819 20 90980–11868 90980–11971 1 2 3 4 5 6 7 8 9 10 1 11 12 13 14 15 16 17 18 19 20 90980–11974 3 4 5 6 7 8 9 10 11 2 12 13 14 15 16 17 18 19 20 90980–12034 Wire Harness Repair Manual (RM1022E) 161 D–87 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–12038 1 7 8 9 10 17 18 19 20 90980–12106 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 90980–12166 90980–12259 Wire Harness Repair Manual (RM1022E) 162 1 2 3 4 5 6 11 12 13 14 15 16 D–88 TABLE OF HOUSING SHAPE 21P Non–waterproof Type 1 2 3 4 5 11 12 13 14 15 6 7 8 9 10 17 18 19 20 21 16 90980–10064 1 6 2 7 13 14 15 3 8 9 10 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 90980–10207 4 5 11 12 1 2 3 4 5 6 7 8 9 101112131415161718192021 19 20 21 90980–10473 90980–11125 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 9 10 10 11 12 13 14 15 16 17 18 19 20 21 111213 141516171819 2021 90980–11379 90980–11956 Wire Harness Repair Manual (RM1022E) 163 D–89 TABLE OF HOUSING SHAPE 21P Non–waterproof Type 1 2 6 7 8 9 3 4 5 101112 13141516171819 2021 90980–11957 Wire Harness Repair Manual (RM1022E) 164 D–90 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 90980–10010 90980–10328 1 2 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22 5 6 3 4 7 10 11 12 15 16 17 8 9 13 14 18 19 20 21 22 90980–10456 1 2 3 4 5 11 12 13 14 15 16 90980–10458 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22 90980–10526 90980–10741 Wire Harness Repair Manual (RM1022E) 165 D–91 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 11 12 13 14 15 16 17 18 19 20 21 22 90980–10765 90980–10875 B 2 1 A 5 8 11 4 7 10 3 6 9 11 8 5 10 7 4 9 6 3 2 1 1 2 3 4 5 6 7 8 18 19 90980–10953 20 21 22 90980–11220 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22 90980–11238 90980–11392 Wire Harness Repair Manual (RM1022E) 166 9 10 11 121314151617 D–92 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10111213141516171819202122 10 11 12 13 14 15 16 17 18 19 20 21 22 90980–11502 90980–11628 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 12 13 1415161718192021 22 16 17 18 19 20 21 22 90980–11638 90980–11788 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 1213141516171819 202122 90980–11915 90980–11927 Wire Harness Repair Manual (RM1022E) 167 D–93 TABLE OF HOUSING SHAPE 23P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 1 2 3 90980–10921 4 5 6 5 6 18 19 7 8 9 12 13 14 1 2 3 4 10 11 20 15 16 17 21 22 23 90980–11195 18 19 7 8 9 12 13 14 10 11 20 15 16 17 21 22 23 1 2 3 4 5 1112 13 14 15161718 19 20 21 22 23 90980–11323 90980–11381 Wire Harness Repair Manual (RM1022E) 168 6 7 8 9 10 D–94 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–10296 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–10585 1 2 3 4 5 6 7 11 12 13 19 20 8 9 10 14 15 21 22 16 17 18 23 24 90980–10881 12 11 10 9 8 7 6 5 4 3 2 1 A 7 12 6 11 5 4 10 3 9 1 2 8 B 90980–10955 Wire Harness Repair Manual (RM1022E) 169 D–95 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–11476 1 2 3 4 5 6 7 8 9 10111213 14 15 16 17 1819 2021 22 23 24 90980–11509 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12070 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12079 Wire Harness Repair Manual (RM1022E) 170 D–96 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 5 6 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12149 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12200 Wire Harness Repair Manual (RM1022E) 171 D–97 TABLE OF HOUSING SHAPE 25P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122232425 90980–11043 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122232425 90980–11055 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–11058 1 2 3 4 5 6 7 8 9 1011 121314 151617 1819 20 21 22 232425 90980–11375 Wire Harness Repair Manual (RM1022E) 172 D–98 TABLE OF HOUSING SHAPE 25P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–11404 1 2 3 4 5 6 7 8 9 101112 13 14 15 16171819 2021222324 25 90980–11877 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–12278 Wire Harness Repair Manual (RM1022E) 173 D–99 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 13 14 15 16 17 18 19 7 8 9 10 11 12 20 21 22 23 24 25 26 90980–10587 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10739 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10763 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10918 Wire Harness Repair Manual (RM1022E) 174 D–100 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10925 1 2 3 4 14 15 16 17 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 90980–11234 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11390 1 2 3 4 5 6 7 8 14 15 16 17 18 19 20 21 22 9 10 11 12 13 23 24 25 26 90980–11406 Wire Harness Repair Manual (RM1022E) 175 D–101 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11422 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11423 1 2 3 4 5 6 7 8 9 13 14 15 16 10 11 12 17 18 19 20 21 22 23 24 25 26 90980–11611 1 5 13 2 3 6 7 8 9 10 11 14 15 16 17 18 19 20 22 23 24 25 26 4 12 21 90980–11632 Wire Harness Repair Manual (RM1022E) 176 D–102 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617181920212223 24 25 26 90980–11786 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–12150 1 2 3 10 11 12 4 5 6 7 8 9 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–12203 Wire Harness Repair Manual (RM1022E) 177 D–103 TABLE OF HOUSING SHAPE 27P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 14 90980–11670 Wire Harness Repair Manual (RM1022E) 178 D–104 TABLE OF HOUSING SHAPE 28P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 141516171819 2021 22 23 24 25 26 27 28 90980–11218 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 90980–11637 A B 1 2 3 4 5 6 7 8 9 1011121314151617 1819 2021 22 23 2425 26 27 28 90980–11872 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 90980–12102 Wire Harness Repair Manual (RM1022E) 179 D–105 TABLE OF HOUSING SHAPE 30P Non–waterproof Type 1 10 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 90980–12151 1 2 3 4 5 6 7 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 23 24 25 26 27 28 29 30 90980–12277 Wire Harness Repair Manual (RM1022E) 180 D–106 TABLE OF HOUSING SHAPE 31P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 90980–11421 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 90980–11935 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 28 29 90980–12142 Wire Harness Repair Manual (RM1022E) 181 D–107 TABLE OF HOUSING SHAPE 32P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12071 1 2 3 4 5 6 7 8 9 10 11 12 13141516 17 18 19 20 21 22 23 24 25 26 272829303132 90980–12096 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12153 Wire Harness Repair Manual (RM1022E) 182 D–108 TABLE OF HOUSING SHAPE 32P Non–waterproof Type 1 2 3 4 5 6 17 18 19 20 21 22 7 8 9 10 11 12 13 14 15 16 23 24 25 26 27 28 29 30 31 32 90980–12275 Wire Harness Repair Manual (RM1022E) 183 D–109 TABLE OF HOUSING SHAPE 34P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 272829 30 31323334 90980–11221 1 2 3 4 5 6 18 19 20 21 22 23 7 8 9 10 11 12 13 14 15 16 17 24 25 26 27 28 29 30 31 32 33 34 90980–12114 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 90980–12144 Wire Harness Repair Manual (RM1022E) 184 D–110 TABLE OF HOUSING SHAPE 35P, 36P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90980–12145 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90980–12146 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 90980–12274 Wire Harness Repair Manual (RM1022E) 185 D–111 TABLE OF HOUSING SHAPE 38P Non–waterproof Type 1 2 3 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 90980–11555 1 2 3 4 5 6 7 20 21 22 23 24 25 8 9 10 11 12 13 14 15 16 17 18 19 26 27 28 29 30 31 32 33 34 35 36 37 38 90980–12276 Wire Harness Repair Manual (RM1022E) 186 D–112 TABLE OF HOUSING SHAPE 40P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1011121314 15 1617 181920 21 22232425262728 29 3031 32 33 34 3536 37383940 90980–11508 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–11618 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–12169 Wire Harness Repair Manual (RM1022E) 187 D–113 TABLE OF HOUSING SHAPE 40P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–12170 Wire Harness Repair Manual (RM1022E) 188 D–114 TABLE OF HOUSING SHAPE 42P, 43P, 46P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 90980–12184 A 1 2 3 4 5 6 7 8 9 10 1112 1314 1516 1718 1920 2021 1617 9 10 1 2 3 2223 1819 1112131415 4 5 6 7 8 B 90980–11360 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 90980–12179 Wire Harness Repair Manual (RM1022E) 189 D–115 TABLE OF HOUSING SHAPE 49P, 55P, 83P Non–waterproof Type A 9 10 13 14 17 18 21 1 2 5 6 26 24 2021 1415 16 7 8 9 1 10 2 3 3 4 7 8 1112 1516 19 20 22 27 25 2223 17 1819 11 1213 4 5 6 B 90980–11431 D F 1 2 3 4 5 6 7 8 9 1011 12 2 3 4 5 7 8 9 10 6 11 12 13 14 1 131415 9 1011 12 5 6 7 8 1 2 3 4 11 12 13 14 7 8 9 10 1 2 3 4 5 6 C E 90980–11359 90980–11906 Wire Harness Repair Manual (RM1022E) 190 D–116 TABLE OF HOUSING SHAPE 88P Non–waterproof Type B F E 1 3 2 6 5 4 9 8 7 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 20 21 22 23 24 25 26 13 14 15 16 17 18 19 6 7 8 9 10 11 12 1 2 3 4 5 1 2 3 4 5 6 7 8 9 7 8 9 4 5 6 2 3 1 D C A 90980–10950 Wire Harness Repair Manual (RM1022E) 191 D–117 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 90980–10158 1 2 3 4 5 6 7 8 9 10 90980–10282 1 2 3 4 5 7 8 9 10 90980–10304 1 2 5 6 7 3 4 8 9 10 90980–10469 7 8 2 7 3 8 4 5 9 10 90980–10177 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 90980–10294 90980–10302 5 6 7 3 4 8 9 10 90980–10322 1 2 3 4 6 7 8 9 10 90980–10377 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 90980–10528 90980–10669 1 2 3 4 Wire Harness Repair Manual (RM1022E) 192 1 6 9 10 90980–10159 1 2 1 2 3 4 5 6 6 5 D–118 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 5 6 3 7 8 1 2 4 9 10 90980–10721 1 2 5 6 7 8 3 4 9 10 3 4 5 6 7 8 9 10 90980–10997 1 2 5 6 3 4 7 8 1 2 1 5 2 6 3 7 8 7 A B 9 10 8 90980–10822 4 9 3 4 5 6 90980–10801 90980–10862 1 2 3 4 5 6 7 8 9 10 1 10 90980–10965 1 2 3 4 5 6 7 8 9 10 2 3 4 6 5 7 8 9 10 90980–10993 1 3 7 4 8 2 5 6 9 10 90980–11116 90980–11276 1 2 5 6 7 1 2 3 4 8 9 10 5 6 3 4 7 8 9 10 9 10 90980–11366 90980–11450 90980–11527 Wire Harness Repair Manual (RM1022E) 193 D–119 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 1 2 3 4 6 7 8 9 10 6 7 8 9 10 90980–11537 90980–11581 90980–11614 1 3 5 2 A B 1 2 4 3 4 1 2 3 4 5 6 7 8 9 10 5 6 7 8 9 10 90980–11642 90980–11657 90980–11781 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 6 7 8 9 10 90980–11817 90980–11923 5 6 7 8 9 10 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 90980–12008 Wire Harness Repair Manual (RM1022E) 194 90980–11924 1 2 3 4 5 6 7 8 9 10 6 7 8 9 10 90980–11948 6 7 8 9 10 90980–12135 D–120 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 1 1 2 3 4 5 6 7 8 9 10 90980–12162 2 3 4 5 6 7 8 9 10 90980–12226 1 2 3 4 5 6 7 8 9 10 90980–12272 Wire Harness Repair Manual (RM1022E) 195 D–121 TABLE OF HOUSING SHAPE 11P Non–waterproof Type 1 2 6 7 8 1 2 3 4 5 6 7 8 9 10 11 3 4 5 9 1011 90980–10319 1 3 6 9 4 7 10 90980–10337 2 5 8 11 1 2 3 6 7 8 90980–10450 1 2 3 4 5 6 7 8 9 2 5 6 7 8 9 10 11 3 4 90980–10873 4 5 10 11 9 10 11 1 2 3 6 7 8 4 9 1 2 6 3 7 8 9 5 1 2 8 9 5 10 3 4 5 6 7 8 9 10 11 1 2 11 90980–10966 Wire Harness Repair Manual (RM1022E) 196 7 4 90980–10830 5 10 3 90980–10723 10 11 4 2 6 90980–10781 1 2 5 8 11 90980–10338 90980–10537 90980–10727 1 1 3 4 6 7 9 10 3 4 5 6 7 8 9 1011 90980–11041 11 D–122 TABLE OF HOUSING SHAPE 11P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 5 6 7 8 9 1011 90980–11083 90980–11539 1 2 3 4 5 6 7 8 9 1011 90980–12003 Wire Harness Repair Manual (RM1022E) 197 D–123 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 101112 3 7 90980–10006 1 2 3 4 5 6 90980–10150 7 8 9 10 11 12 90980–10303 1 2 3 4 5 6 7 8 9 90980–10397 1 2 3 9 7 8 4 5 6 10 11 12 90980–10421 1 2 4 5 6 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–10351 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 90980–10372 1 2 3 4 5 6 7 8 9 10 11 12 90980–10408 1 2 3 1 2 4 5 10 11 12 90980–10153 90980–10406 3 4 5 6 7 8 9 10 11 12 6 7 8 9 10 11 12 90980–10432 90980–10524 Wire Harness Repair Manual (RM1022E) 198 1 2 3 D–124 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 90980–10565 1 2 3 4 8 90980–10632 5 6 7 9 10 11 12 1 2 7 90980–10714 1 2 6 7 5 6 7 3 4 9 10 11 12 90980–10932 4 9 10 5 6 1 11 12 7 2 7 3 8 4 9 10 4 9 10 5 6 11 12 90980–10725 1 2 3 4 7 8 90980–10803 2 3 8 1 2 3 4 5 6 7 8 9 101112 1 4 5 9 10 11 12 90980–10658 90980–10724 90980–10743 8 3 8 3 4 5 8 9 10 11 12 1 2 1 2 3 6 7 8 10 11 12 9 5 6 10 1112 90980–10879 5 6 1 11 12 7 90980–10967 2 8 3 4 9 10 5 6 11 12 90980–10968 Wire Harness Repair Manual (RM1022E) 199 D–125 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 7 8 9 10 11 12 90980–10973 1 2 3 4 5 6 7 8 9 10 11 12 90980–11311 1 2 3 4 56 7 89 10 1112 7 8 9 10 1112 90980–11121 90980–11129 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 12 90980–11408 90980–11424 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–11475 90980–11531 1 2 10 1112 90980–11453 1 4 5 6 7 8 9 3 4 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 8 9 10 11 12 90980–11626 90980–11649 Wire Harness Repair Manual (RM1022E) 200 90980–11656 101112 D–126 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–11661 90980–11693 1 2 3 4 5 6 1 2 3 90980–11720 A 1 2 3 4 5 1 2 3 4 5 6 6 7 8 9 10 11 12 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12 B 1 2 3 4 5 6 7 8 9 101112 90980–11782 A B 90980–11847 A B 90980–11867 A B 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 101112 7 8 9 101112 7 8 9 101112 90980–11869 90980–11871 90980–11873 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 101112 7 8 9 10 11 12 90980–11947 90980–12032 90980–12090 1 2 3 4 5 6 Wire Harness Repair Manual (RM1022E) 201 D–127 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 90980–12183 90980–12222 Wire Harness Repair Manual (RM1022E) 202 1 2 7 8 9 10 11 12 3 4 5 6 90980–12273 D–128 TABLE OF HOUSING SHAPE 13P Non–waterproof Type 1 2 3 7 8 9 4 5 6 10 11 12 13 90980–10033 1 2 3 7 8 9 90980–10062 90980–10132 4 5 6 10 11 12 13 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 7 8 9 90980–10324 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 7 8 9 10 11 12 13 10 4 5 6 7 8 11 12 13 9 10 11 12 13 90980–10480 1 2 3 4 5 6 3 4 5 6 90980–10805 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–11114 1 2 3 7 8 4 5 6 9 10 11 12 13 90980–11350 90980–11115 1 2 3 4 5 90980–11199 1 2 3 7 8 9 10 4 5 6 11 12 13 6 7 8 9 10111213 90980–11394 90980–11478 Wire Harness Repair Manual (RM1022E) 203 D–129 TABLE OF HOUSING SHAPE 13P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10111213 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10111213 90980–11542 90980–11604 90980–11695 1 2 3 4 5 6 7 8 9 10111213 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–11714 90980–11827 90980–11848 1 2 3 4 5 1 2 6 7 8 9 5 6 7 8 9 10 11 12 13 1011 1213 90980–11952 3 4 90980–12007 Wire Harness Repair Manual (RM1022E) 204 1 2 3 4 5 6 7 8 9 10 11 12 13 90980–12027 D–130 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 90980–10330 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10368 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10369 1 2 3 90980–10371 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14 90980–10471 90980–10507 Wire Harness Repair Manual (RM1022E) 205 D–131 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 7 2 3 4 5 6 8 9 10 11 12 13 14 1 2 3 7 8 9 10 11 12 13 14 90980–10538 90980–10608 1 2 3 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–10633 90980–10634 4 5 6 1 2 1 2 3 4 5 6 7 8 9 1011121314 90980–10807 90980–11437 3 4 5 6 7 8 9 10 11 12 13 14 90980–10813 Wire Harness Repair Manual (RM1022E) 206 4 5 6 D–132 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 1 2 8 9 10 11 12 13 14 4 5 6 7 8 9 10 A B 11 12 13 14 90980–10852 3 4 5 6 90980–11225 1 2 3 1 2 5 6 7 A B 3 4 7 8 9 10 11 12 13 14 90980–11433 1 2 4 5 6 8 9 10 11 12 13 14 90980–11383 1 7 A B 3 2 3 4 5 6 7 8 4 9 1011121314 5 6 7 8 9 10 11 12 13 14 90980–11465 90980–11511 Wire Harness Repair Manual (RM1022E) 207 D–133 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–11556 1 2 3 2 3 4 5 6 7 8 9 10 11 12 13 14 90980–11591 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14 90980–11791 90980–11805 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8 9 1011121314 90980–11911 90980–11925 Wire Harness Repair Manual (RM1022E) 208 1 D–134 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 7 6 5 4 3 2 1 14 13 12 11 10 9 8 90980–12082 Wire Harness Repair Manual (RM1022E) 209 D–135 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 8 9 10 11 90980–10066 1 3 5 6 7 8 9 10 11 12 13 14 15 12 13 14 15 90980–10331 2 4 1 2 3 7 8 9 10 90980–10443 1 3 4 5 6 12 13 14 15 90980–10563 1 2 2 5 11 4 3 6 7 4 5 6 7 8 9 8 9 10 11 12 10 11 12 13 14 15 13 14 15 90980–10815 90980–10828 Wire Harness Repair Manual (RM1022E) 210 5 6 7 D–136 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 1 2 3 7 8 9 1011121314 15 4 5 6 1 2 3 90980–11042 1 2 3 90980–11056 1 2 3 4 4 5 6 8 9 7 8 9 101112131415 90980–11179 1 2 3 4 8 9 4 5 6 7 8 9 1011121314 15 10 11 12 13 5 6 7 14 15 90980–11264 5 6 7 10 11 12 13 14 15 90980–11372 Wire Harness Repair Manual (RM1022E) 211 D–137 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 9 10 11 90980–10008 1 2 3 7 8 13 10 16 1 2 3 4 5 6 7 8 9 10 11 12 11 12 13 14 15 16 14 90980–10454 1 5 2 6 7 5 6 7 8 13 14 15 16 90980–10028 4 5 6 9 15 4 12 90980–10486 3 4 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 90980–10522 90980–10525 Wire Harness Repair Manual (RM1022E) 212 D–138 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10539 1 2 90980–10543 3 4 1234 5 6 7 8 9 10 9 10 11 12 13 14 15 16 11 12 13 14 15 16 90980–10561 1 2 3 4 567 8 90980–10611 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 90980–10613 90980–10614 Wire Harness Repair Manual (RM1022E) 213 D–139 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10635 90980–10636 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 90980–10740 90980–10764 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10809 90980–11445 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–10848 Wire Harness Repair Manual (RM1022E) 214 1 2 D–140 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 5 6 3 4 7 11 12 13 8 1 2 3 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 14 15 16 90980–10885 90980–11082 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 5 6 7 8 9 10 11 12 13 14 15 16 90980–11113 90980–11219 1 2 3 4 5 6 7 8 1 2 3 4 5 6 9 10 11 12 13 14 15 16 7 8 9 10 11 12 13 14 15 16 90980–11391 90980–11416 Wire Harness Repair Manual (RM1022E) 215 D–141 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 90980–11425 1 2 3 4 9 10 11 12 90980–11435 5 6 7 8 13 14 15 16 90980–11547 1 2 3 7 8 9 10 11 12 13 14 15 16 90980–11562 1 2 3 1 2 3 4 5 6 7 8 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 11 12 13 90980–11565 14 15 16 90980–11574 Wire Harness Repair Manual (RM1022E) 216 4 5 6 D–142 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 1 2 3 4 5 6 7 8 90980–11648 90980–11652 16 15 14 13 12 11 10 9 1 2 3 4 9 10 1112 A 8 7 6 5 4 3 2 1 90980–11665 90980–11978 3 4 A 9 10 1112 6 7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 1 2 4 5 5 6 7 8 1314 1516 B 90980–11681 5 6 7 8 1314 1516 B 90980–11683 1 2 3 4 5 6 7 8 9 10111213141516 90980–11787 Wire Harness Repair Manual (RM1022E) 217 D–143 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 90980–12093 90980–12094 1 2 3 4 5 6 9 10 11 12 13 14 7 8 15 16 90980–12101 7 8 9 10 11 12 13 14 15 16 90980–12104 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 90980–12105 90980–12155 Wire Harness Repair Manual (RM1022E) 218 1 2 3 4 5 6 D–144 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 90980–12156 Wire Harness Repair Manual (RM1022E) 219 D–145 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 1 2 3 4 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 90980–10031 17 16 5 6 7 8 14 15 16 17 90980–10037 15 14 1 2 3 4 13 12 11 10 9 8 7 5 6 7 6 5 4 3 2 1 8 9 1011121314151617 90980–10731 90980–11417 90980–11420 90980–11203 1 2 3 4 1 2 3 5 6 7 4 5 6 7 8 9 10111213141516 17 8 9 10 11 12 13 14 15 16 17 90980–11310 90980–11335 Wire Harness Repair Manual (RM1022E) 220 13 D–146 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 1 2 3 1 2 3 4 4 5 6 7 8 9 10 5 6 7 8 9 10 11 12 11 12 13 14 15 16 17 13 14 15 90980–11506 16 17 90980–11560 1 2 3 4 5 6 1 7 8 9 10 11 12 13 14 15 2 3 4 5 6 7 6 7 8 9 10 1112131415 16 17 16 17 90980–11586 1 2 3 4 5 90980–11671 1 2 6 7 3 4 5 8 9 8 9 10 1112131415 16 17 1011121314151617 90980–11672 90980–11954 Wire Harness Repair Manual (RM1022E) 221 D–147 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 9 10 1 2 3 4 5 6 7 8 9 14 10 11 12 13 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 90980–10285 90980–10295 3 4 11 12 13 14 5 6 7 8 15 16 17 18 90980–10326 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 90980–10350 12 13 14 15 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 16 17 18 90980–10530 90980–10656 Wire Harness Repair Manual (RM1022E) 222 D–148 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 12 13 14 15 11 16 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 90980–10778 1 2 3 4 5 6 7 8 90980–10819 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 90980–11224 90980–11226 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 8 9 101112131415161718 10 11 12 131415 16 17 18 90980–11497 90980–11594 Wire Harness Repair Manual (RM1022E) 223 D–149 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 1213141516 17 18 10 11 12 13 14 15 16 17 18 90980–11595 90980–11913 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 101112131415161718 90980–11914 1 2 3 4 5 6 90980–11973 1 2 3 4 5 6 7 8 9 7 8 9 1011121314151617 18 10 11 12 13 14 15 16 17 18 90980–12122 90980–12174 Wire Harness Repair Manual (RM1022E) 224 D–150 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 8 9 7 10 11 12 13 14 15 16 17 18 19 18 19 90980–10675 1 3 4 7 8 9 90980–10857 2 5 6 1 2 3 4 10 11 12 13 14 15 16 17 18 19 90980–10883 1 2 3 4 5 6 7 8 9 101112131415161718 19 90980–11205 1 2 3 4 5 6 7 8 5 6 7 8 9 101112131415161718 19 9 10 11 12131415 16 1718 19 90980–11308 90980–11377 Wire Harness Repair Manual (RM1022E) 225 D–151 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 5 6 7 8 9 10 11 12 8 9 10 13 14 15 16 13141516171819 17 18 19 90980–11571 90980–11955 Wire Harness Repair Manual (RM1022E) 226 1112 D–152 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 90980–10327 1 2 3 4 5 10 11 12 90980–10589 6 7 8 9 13 14 15 16 17 18 19 20 1 2 3 4 5 5 6 7 11 12 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10607 1 2 5 6 7 8 9 15 16 17 18 19 20 90980–10612 3 4 1 2 8 9 10 5 6 7 13 14 11 12 15 16 17 18 19 20 3 4 8 9 10 13 14 15 16 17 18 19 20 90980–10811 90980–11441 90980–10640 Wire Harness Repair Manual (RM1022E) 227 D–153 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10817 A 2 1 4 3 7 10 6 9 5 8 10 7 9 6 8 5 90980–10821 4 3 B 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–10952 1 2 3 4 5 10 11 12 90980–11260 6 7 8 9 13 14 15 16 17 18 19 20 1 2 3 4 9 10 11 12 13 14 15 16 17 18 19 20 90980–11432 90980–11469 Wire Harness Repair Manual (RM1022E) 228 5 6 7 8 D–154 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 13 14 15 16 17 18 19 20 90980–11499 90980–11558 A B 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 5 6 7 8 9 101112 13 1415 16 171819 20 90980–11868 90980–11971 1 2 3 4 5 6 7 8 9 10 1 11 12 13 14 15 16 17 18 19 20 90980–11974 3 4 5 6 7 8 9 10 11 2 12 13 14 15 16 17 18 19 20 90980–12034 Wire Harness Repair Manual (RM1022E) 229 D–155 TABLE OF HOUSING SHAPE 20P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 90980–12038 1 7 8 9 10 17 18 19 20 90980–12106 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 90980–12166 90980–12259 Wire Harness Repair Manual (RM1022E) 230 1 2 3 4 5 6 11 12 13 14 15 16 D–156 TABLE OF HOUSING SHAPE 21P Non–waterproof Type 1 2 3 4 5 11 12 13 14 15 6 7 8 9 10 17 18 19 20 21 16 90980–10064 1 6 2 7 13 14 15 3 8 9 10 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 90980–10207 4 5 11 12 1 2 3 4 5 6 7 8 9 101112131415161718192021 19 20 21 90980–10473 90980–11125 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 9 10 10 11 12 13 14 15 16 17 18 19 20 21 111213 141516171819 2021 90980–11379 90980–11956 Wire Harness Repair Manual (RM1022E) 231 D–157 TABLE OF HOUSING SHAPE 21P Non–waterproof Type 1 2 6 7 8 9 3 4 5 101112 13141516171819 2021 90980–11957 Wire Harness Repair Manual (RM1022E) 232 D–158 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 90980–10010 90980–10328 1 2 1 2 3 4 5 11 12 13 14 15 16 6 7 8 9 10 17 18 19 20 21 22 5 6 3 4 7 10 11 12 15 16 17 8 9 13 14 18 19 20 21 22 90980–10456 1 2 3 4 5 11 12 13 14 15 16 90980–10458 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22 90980–10526 90980–10741 Wire Harness Repair Manual (RM1022E) 233 D–159 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 11 12 13 14 15 16 17 18 19 20 21 22 90980–10765 90980–10875 B 2 1 A 5 8 11 4 7 10 3 6 9 11 8 5 10 7 4 9 6 3 2 1 1 2 3 4 5 6 7 8 18 19 90980–10953 20 21 22 90980–11220 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 12 13 14 15 16 17 18 19 20 21 22 90980–11238 90980–11392 Wire Harness Repair Manual (RM1022E) 234 9 10 11 121314151617 D–160 TABLE OF HOUSING SHAPE 22P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10111213141516171819202122 10 11 12 13 14 15 16 17 18 19 20 21 22 90980–11502 90980–11628 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 8 9 10 11 12 13 14 15 12 13 1415161718192021 22 16 17 18 19 20 21 22 90980–11638 90980–11788 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 1213141516171819 202122 90980–11915 90980–11927 Wire Harness Repair Manual (RM1022E) 235 D–161 TABLE OF HOUSING SHAPE 23P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1718 19 20 21 22 23 1 2 3 90980–10921 4 5 6 5 6 18 19 7 8 9 12 13 14 1 2 3 4 10 11 20 15 16 17 21 22 23 90980–11195 18 19 7 8 9 12 13 14 10 11 20 15 16 17 21 22 23 1 2 3 4 5 1112 13 14 15161718 19 20 21 22 23 90980–11323 90980–11381 Wire Harness Repair Manual (RM1022E) 236 6 7 8 9 10 D–162 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–10296 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–10585 1 2 3 4 5 6 7 11 12 13 19 20 8 9 10 14 15 21 22 16 17 18 23 24 90980–10881 12 11 10 9 8 7 6 5 4 3 2 1 A 7 12 6 11 5 4 10 3 9 1 2 8 B 90980–10955 Wire Harness Repair Manual (RM1022E) 237 D–163 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–11476 1 2 3 4 5 6 7 8 9 10111213 14 15 16 17 1819 2021 22 23 24 90980–11509 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12070 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12079 Wire Harness Repair Manual (RM1022E) 238 D–164 TABLE OF HOUSING SHAPE 24P Non–waterproof Type 1 2 5 6 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12149 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 90980–12200 Wire Harness Repair Manual (RM1022E) 239 D–165 TABLE OF HOUSING SHAPE 25P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122232425 90980–11043 1 2 3 4 5 6 7 8 9 1011 1213141516171819 202122232425 90980–11055 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–11058 1 2 3 4 5 6 7 8 9 1011 121314 151617 1819 20 21 22 232425 90980–11375 Wire Harness Repair Manual (RM1022E) 240 D–166 TABLE OF HOUSING SHAPE 25P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–11404 1 2 3 4 5 6 7 8 9 101112 13 14 15 16171819 2021222324 25 90980–11877 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 90980–12278 Wire Harness Repair Manual (RM1022E) 241 D–167 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 13 14 15 16 17 18 19 7 8 9 10 11 12 20 21 22 23 24 25 26 90980–10587 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10739 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10763 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10918 Wire Harness Repair Manual (RM1022E) 242 D–168 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–10925 1 2 3 4 14 15 16 17 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 90980–11234 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11390 1 2 3 4 5 6 7 8 14 15 16 17 18 19 20 21 22 9 10 11 12 13 23 24 25 26 90980–11406 Wire Harness Repair Manual (RM1022E) 243 D–169 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11422 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–11423 1 2 3 4 5 6 7 8 9 13 14 15 16 10 11 12 17 18 19 20 21 22 23 24 25 26 90980–11611 1 5 13 2 3 6 7 8 9 10 11 14 15 16 17 18 19 20 22 23 24 25 26 4 12 21 90980–11632 Wire Harness Repair Manual (RM1022E) 244 D–170 TABLE OF HOUSING SHAPE 26P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617181920212223 24 25 26 90980–11786 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–12150 1 2 3 10 11 12 4 5 6 7 8 9 13 14 15 16 17 18 19 20 21 22 23 24 25 26 90980–12203 Wire Harness Repair Manual (RM1022E) 245 D–171 TABLE OF HOUSING SHAPE 27P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 14 90980–11670 Wire Harness Repair Manual (RM1022E) 246 D–172 TABLE OF HOUSING SHAPE 28P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 141516171819 2021 22 23 24 25 26 27 28 90980–11218 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 90980–11637 A B 1 2 3 4 5 6 7 8 9 1011121314151617 1819 2021 22 23 2425 26 27 28 90980–11872 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 90980–12102 Wire Harness Repair Manual (RM1022E) 247 D–173 TABLE OF HOUSING SHAPE 30P Non–waterproof Type 1 10 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 90980–12151 1 2 3 4 5 6 7 16 17 18 19 20 21 22 8 9 10 11 12 13 14 15 23 24 25 26 27 28 29 30 90980–12277 Wire Harness Repair Manual (RM1022E) 248 D–174 TABLE OF HOUSING SHAPE 31P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 90980–11421 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 90980–11935 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 30 31 28 29 90980–12142 Wire Harness Repair Manual (RM1022E) 249 D–175 TABLE OF HOUSING SHAPE 32P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12071 1 2 3 4 5 6 7 8 9 10 11 12 13141516 17 18 19 20 21 22 23 24 25 26 272829303132 90980–12096 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 90980–12153 Wire Harness Repair Manual (RM1022E) 250 D–176 TABLE OF HOUSING SHAPE 32P Non–waterproof Type 1 2 3 4 5 6 17 18 19 20 21 22 7 8 9 10 11 12 13 14 15 16 23 24 25 26 27 28 29 30 31 32 90980–12275 Wire Harness Repair Manual (RM1022E) 251 D–177 TABLE OF HOUSING SHAPE 34P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 272829 30 31323334 90980–11221 1 2 3 4 5 6 18 19 20 21 22 23 7 8 9 10 11 12 13 14 15 16 17 24 25 26 27 28 29 30 31 32 33 34 90980–12114 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 90980–12144 Wire Harness Repair Manual (RM1022E) 252 D–178 TABLE OF HOUSING SHAPE 35P, 36P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90980–12145 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90980–12146 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 90980–12274 Wire Harness Repair Manual (RM1022E) 253 D–179 TABLE OF HOUSING SHAPE 38P Non–waterproof Type 1 2 3 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 90980–11555 1 2 3 4 5 6 7 20 21 22 23 24 25 8 9 10 11 12 13 14 15 16 17 18 19 26 27 28 29 30 31 32 33 34 35 36 37 38 90980–12276 Wire Harness Repair Manual (RM1022E) 254 D–180 TABLE OF HOUSING SHAPE 40P Non–waterproof Type 1 2 3 4 5 6 7 8 9 1011121314 15 1617 181920 21 22232425262728 29 3031 32 33 34 3536 37383940 90980–11508 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–11618 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–12169 Wire Harness Repair Manual (RM1022E) 255 D–181 TABLE OF HOUSING SHAPE 40P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 90980–12170 Wire Harness Repair Manual (RM1022E) 256 D–182 TABLE OF HOUSING SHAPE 42P, 43P, 46P Non–waterproof Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 90980–12184 A 1 2 3 4 5 6 7 8 9 10 1112 1314 1516 1718 1920 2021 1617 9 10 1 2 3 2223 1819 1112131415 4 5 6 7 8 B 90980–11360 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 90980–12179 Wire Harness Repair Manual (RM1022E) 257 D–183 TABLE OF HOUSING SHAPE 49P, 55P, 83P Non–waterproof Type A 9 10 13 14 17 18 21 1 2 5 6 26 24 2021 1415 16 7 8 9 1 10 2 3 3 4 7 8 1112 1516 19 20 22 27 25 2223 17 1819 11 1213 4 5 6 B 90980–11431 D F 1 2 3 4 5 6 7 8 9 1011 12 2 3 4 5 7 8 9 10 6 11 12 13 14 1 131415 9 1011 12 5 6 7 8 1 2 3 4 11 12 13 14 7 8 9 10 1 2 3 4 5 6 C E 90980–11359 90980–11906 Wire Harness Repair Manual (RM1022E) 258 D–184 TABLE OF HOUSING SHAPE 88P Non–waterproof Type B F E 1 3 2 6 5 4 9 8 7 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 20 21 22 23 24 25 26 13 14 15 16 17 18 19 6 7 8 9 10 11 12 1 2 3 4 5 1 2 3 4 5 6 7 8 9 7 8 9 4 5 6 2 3 1 D C A 90980–10950 Wire Harness Repair Manual (RM1022E) 259 D–185 TABLE OF HOUSING SHAPE 1P Waterproof Type 1 1 1 1 90980–10114 90980–10125 90980–10200 90980–10240 1 1 1 90980–10246 90980–10438 90980–10836 90980–10892 1 1 1 1 90980–10982 90980–11006 90980–11183 90980–11270 1 90980–11962 Wire Harness Repair Manual (RM1022E) 260 1 D–186 TABLE OF HOUSING SHAPE 2P Waterproof Type 2 90980–10091 2 1 1 2 2 90980–10122 90980–10156 90980–10412 90980–10192 2 1 2 1 1 1 2 1 2 1 90980–10242 90980–10374 90980–10495 90980–10497 2 1 2 1 2 1 2 1 90980–10533 90980–10555 90980–10707 90980–10566 90980–10571 2 1 90980–10575 2 1 90980–10594 2 1 90980–10580 2 1 90980–10625 90980–10788 2 90980–10582 2 2 1 1 1 90980–10665 90980–10592 2 1 90980–10838 Wire Harness Repair Manual (RM1022E) 261 D–187 TABLE OF HOUSING SHAPE 2P Waterproof Type 2 1 2 1 2 1 2 1 90980–10842 90980–10886 90980–10898 90980–10900 2 1 2 1 90980–10948 90980–10959 90980–10970 2 1 2 1 2 1 90980–11004 90980–11008 90980–11029 1 2 1 90980–10927 2 1 90980–11002 2 1 90980–11031 2 1 90980–11050 2 2 2 1 90980–11069 2 90980–11137 1 90980–11141 Wire Harness Repair Manual (RM1022E) 262 2 1 90980–11072 1 1 90980–11073 90980–11074 2 2 1 90980–11155 D–188 TABLE OF HOUSING SHAPE 2P Waterproof Type 2 1 90980–11168 2 1 90980–11247 2 90980–11175 2 1 1 90980–11303 2 1 90980–11249 2 2 2 2 1 1 90980–11322 1 90980–11188 90980–11236 2 1 2 1 90980–11254 90980–11272 2 1 2 1 90980–11409 90980–11447 2 1 2 1 90980–11789 90980–11854 1 2 90980–11466 2 1 90980–11863 1 90980–11486 1 2 1 90980–11865 2 1 1 90980–11901 90980–11945 Wire Harness Repair Manual (RM1022E) 263 D–189 TABLE OF HOUSING SHAPE 2P Waterproof Type 2 1 90980–12194 Wire Harness Repair Manual (RM1022E) 264 D–190 TABLE OF HOUSING SHAPE 3P Waterproof Type 1 3 1 3 2 90980–10093 2 90980–10190 2 1 1 3 3 2 90980–10235 90980–10244 2 1 3 3 2 1 90980–10394 90980–10444 90980–10492 90980–10493 90980–10774 90980–10787 90980–10500 2 1 1 3 2 2 3 90980–10553 90980–10577 90980–10777 3 3 2 90980–10248 90980–10347 2 1 3 2 1 1 2 1 90980–10840 90980–10944 2 1 3 1 90980–11131 90980–10689 2 1 3 3 1 3 2 3 90980–10682 3 1 90980–11015 90980–10698 2 1 3 90980–11044 2 2 90980–11160 321 90980–11169 1 3 90980–11244 90980–11295 90980–11407 Wire Harness Repair Manual (RM1022E) 265 D–191 TABLE OF HOUSING SHAPE 3P Waterproof Type 3 2 1 90980–11293 3 2 2 1 3 90980–11341 3 2 90980–11348 1 90980–11622 90980–12131 Wire Harness Repair Manual (RM1022E) 266 1 3 2 1 90980–11607 D–192 TABLE OF HOUSING SHAPE 4P Waterproof Type 2 1 4 3 90980–10094 2 1 4 90980–10139 2 2 1 4 3 90980–10475 2 1 4 3 90980–10662 2 1 4 3 90980–10941 2 4 1 3 90980–11063 90980–11064 3 2 1 4 3 90980–10202 1 3 90980–10217 1 2 1 4 3 1 2 90980–10510 90980–11076 2 1 4 2 4 3 90980–10749 2 1 4 3 90980–10989 2 1 4 3 90980–11122 2 1 4 3 90980–10590 90980–10648 2 1 4 3 2 1 90980–10751 90980–10768 2 4 1 3 90980–11027 2 1 4 3 90980–11138 4 3 90980–10868 2 1 4 3 90980–11035 2 4 1 3 90980–11177 Wire Harness Repair Manual (RM1022E) 267 D–193 TABLE OF HOUSING SHAPE 4P Waterproof Type 2 1 4 3 2 1 4 3 90980–11262 90980–11328 90980–11268 2 4 1 3 90980–11929 2 4 90980–11287 4 3 90980–12177 Wire Harness Repair Manual (RM1022E) 268 1 3 2 1 4 3 90980–11291 D–194 TABLE OF HOUSING SHAPE 5P Waterproof Type 3 2 5 1 4 2 5 1 4 3 90980–10161 90980–10392 3 2 1 2 1 5 4 5 4 3 54321 90980–10557 90980–10570 3 2 1 5 4 90980–10709 90980–10945 90980–11021 2 1 5 4 3 3 2 1 5 4 3 2 1 90980–11181 90980–11412 90980–11598 5 4 54 321 90980–10642 3 2 5 1 4 90980–11078 1 3 5 2 4 90980–11689 Wire Harness Repair Manual (RM1022E) 269 D–195 TABLE OF HOUSING SHAPE 6P, 7P Waterproof Type 6 5 4 3 2 1 6 5 4 90980–10194 90980–10477 3 2 1 6 5 4 3 2 1 6 5 4 90980–10987 90980–11033 3 2 1 3 2 1 3 6 5 4 6 90980–11267 2 5 3 2 1 6 5 4 90980–10596 3 6 2 5 90980–11289 1 6 5 4 90980–10650 90980–10984 3 2 1 6 5 4 90980–11196 7 6 5 4 3 2 1 2 1 5 4 3 7 6 90980–10627 90980–10930 1 4 2 90980–11193 3 2 1 7 6 5 4 90980–11171 Wire Harness Repair Manual (RM1022E) 270 1 4 3 D–196 TABLE OF HOUSING SHAPE 8P, 9P Waterproof Type 2 5 8 1 4 3 7 6 90980–10204 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 90980–10890 4 8 3 7 2 6 1 5 2 5 8 6 1 4 7 90980–10894 2 5 8 90980–10896 3 3 6 1 4 7 90980–11241 90980–11460 987654321 3 2 1 6 5 4 9 8 7 90980–10379 90980–10677 90980–10775 987654321 9 8 7 6 5 4 3 2 1 90980–10826 90980–11191 3 2 1 6 5 4 9 8 7 Wire Harness Repair Manual (RM1022E) 271 D–197 TABLE OF HOUSING SHAPE 11P, 12P, 13P, 15P Waterproof Type 11 10 9 8 7 6 5 4 3 2 1 90980–11173 3 6 8 11 2 5 10 1 4 7 9 90980–11609 3 2 5 6 8 11 10 1 4 7 9 90980–11239 90980–11256 2 1 6 5 4 3 10 9 8 7 12 11 4 3 2 1 8 7 6 5 12 11 10 9 90980–10568 90980–11086 5 4 3 2 1 9 8 13 12 7 6 11 10 90980–10653 6 5 4 3 2 1 151413121110 9 8 7 90980–11088 Wire Harness Repair Manual (RM1022E) 272 5 4 3 2 1 1110 9 8 7 6 D–198 TABLE OF HOUSING SHAPE 16P, 17P Waterproof Type 3 2 1 8 7 6 5 4 4 3 2 1 8 7 6 5 12 11 10 9 13 12 11 10 9 16 15 14 90980–10287 7 6 5 3 90980–10547 7 4 3 2 1 16 15 14 13 12 11 10 9 8 1 2 4 6 5 4 3 11 10 17 16 90980–11462 15 14 2 1 9 8 13 12 90980–11600 Wire Harness Repair Manual (RM1022E) 273 D–199 TABLE OF HOUSING SHAPE 120P Waterproof Type 20 19 18 17 16 15 14 13 12 11 40 39 38 37 36 35 34 33 32 31 60 59 58 57 56 55 54 53 52 51 80 79 78 77 76 75 74 73 72 71 10 9 8 7 6 5 4 3 2 1 30 29 28 27 26 25 24 23 22 21 50 49 48 47 46 45 44 43 42 41 70 69 68 67 66 65 64 63 62 61 90980–11213 Wire Harness Repair Manual (RM1022E) 274 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 40 39 38 37 36 35 34 33 32 31 D–200 TABLE OF HOUSING SHAPE 1P Non–waterproof Type 1 1 1 1 90980–10160 90980–10178 90980–10182 90980–10251 1 1 90980–10253 90980–10342 90980–10396 90980–10433 90980–10434 1 1 1 90980–10994 90980–11146 90980–11258 1 90980–10870 90980–11026 90980–11097 1 1 90980–11737 90980–11774 1 1 1 90980–12041 Wire Harness Repair Manual (RM1022E) 275 D–201 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 2 1 90980–10011 2 1 90980–10286 2 1 2 2 90980–10038 90980–10213 90980–10305 90980–10255 2 1 2 1 90980–10344 90980–10346 90980–10354 90980–10437 2 1 2 1 90980–10620 90980–10687 2 1 90980–10297 2 1 90980–10356 90980–10424 2 1 2 1 2 1 2 90980–10824 2 1 90980–10905 90980–10833 90980–11299 2 1 1 90980–10849 1 90980–10859 2 1 2 90980–10915 90980–10934 Wire Harness Repair Manual (RM1022E) 276 1 2 1 90980–10958 D–202 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 1 2 1 2 90980–11014 21 2 90980–11060 2 1 90980–11093 90980–11159 21 2 1 90980–11305 90980–11367 2 1 90980–11211 90980–11300 2 1 2 1 1 21 2 1 90980–11368 2 90980–11395 2 1 1 90980–11655 2 1 90980–11889 90980–11724 90980–11545 2 1 2 1 90980–11735 2 1 90980–11917 90980–11589 2 1 90980–11933 90980–11883 2 1 90980–11967 Wire Harness Repair Manual (RM1022E) 277 D–203 TABLE OF HOUSING SHAPE 2P Non–waterproof Type 2 1 90980–11992 2 1 90980–12062 Wire Harness Repair Manual (RM1022E) 278 D–204 TABLE OF HOUSING SHAPE 3P Non–waterproof Type 2 3 2 3 2 1 3 90980–10055 90980–10163 3 1 1 1 1 3 2 90980–10188 90980–10215 90980–10283 90980–10299 3 2 1 3 2 1 90980–10231 3 2 1 2 90980–10257 90980–10300 90980–10410 1 3 90980–10364 90980–10573 321 2 90980–10979 90980–11052 3 2 1 321 90980–11385 90980–11470 90980–10544 90980–10907 3 2 1 3 2 1 90980–11229 90980–11298 1 321 90980–11620 3 3 2 1 90980–11763 1 2 3 2 90980–11484 3 2 1 90980–11874 90980–11489 3 2 1 90980–11936 Wire Harness Repair Manual (RM1022E) 279 D–205 TABLE OF HOUSING SHAPE 3P Non–waterproof Type 3 90980–11937 2 1 90980–11994 3 2 90980–12196 Wire Harness Repair Manual (RM1022E) 280 1 D–206 TABLE OF HOUSING SHAPE 4P Non–waterproof Type 2 1 4 3 90980–10001 2 1 4 3 90980–10399 4 321 90980–10600 4 3 2 4 3 90980–10126 90980–10144 1 4 2 1 1 1 4 3 2 90980–10219 4 3 2 2 1 3 90980–10237 2 1 4 3 90980–10259 2 1 4 3 90980–10170 2 1 4 3 90980–10306 2 1 4 3 2 1 4 3 2 1 4 3 90980–10466 90980–10502 90980–10503 4 3 2 1 2 1 4 3 2 1 4 3 90980–10691 90980–10794 90980–10858 4 3 2 1 4 3 2 1 4 3 2 1 90980–10866 90980–11012 90980–11023 90980–11100 Wire Harness Repair Manual (RM1022E) 281 D–207 TABLE OF HOUSING SHAPE 4P Non–waterproof Type 2 4321 1 4 90980–11106 3 90980–11126 2 1 4 3 1 2 3 4 90980–11135 BA 2 1 4 3 4 90980–11186 2 1 3 2 1 4 3 2 1 2 1 90980–11301 2 1 4 3 90980–11765 90980–11399 90980–11426 90980–11605 2 1 4 3 2 1 2 1 4 3 90980–11779 4 3 90980–11809 90980–11812 2 1 2 1 4 3 4 3 2 1 90980–11891 90980–11965 4 3 2 1 4 3 90980–11878 4 3 2 1 4 3 2 1 4 3 2 1 90980–11985 2 1 4 3 90980–12016 90980–12123 90980–12159 Wire Harness Repair Manual (RM1022E) 282 90980–12212 D–208 TABLE OF HOUSING SHAPE 5P Non–waterproof Type 2 1 5 4 3 90980–10040 4 3 2 5 1 90980–10519 3 1 2 4 5 2 5 1 4 4 3 90980–10261 90980–10308 5 4 3 2 1 5 4 3 2 1 90980–10762 90980–10790 90980–10518 2 5 4 2 5 4 3 2 1 5 4 3 2 90980–11085 90980–11318 90980–11327 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 1 3 90980–10985 1 90980–11843 3 2 5 1 5 1 4 3 90980–11602 5 4 3 2 1 90980–11920 90980–11968 90980–12036 2 1 3 2 1 5 4 5 4 3 90980–12050 90980–12189 Wire Harness Repair Manual (RM1022E) 283 D–209 TABLE OF HOUSING SHAPE 6P Non–waterproof Type 2 1 4 3 6 5 2 6 90980–10003 5 1 3 4 90980–10027 3 6 3 2 1 90980–10401 6 4 2 4 6 3 90980–10446 90980–10671 2 1 65 43 90980–10909 4 4 1 2 2 6 5 4 90980–10975 90980–10384 90980–10416 90980–10641 1 4 90980–10603 1 6 5 4 3 1 3 1 3 2 6 5 6 5 4 3 90980–10694 90980–10223 6 5 4 3 90980–10602 90980–10793 2 1 6 5 43 90980–10796 2 1 3 2 1 6 5 4 90980–10998 Wire Harness Repair Manual (RM1022E) 284 1 5 1 3 5 2 2 2 1 6 5 4 3 2 6 90980–10366 90980–10505 1 5 3 32 1 65 4 90980–10312 2 6 5 4 5 1 90980–10172 3 2 1 6 5 4 90980–10289 2 4 3 6 5 90980–11010 D–210 TABLE OF HOUSING SHAPE 6P Non–waterproof Type 2 1 2 1 6 5 4 3 6 5 4 3 6 5 4 3 2 1 2 1 6 5 4 3 90980–11067 90980–11099 90980–11101 90980–11110 3 2 1 6 5 4 3 2 1 2 1 6 5 4 4 3 2 1 4 3 6 5 6 5 90980–11452 2 6 90980–11487 1 5 4 2 1 4 3 3 90980–11696 3 2 1 6 5 4 90980–12064 90980–11492 6 5 4 3 2 1 90980–12004 3 2 1 3 2 1 6 5 4 6 5 4 90980–12198 3 2 1 6 5 4 6 5 90980–11814 90980–11587 90980–12013 90980–12204 Wire Harness Repair Manual (RM1022E) 285 D–211 TABLE OF HOUSING SHAPE 7P Non–waterproof Type 3 2 1 7 6 5 4 3 7 90980–10042 7 6 5 4 2 5 6 1 3 7 4 90980–10263 3 2 1 90980–10459 2 1 6 5 4 3 2 1 7 6 5 4 90980–10310 90980–10451 7 6 5 4 3 7 6 5 4 3 2 1 7 6 5 4 3 2 1 90980–10728 90980–10771 90980–11164 90980–11339 2 1 2 1 2 7 6 5 4 3 2 1 90980–11402 1 2 3 4 5 6 1 2 7 6 5 4 3 7 6 5 4 3 90980–11528 90980–11739 7 90980–12092 Wire Harness Repair Manual (RM1022E) 286 1 3 7 6 5 4 90980–12059 D–212 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 2 1 4 3 2 1 8 7 6 5 5 4 3 8 7 6 90980–10018 2 1 8 7 6 5 4 3 90980–10208 90980–10210 90980–10383 90980–10411 3 2 1 8 7 6 5 4 90980–10360 3 2 1 8 7 6 5 4 90980–10430 90980–10546 90980–10147 4 8 3 7 2 6 1 5 90980–10225 2 4 8 7 1 3 5 6 90980–10403 5 4 3 8 2 1 7 6 90980–10462 4 3 2 1 8 7 6 5 90980–10174 4 3 2 1 8 7 6 5 90980–10279 1 3 2 8 765 4 90980–10418 3 2 1 8 7 6 5 4 90980–10769 Wire Harness Repair Manual (RM1022E) 287 D–213 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 3 21 8 76 54 90980–10798 3 3 2 1 8 7 6 5 4 90980–10876 90980–11438 2 1 8 7 6 5 4 90980–11123 90980–11134 90980–11353 2 1 876543 90980–11532 2 1 8 7 6 5 4 3 1 90980–11320 2 1 8 7 6 5 4 3 8 7 6 5 4 3 90980–11361 90980–11389 4 3 2 1 8 7 6 5 90980–11551 Wire Harness Repair Manual (RM1022E) 288 90980–10963 2 3 2 1 8 7 6 5 4 2 1 6 5 4 3 8 7 3 2 1 8 7 6 5 4 2 1 8 7 6 5 4 3 90980–11582 D–214 TABLE OF HOUSING SHAPE 8P Non–waterproof Type 2 1 8 7 6 5 4 3 2 1 2 B A 1 8 7 6 5 4 3 8 7 6 5 4 3 90980–11588 2 90980–11623 90980–11629 1 4 3 2 1 8 7 6 5 4 3 90980–11636 8 7 6 5 4 3 2 1 8 7 6 5 90980–12061 90980–12112 4 3 2 1 8 7 6 5 90980–12220 Wire Harness Repair Manual (RM1022E) 289 D–215 TABLE OF HOUSING SHAPE 9P Non–waterproof Type 4 3 9 8 7 3 2 1 6 5 7 9 90980–10044 3 2 1 9 8 7 6 5 4 90980–11534 1 2 5 6 4 2 1 9 8 7 6 5 4 90980–11543 Wire Harness Repair Manual (RM1022E) 290 7 2 1 6 5 8 90980–10265 3 4 3 9 8 90980–10317 3 2 1 9 8 7 6 5 4 90980–11709 D–216 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 5 10 4 9 3 8 2 7 1 6 90980–10176 4 3 10 9 8 7 2 1 6 5 90980–10468 4 3 2 7 6 10 5 9 1 4 3 8 90980–10281 90980–10527 90980–10719 90980–10666 2 1 4 3 2 1 10 9 8 7 6 5 90980–10693 90980–10800 4 3 2 1 10 9 8 7 6 5 90980–10865 90980–11419 90980–10375 90980–10417 90980–10427 90980–10516 4 3 2 1 10 9 8 7 6 5 4 3 2 1 2 1 2 1 10 9 8 7 6 5 10 9 8 7 6 5 4 3 4 3 10 9 8 7 6 5 4 3 10 9 8 7 2 1 6 5 90980–10861 5 4 3 2 1 10 9 8 7 6 5 10 9 8 7 90980–10961 90980–10992 6 Wire Harness Repair Manual (RM1022E) 291 D–217 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 4 3 4 3 2 1 10 9 8 7 6 5 90980–11102 4 3 10 9 8 2 1 7 6 5 90980–11449 4 3 10 9 8 2 1 4 3 10 9 8 7 6 5 10 9 90980–11325 90980–11331 90980–11365 4 3 10 9 90980–11544 7 4 3 2 1 10 9 8 7 6 90980–11613 6 5 5 4 3 2 1 2 1 8 7 6 5 90980–11596 1 B A 4 3 3 2 1 10 9 8 7 6 5 10 9 8 7 6 5 90980–11641 Wire Harness Repair Manual (RM1022E) 292 90980–11536 10 9 90980–11580 4 6 5 5 4 3 2 1 10 9 8 7 6 4 3 10 9 8 7 6 2 5 7 2 1 8 90980–11526 2 1 7 6 5 2 1 8 90980–11752 D–218 TABLE OF HOUSING SHAPE 10P Non–waterproof Type 5 4 3 2 1 5 4 3 2 1 4 3 2 1 10 9 8 7 6 5 10 9 8 7 6 90980–11757 90980–11823 5 4 3 2 1 5 4 3 2 1 10 9 8 7 6 10 9 8 7 6 90980–11993 90980–12009 10 9 8 7 6 90980–11922 5 4 3 2 1 10 9 8 7 6 90980–12023 5 4 3 2 1 10 9 8 7 6 90980–12249 Wire Harness Repair Manual (RM1022E) 293 D–219 TABLE OF HOUSING SHAPE 11P Non–waterproof Type 3 2 1 4 7 6 5 11 4 3 2 1 11 10 9 8 7 6 5 10 9 8 90980–10531 90980–10829 4 3 2 11 10 9 8 7 6 90980–10872 2 4 3 2 1 11 10 9 8 7 6 5 90980–11200 6 5 4 3 2 1 11 10 9 8 7 1 11 10 9 8 7 6 5 7 6 5 4 3 1110 9 8 90980–11538 90908–12002 4 3 2 1 90980–12250 Wire Harness Repair Manual (RM1022E) 294 1 5 D–220 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 2 6 5 10 9 12 1 4 3 8 7 11 6 5 4 90980–10149 6 5 4 12 11 10 9 3 2 1 8 7 90980–10415 3 2 1 5 4 3 12 11 10 9 8 7 12 11 10 9 8 7 6 90980–10405 90980–10407 90980–10529 5 4 3 2 1 5 4 12 11 10 9 8 7 6 90980–10436 90980–10440 90980–10513 12 11 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 121110 9 8 7 6 90980–10564 90980–10802 6 5 12 11 10 9 3 2 1 12 11 10 9 8 7 6 5 4 2 2 1 1 5 4 3 2 1 4 3 12 11 10 9 8 7 6 3 2 1 12 11 10 9 8 7 6 90980–10864 4 3 2 1 12 11 10 9 8 7 6 5 8 7 90980–10878 90980–10938 90980–11105 90980–11474 Wire Harness Repair Manual (RM1022E) 295 D–221 TABLE OF HOUSING SHAPE 12P Non–waterproof Type 4 3 2 1 12 11 10 9 8 7 6 5 90980–11500 2 1 7 6 5 4 3 3 2 1 12 11 10 9 8 7 6 12 11 10 9 8 90980–11530 Wire Harness Repair Manual (RM1022E) 296 5 4 90980–11747 D–222 TABLE OF HOUSING SHAPE 13P Non–waterproof Type 6 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 90980–10032 90980–10061 5 4 3 2 10 9 8 1 7 90980–10479 8 7 6 5 4 3 90980–10323 2 1 6 5 4 13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 90980–10804 90980–11198 3 5 4 3 2 1 13121110 9 8 7 6 90980–11393 5 4 13 12 11 10 9 8 7 6 2 1 5 4 3 2 1 13 12 11 10 9 8 7 6 13 12 11 10 9 90980–11541 90980–11568 3 2 1 90980–11635 2 1 13 12 11 10 9 8 7 13 12 11 3 5 4 3 2 1 13 12 11 10 9 8 7 6 90980–11694 8 7 6 5 4 5 4 3 2 1 9 8 7 6 13 12 11 10 90980–11951 Wire Harness Repair Manual (RM1022E) 297 D–223 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 4 3 2 1 9 8 7 6 5 14 13 12 11 10 4 3 2 1 7 9 8 6 5 14 13 12 11 10 90980–10329 6 5 4 90980–10422 6 5 4 3 2 1 14 13 12 11 10 9 8 7 14 13 12 11 10 9 8 7 90980–10470 90980–10506 90980–10715 4 3 2 1 9 8 7 6 5 14 13 12 11 10 B A 2 1 90980–10545 4 3 10 9 8 B A 2 1 7 6 5 90980–10767 Wire Harness Repair Manual (RM1022E) 298 3 2 1 B A 2 1 D–224 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 4 3 6 5 4 3 2 1 1413 12 11 10 9 8 7 9 8 14 13 90980–10806 14 13 12 11 3 2 1 B A 3 B 3 2 1 14 13 12 11 10 9 8 7 10 9 8 7 90980–10971 90980–11265 90980–10851 4 6 5 12 11 10 90980–10812 6 5 4 6 5 4 2 1 7 A 14 13 12 11 10 9 8 2 1 7 6 5 90980–11312 6 5 4 3 2 1 14 13 12 11 10 9 8 7 90980–11337 Wire Harness Repair Manual (RM1022E) 299 D–225 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 4 3 B 2 A 2 1 8 7 6 5 4 3 14 13 12 11 10 9 8 7 6 5 90980–11464 1413121110 9 90980–11510 5 4 5 4 3 2 1 14 13 12 11 10 9 8 7 6 3 2 1 14 13 12 11 10 9 8 7 6 90980–11644 90980–11743 90980–11744 90980–11590 5 4 1 3 2 1 5 4 14 13121110 9 8 7 6 3 2 1 1413121110 9 8 7 6 90980–11651 90980–11654 Wire Harness Repair Manual (RM1022E) 300 D–226 TABLE OF HOUSING SHAPE 14P Non–waterproof Type 3 2 1 7 6 5 4 3 2 1 14 13 12 11 10 9 8 7 6 5 4 14 13 12 11 10 9 8 90980–11753 90980–11910 7 6 5 4 3 2 1 1413121110 9 8 90980–11969 90980–12015 Wire Harness Repair Manual (RM1022E) 301 D–227 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 3 2 1 6 5 4 9 8 7 12 11 10 15 14 13 90980–10065 90980–10442 4 3 2 1 6 5 4 15 14 13 12 11 10 9 8 15 14 13 12 7 6 5 90980–10461 2 7 6 3 4 3 14 8 7 2 1 15 14 13 12 11 10 13 90980–10814 90980–10827 Wire Harness Repair Manual (RM1022E) 302 10 9 9 8 7 6 5 4 12 11 10 9 8 15 2 1 90980–10562 1 5 11 3 D–228 TABLE OF HOUSING SHAPE 15P Non–waterproof Type 7 5 4 6 5 4 3 2 1 15 14 13121110 9 8 7 15 14 13121110 9 8 7 90980–11180 7 6 5 15 14 90980–11201 7 6 5 4 3 2 1 15 1413121110 9 8 4 3 2 1 13 12 11 10 3 2 1 9 8 90980–11263 90980–11370 7 6 5 4 3 2 1 15 1413121110 9 8 90980–11371 Wire Harness Repair Manual (RM1022E) 303 D–229 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 8 7 6 5 16 15 14 13 4 12 6 5 4 3 2 1 11 10 9 12 11 14 90980–10026 4 3 10 16 9 15 8 7 13 90980–10453 2 1 4 3 10 9 8 7 6 5 9 8 14 13 12 11 2 1 7 6 5 16 15 16 15 14 13 12 11 10 90980–10485 90980–10521 4 3 2 1 7 6 5 10 9 8 7 6 5 16 15 14 13 12 11 16 15 14 13 12 11 90980–10542 90980–10560 10 9 8 4 3 Wire Harness Repair Manual (RM1022E) 304 3 2 1 2 1 D–230 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 4 3 2 1 10 9 8 7 6 5 90980–10744 4 3 2 1 6 5 4 3 90980–10753 2 1 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 10 9 8 7 6 5 16 15 14 13 12 11 90980–10808 90980–11444 4 3 8 10 9 16 15 14 90980–10874 2 1 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 13 12 11 90980–10884 90980–11167 Wire Harness Repair Manual (RM1022E) 305 D–231 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 4 3 2 1 2 10 9 8 7 6 5 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 1 6 5 4 3 90980–11324 90980–11351 6 5 4 3 2 1 12 11 10 9 8 7 16 15 14 13 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 90980–11415 90980–11434 6 8 7 6 5 16 15 14 13 4 3 2 1 4 3 2 1 16 15 14 13 12 11 10 9 8 7 12 11 10 9 90980–11546 90980–11561 Wire Harness Repair Manual (RM1022E) 306 5 D–232 TABLE OF HOUSING SHAPE 16P Non–waterproof Type 3 2 1 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 10 9 8 7 6 5 4 16 15 14 13 12 11 90980–11573 8 7 6 5 1615 1413 B A 90980–11624 4 3 2 1 8 7 6 5 12 11 10 9 1615 1413 90980–11680 B A 4 3 2 1 12 11 10 9 90980–11682 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 90980–12192 Wire Harness Repair Manual (RM1022E) 307 D–233 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 6 5 4 3 2 1 8 7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 13 12 11 10 9 8 7 17 16 90980–10030 6 5 11 10 4 15 14 90980–10730 3 2 1 7 6 5 9 8 7 4 3 2 1 17 16 1514131211 10 9 8 17 16 15 14 13 12 90980–11046 7 6 5 90980–11202 4 3 2 1 7 6 5 4 17 16 1514131211 10 9 8 3 2 1 17 16 15 14 13 12 11 10 9 8 90980–11309 90980–11334 Wire Harness Repair Manual (RM1022E) 308 D–234 TABLE OF HOUSING SHAPE 17P Non–waterproof Type 3 2 4 1 3 2 1 10 9 8 7 6 5 4 12 11 10 9 8 7 6 5 17 16 15 14 13 12 11 17 16 90980–11505 5 4 9 8 3 2 1 7 6 15 14 13 90980–11559 1716151413121110 90980–12161 Wire Harness Repair Manual (RM1022E) 309 D–235 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 2 1 8 7 6 5 4 3 10 14 13 12 11 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 18 17 16 15 90980–10284 8 7 6 5 90980–10325 4 3 2 1 8 7 6 5 18 17 16 15 14 13 12 11 10 9 90980–10441 90980–10655 90980–11017 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 90980–10818 90980–10863 Wire Harness Repair Manual (RM1022E) 310 4 3 2 1 18 17 16 15 14 13 12 11 10 9 D–236 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 9 18 90980–10937 90980–11127 B A 2 1 4 3 BA 2 8 7 6 5 4 3 17 16 15 14 13 12 2 1 11 10 90980–11223 1 1413121110 9 8 7 6 5 B A 2 7 6 5 4 3 2 1 1 181716151413121110 9 8 90980–11382 90980–11496 4 3 2 1 8 7 6 5 4 3 2 1 181716151413121110 9 8 18 17 16 15 14 13 12 11 10 9 7 6 5 90980–11745 90980–11748 Wire Harness Repair Manual (RM1022E) 311 D–237 TABLE OF HOUSING SHAPE 18P Non–waterproof Type 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 18 17 16 15 14 13 12 11 10 90980–11751 90980–11912 9 9 8 7 6 5 4 3 2 1 1 18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10 90980–11949 90980–12010 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 90980–12108 Wire Harness Repair Manual (RM1022E) 312 8 7 6 5 4 3 2 D–238 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 6 5 4 3 2 1 4 3 2 1 7 9 8 6 5 13 12 1110 19 18 17 16 1514 14 13 12 11 10 9 8 7 19 18 17 16 15 90980–10674 2 6 5 90980–10856 1 8 7 6 5 4 3 19 18 17 1615141312 11 10 9 4 3 2 1 12 11 10 9 8 7 19 18 17 16 15 14 13 90980–10882 8 7 6 5 90980–11204 4 3 2 1 8 7 6 5 19 18 17 1615141312 11 10 9 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 90980–11307 90980–11376 Wire Harness Repair Manual (RM1022E) 313 D–239 TABLE OF HOUSING SHAPE 19P Non–waterproof Type 4 3 2 1 12 11 10 9 8 7 6 5 19 18 17 16 15 14 13 90980–11570 Wire Harness Repair Manual (RM1022E) 314 A–8 INTRODUCTION–CIRCUIT PROTECTION CIRCUIT PROTECTION All electrical circuits are protected against excessive loads which might occur because of shorts or overloads in the wiring system. Such protection is provided by a fuse, circuit breaker, or fusible link, A short circuit may cause a fuse to blow or a circuit breaker to open. RESET CIRCUIT BREAKER 1. Remove Circuit Breaker Push (a) (b) 2. A Disconnect the negative (–) cable from the battery. Remove the circuit breaker. Reset Circuit Breaker (a) Insert the needle into the reset hole and push it. (b) Using an ohmmeter, check that there is continuity between both terminals of the circuit breaker. If continuity is not as specified, replace the circuit breaker. HINT: If replacing the circuit breaker, be sure to replace it with a breaker with an equal amperage rating. Equal Amperage Rating 3. Install Circuit Breaker (a) Install the circuit breaker. (b) Connect the negative (–) cable to the battery. HINT: If a circuit breaker continues to cut out, a short circuit is indicated. Have the system checked by a qualified technician. Wire Harness Repair Manual (RM1022E) 9 A–9 INTRODUCTION–CIRCUIT PROTECTION REPLACEMENT OF FUSE AND FUSIBLE LINK Equal Amperage Rating A HINT: If replacing the fuse or fusible link, be sure to replace it with a fuse or fusible link with an equal amperage rating. Equal Amperage Rating Puller NOTICE: 1. Turn off all electrical components and the ignition switch before replacing a fuse or fusible link. Do not exceed the fuse or fusible link amperage rating. 2. Always use a fuse puller for removing and inserting a fuse. Remove and insert straight in and out without twisting. Twisting could force open the terminals too much, resulting in a bad connection. If a fuse or fusible link continues to blow, a short circuit is indicated. The system must be checked by a qualified technician. HINT: The puller is located at Junction Block No.2. Wire Harness Repair Manual (RM1022E) 10 A–1 INTRODUCTION–GENERAL INFORMATION GENERAL INFORMATION This manual provides instruction in the following repairs:
How to Inspect for System Inspection
Circuit Protection
Terminal and Connector Repair Procedure NOTICE: When inspecting or repairing the SRS AIRBAG, be sure to carefully read the precautionary instructions and procedure in the Repair Manual for the applicable model. A After any electrical repair is made, always test the circuit by operating the devices in the circuit. This confirms not only that the repair is correct, but also that the cause of the complaint was correctly identified. Terminal type number name Tab width 0.64 mm The terminal type number naming system has changed: the metric system will be used in place of the inch system. To be more specific, male tab width ”in millimeters” will be used as terminal type number from now on –– in place of male tab width in inches which has been in use so far. Below is a table of comparison: New terminal type No. (mm) Old terminal type No. (inch) 025 → 0.64 040 (II, III, IV) → 1.0 (II, III, IV) 050 → 1.3 070 (II) → 1.8 (II) 090 (II) → 2.3 (II) 187 → 4.8 250 (II) → 6.3 (II) 305 → 7.7 312 → 8.0 375 → 9.5 For those connectors which are not shown above, the terminal type numbers remain unchanged. Wire Harness Repair Manual (RM1022E) 2 A–2 INTRODUCTION–GENERAL INFORMATION What is Wire Harness? Terminal (Female) Housing (Female) Housing (Male) Terminal (Male) Electric Wire Terminal Wire Harness (W/H) Housing The wire harness (W/H) is systems of electric wires for automobiles to connect all the electronics parts in automobile electrically and work them. As more electronics parts are introduced in automobiles recently, the electric wires used for the wire harness are increasing in number and the structure is becoming more complicated. As a result of that, there are hundreds of connectors, which is the parts which connects wires mechanically and electrically, in one vehicle. Therefore, numbers of the connector terminal (Terminal) or the connector housing (Housing) are designed to meet many kinds of uses of circuits. Various components have been improved to ensure the product reliability or realize a wider space in the vehicles. Wire Harness Components Fuse J/B (Junction Block) Wire harness mainly consists of wires, terminals, or housings. There are various components are designed for many parts of vehicles, such as one with high heat–resistance, water–resistance, or bending ability, ones have different current capacities, or ones are hardly influenced by electromagnetic noise. R/B (Relay Block) Other Electric Wire Insulator The electric wires used for the wire harness consists of the conductor made from numbers of twisted mild copper wire with a diameter of less than 0.5 mm and the insulator surrounding the conductor. The insulator is generally made from vinyl chloride and covers the conductor with even thickness. The insulators are color–coded in order to distinguish each wire. The base colors or the stripe patterns is used to make difference between insulators. Each color of wires is indicated by the abbreviation in the repair manual and the electrical wiring diagram. Copper Wires (Conductor) B L V R P Y O = = = = = = = Black Blue Violet Red Pink Yellow Orange W BR SB G LG GR = = = = = = White Brown Sky Blue Green Light Green Gray Wire Harness Repair Manual (RM1022E) 3 A A–3 INTRODUCTION–GENERAL INFORMATION The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: L–Y L (Blue) – Y (Yellow) Terminal and housing A Tab width 1.3 mm Rubber Plug Rubber Ring Terminal connects wires and housing insulates connecting parts. There are the male terminal and the female terminal. The types of terminals are decided by tab width of male terminal. And the terminal with the rubber plug or the rubber ring is used in the part, such as the engine compartment, which become wet. For the circuit with slight current at EFI system or ABS system, the gold–plated terminal is introduced for ensuring reliabilities. As the number of the circuit is increasing recently, there are new types of parts introduced. For example, there is the hybrid type housing, which is a combination of terminals with different tab width, such as the power source terminal or the signal terminal. Also, new type of connector such as the double lock housing, which is designed with the retainer in addition to the lance to prevent terminal from slipping off, is available. The new type of connectors are produced to realize higher product reliabilities and utilized widely recently. The major characteristics of these new connectors are shown in the table 1. There are two types of lances: housing lance, which is inside the housing and terminal lance, which is inside the terminal. Housing Lance Type Terminal Lance Type Wire Harness Repair Manual (RM1022E) 4 A–4 INTRODUCTION–GENERAL INFORMATION Table 1 : Characteristics of the new types of connector (Improvement) Characteristics (Improvement) Note If terminal is not inserted to housing correctly, the retailer does not fit. 1. Double Lock Lance (Primary Lock) Retainer (Double Lock) Housing A Terminal 2. Extension of Housing Housing This is to prevent deformation of the terminal when it is inserted diagonally. Extension Terminal Shortening 3. Change of Contact Structure and Introduction of Box–Shaped Structure 4. Change of Locking Shape Expansion of contact section Stabilization of contact pressure This improves the close fit of locking and you can hear the click sound and feel that the connector is completely installed. Ribs are added Wire Harness Repair Manual (RM1022E) 5 A–5 INTRODUCTION–HOW TO PERFORM FOR SYSTEM INSPECTION HOW TO PERFORM FOR SYSTEM INSPECTION This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and is based on the assumption of system component trouble Always inspect the trouble taking the following items into consideration:
Ground point fault
Open or short circuit of the wire harness
Connector or terminal connection fault
Fuse or fusible link fault A NOTICE:
This is an on–vehicle inspection during system operation. Therefore, inspect the trouble with due regard for safety.
If connecting the battery directly, be careful not to cause a short circuit, and select the applicable voltage. 1. Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) (a) To Ignition SW IG Terminal Fuse [A] SW1 Voltage Check (b) Voltmeter [B] Using a voltmeter, connect the negative (–) lead to a good ground point or negative (–) battery terminal and the positive (+) lead to the connector or component terminal. This check can be done with a test bulb instead of a voltmeter. Relay [C] SW2 Solenoid 2. Continuity and Resistance Check (a) Ohmmeter (b) Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. SW Wire Harness Repair Manual (RM1022E) 6 A–6 INTRODUCTION–HOW TO PERFORM FOR SYSTEM INSPECTION If the circuit has diodes, reverse the two leads and check again. When touching the negative (–) lead to the diode positive (+) side and the positive (+) lead to the negative (–) side, there should be continuity. When touching the two leads in reverse, there should be no continuity. HINT: Specifications may vary depending on the type of tester, so refer to the tester’s instruction manual before performing the inspection. Ohmmeter Diode Check LED (Light Emitting Diode) in the same manner as that for diodes. HINT:
Use a tester with a power source of 3V or greater to overcome the circuit resistance.
If a suitable tester is not available, apply battery voltage and check that the LED lights up. Ohmmeter Diode Digital Type (c) Analog Type 3. Ohmmeter Bulb Check (a) (b) (c) Bulb Use a volt/ohmmeter with high impedance (10kΩ/V minimum) for troubleshooting of the electrical circuit. (d) Remove the bulb. There should be continuity between the respective terminals of the bulb together with a certain amount of resistance. Apply the two leads of the ohmmeter to each of the terminals. Apply battery voltage and check that the bulb light up. Wire Harness Repair Manual (RM1022E) 7 A A–7 INTRODUCTION–HOW TO PERFORM FOR SYSTEM INSPECTION 4. Finding a Short Circuit Remove the blown fuse and eliminate all loads from the fuse. (b) Connect a test bulb in place of the fuse. (c) Establish conditions in which the test bulb comes on. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or disconnect SW 2) (a) To Ignition SW IG Terminal Test Bulb Fuse Case Short [A] (d) SW1 A Disconnect Short [B] Disconnect Relay Light (e) Disconnect and reconnect the connectors while watching the test bulb. The short lies between the connector where the test bulb stays lit and the connector where the bulb goes out. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). (a) Short [C] Disconnect SW2 Solenoid Wire Harness Repair Manual (RM1022E) 8 F–17 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Hole Plug Type P/N Type 6.3, 7.7, TODC 90950–01730 90980–09325 8.0 P/N 90980–09353 Type TLC P/N 90980–09162 4.8 2.3, 2.3II 90980–09152 1.3 90980–09414 Wire Harness Repair Manual (RM1022E) 413 F–18 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Press Sleeve Color P/N Color P/N YELLOW 82999–12030 82999–12020 RED 82999–12010 Wire Harness Repair Manual (RM1022E) 414 BLUE F–15 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Terminal Packing Type Cav. No. P/N 6.3 1 90980–09210 Type Cav. No. P/N P/N 90980–09211 7.7 1 90980–09380 Type Cav. No. 3 TODC 1 3 90980–09378 90980–09379 Wire Harness Repair Manual (RM1022E) 411 F–16 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Terminal Packing Type Cav. No. P/N 2.3 1 90980–09148, 09151, 09149 Type Cav. No. P/N 2.3II 1 90980–09451 Type Cav. No. P/N HB3, HB4 1 90980–09396 Wire Harness Repair Manual (RM1022E) 412 F–6 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 0.64 Male Female Sleeve : Medium (Blue) P/N 82998–12750 82998–12760* Type 0.64 IDC Male Female Sleeve : Medium (Blue) F P/N 82998–12770 Type 1.0 Male Female Sleeve : Medium (Blue) P/N 82998–12310 82998–12320* Wire Harness Repair Manual (RM1022E) 384 F–7 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 1.0II Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) Size : S 82998–24010 Type 82998–24020 82998–24110* 1.0II Male Female Sleeve : Medium (Blue) Size : M F P/N 82998–24120* Type 1.0III Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12670 82998–12680* 82998–12690 82998–12700* Wire Harness Repair Manual (RM1022E) 385 F–8 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 1.0III IDC Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12660 Type 82998–12640 1.0IV Male Female Sleeve : Medium (Blue) F P/N 82998–12740 Type 1.3 Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12410 82998–12420 Wire Harness Repair Manual (RM1022E) 386 F–9 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 1.8 Male Female Sleeve : Medium (Blue) P/N Sleeve : Medium (Blue) 82998–12180 82998–12190 82998–12300* Type 1.8II Male Female Sleeve : Medium (Blue) or Large (Yellow) Size : S, M Sleeve : Medium (Blue) or Large (Yellow) Size : S, M F P/N 82998–24090 82998–24130* 82998–24100 Type 1.8II Male P/N Female Sleeve : Medium (Blue) or Large (Yellow) Size : L Sleeve : Medium (Blue) or Large (Yellow) Size : L 82998–24030 82998–24040 Wire Harness Repair Manual (RM1022E) 387 F–10 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 2.3 Male Female Sleeve : Medium (Blue) P/N Sleeve : Medium (Blue) 82998–12160 82998–24050* 82998–12170 Type 2.3II Male Female Sleeve : Medium (Blue) or Large (Yellow) Sleeve : Medium (Blue) or Large (Yellow) F P/N 82998–12330 82998–12350* Type 82998–12340 82998–12360* 2.3II IDC Male Female Sleeve : Medium (Blue) P/N 82998–24220 Wire Harness Repair Manual (RM1022E) 388 F–11 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 4.8 Male Sleeve : Large (Yellow) P/N Female Sleeve : Large (Yellow) 82998–12370 Type 82998–12380 6.3 Male Sleeve : Large (Yellow) P/N 82998–12050 Type Female Sleeve : Large (Yellow) 82998–12060 (160mm) 82998–12580(500mm) 6.3 Male Female Sleeve : Large (Yellow) P/N 82998–12070 Wire Harness Repair Manual (RM1022E) 389 F–12 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 6.3II Male Female Sleeve : Large (Yellow) P/N 82998–24170 Type 7.7 Terminal Lance Male Sleeve : Large (Yellow) P/N Female Sleeve : Large (Yellow) 82998–12010 Type 82998–12020 7.7 Housing Lance Male Sleeve : Large (Yellow) P/N Female Sleeve : Large (Yellow) 82998–12030 82998–12040 Wire Harness Repair Manual (RM1022E) 390 F–13 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type 8.0 Male Sleeve : Large (Yellow) P/N Female Sleeve : Large (Yellow) 82998–12390 Type 82998–12400 BLADE FUSE Male Female Sleeve : Large (Yellow) P/N 82998–12140 Type C–Type Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12560 82998–12570 Wire Harness Repair Manual (RM1022E) 391 F–14 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type FOG–LP Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–24210 Type FTC Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12510 Type HEAD LAMP Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–24140 (160mm) 82998–24200(500mm) Wire Harness Repair Manual (RM1022E) 392 F–15 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type LAC Male P/N Female Sleeve : Medium (Blue) or Large (Yellow) Sleeve : Medium (Blue) or Large (Yellow) 82998–12100 82998–12110 Type MFPC Male Female Sleeve : Medium (Blue) P/N 82998–12150 Type MIC Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12120 Wire Harness Repair Manual (RM1022E) 393 F–16 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type PULSE LOCK Female (Power) P/N Female (Signal) 82998–12200 Type 82998–12210 SFPC Male Female Sleeve : Medium (Blue) P/N 82998–24180 Type SL Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12130 Wire Harness Repair Manual (RM1022E) 394 F–17 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type SP Female (Power) P/N Female (Signal) Sleeve : Medium (Blue) or Large (Yellow) Sleeve : Medium (Blue) or Large (Yellow) 82998–12520 82998–12530 Type TLC Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12220 Type 82998–12230 TNS Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12240 82998–12250 Wire Harness Repair Manual (RM1022E) 395 F–18 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Non–waterproof Type) Type TODC Male Sleeve : Medium (Blue) or Large (Yellow) P/N Female Sleeve : Medium (Blue) or Large (Yellow) 82998–12080 82998–12090 Wire Harness Repair Manual (RM1022E) 396 F–1 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Waterproof Type) Type 1.0II Male Female Sleeve : Medium (Blue) P/N 82998–24060 Type 1.0III Male Sleeve : Medium (Blue) Female Sleeve : Medium (Blue) F P/N 82998–12710 Type 82998–12720 82998–12730* 1.3 Male Sleeve : Medium (Blue) P/N Female Sleeve : Medium (Blue) 82998–12630 82998–12650 Wire Harness Repair Manual (RM1022E) 379 F–2 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Waterproof Type) Type 1.8 Male Female Sleeve : Medium (Blue) P/N 82998–12620 Type 2.3 Male Female Sleeve : Medium (Blue) Sleeve : Medium (Blue) F P/N 82998–12260 82998–24070* Type 82998–12270 (160mm) 82998–12600(500mm) 82998–24080* 2.3II (6mm Pitch Type) Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12430 82998–12450* Sleeve : Medium (Blue) or Large (Yellow) 82998–12440 (160mm) 82998–12590(500mm) 82998–12460* Wire Harness Repair Manual (RM1022E) 380 F–3 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Waterproof Type) Type 2.3II (5mm Pitch Type) Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12790 82998–12780* Type 4.8 Male Sleeve : Large (Yellow) Female Sleeve : Large (Yellow) F P/N 82998–12470 Type 82998–12480 6.3 Male Female Sleeve : Large (Yellow) P/N 82998–12540 Wire Harness Repair Manual (RM1022E) 381 F–4 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Waterproof Type) Type 6.3II Male Female Sleeve : Medium (Blue) P/N 82998–24160 Type 8.0 Male Sleeve : Large (Yellow) Female Sleeve : Large (Yellow) F P/N 82998–12490 Type 82998–12500 HEAD LAMP Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–24150 (160mm) 82998–24190(500mm) Wire Harness Repair Manual (RM1022E) 382 F–5 TABLE OF REPAIR WIRE, TERMINAL PACKING, HOLE PLUG AND PRESS SLEEVE Repair Wire (Waterproof Type) Type HB3, HB4 Male Female Sleeve : Medium (Blue) or Large (Yellow) P/N 82998–12550 (160mm) 82998–12610(500mm) Type TLC Male Sleeve : Small (Red) Female Sleeve : Small (Red) F P/N 82998–12280 82998–12290 Wire Harness Repair Manual (RM1022E) 383 A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4R... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLK008X Title: A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4R... A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: INSTALLATION (2007 4... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLJ008X Title: A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL OIL COOLER ASSEMBLY (a) Install the oil cooler assembly, bolt and 4 bolts. Torque: 5.0 N·m (51 kgf·cm, 40 in·lbf) (b) Install the transmission oil cooler hose and clip. (c) Install the oil cooler sub tube. (d) Install the oil cooler hose and clip. 2. ADD AUTOMATIC TRANSMISSION FLUID HINT: 3. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0009X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0009X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLL008X Title: A750E AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID 2. REMOVE OIL COOLER ASSEMBLY (a) Loosen the clip and disconnect the oil cooler hose. (b) Loosen the clip and disconnect the transmission oil cooler hose. (c) Disconnect the oil cooler sub tube. (d) Remove the bolt, 4 bolts and oil cooler assembly. A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4R... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLK007X Title: A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: COMPONENTS (2007 4R... A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: INSTALLATION (2007 4... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLJ007X Title: A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL OIL COOLER ASSEMBLY (a) Install the oil cooler assembly, bolt and 4 bolts. Torque: 5.0 N·m (51 kgf·cm, 40 in·lbf) (b) Install the transmission oil cooler hose and clip. (c) Install the oil cooler sub tube. (d) Install the oil cooler hose and clip. 2. ADD AUTOMATIC TRANSMISSION FLUID HINT: 3. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0008X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0008X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLL007X Title: A750F AUTOMATIC TRANSMISSION: AIR COOLED OIL COOLER: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID 2. REMOVE OIL COOLER ASSEMBLY (a) Loosen the clip and disconnect the oil cooler hose. (b) Loosen the clip and disconnect the transmission oil cooler hose. (c) Disconnect the oil cooler sub tube. (d) Remove the bolt, 4 bolts and oil cooler assembly. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLD006X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLC006X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate. (b) Aligning the matchmarks on the transmission case and torque converter assembly, engage the splines of the input shaft and turbine runner. (c) Engage the splines of the stator shaft and stator while turning the torque converter assembly. HINT: Turn the torque converter assembly approximately 180°. (d) Turn the torque converter assembly and align the matchmarks on the torque converter assembly and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... assembly. (procedure "1") NOTICE: Do not push on the torque converter when aligning the matchmarks. (e) Using calipers and a straight edge, measure dimension B shown in the illustration and check that B is greater than A measured in procedure "1". Standard: A + 1 mm (0.03937 in.) or more 2. INSTALL NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 transmission control cable bracket to the transmission assembly with the 2 bolts. Torque: 14 N·m (143 kgf·cm, 10 ft·lbf) 3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (a) Install the automatic transmission assembly to the engine with the 9 bolts. Torque: 71 N·m (720 kgf·cm, 53 ft·lbf) Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (b) Install the 6 torque converter mounting bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) HINT: First install the black colored bolt and then the remaining 5 bolts. (c) Install the torque converter housing side cover to the engine. 4. INSTALL NO.1 REAR ENGINE MOUNTING INSULATOR (a) Install the No. 1 rear engine mounting insulator to the automatic transmission with the 4 bolts. Torque: 65 N·m (663 kgf·cm, 48 ft·lbf) 5. INSTALL NO.2 MANIFOLD STAY 6. INSTALL MANIFOLD STAY 7. INSTALL STARTER ASSEMBLY HINT: for Standard or for Cold Area) 8. CONNECT CONNECTOR (a) Connect the speed sensor SP2 connector. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (b) Install the wire harness with the bolt. Torque: 8.0 N·m (83 kgf·cm, 71 in·lbf) (c) Connect the speed sensor NT connector (a). (d) Connect the transmission wire connector (b). (e) Connect the park/neutral position switch assembly connector (c). 9. INSTALL NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts. Torque: 72 N·m (735 kgf·cm, 53 ft·lbf) (b) Tighten the 4 bolts to the No. 3 frame crossmember sub-assembly and No. 1 engine mounting insulator rear. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 10. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable assembly to the automatic transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (b) Install the nut and clip on the transmission control cable assembly. Torque: 14 N·m (143 kgf·cm, 10 ft·lbf) 11. INSTALL NO.1 OIL COOLER OUTLET TUBE (a) Temporarily install the No. 1 oil cooler outlet tube. (b) Temporarily install the No. 1 oil cooler inlet tube. (c) Install the 2 clamps and 2 bolts. Torque: 5 N·m (50 kgf·cm, 43 in·lbf) (d) Using SST, tighten the No. 1 oil cooler outlet tube. SST: 09023-12701 Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) 12. INSTALL NO.1 OIL COOLER INLET TUBE (a) Using SST, tighten the No. 1 oil cooler inlet tube. SST: 09023-12701 Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) 13. INSTALL FRONT SUSPENSION MEMBER BRACKET LH A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (a) Install the front suspension member bracket LH with the 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 14. INSTALL FRONT SUSPENSION MEMBER BRACKET (a) Install the front suspension member bracket with the 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 15. INSTALL PROPELLER SHAFT ASSEMBLY 16. INSTALL EXHAUST PIPE HINT: 17. INSTALL OXYGEN SENSOR HINT: 18. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 19. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 20. ADD AUTOMATIC TRANSMISSION FLUID HINT: 21. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: 22. ADJUST SHIFT LEVER POSITION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... HINT: 23. INSPECT SHIFT LEVER POSITION HINT: 24. CHECK FOR EXHAUST GAS LEAKS HINT: 25. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY cannot be completed by only disconnecting the battery terminal. 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEG004X Title: 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL STARTER ASSEMBLY (for 2WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 2. CONNECT WIRE HARNESS (for 2WD) (a) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) 3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Connect the battery negative terminal. 6. INSTALL STARTER ASSEMBLY (for 4WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) 1GR-FE STARTING: STARTER (for Standard): INSTALLATION (2007 4Runner) (a) Install the steering sliding yoke to No. 2 steering intermediate shaft. (b) Install the bolt B and tighten the bolt B and A. Torque: 36 N·m (370 kgf·cm, 27 ft·lbf) 8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Install the front fender rear splash shield LH with the 5 clips. 9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) (b) Connect the heated oxygen sensor (bank 2) connector. 10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Connect the battery negative terminal. 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM000002DEG005X Title: 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL STARTER ASSEMBLY (for 2WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 2. CONNECT WIRE HARNESS (for 2WD) (a) Connect the wire harness to the cylinder block and install the bolt. Torque: 13 N·m (133 kgf·cm, 10 ft·lbf) 3. INSTALL NO. 2 MANIFOLD STAY (for 2WD) (a) Install the No. 2 manifold stay with the 3 bolts. Torque: 40 N·m (408 kgf·cm, 30 ft·lbf) 4. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 5. CONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Connect the battery negative terminal. 6. INSTALL STARTER ASSEMBLY (for 4WD) (a) Install the starter assembly with the 2 bolts. Torque: 37 N·m (377 kgf·cm, 27 ft·lbf) (b) Connect the wire harness to the terminal 30 and install the nut. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) (c) Connect the terminal 50 to the starter assembly. 7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) 1GR-FE STARTING: STARTER (for Cold Area): INSTALLATION (2007 4Runner) (a) Install the steering sliding yoke to No. 2 steering intermediate shaft. (b) Install the bolt B and tighten the bolt B and A. Torque: 36 N·m (367 kgf·cm, 27 ft·lbf) 8. INSTALL FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Install the front fender rear splash shield LH with the 5 clips. 9. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Install 2 new gaskets and No. 2 exhaust manifold with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) (b) Connect the heated oxygen sensor (bank 2) connector. 10. INSTALL ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Install the engine rear under cover assembly with the 4 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 11. CONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Connect the battery negative terminal. PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): INSTALLATION (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000290F002X Title: PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL PROPELLER SHAFT ASSEMBLY (a) Remove the SST from the extension housing. SST: 09325-40010 (b) Install the propeller shaft assembly in the extension housing. (c) Align the matchmarks on the propeller shaft flange and differential flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N·m (897 kgf·cm, 65 ft·lbf) 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1H001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 2. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) 3. INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 4. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install 2 new gaskets and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 5. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using a vernier caliper, measure the free length to the 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) compression spring. Minimum length: 40.5 mm (4.5645 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with the 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 6. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 7. INSPECT EXHAUST GAS LEAK 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1H001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 2. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) 3. INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 4. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install 2 new gaskets and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 5. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using a vernier caliper, measure the free length to the 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) compression spring. Minimum length: 40.5 mm (4.5645 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with the 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 6. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 7. INSPECT EXHAUST GAS LEAK A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0009X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0009X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1H001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL HEATED OXYGEN SENSOR (for Bank 2) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 2. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) 3. INSTALL HEATED OXYGEN SENSOR (for Bank 1) (a) Install the heated oxygen sensor to the exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 4. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install 2 new gaskets and the front pipe to the exhaust manifold. (b) Install the exhaust pipe front with the 2 bolts and 2 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 5. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using a vernier caliper, measure the free length to the 1GR-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) compression spring. Minimum length: 40.5 mm (4.5645 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with the 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 6. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 7. INSPECT EXHAUST GAS LEAK A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03YX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLE006X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR HINT: 4. REMOVE EXHAUST PIPE HINT: 5. REMOVE PROPELLER SHAFT ASSEMBLY 6. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain the ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 7. REMOVE FRONT SUSPENSION MEMBER BRACKET A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (a) Remove the 4 bolts and front suspension member bracket. 8. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (a) Remove the 4 bolts and front suspension member bracket LH. 9. DISCONNECT NO.1 OIL COOLER OUTLET TUBE (a) Remove the 2 bolts and 2 clamps. (b) Using SST, disconnect the No. 1 oil cooler outlet tube. SST: 09023-12701 10. REMOVE NO.1 OIL COOLER INLET TUBE (a) Using SST, disconnect the No. 1 oil cooler inlet tube. SST: 09023-12701 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 11. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket. 12. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY (a) Support the transmission with a transmission jack. 13. REMOVE NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Remove the 4 nuts, 8 bolts and No. 3 frame crossmember sub-assembly. 14. DISCONNECT CONNECTOR (a) Tilt down the transmission. NOTICE: Take care so that the cooling fan does not come in contract with the fan shroud. (1) Disconnect the park/neutral position switch connector(a). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (2) Disconnect the transmission wire connector(b). (3) Disconnect the speed sensor NT connector(c). (4) Remove the bolt and wire harness from the transmission. (5) Disconnect the speed sensor SP2 connector. 15. REMOVE STARTER ASSEMBLY HINT: for Standard or for Cold Area) 16. REMOVE MANIFOLD STAY 17. REMOVE NO.2 MANIFOLD STAY 18. REMOVE NO.1 REAR ENGINE MOUNTING INSULATOR (a) Remove the 4 bolts 8 and No. 1 rear engine mounting insulator. 19. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (a) Remove the torque converter housing side cover from the engine. (b) Turn the crankshaft to gain access to each bolt. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (c) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. (d) Remove the 9 bolts. (e) Separate and remove the automatic transmission assembly. 20. REMOVE NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the 2 bolts and No.1 transmission control cable bracket from the transmission assembly. 21. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (a) Put matchmarks on the transmission case and torque converter clutch assembly. (b) Remove the torque converter assembly from the automatic transmission assembly. 22. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... SST: 09350-32014 09351-32010 09351-32020 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1J001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE EXHAUST PIPE ASSEMBLY TAIL (a) Remove the 2 bolts, exhaust pipe support and tail pipe. 2. REMOVE EXHAUST PIPE ASSEMBLY CENTER (a) Remove the 2 bolts and 2 compression springs. (b) Remove the 4 exhaust pipe supports and exhaust pipe center. 3. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and No. 2 exhaust front pipe assembly. 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 5. REMOVE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 nuts and exhaust pipe assembly front. 6. REMOVE HEATED OXYGEN SENSOR (for Bank 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B1J001X Title: 1GR-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE EXHAUST PIPE ASSEMBLY TAIL (a) Remove the 2 bolts, exhaust pipe support and tail pipe. 2. REMOVE EXHAUST PIPE ASSEMBLY CENTER (a) Remove the 2 bolts and 2 compression springs. (b) Remove the 4 exhaust pipe supports and exhaust pipe center. 3. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and No. 2 exhaust front pipe assembly. 4. REMOVE HEATED OXYGEN SENSOR (for Bank 1) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 5. REMOVE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 nuts and exhaust pipe assembly front. 6. REMOVE HEATED OXYGEN SENSOR (for Bank 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000290I002X Title: PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange. (b) Remove the 4 nuts and 4 washers. (c) Remove the propeller shaft. (d) Insert SST in the transmission to prevent oil leakage. SST: 09325-40010 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM0000026Q1004X Title: 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Disconnect the battery negative terminal. 2. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Remove the 4 bolts and engine rear under cover assembly. 3. REMOVE NO. 2 MANIFOLD STAY (for 2WD) (a) Remove the 3 bolts and No. 2 manifold stay. 4. DISCONNECT WIRE HARNESS (for 2WD) (a) Remove the bolt and disconnect the wire harness from the cylinder block. 5. REMOVE STARTER ASSEMBLY (for 2WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 6. DISCONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Disconnect the battery negative terminal. 7. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Remove the 4 bolts and engine rear under cover assembly. 8. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor (bank 2) connector. (b) Remove the 2 bolts, 2 nuts, No. 2 front exhaust pipe assembly and 2 gaskets. 9. REMOVE FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Remove the 5 clips and front fender rear splash shield LH. 1GR-FE STARTING: STARTER (for Standard): REMOVAL (2007 4Runner) 10. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) (a) Loosen the bolt A and remove the bolt B, then separate the No. 2 steering intermediate shaft sub-assembly. 11. REMOVE STARTER ASSEMBLY (for 4WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Starting Model Year: 2007 Model: 4Runner Doc ID: RM0000026Q1005X Title: 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) REMOVAL 1. DISCONNECT BATTERY NEGATIVE TERMINAL (for 2WD) (a) Disconnect the negative battery terminal. 2. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 2WD) (a) Remove the 4 bolts and engine rear under cover assembly. 3. REMOVE NO. 2 MANIFOLD STAY (for 2WD) (a) Remove the 3 bolts and No. 2 manifold stay. 4. DISCONNECT WIRE HARNESS (for 2WD) (a) Remove the bolt and disconnect the wire harness from the cylinder block. 5. REMOVE STARTER ASSEMBLY (for 2WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. 6. DISCONNECT BATTERY NEGATIVE TERMINAL (for 4WD) (a) Disconnect the negative battery terminal. 7. REMOVE ENGINE REAR UNDER COVER ASSEMBLY (for 4WD) (a) Remove the 4 bolts and engine rear under cover assembly. 8. REMOVE NO. 2 FRONT EXHAUST PIPE ASSEMBLY (for 4WD) (a) Disconnect the heated oxygen sensor (bank 2) connector. (b) Remove the 2 bolts, 2 nuts, No. 2 front exhaust pipe assembly and 2 gaskets. 9. REMOVE FRONT FENDER REAR SPLASH SHIELD LH (for 4WD) (a) Remove the 5 clips and front fender rear splash shield LH. 1GR-FE STARTING: STARTER (for Cold Area): REMOVAL (2007 4Runner) 10. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for 4WD) (a) Loosen the bolt A and remove the bolt B, then separate the No. 2 steering intermediate shaft sub-assembly. 11. REMOVE STARTER ASSEMBLY (for 4WD) (a) Disconnect the terminal 50 connector from the starter assembly. (b) Remove the nut and disconnect the wire harness from the terminal 30. (c) Remove the 2 bolts and starter assembly. A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLI008X Title: A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST: 09350-32014 09351-32020 (2) Press on the serrations of stater with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks up when turned counterclockwise. If necessary, clean the converter and retest the oneway clutch. Replace the converter if the one-way clutch still fails the test. (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. (See the sample.) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Replace the ATF in the torque converter clutch. A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: z z Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts shall have the same length. (3) No missing spring washer. 2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Set up a dial indicator and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLD005X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLC005X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate. (b) Aligning the matchmarks on the transmission case and torque converter assembly, engage the splines of the input shaft and turbine runner. (c) Engage the splines of the stator shaft and stator while turning the torque converter assembly. HINT: Turn the torque converter assembly approximately 180°. (d) Turn the torque converter assembly and align the matchmarks on the torque converter assembly and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... assembly. (procedure "1") NOTICE: Do not push on the torque converter when aligning the matchmarks. (e) Using calipers and a straight edge, measure dimension B shown in the illustration and check that B is greater than A measured in procedure "1". Standard: A + 1 mm (0.03937 in.) or more 2. INSTALL TRANSFER ASSEMBLY 3. INSTALL NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 transmission control cable bracket to the transmission assembly with the 2 bolts. Torque: 14 N·m (143 kgf·cm, 10 ft·lbf) 4. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY (a) Install the transfer breather hose sub-assembly. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (a) Install the automatic transmission assembly to the engine with the 9 bolts. Torque: 71 N·m (720 kgf·cm, 53 ft·lbf) Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) (b) Install the 6 torque converter mounting bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) HINT: First install the black colored bolt and then the remaining 5 bolts. (c) Install the torque converter housing side cover to the engine. 6. INSTALL NO.1 REAR ENGINE MOUNTING INSULATOR (a) Install the No. 1 rear engine mounting insulator to the automatic transmission with the 4 bolts. Torque: 65 N·m (663 kgf·cm, 48 ft·lbf) 7. INSTALL FRONT DIFFERENTIAL ASSEMBLY 8. INSTALL NO.2 MANIFOLD STAY 9. INSTALL MANIFOLD STAY 10. INSTALL STARTER ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... HINT: for Standard or for Cold Area) 11. CONNECT CONNECTOR (a) Transmission side: (1) Connect the speed sensor SP2 connector(a). (2) Install the wire harness with the bolt. Torque: 8.0 N·m (83 kgf·cm, 71 in·lbf) (3) Connect the speed sensor NT connector (b). (4) Connect the transmission wire connector (c). (5) Connect the park/neutral position switch assembly connector . (b) Transfer side: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (1) Connect the transfer shift actuator connector. (with transfer shift actuator) 12. INSTALL NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts. Torque: 72 N·m (735 kgf·cm, 53 ft·lbf) (b) Tighten the 4 bolts to the No. 3 frame crossmember sub-assembly and No. 1 engine mounting insulator rear. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 13. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable assembly to the automatic transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (b) Install the nut and clip on the transmission control cable assembly. Torque: 14 N·m (143 kgf·cm, 10 ft·lbf) 14. INSTALL NO.1 OIL COOLER OUTLET TUBE (a) Temporarily install the No. 1 oil cooler outlet tube. (b) Temporarily install the No. 1 oil cooler inlet tube. (c) Install the 2 clamps and 2 bolts. Torque: 5 N·m (50 kgf·cm, 43 in·lbf) (d) Using SST, tighten the No. 1 oil cooler outlet tube. SST: 09023-12701 Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) 15. INSTALL NO.1 OIL COOLER INLET TUBE (a) Using SST, tighten the No. 1 oil cooler inlet tube. SST: 09023-12701 Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) 16. INSTALL FRONT SUSPENSION MEMBER BRACKET LH A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (a) Install the front suspension member bracket LH with the 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 17. INSTALL FRONT SUSPENSION MEMBER BRACKET (a) Install the front suspension member bracket with the 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 18. INSTALL PROPELLER SHAFT HEAT INSULATOR (a) Install the propeller shaft heat insulator with the 2 bolts. Torque: 16 N·m (163 kgf·cm, 12 ft·lbf) 19. INSTALL PROPELLER SHAFT ASSEMBLY 20. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 21. INSTALL EXHAUST PIPE HINT: 22. INSTALL OXYGEN SENSOR HINT: 23. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 24. INSTALL REAR ENGINE UNDER COVER ASSEMBLY Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 25. ADD AUTOMATIC TRANSMISSION FLUID HINT: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 26. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: 27. ADJUST SHIFT LEVER POSITION HINT: 28. INSPECT SHIFT LEVER POSITION HINT: 29. CHECK FOR EXHAUST GAS LEAKS HINT: 30. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY cannot be completed by only disconnecting the battery terminal. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLE005X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR HINT: 4. REMOVE EXHAUST PIPE HINT: 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY 6. REMOVE PROPELLER SHAFT ASSEMBLY 7. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain the ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 8. REMOVE PROPELLER SHAFT HEAT INSULATOR (a) Remove the 2 bolts and propeller shaft heat insulator. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 9. REMOVE FRONT SUSPENSION MEMBER BRACKET (a) Remove the 4 bolts and front suspension member bracket. 10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (a) Remove the 4 bolts and front suspension member bracket LH. 11. DISCONNECT NO.1 OIL COOLER OUTLET TUBE (a) Remove the 2 bolts and 2 clamps. (b) Using SST, disconnect the No. 1 oil cooler outlet tube. SST: 09023-12701 12. REMOVE NO.1 OIL COOLER INLET TUBE (a) Using SST, disconnect the No. 1 oil cooler inlet tube. SST: 09023-12701 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 13. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket. 14. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY (a) Support the transmission with a transmission jack. 15. REMOVE NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Remove the 4 nuts, 8 bolts and No. 3 frame crossmember sub-assembly. 16. DISCONNECT CONNECTOR (a) Tilt down the transmission. NOTICE: Take care so that the cooling fan does not come in contract with the fan shroud. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (b) Transmission side: (1) Disconnect the park/neutral position switch connector(a). (2) Disconnect the transmission wire connector(b). (3) Disconnect the speed sensor NT connector(c). (4) Remove the bolt and wire harness from the transmission and transfer. (5) Disconnect the speed sensor SP2 connector. (c) Transfer side: (1) Disconnect the transfer shift actuator connector. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... 17. REMOVE STARTER ASSEMBLY HINT: for Standard or for Cold Area) 18. REMOVE MANIFOLD STAY 19. REMOVE NO.2 MANIFOLD STAY 20. SEPARATE FRONT DIFFERENTIAL ASSEMBLY 21. REMOVE NO.1 REAR ENGINE MOUNTING INSULATOR (a) Remove the 4 bolts and No. 1 Rear engine mounting insulator. 22. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (a) Remove the torque converter housing side cover from the engine. (b) Turn the crankshaft to gain access to each bolt. (c) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. (d) Remove the 9 bolts. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... (e) Separate and remove the automatic transmission assembly. 23. SEPARATE TRANSFER BREATHER HOSE SUB-ASSEMBLY (a) Separate the transfer breather hose sub-assembly from the transmission assembly. 24. REMOVE NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the 2 bolts and No.1 transmission control cable bracket from the transmission assembly. 25. REMOVE TRANSFER ASSEMBLY 26. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (a) Put matchmarks on the transmission case and torque A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-... converter clutch assembly. (b) Remove the torque converter assembly from the automatic transmission assembly. 27. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: SST: 09350-32014 09351-32010 09351-32020 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLG008X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLF008X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Install the torque converter clutch to the automatic transmission. (b) Using calipers and a straight edge, measure dimension A between the engine and the end surface of the drive plate. (c) Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in (b). Standard: A + 1 mm (0.03937 in.) or more 2. INSTALL NO.1 ENGINE MOUNTING INSULATOR REAR (a) Install the engine mounting insulator rear and 4 bolts to the automatic transmission. Torque: 65 N·m (663 kgf·cm, 48 ft·lbf) 3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (a) Install the automatic transmission and 10 bolts to the engine. Torque: 71 N·m (720 kgf·cm, 53 ft·lbf) Torque: 37 N·m (380 kgf·cm, 35 ft·lbf) (b) Install the 6 torque converter clutch mounting bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) HINT: First install black colored bolt and then the 5 bolts. 4. INSTALL FLYWHEEL HOUSING UNDER COVER (a) Install the flywheel housing under cover and 2 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 5. INSTALL WIRE HARNESS 6. INSTALL NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Install the No. 3 frame crossmember sub-assembly with 4 bolts and 4 nuts. Torque: 72 N·m (734 kgf·cm, 53 ft·lbf) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (b) Install the No. 3 frame crossmember sub-assembly with 4 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 7. INSTALL NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 transmission control cable bracket with 2 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 8. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable with nut. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 9. INSTALL NO.1 OIL COOLER OUTLET TUBE (a) Temporarily install the No. 1 oil cooler outlet tube. (b) Temporarily install the No. 1 oil cooler inlet tube. (c) Install the 2 clamps and 2 bolts. Torque: 5 N·m (50 kgf·cm, 43 in·lbf) (d) Using SST, tighten the No. 1 oil cooler outlet tube. Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) SST: 09023-12701 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 10. INSTALL NO.1 OIL COOLER INLET TUBE (a) Using SST, tighten the No. 1 oil cooler inlet tube. Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) SST: 09023-12701 11. INSTALL FRONT SUSPENSION MEMBER BRACKET LH (a) Install the front suspension member bracket LH with 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 12. INSTALL FRONT SUSPENSION MEMBER BRACKET (a) Install the front suspension member bracket with 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 13. INSTALL PROPELLER SHAFT ASSEMBLY 14. ADJUST SHIFT LEVER POSITION HINT: 15. INSTALL EXHAUST PIPE HINT: 16. INSTALL OXYGEN SENSOR HINT: 17. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 18. INSTALL ENGINE UNDER COVER ASSEMBLY REAR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 19. ADD AUTOMATIC TRANSMISSION FLUID HINT: 20. ADJUST AUTOMATIC TRANSMISSION FLUID HINT: 21. INSPECT SHIFT LEVER POSITION HINT: 22. CHECK FOR EXHAUST GAS LEAKS HINT: 23. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY cannot be completed by only disconnecting the battery terminal. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLH008X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR HINT: 4. REMOVE EXHAUST PIPE HINT: 5. REMOVE PROPELLER SHAFT ASSEMBLY 6. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug, gasket and drain ATF. (b) Install a new gasket and drain plug. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) 7. REMOVE FRONT SUSPENSION MEMBER BRACKET (a) Remove the 4 bolts and front suspension member bracket. 8. REMOVE FRONT SUSPENSION MEMBER BRACKET LH A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (a) Remove the 4 bolts and front suspension member bracket LH. 9. DISCONNECT NO.1 OIL COOLER OUTLET TUBE (a) Remove the 2 bolts and 2 clamps. (b) Using SST, disconnect the No. 1 oil cooler outlet tube. SST: 09023-12701 10. REMOVE NO.1 OIL COOLER INLET TUBE (a) Using SST, disconnect the No. 1 oil cooler inlet tube. SST: 09023-12701 11. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and disconnect the transmission control cable. (b) Remove the 2 bolts and disconnect the transmission control cable. 12. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (a) Support the automatic transmission assembly with a transmission jack. 13. REMOVE NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Remove the 4 bolts on the No. 3 frame crossmember sub-assembly. (b) Remove the 4 nuts, 4 bolts and No. 3 frame crossmember sub-assembly. 14. DISCONNECT CONNECTOR (a) Tilt down the transmission. NOTICE: Take care so that the cooling fan does not come in contact with the fan shroud. (b) Disconnect the park/neutral position switch connector. (c) Disconnect the transmission wire connector. (d) Disconnect the 2 speed sensor connectors. 15. DISCONNECT WIRE HARNESS 16. REMOVE FLYWHEEL HOUSING UNDER COVER A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (a) Remove the 2 bolts and flywheel housing under cover. 17. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (a) Turn the crankshaft to gain access to each bolt. (b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. (c) Remove the 10 bolts. (d) Separate and remove the automatic transmission. 18. REMOVE NO.1 REAR ENGINE MOUNTING INSULATOR (a) Remove the 4 bolts and engine mounting insulator rear from the automatic transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 19. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY 20. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: SST: 09350-32014 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLG007X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLF007X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (a) Install the torque converter clutch to the automatic transmission. (b) Using calipers and a straight edge, measure dimension A between the engine and the end surface of the drive plate. (c) Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in (b). Standard: A + 1 mm (0.03937 in.) or more 2. INSTALL NO.1 REAR ENGINE MOUNTING INSULATOR (a) Install the engine mounting insulator rear and 4 bolts to the automatic transmission. Torque: 65 N·m (663 kgf·cm, 48 ft·lbf) 3. INSTALL TRANSFER ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 5. INSTALL FLYWHEEL HOUSING UNDER COVER (a) Install the flywheel housing under cover and 2 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 6. INSTALL WIRE HARNESS 7. INSTALL NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Install the No. 3 frame crossmember sub-assembly with 4 bolts and 4 nuts. Torque: 72 N·m (734 kgf·cm, 53 ft·lbf) (b) Install the No. 3 frame crossmember sub-assembly with 4 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 8. INSTALL NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Install the No. 1 transmission control cable bracket with 2 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 9. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Connect the transmission control cable with nut. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 10. INSTALL NO.1 OIL COOLER OUTLET TUBE (a) Temporarily install the No. 1 oil cooler outlet tube. (b) Temporarily install the No. 1 oil cooler inlet tube. (c) Install the 2 clamps and 2 bolts. Torque: 5 N·m (50 kgf·cm, 43 in·lbf) (d) Using SST, tighten the No. 1 oil cooler outlet tube. Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) SST: 09023-12701 11. INSTALL NO.1 OIL COOLER INLET TUBE (a) Using SST, tighten the No. 1 oil cooler inlet tube. Torque: 34 N·m (346 kgf·cm, 25 ft·lbf) SST: 09023-12701 12. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install them to the oil filler tube. (b) Install the oil filler tube and bolt to the automatic transmission. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (c) Install the ATF level gauge. 13. INSTALL FRONT SUSPENSION MEMBER BRACKET LH (a) Install the front suspension member bracket LH with 4 bolts. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 14. INSTALL FRONT SUSPENSION MEMBER BRACKET (a) Install the front suspension member bracket with 4 bolts. Torque: 33 N·m (336 kgf·cm, 24 ft·lbf) 15. INSTALL PROPELLER SHAFT ASSEMBLY 16. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 17. ADJUST SHIFT LEVER POSITION HINT: 18. INSTALL EXHAUST PIPE HINT: 19. INSTALL OXYGEN SENSOR HINT: 20. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 21. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 22. ADD AUTOMATIC TRANSMISSION FLUID HINT: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 23. ADJUST AUTOMATIC TRANSMISSION FLUID HINT: 24. INSPECT SHIFT LEVER POSITION HINT: 25. CHECK FOR EXHAUST GAS LEAKS HINT: 26. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY cannot be completed by only disconnecting the battery terminal. VF4BM TRANSFER: TRANSFER ASSEMBLY: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Transfer/4wd/Awd Model Year: 2007 Model: 4Runner Doc ID: RM000001QHX007X Title: VF4BM TRANSFER: TRANSFER ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSFER ASSEMBLY (a) Install the transfer assembly with the 8 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) NOTICE: Take care not to damage the adaptor rear oil seal with the transfer input gear spline. 2. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER 3. INSTALL FLYWHEEL HOUSING UNDER COVER 4. CONNECT WIRE HARNESS 5. CONNECT CONNECTOR 6. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY 7. INSTALL TRANSFER CASE LOWER PROTECTOR (a) Install the transfer case lower protector with the 4 bolts. Torque: 18 N·m (184 kgf·cm, 13 ft·lbf) 8. INSTALL NO. 1 TRANSFER CONTROL CABLE BRACKET 9. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY VF4BM TRANSFER: TRANSFER ASSEMBLY: INSTALLATION (2007 4Runner) 10. INSTALL NO. 1 OIL COOLER INLET TUBE 11. CONNECT NO. 1 OIL COOLER OUTLET TUBE 12. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 13. INSTALL FRONT SUSPENSION MEMBER BRACKET LH 14. INSTALL FRONT SUSPENSION MEMBER BRACKET 15. ADD TRANSFER OIL HINT: 16. ADD AUTOMATIC TRANSMISSION FLUID 17. INSPECT AUTOMATIC TRANSMISSION FLUID 18. INSTALL PROPELLER SHAFT ASSEMBLY 19. INSTALL PROPELLER SHAFT ASSEMBLY FRONT 20. INSTALL EXHAUST PIPE ASSEMBLY 21. CONNECT OXYGEN SENSOR 22. INSTALL ENGINE UNDER COVER ASSEMBLY REAR 23. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 24. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: 25. INSPECT SHIFT LEVER POSITION 26. CHECK FOR EXHAUST GAS LEAKAGE 27. WARM UP 28. DRIVE TEST VF4BM TRANSFER: TRANSFER ASSEMBLY: INSTALLATION (2007 4Runner) PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): INSTALLATION (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000290F002X Title: PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL PROPELLER SHAFT ASSEMBLY (a) Remove the SST from the extension housing. SST: 09325-40010 (b) Install the propeller shaft assembly in the extension housing. (c) Align the matchmarks on the propeller shaft flange and differential flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N·m (897 kgf·cm, 65 ft·lbf) PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSTALLATION (2007 4Run... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000291O003X Title: PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (a) Align the matchmarks on the yoke and differential flange. (b) Install the propeller shaft assembly with the 4 bolts, 4 nuts and 4 washers. Torque: 88 N·m (897 kgf·cm, 65 ft·lbf) (c) Align the matchmarks on the yoke and transfer flange. (d) Install the propeller shaft assembly with the 4 nuts and 4 washers. Torque: 88 N·m (897 kgf·cm, 65 ft·lbf) A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B20003X Title: 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (633 kgf·cm, 46 ft·lbf) 2. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install the 2 new gaskets and the front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 bolts and 2 nuts. Torque: 62 N·m (633 kgf·cm, 46 ft·lbf) Torque: 48 N·m (489 kgf·cm, 35 ft·lbf) 3. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using vernier calipers, measure the free length to the compression spring. Minimum length: 40.5 mm (1.5945 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 4. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with 2 bolts. Torque: 48 N·m (489 kgf·cm, 35 ft·lbf) 5. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 6. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 7. INSPECT EXHAUST GAS LEAK A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0008X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B20003X Title: 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL EXHAUST PIPE ASSEMBLY FRONT (a) Install a new gasket and front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 nuts. Torque: 62 N·m (633 kgf·cm, 46 ft·lbf) 2. INSTALL NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Install the 2 new gaskets and the front pipe to exhaust manifold. (b) Install the exhaust pipe front with 2 bolts and 2 nuts. Torque: 62 N·m (633 kgf·cm, 46 ft·lbf) Torque: 48 N·m (489 kgf·cm, 35 ft·lbf) 3. INSTALL EXHAUST PIPE ASSEMBLY CENTER (a) Using vernier calipers, measure the free length to the compression spring. Minimum length: 40.5 mm (1.5945 in.) If the free length is less than minimum, replace the compression spring. (b) Install a new gasket on the exhaust pipe assembly front. (c) Install the exhaust pipe assembly center with 2 bolts and 2 springs. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 4. INSTALL EXHAUST PIPE ASSEMBLY TAIL (a) Install a new gasket on the exhaust pipe center. (b) Install the tail pipe with 2 bolts. Torque: 48 N·m (489 kgf·cm, 35 ft·lbf) 5. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) 2UZ-FE EXHAUST: EXHAUST PIPE: INSTALLATION (2007 4Runner) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 6. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Install heated oxygen sensor to exhaust pipe front. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) (b) Connect the heated oxygen sensor connector. HINT: After installing heated oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it. 7. INSPECT EXHAUST GAS LEAK A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03XX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903UX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 40°C (104°F) or less and vehicle speed is at 28 mph (45 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Last Modified: 4-26-2007 1.6 F Service Category: General Section: Specifications Model Year: 2007 Model: 4Runner Doc ID: RM000002E14001X Title: SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4Runner) SERVICE DATA 2UZ-FE: Engine idling D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) Line pressure (Wheel locked) Engine stall revolution Time lag R position 495 to 576 kPa (5.0 to 5.9 kgf*cm 2, 71 to 84 psi) AT stall (Throttle valve fully open) D position 1,235 to 1,332 kPa (12.6 to 13.6 kgf*cm 2, 179 to 193 psi) R position 1,229 to 1,350 kPa (12.5 to 13.8 kgf*cm 2, 178 to 196 psi) D position 2,200 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully open) 4 → 5 186 to 200 km/h (116 to 124 mph) 5 → 4 181 to 194 km/h (112 to 121 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully close) 4 → 5 50 to 56 km/h (31 to 35 mph) 5 → 4 26 to 31 km/h (16 to 19 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 4 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully close) 5 → 4 198 to 212 km/h (122 to 132 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 3 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) (Throttle valve fully open) 4 → 3 139 to 151 km/h (86 to 94 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 2 position 1 → 2 52 to 64 km/h (32 to 40 mph) (Throttle valve fully open) 3 → 2 92 to 103 km/h (57 to 64 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) L position 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 72 to 79 km/h (45 to 49 mph) Lock-up OFF 65 to 71 km/h (40 to 44 mph) 4 position 4th gear Lock-up ON 117 to 125 km/h (73 to 78 mph) Lock-up OFF 110 to 117 km/h (68 to 73 mph) 1GR-FE: Engine idling Line pressure (Wheel locked) D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) R position 484 to 565 kPa (4.9 to 5.8 kgf*cm 2, 70 to 82 psi) AT stall (Throttle valve fully opened) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Engine stall revolution Time lag D position 1,282 to 1,381 kPa (13.1 to 14.1 kgf*cm 2, 186 to 200 psi) R position 1,218 to 1,338 kPa (12.4 to 13.6 kgf*cm 2, 177 to 194 psi) D positions 2,400 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 4 → 5 179 to 189 km/h (111 to 117 mph) 5 → 4 171 to 182 km/h (106 to 113 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) (Throttle valve fully close) 4 → 5 46 to 51 km/h (29 to 32 mph) 5 → 4 27 to 33 km/h (17 to 21 mph) 4 position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 5 → 4 191 to 202 km/h (119 to 126 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 3 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 2 → 3 97 to 106 km/h (60 to 66 mph) 4 → 3 133 to 143 km/h (83 to 88 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 2 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 3 → 2 88 to 98 km/h (55 to 61 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) L position (Throttle valve fully open) Lock-up point 2 → 1 42 to 48 km/h (26 to 30 mph) Throttle valve opening 5% D position 5th gear Lock-up ON 57 to 63 km/h (35 to 39 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) 4 position 4th gear Lock-up ON 69 to 74 km/h (43 to 46 mph) Lock-up OFF 61 to 67 km/h (38 to 42 mph) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLH007X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-FE): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR HINT: 4. REMOVE EXHAUST PIPE HINT: 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY 6. REMOVE PROPELLER SHAFT ASSEMBLY 7. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug, gasket and drain ATF. (b) Install a new gasket and drain plug. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) 8. REMOVE FRONT SUSPENSION MEMBER BRACKET (a) Remove the 4 bolts and front suspension member bracket. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... 9. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (a) Remove the 4 bolts and front suspension member bracket LH. 10. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (a) Remove the ATF level gauge. (b) Remove the bolt and oil filler tube. (c) Remove the O-ring from the oil filler tube. 11. DISCONNECT NO.1 OIL COOLER OUTLET TUBE (a) Remove the 2 bolts and 2 clamps. (b) Using SST, disconnect the No. 1 oil cooler outlet tube. SST: 09023-12701 12. REMOVE NO.1 OIL COOLER INLET TUBE (a) Using SST, disconnect the No. 1 oil cooler inlet tube. SST: 09023-12701 13. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Remove the nut and disconnect the transmission control cable. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (b) Remove the 2 bolts and disconnect the transmission control cable. 14. REMOVE NO.1 TRANSMISSION CONTROL CABLE BRACKET (a) Remove the 2 bolts and transmission control cable bracket 15. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY (a) Support the automatic transmission assembly with a transmission jack. 16. REMOVE NO.3 FRAME CROSSMEMBER SUB-ASSEMBLY (a) Remove the 4 bolts on the No. 3 frame crossmember sub-assembly. (b) Remove the 4 nuts, 4 bolts and No. 3 frame crossmember sub-assembly. 17. DISCONNECT CONNECTOR (a) Tilt down the transmission. NOTICE: Take care so that the cooling fan does not come in contact with the fan shroud. (b) Disconnect the park/neutral position switch connector. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (c) Disconnect the transmission wire connector. (d) Disconnect the 2 speed sensor connectors. 18. DISCONNECT WIRE HARNESS 19. REMOVE FLYWHEEL HOUSING UNDER COVER (a) Remove the 2 bolts and flywheel housing under cover. 20. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (a) Turn the crankshaft to gain access to each bolt. (b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. (c) Remove the 10 bolts. (d) Separate and remove the automatic transmission. 21. REMOVE TRANSFER ASSEMBLY 22. REMOVE NO.1 REAR ENGINE MOUNTING INSULATOR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY (for 2UZ-... (a) Remove the 4 bolts and No.1 rear engine mounting insulator from the automatic transmission. 23. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY 24. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: SST: 09350-32014 2UZ-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Engine/Hybrid System Section: Intake/Exhaust Model Year: 2007 Model: 4Runner Doc ID: RM000002B22003X Title: 2UZ-FE EXHAUST: EXHAUST PIPE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 2. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) (a) Disconnect a heated oxygen sensor connector. (b) Remove the heated oxygen sensor. 3. REMOVE EXHAUST PIPE ASSEMBLY TAIL (a) Remove the 2 bolts, exhaust pipe support and tail pipe. 4. REMOVE EXHAUST PIPE ASSEMBLY CENTER (a) Remove the 2 bolts and 2 compression springs. (b) Remove the 4 exhaust pipe supports and exhaust pipe center. 5. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY (a) Remove the 2 bolts, 2 nuts and No. 2 exhaust front pipe assembly. 6. REMOVE EXHAUST PIPE ASSEMBLY FRONT (a) Remove the 2 nuts and exhaust pipe assembly front. PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000291R003X Title: PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential. (b) Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly. (c) Place matchmarks on the propeller shaft flange and transfer flange. (d) Remove the 4 nuts, 4 washers and front propeller shaft assembly. PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Drive Shaft/Propeller Shaft Model Year: 2007 Model: 4Runner Doc ID: RM00000290I002X Title: PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 2WD): REMOVAL (2007 4Runner) REMOVAL 1. REMOVE PROPELLER SHAFT ASSEMBLY (a) Place matchmarks on the propeller shaft flange and differential flange. (b) Remove the 4 nuts and 4 washers. (c) Remove the propeller shaft. (d) Insert SST in the transmission to prevent oil leakage. SST: 09325-40010 VF4BM TRANSFER: TRANSFER ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Transfer/4wd/Awd Model Year: 2007 Model: 4Runner Doc ID: RM000001QHY007X Title: VF4BM TRANSFER: TRANSFER ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT OXYGEN SENSOR 4. REMOVE EXHAUST PIPE ASSEMBLY 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY 6. REMOVE PROPELLER SHAFT ASSEMBLY 7. DRAIN AUTOMATIC TRANSMISSION FLUID 8. DRAIN TRANSFER OIL 9. REMOVE FRONT SUSPENSION MEMBER BRACKET 10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH 11. REMOVE TRANSMISSION OIL FILTER TUBE SUB-ASSEMBLY 12. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE 13. REMOVE NO. 1 OIL COOLER INLET TUBE 14. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 15. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET 16. REMOVE TRANSFER CASE LOWER PROTECTOR (a) Remove the 4 bolts and transfer case lower protector. VF4BM TRANSFER: TRANSFER ASSEMBLY: REMOVAL (2007 4Runner) 17. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER 18. REMOVE NO. 3 CROSSMEMBER SUB-ASSEMBLY 19. DISCONNECT CONNECTOR 20. DISCONNECT WIRE HARNESS 21. REMOVE FLYWHEEL HOUSING UNDER COVER 22. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER 23. REMOVE TRANSFER ASSEMBLY (a) Remove the 8 bolts and 2 clamps. (b) Remove the transfer from the automatic transmission. A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLI007X Title: A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST: 09350-32014 09351-32020 (2) Press on the serrations of stater with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks up when turned counterclockwise. If necessary, clean the converter and retest the oneway clutch. Replace the converter if the one-way clutch still fails the test. (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. (See the sample.) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Replace the ATF in the torque converter clutch. A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: z z Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts shall have the same length. (3) No missing spring washer. 2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Set up a dial indicator and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0009X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL0008X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. BEFORE FILLING TRANSMISSION z z z z This transmission requires Toyota Genuine ATF WS. It is necessary to refill the transmission with the correct amount of fluid. The vehicle must remain level while adjusting the transmission fluid level. On vehicles equipped with active suspension, turn the suspension control switch OFF if it is necessary to jack up the vehicle with the engine running. 2. TRANSMISSION PAN FILL (a) Remove the refill plug and overflow plug. (b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (c) Reinstall the overflow plug. 3. TRANSMISSION FILL (a) Fill the transmission with the correct amount of fluid as listed in the table below. (b) Reinstall the refill plug to avoid fluid splash. REPAIR FILL AMOUNT Transmission pan and drain plug removal 1.3 L (1.37 US qts, 1.14 Imp qts) Transmission valve body removal 3.9 L (4.12 US qts, 3.43 Imp qts) Torque converter removal 5.3 L (5.60 US qts, 4.66 Imp qts) Entire transmission assembly 5.3 L (5.60 US qts, 4.66 Imp qts) HINT: If you cannot add the listed amount of fluid, do the following: z z z z z z z Install the refill plug. Allow the engine to idle with the air conditioning OFF. Move the shift lever through entire gear range to circulate fluid. Wait for 30 seconds with the engine idling. Stop the engine. Remove the refill plug and add fluid. Reinstall the refill plug. 4. FLUID CIRCULATION (a) Allow the engine to idle with the air conditioning OFF. (b) Move the shift lever through entire gear range to circulate fluid. 5. FLUID TEMPERATURE CHECK NOTICE: The fluid temperature should be less than 30°C (86°F) before beginning the fluid temperature check. (a) With intelligent tester (1) Connect the intelligent tester to the DLC3. (2) Select the tester menus: OBD/MOBD, ENGINE, DATA LIST and A/T. (3) Check A/T OIL TEMP. (4) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Without intelligent tester (Using A/T OIL TEMP indicator) (1) Connect terminals between CG (4) and TC (13) of the DLC3 using SST (09843-18040). SST: 09843-18040 (2) Move the shift lever back and forth between N and D every 1.5 seconds for six seconds. (3) The D shift indicator on the combination meter comes on for two seconds. This indicates that the fluid temperature check mode has been started. (4) The D shift indicator will come on again when the fluid temperature reaches 46°C (115°F) and will blink when it exceeds 56°C (130°F). (5) Allow the engine to idle until the fluid temperature reaches 46°C (115°F). 6. FLUID LEVEL CHECK NOTICE: The fluid temperature must be between 46°C (115°F) and 56°C (130°F) to accurately check the fluid level. (a) Remove the overflow plug with the engine idling. (b) Check that the fluid comes out of the overflow tube. If fluid does not come out, proceed to step 7. If fluid comes out, wait until the overflow slows to a trickle and proceed to step 8. 7. TRANSMISSION REFILL (a) Install the overflow plug. (b) Stop the engine. (c) Remove the refill plug. (d) Add 0.4 liters (0.42 US qts, 0.35 Imp qts) of fluid. (e) Allow the engine to idle and wait for 10 seconds. (f) Proceed to step 6. 8. COMPLETE (a) Install the overflow plug with a new gasket. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMEN... (b) Stop the engine. (c) Install the refill plug with a new gasket. Torque: 20 N·m (250 kgf·cm, 15 ft·lbf) Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W78043X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): CHECK MODE PROCEDURE (2007 4Runner) CHECK MODE PROCEDURE 1. DESCRIPTION (a) Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 2. CHECK MODE PROCEDURE (a) Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF (b) Turn the engine switch off. (c) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (f) Change the ECM to check mode. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if:1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the engine switch is turned from on (IG) to on (ACC) or off. NOTICE: Before check mode, make notes of the DTCs and freeze frame data. (g) Start the engine. The MIL should turn off after the engine starts. (h) Perform "MONITOR DRIVE PATTERN" for the ECT test . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (Or, simulate the conditions of the malfunction described by the customer). (i) After simulating the malfunction conditions, use the intelligent tester diagnosis selector to check the DTC and freeze frame data. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7E048X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DATA LIST / ACTIVE TEST (2007 4Runner) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) NORMAL CONDITION Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) DIAGNOSTIC NOTE - Lock-up is Input shaft speed/ SPD(NT) z Min.: 0 rpm Max.: 12,750 rpm z ON (after warming up engine): Input turbine speed (NT) is equal to engine speed OFF (idling with shift lever on N): Input turbine speed Data is displayed in increments of 50 rpm A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (NT) is nearly equal to engine speed PNP SW [NSW] PNP switch status/ ON or OFF Shift lever is: z z On P and N: ON Not on P and N: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 Stop light switch STOP LIGHT status/ SW ON or OFF Brake pedal is z z Depressed: ON Released: OFF - Shift lever position is SHIFT ECM gear shift command/ z 1st, 2nd, 3rd, 4th or 5th z z z z REVERSE PNP switch status/ ON or OFF On D: 1st, 2nd, 3rd, 4th or 5th On 4: 1st, 2nd, 3rd or 4th On 3: 1st, 2nd or 3rd On 2: 1st or 2nd On L: 1st Shift lever is: z z On R: ON Not on R: OFF - When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 DRIVE PNP switch status/ ON or OFF Shift lever is: z z On D: ON Not on D: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... P0705 4TH/DRIVE PNP switch status/ ON or OFF Shift lever is: z z On 4: ON Not on 4: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 3RD PNP switch status/ ON or OFF Shift lever is: z z On 3: ON Not on 3: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 2ND PNP switch status/ ON or OFF Shift lever is: z z On 2: ON Not on 2: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 LOW PNP switch status/ ON or OFF Shift lever is: z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A/T OIL TEMP1 ATF temperature sensor No. 1 value/ Min.: -40°C (-40° F) z z Max.: 215°C (419° F) A/T OIL TEMP2 ATF temperature sensor No. 2 value/ Min.: -40°C (-40° F) LOCK UP ON or OFF z z SOLENOID (SLU) SOLENOID (SLT) Lock-up solenoid status/ ON or OFF Shift solenoid SLU status/ ON or OFF After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited Lock-up is z z LOCK UP SOL If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited cold Max.: 215°C (419° F) Lock up/ After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is Operating: ON Not operating: OFF - Lock-up solenoid is z z Operating: ON Not operating: OFF - Shift solenoid SLU is z z Shift solenoid SLT status/ z ON or OFF z Operating: ON Not operating: OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (e) Push the "ON" button of the intelligent tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE [Vehicle Condition] SOLENOID (SLU) Operate the shift solenoid SLU ON or OFF z z Engine stopped Shift lever P or N position ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure HINT: z z [Vehicle Condition] OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling [Vehicle Condition] SOLENOID (S1) Operate the shift solenoid S1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (S2) Operate the shift solenoid S2 ON or OFF z z Engine stopped Shift lever P or N position Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic transmission to lock-up condition [Vehicle Condition] ON or OFF z z SHIFT Operate shift solenoid valve and set each shift position by yourself z z Press "→" button: Shift up Press "←" button: Shift down Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less [Vehicle Condition] A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... SOLENOID (SR) Operate the shift solenoid SR ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL1) Operate the shift solenoid SL1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL2) Operate the shift solenoid SL2 ON or OFF z z Engine stopped Shift lever P or N position *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. as A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7I041X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DEFINITION OF TERMS (2007 4Runner) DEFINITION OF TERMS TERM DEFINITION Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Sequence of operation Required sensor/components Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. The sensors and components that are used by the ECM to detect malfunctions. The number of times that the ECM checks for malfunctions per driving cycle. "Once per driving cycle" means that the ECM detects malfunction only one Frequency of operation time during a single driving cycle. "Continuous" means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL illumination timing after a defect is detected. MIL operation "Immediately" means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. "2 driving cycle" means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W76048X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DIAGNOSIS SYSTEM (2007 4Runner) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (complying with SAE J1987). Various data output from the vehicle's ECM can then be read. (b) OBD II regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (1) The emission control system/components (2) The power train control components (which affect vehicle emissions) (3) The computer In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. (c) To check DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) of the vehicle. The intelligent tester displays DTCs, the freeze frame data and a variety of the engine data. The DTCs and freeze frame data can be erased with the intelligent tester . 2. NORMAL MODE AND CHECK MODE (a) The diagnosis system operates in "normal mode" during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available to technicians as an option. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunctions. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. 2 TRIP DETECTION LOGIC (a) When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate. 4. FREEZE FRAME DATA (a) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. (b) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 times before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. 5. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Terminal of DLC3 SYMBOLS (TERMINAL NO.) TERMINAL DESCRIPTION CONDITION SPECIFIED CONDITION SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) Body ground Chassis ground Always Below 1 Ω Always Below 1 Ω SG (5) - Body Signal ground ground BAT (16) Body ground Battery positive Always CANH (6) CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω HIGH-level Ignition 6 kΩ or CANH (6) Battery 9 to 14 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... positive CAN bus line switch OFF* higher CANH (6) CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. 6. CHECK BATTERY VOLTAGE Battery voltage: 11 to 14 V (a) If voltage is below 11 V, replace the battery before proceeding. 7. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch to the ON position. If the MIL does not illuminate, there is a problem in the MIL circuit . (b) When the engine is started, the MIL should turn off. 8. ALL READINESS (a) For this vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Enter the following menus: ENHANCED OBD II / MONITOR STATUS on the intelligent tester. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 S Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W71045X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DIAGNOSTIC TROUBLE CODE CHART (2007 4Runner) DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT: z z z *1: Comes on MIL (Malfunction Indicator Lamp) light up *2: "DTC stored" mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition. This DTC may be output when the clutch, brake and gear components etc. inside the automatic transmission are damaged. AUTOMATIC TRANSMISSION SYSTEM: DTC CODE P0705 DETECTION ITEM Transmission Range Sensor Circuit Malfunction (PRNDL Input) TROUBLE AREA MIL *1 1. Open or short in Comes park/neutral position switch on circuit MEMORY *2 DTC stored 2. Park/neutral position switch 3. ECM P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor No. 1 circuit Comes on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0711 Transmission Fluid Temperature Sensor "A" Performance Transmission wire (ATF temperature sensor No. 1) Comes on DTC stored P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor No. 1 circuit Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 1 circuit on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0717 Turbine Speed Sensor Circuit No Signal 1. Open or short in speed sensor (NT) circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Speed sensor (NT) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0722 Output Speed Sensor Circuit No Signal 1. Open or short in speed sensor (SP2) circuit 2. Speed sensor (SP2) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains closed 2. Shift solenoid valve SR remains open or closed 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. ECM P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) 1. Shift solenoid valve S1 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) 1. Shift solenoid valve S2 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) 1. Shift solenoid valve SR remains open or closed 2. Shift solenoid valve SL1 remains closed A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. ECM P0781 1-2 Shift (1-2 Shift Valve) 1. Valve body is blocked up or stuck (1-2 shift valve) 2. Automatic transmission (clutch, brake or gear, etc.) P0894 Transmission Component Slipping 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) 1. Short in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) 1. Open in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) 1. Short in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) 1. Open in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) 1. Short in shift solenoid valve SR circuit 2. Shift solenoid valve SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. ECM P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) 1. Open in shift solenoid valve SR circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 2 circuit on DTC stored 2. Shift solenoid valve SR 3. ECM P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. ECM P2740 Transmission Fluid Temperature Sensor "B" Circuit 1. Open or short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input 1. Short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) 1. Shift solenoid valve SLU remains open or closed Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transmission (clutch, brake or gear, etc.) 5. Line pressure is too low P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit 1. Open or short in shift solenoid valve SLU circuit A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Electrical (Shift Solenoid Valve SLU) 2. Shift solenoid valve SLU 3. ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W77043X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DTC CHECK / CLEAR (2007 4Runner) DTC CHECK / CLEAR 1. CHECK DTC (a) DTCs which are stored in the ECM can be displayed with the intelligent tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTC aren't stored if the ECM doesn't detect a malfunction during consecutive driving. However, the detected malfunction during once driving is stored as pending DTC. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch to the ON position. (3) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Confirm the DTCs and freeze frame data and then write them down. (5) Confirm the details of the DTCs . NOTICE: When simulating a symptom with the scan tool to check the DTCs, use normal mode. For codes on DIAGNOSTIC TROUBLE CODE CHART which are subject to "2-trip detection logic", perform the following actions. Turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM. 2. CLEAR DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... press YES. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O8L048X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): FAILSAFE CHART (2007 4Runner) FAIL-SAFE CHART 1. FAIL-SAFE CHART This function minimizes the loss of the ECT functions when a malfunction occurs in each sensor or solenoid. MALFUNCTION PART FUNCTION No. 1 ATF Temperature Sensor During a No. 1 ATF temperature sensor malfunction, up-shift to the 5th gear and flex lock-up clutch control are prohibited. Output Speed Sensor During an output speed sensor malfunction, shift control is effected through the (SP2) input speed sensor signal (NT). Shift Solenoid Valve S1, S2 and SR The current to the failed solenoid valve is cut off and control is effected by operating the other solenoid valves with normal operation. Shift control is effected depending on the failed solenoid as described in the table below. Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction, up-shift to the 5th gear is prohibited. Shift Solenoid Valve SLT During a solenoid valve SLT malfunction, the current to the solenoid valve is stopped. This stops line pressure optimal control, and shift shock increases. However, shifting is effected through normal clutch pressure control. Shift Solenoid Valve SLU During a solenoid valve SLU malfunction, the current to the solenoid valve is stopped. This stops lock-up control and flex lock-up control, and fuel economy decreases. Fail-safe function: If either of the shift solenoid valve circuits has an open or short failure, the ECM turns the other shift solenoid ON and OFF in order to shift into the gear positions shown in the table below. In case of a short circuit, the ECM stops sending current to the short circuit solenoid. Even if starting the engine again in the fail-safe mode, the gear position remains in the same position. HINT: z z z ↓: Condition in the electrical malfunction is shown above "↓". ↓: Condition in fail-safe mode is shown below "↓". E/B: Engine brake. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... POSITION R NORMAL S1 OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th 1st ON OFF OFF OFF ON ↓ OFF OFF 3rd D ↓ ON 2nd ON ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON OFF OFF 3rd ↓ OFF OFF 3rd E/B ↓ ON OFF ON 3rd 3 2 L 2nd ON D OFF OFF ON ↓ ON OFF ON OFF OFF ↓ OFF 3rd E/B 3rd E/B OFF ON OFF OFF OFF 3rd E/B OFF ON OFF OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON 1st OFF OFF OFF OFF ON 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st E/B ON OFF OFF OFF OFF 1st E/B OFF OFF OFF OFF OFF 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF POSITION R ON ↓ S2 OFF SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ OFF OFF OFF ON 2nd ON ON OFF OFF ON 4th OFF A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 4th OFF OFF OFF ON OFF 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ 2nd ON ON OFF OFF ON 3rd E/B OFF 3rd E/B OFF OFF ON OFF OFF ON OFF OFF OFF ↓ OFF 3rd E/B OFF OFF OFF OFF 3 ↓ OFF 3rd ON OFF 4th OFF OFF ON OFF ON 3rd OFF ↓ ON OFF OFF ON 3rd E/B 5th OFF OFF ON ON OFF ↓ OFF ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF OFF ON OFF 1st E/B ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF ON OFF OFF ON OFF ON OFF ↓ 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ON OFF ON OFF ↓ OFF 2nd OFF OFF ON ON OFF ON OFF OFF OFF OFF ON OFF ON OFF OFF ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF ↓ ↓ 2nd ON 1st E/B ON OFF OFF OFF OFF ON 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ↓ OFF ON ON OFF ↓ OFF OFF OFF ↓ ON OFF ON OFF ↓ OFF 2nd ON 4th ↓ OFF OFF L ↓ ON ON 5th ON OFF OFF 2 OFF OFF ON 1st OFF 4th ↓ ↓ ON OFF 3rd 1st ↓ OFF ON OFF ON ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF OFF ON ↓ OFF ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 5th OFF POSITION R D OFF ON ON OFF ↓ ↓ ↓ 2nd ON ON S1 S2 OFF OFF ↓ OFF S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R ON OFF OFF OFF ON 4th OFF OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON 4th OFF OFF OFF OFF ON ↓ ↓ OFF OFF OFF ON 4th OFF 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF ON 3rd ↓ ON OFF OFF OFF OFF ↓ 1st ON 3rd E/B OFF 3rd ON 1st E/B ON ↓ ↓ ↓ OFF 3rd OFF ↓ OFF OFF OFF OFF 3rd E/B OFF OFF ON OFF OFF OFF 3rd E/B OFF OFF OFF OFF OFF ↓ ↓ ON 3rd E/B 3 OFF OFF OFF OFF OFF OFF 3rd ↓ ON ON 4th OFF OFF ON OFF ON 3rd OFF OFF OFF OFF ↓ ON 1st E/B 5th OFF OFF ON ON OFF ↓ OFF OFF OFF 3rd 1st Fail 4th 2 Fail 4th OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON 1st OFF 1st E/B ↓ ↓ ON 1st OFF 1st E/B ON OFF OFF ON OFF ↓ ↓ OFF ON OFF ON OFF ON OFF OFF OFF ↓ ON OFF ↓ ↓ ↓ ON 1st ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st ↓ ON OFF OFF OFF ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1st E/B 5th OFF OFF ON ON 1st E/B OFF OFF OFF OFF Fail 4th OFF OFF ON OFF Fail 4th OFF OFF ON OFF L OFF OFF ON OFF ↓ ↓ 1st ON OFF 1st E/B ON OFF OFF 1st E/B ↓ ↓ ON OFF ON 1st OFF 1st E/B OFF ↓ ↓ ↓ ON 1st ON OFF OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st OFF ↓ OFF OFF ON ON OFF ON 1st E/B 5th OFF POSITION R ON ON OFF ↓ ↓ 1st ON OFF ↓ ↓ OFF ON S1 S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON ↓ OFF OFF 3rd ↓ ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF 3rd OFF ↓ 3rd OFF ON 4th OFF OFF OFF ↓ ↓ OFF ON ON OFF OFF ON 3 OFF S1 SR OFF 4th D OFF OFF OFF OFF ↓ ON 3rd OFF OFF OFF OFF ON ON ON ↓ 3rd OFF OFF OFF OFF ON 3rd E/B ↓ OFF ON OFF OFF 3rd 3rd OFF OFF ↓ OFF OFF ↓ ON ON OFF 3rd E/B ↓ ↓ ON 3rd ON 3rd ↓ ↓ OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ON ↓ A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ON 3rd E/B ↓ OFF OFF 3rd 1st ON ↓ OFF ON OFF OFF OFF ON ON OFF 3rd E/B ↓ ↓ ↓ OFF ON 3rd OFF ON 1st OFF OFF OFF OFF OFF OFF ON OFF ↓ ↓ OFF ON OFF ON 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF 2 ↓ OFF OFF OFF OFF OFF ON 1st E/B OFF ↓ OFF OFF OFF OFF 1st 1st ↓ OFF OFF 2nd 2nd 1st E/B OFF ↓ ON OFF ON OFF OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF ↓ 1st E/B OFF OFF OFF OFF ↓ 1st OFF 1st E/B OFF OFF OFF 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF L ↓ OFF OFF OFF OFF OFF ↓ OFF OFF 2nd ON 1st E/B OFF ↓ OFF OFF OFF OFF 2nd ↓ ON ON OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF ↓ ON OFF ON 1st E/B ↓ ↓ ↓ 1st 1st 1st ↓ ON ON OFF ON 1st E/B ↓ ↓ ↓ 1st ON OFF ↓ OFF 1st E/B OFF ↓ 1st A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W6Z049X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): HOW TO PROCEED WITH TROUBLESHOOTING (2007 4Runner) HOW TO PROCEED WITH TROUBLESHOOTING HINT: z z The ECM of this system is connected to the CAN and multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN and multiplex communication systems. *: Use the intelligent tester. 1. VEHICLE BROUGHT TO WORKSHOP NEXT 2. CUSTOMER PROBLEM ANALYSIS NEXT 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4. CONNECT INTELLIGENT TESTER TO DLC3* NEXT 5. CHECK AND CLEAR DTCS AND FREEZE FRAME DATA* A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Refer to the DTC CHECK/CLEAR . NEXT 6. VISUAL INSPECTION NEXT 7. SETTING CHECK MODE DIAGNOSIS* . (a) Refer to the CHECK MODE PROCEDURE NEXT 8. PROBLEM SYMPTOM CONFIRMATION (a) Refer to the ROAD TEST . Result: RESULT PROCEED TO Symptom does not occur A Symptom occurs B B GO TO STEP 10 A 9. SYMPTOM SIMULATION (a) Refer to the ELECTRONIC CIRCUIT INSPECTION PROCEDURE NEXT 10. DTC CHECK* . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Refer to the DTC CHECK / CLEAR . Result: RESULT PROCEED TO DTC is not output A DTC is output B B GO TO STEP 19 A 11. BASIC INSPECTION (a) Refer to the AUTOMATIC TRANSMISSION FLUID . (b) Refer to the PARK/NEUTRAL POSITION SWITCH . . (c) Refer to the SHIFT LEVER ASSEMBLY NG GO TO STEP 22 OK 12. MECHANICAL SYSTEM TEST . (a) Refer to the MECHANICAL SYSTEM TEST NG GO TO STEP 18 NG GO TO STEP 18 OK 13. HYDRAULIC TEST (a) Refer to the HYDRAULIC TEST . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 14. MANUAL SHIFTING TEST (a) Refer to the MANUAL SHIFTING TEST . NG GO TO STEP 17 OK 15. PROBLEM SYMPTOMS TABLE CHAPTER 1 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 20 OK 16. PROBLEM SYMPTOMS TABLE CHAPTER 2 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 18 OK 17. PROBLEM SYMPTOMS TABLE CHAPTER 3 (a) Refer to the PROBLEM SYMPTOMS TABLE . NEXT 18. PART INSPECTION NEXT GO TO STEP 22 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 19. DTC CHART (a) Refer to the DIAGNOSTIC TROUBLE CODE CHART . NEXT 20. CIRCUIT INSPECTION NEXT 21. IDENTIFICATION OF PROBLEM NEXT 22. REPAIR OR REPLACE NEXT 23. CONFIRMATION TEST NEXT END A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7B044X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): HYDRAULIC TEST (2007 4Runner) HYDRAULIC TEST 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: z z z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. Be careful to prevent SST hose from interfering with the exhaust pipe. This Check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. When conducting stall test, do not continue more than 5 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Turn the ignition switch off. (3) Lift the vehicle up. (4) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (5) Lower the vehicle. (6) Fully apply the parking brake and chock the 4 wheels. (7) Start the engine and check idling speed. (8) Keep your left foot pressing firmly on the brake pedal and shift into D position. (9) Measure the line pressure when the engine is idling. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (10) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (11) In the same manner, do the test in R position. Specified line pressure: CONDITION Idling D POSITION KPA R POSITION KPA (KGF/CM 2, PSI) (KGF/CM 2, PSI) 362 to 423 kPa 484 to 565 kPa (3.7 to 4.3 kgf/cm 2, 53 to 61 psi) (4.9 to 5.8 kgf/cm 2, 70 to 82 psi) 1,282 to 1,381 kPa Stall test 1,218 to 1,338 kPa 2 (13.1 to 14.1 kgf/cm , (12.4 to 13.6 kgf/cm 2, 186 to 200 psi) 177 to 194 psi) Evaluation: PROBLEM If the measured values at all position are higher POSSIBLE CAUSE z z If the measured values at all position are lower z z z If pressure is low in the D position only z z If pressure is low in the R position only z z z Shift solenoid valve (SLT) defective Regulator valve defective Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective D position circuit fluid leak Clutch No.1 (C 1) defective R position circuit fluid leak Clutch No.3 (C 3) defective Brake No.4 (B 4) defective A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03YX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7C046X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MANUAL SHIFTING TEST (2007 4Runner) MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transmission. If any abnormalities are found in the following test, the problem is in the transmission itself. z z (a) Disconnect the connector of the transmission wire. (b) Drive with the transmission wire disconnected. Shifting the shift lever to the L, 2, 3, 4 and D position to check whether the shifting condition changes the table below. SHIFT POSITION SHIFTING CONDITION L ←→ 2 No Shift (Not Change) 2 ←→ 3 Down Shift ←→ Up Shift 3 ←→ 4 Down Shift ←→ Up Shift 4 ←→ D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the gear position will be as follows: z z z z When the shift When the shift When the shift When the shift respectively. lever lever lever lever is is is is in in in in the the the the L or the 2 position, the gear is held in the 1st position. 3 position, the gear is held in the 3rd position. 4 or the D position, the gear is held in the 4th position. R or the P position, the gear is also in the R or the P position A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (c) Connect the connector of the transmission wire. (d) Clear the DTC . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7A046X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MECHANICAL SYSTEM TESTS (2007 4Runner) MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D position. NOTICE: z z z z z Driving test should be done on a paved road (a nonskid road). Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). Do not continuously run this test for longer than 5 seconds. To ensure safety, do this test in a wide, clear level area which provides good traction. The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,400 +- 150 rpm Evaluation: PROBLEM POSSIBLE CAUSE z z (a) Stall engine speed is low in D position Engine power output may be insufficient Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. z Line pressure is too low A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Stall engine speed is high in D position Clutch No. 1 (C 1) slipping One-way clutch No. 3 (F 3) not operating properly z z Improper fluid level z (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutch, and brake. NOTICE: z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). Be sure to allow 1 minute interval between tests. Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): PROBLEM N → D time lag is longer POSSIBLE CAUSE z z z z N → R time lag is longer z z z Line pressure is too low Clutch No.1 (C 1) worn One-way clutch No. 3 (F 3) not operating properly Line pressure is too low Clutch No. 3 (C 3) worn Brake No. 4 (B 4) worn One-way clutch No. 1 (F 1) not operating properly A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7K042X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MONITOR DRIVE PATTERN (2007 4Runner) MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern.) HINT: Preparation for driving z z Warm up the engine sufficiently. (Engine coolant temperature is 60°C (140°F) or higher) Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction is not detected when the atmospheric temperature is less than -10°C (14°F)) Notice in driving z Drive the vehicle through all gears. z Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON). Repeat the above driving pattern three times or more. NOTICE: z z z The monitor status can be checked using the OBD II scan tool or intelligent tester. When using the intelligent tester, monitor status can be found in the "ENHANCED OBD II / DATA LIST" or under "CARB OBD II". In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8404GX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input) (2007 4Runner) DTC P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC NO. DTC DETECTION CONDITION P0705 TROUBLE AREA z Open or short in park/neutral position switch circuit Park/neutral position switch z ECM z (2-trip detection logic) MONITOR DESCRIPTION These DTCs indicate a problem with the park/neutral position switch and the wire harness in the park/neutral position switch circuit. The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position. The park/neutral position switch sends a signal to the ECM according to the shift position (P, R, N, D, 4, 3, 2 or L). The ECM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P0705: Park/neutral position switch/Verify switch input Required sensors/Components Park/neutral position switch Frequency of operation Continuous Condition (A) and (C) Duration 2 sec. Condition (B) 60 sec. MIL operation 2 driving cycles Sequence of operation None A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Engine switch ON Battery voltage 10.5 V or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A), (B) or (C) Condition (A) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (B) All of following conditions are met NSW switch OFF R switch OFF D switch OFF 3 switch OFF 2 switch OFF Condition (C) Both (i) and (ii) are met (i) One of following conditions is met NSW switch ON R switch ON (ii) One of following condition is met 4 switch ON L switch ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... COMPONENT OPERATING RANGE Park/neutral position switch The park/neutral position switch sends only one signal to the ECM. WIRING DIAGRAM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Shift lever is: PNP SW [NSW] PNP switch status/ z ON or OFF z When shift lever position displayed on intelligent On P and tester differs from actual position, adjustment of N: ON PNP switch or shift cable may be incorrect Not on P and N: OFF Shift lever is: REVERSE PNP switch status/ ON or OFF z z On R: ON Not on R: OFF Shift lever is: DRIVE PNP switch status/ ON or OFF z z On D: ON Not on D: OFF Shift lever is: 4TH/DRIVE PNP switch status/ ON or OFF z z On 4: ON Not on 4: OFF Shift lever is: When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3RD PNP switch status/ z ON or OFF z On 3: ON Not on 3: OFF Shift lever is: PNP switch status/ 2ND ON or OFF z z On 2: ON Not on 2: OFF Shift lever is: PNP switch status/ LOW ON or OFF z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect PROCEDURE 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω Except 2 and L ↑ 10 kΩ or higher NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 2. INSPECT SHIFT LOCK CONTROL ECU SUB-ASSEMBLY (TRANSMISSION CONTROL SWITCH) (a) Connect the park/neutral position switch connector. (b) Disconnect the shift lock control ECU connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION D 4 D 4 2 TESTER CONNECTION 9 - 2 (NSSD - ATD) 9 - 3 (NSSD - AT4) 10 - 5 (NSSL - AT2) SPECIFIED CONDITION Below 1 Ω 10 kΩ or higher 10 kΩ or higher Below 1 Ω Below 1 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... L 10 kΩ or higher 2 10 kΩ or higher 10 - 4 (NSSL - ATL) L NG Below 1 Ω REPLACE SHIFT LOCK CONTROL ECU SUBASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Connect the shift lock control ECU connector. (b) Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P and N E5-8 (NSW) - Body ground Below 2 V Except P and N ↑ 10 to 14 V R E7-11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D and 4 E7-21 (D) - Body ground 10 to 14 V Except D and 4 ↑ Below 1 V 3 E7-19 (3) - Body ground 10 to 14 V Except 3 ↑ Below 1 V 2 and L E7-10 (2) - Body ground 10 to 14 V Except 2 and L ↑ Below 1 V L E7-9 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *: The voltage will drop slightly due to the turning on of the back up light. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8503YX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0710: Transmission Fluid Temperature Sensor "A" Circuit (2007 4Runner) DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor No. 1 resistance is less than 79 Ω. P0710 z (b) ATF temperature sensor No. 1 resistance is more than 156 kΩ. z HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or z Open or short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM from (b) to (a) z P0712 ATF temperature sensor No. 1 resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic) z z z ATF temperature No. 1 sensor resistance is more than 156 kΩ P0713 when 15 minutes or more have elapsed after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic) z z Short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM Open in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω *1 or more than 156 kΩ *2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P0710: ATF temperature sensor/Range check (Chattering) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Related DTCs P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0712: Range check (Low resistance) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω or more than 156 kΩ P0712: Range check (Low resistance) TFT sensor resistance. P0713: Range check (High resistance) Less than 79 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TFT sensor resistance. More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor. Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on tester, read the "DATA LIST". A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal OIL and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150 °C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE 1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 2 (OT-) - 10 (OT+) 79 Ω to 156 kΩ 2 (OT-) - Body ground 10 kΩ or higher 10 (OT+) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with either the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20 °C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Z03NX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0711: Transmission Fluid Temperature Sensor "A" Performance (2007 4Runner) DTC P0711 Transmission Fluid Temperature Sensor "A" Performance DESCRIPTION . DTC NO. DTC DETECTION CONDITION TROUBLE AREA Both (a) and (b) are detected: (2-trip detection logic) P0711 (a) Intake air and engine coolant temps. are more than -10° Transmission wire (ATF C (14°F) at engine start temperature sensor No. 1) (b) After normal driving for over 22 min. and 9 km (6 mile) or more, ATF temp. is less than 20°C (68°F) MONITOR DESCRIPTION This DTC indicates that there is a problem with output from the automatic transmission fluid (ATF) temperature sensor and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault in the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 20°C (68°F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. MONITOR STRATEGY Related DTCs P0711: ATF temperature sensor/Rationality check Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 3 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None TFT sensor circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 21 min. and 40 sec. Driving distance after engine start 5.6 mile (9 km) or more IAT (12 sec. after engine start) -10°C (14°F) or more ECT (12 sec. after engine start) -10°C (14°F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (Transmission fluid temperature) Less than 20°C (60°F) (ATF temperature = -10°C (14°F) at engine start) (Conditions vary with ATF temperature at engine start) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0711" is output A "P0711" and other DTCs B HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. CHECK TRANSMISSION FLUID LEVEL OK: Automatic transmission fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Y01OX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0717: Turbine Speed Sensor Circuit No Signal (2007 4Runner) DTC P0717 Turbine Speed Sensor Circuit No Signal DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input revolution of transmission. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (SP2), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC NO. DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected for 5 secs. or more (1-trip detection logic) (a) Gear change is not performed P0717 (b) Gear position: 4th or 5th (c) T/M input shaft rpm: 300 rpm or less z Open or short in speed sensor (NT) circuit Speed sensor (NT) ECM z Automatic transmission (clutch, z (d) T/M output shaft rpm: 1,000 rpm or more (e) Park/neutral position switch: z NSW input signal is OFF z A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z z R input signal is OFF L input signal is OFF brake or gear, etc.) (f) Shift solenoid valves and park/neutral position switch are in normal operation Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NT- of the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 1 V/DIV, 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) MONITOR DESCRIPTION This DTC indicates that pulse is not output from the speed sensor NT (Turbine (input) speed sensor) or is output only little. The NT terminal of the ECM detects the revolving signal from speed sensor (NT) (input RPM). The ECM outputs a gearshift signal comparing the input speed sensor (NT) with the output speed sensor (SP2). While the vehicle is operating in the 4th or 5th gear position in the shift position of D, if the input shaft revolution is less than 300 rpm *1 although the output shaft revolution is more than 1,000 rpm or more *2 , the ECM detects the trouble, illuminates the MIL and stores the DTC. *1 : Pulse is not output or is irregularly output. *2 : The vehicle speed is approx. 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT)/Verify pulse input Required sensors/Components (Main) Speed sensor (NT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components (Related) Speed sensor (NC) Frequency of operation Continuous Duration 5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Shift change Shift change is completed and before starting next shift change operation ECM selected gear 4th or 5th Output shaft rpm 1,000 rpm or more NSW (STAR) switch OFF R switch OFF L switch OFF Engine Running Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Input speed is equal to engine speed when lock-up ON. WIRING DIAGRAM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Lock-up is Input shaft speed/ SPD(NT) Min.: 0 rpm z Max.: 12,750 rpm z ON (after warming up engine): Input Data is displayed in turbine speed (NT) is equal to engine increments of 50 rpm speed OFF (idling with shift lever on N): Input turbine speed (NT) is nearly equal to A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... engine speed HINT: z SPD(NT) is always 0 while driving: z Open or short in the sensor or circuit. SPD(NT) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (NT) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG SECURELY INSTALL SPEED SENSOR OR REPLACE SPEED SENSOR OK 2. INSPECT SPEED SENSOR (NT) (a) Disconnect the speed sensor connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (NT) OK 3. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-35 (NT+) - E5-27 (NT-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-35 (NT+) - Body ground 10 kΩ or higher E5-27 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012TD00XX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0722: Output Speed Sensor Circuit No Signal (2007 4Runner) DTC P0722 Output Speed Sensor Circuit No Signal DESCRIPTION The speed sensor SP2 detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the speed sensor SP2 coil as the parking gear mounted on the rear planetary gear assembly rotates, and this voltage is sent to the ECM. The parking gear on the rear planetary gear is used as the timing rotor for this sensor. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. DTC NO. P0722 DTC DETECTION CONDITION All conditions below are detected 500 times or more continuously (2-trip detection logic) (a) No signal from speed sensor (SP2) is input to ECM while 4 pulses of No. 1 vehicle speed sensor signal are sent TROUBLE AREA z Open or short in speed sensor (SP2) circuit Speed sensor (SP2) z ECM z A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Vehicle speed is 9 km/h (6 mph) or more for at least 4 sec. z Automatic transmission assembly (clutch, brake or gear, etc.) (c) Park/neutral position switch is OFF. Reference (Using an oscilloscope): Check the waveform between terminals SP2+ and SP2- of the ECM connector. Standard: Refer to the illustration. Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV Vehicle condition Vehicle speed 20 km/h (12 mph) MONITOR DESCRIPTION The output speed sensor SP2 monitors the output shaft speed. The ECM controls the gearshift point and the lock up timing based on the signals from the output speed sensor SP2 and throttle position sensor. If the ECM detects no signal from the output shaft speed sensor SP2 even while the vehicle is moving, it will conclude that is a malfunction of the output speed sensor SP2. The ECM will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0722 : Speed sensor SP2/Verify pulse input Required Sensors/Components Speed sensor SP2 Frequency of operation Continuous Duration 500 output shaft revolution MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Vehicle speed sensor pulse input 4 Vehicle speed range (4 sec. or more) 9 km/h (5.59 mph) or more NSW switch OFF Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output speed sensor pulse input No input WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) - HINT: z SPD(SP2) is always 0 while driving: z Open or short in the sensor or circuit. SPD(SP2) value displayed on the tester is much lower than the actual vehicle speed: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (SP2) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG OK 2. INSPECT SPEED SENSOR (SP2) SECURELY INSTALL SENSOR OR REPLACE SENSOR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Disconnect the speed sensor connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (SP2) OK 3. CHECK WIRE HARNESS AND CONNECTOR (SPEED SENSOR SP2 - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-34 (SP2+) - E5-26 (SP2-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-34 (SP2+) - Body ground 10 kΩ or higher E5-26 (SP2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W88030X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0724: Brake Switch "B" Circuit High (2007 4Runner) DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC NO. DTC DETECTION CONDITION The stop light switch remains ON even when the vehicle is driven in a P0724 STOP (less than 3 km/h (2 mph)) and GO (30 km/h (19 mph) or more) fashion 5 times. (2-trip detection logic). TROUBLE AREA z z z Short in stop light switch signal circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) five times for two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The stop light switch remains on during GO and STOP 5 times. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... GO and STOP is defined as follows; The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.63 mph (30 km/h) or more) Once STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Once Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM . INSPECTION PROCEDURE PROCEDURE 1. READ VALUE OF DATA LIST (STP SIGNAL) HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn on the tester. (e) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read the "DATA LIST". Standard: TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... STOP LIGHT SW Brake pedal is Stop light switch status/ ON or OFF Depressed: ON Released: OFF z z NOTICE: In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty or not. OK CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) NG 2. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Switch pin free 1-2 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher Switch pin free 3-4 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Install the stop light switch assembly. (b) Disconnect the ECM connector. (c) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage: CONDITION TESTER CONNECTION SPECIFIED CONDITION Brake pedal is depressed E8-15 (STP) - Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002SNB001X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0746: Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) DTC P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0746 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z z P0771 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z Shift solenoid valve SL1 remains closed Shift solenoid valve SR remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SR remains open or closed Shift solenoid valve SL1 remains closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates a stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SR and SL1. The ECM commands gear shifts by turning the shift solenoid valves ON/OFF. When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... MONITOR STRATEGY P0746: Shift solenoid valve SL1/OFF malfunction Related DTCs P0771: Shift solenoid valve SR/ON malfunction P0771: Shift solenoid valve SR/OFF malfunction Required sensors/Components (Main) Shift solenoid valve SL1 Shift solenoid valve SR Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous P0746 and P0771 OFF malfunction (A) and (B): 0.4 sec. Duration P0746 and P0771 OFF malfunction (C): Immediate P0771 ON malfunction: 0.15 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting P0746 and P0771: OFF malfunction (A) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear 5th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) P0746 and P0771: OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more P0746 and P0771: OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th P0771: ON malfunction Current ECM selected gear 2nd Last ECM selected gear 1st Throttle valve opening angle (During transition from 1st to 2nd gear) 6.0% or more at 3,000 rpm (Vary with turbine speed) TYPICAL MALFUNCTION THRESHOLDS [P0746 and P0771: OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Not change as follow Turbine speed/Output speed 0.93 to 1.07 ↓ 0.65 to 0.79 OFF malfunction (C) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Output record from ECM for 4th → 5th upshifting Recorded [P0771: ON malfunction] 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON ON malfunction Turbine speed - Output speed x 1st gear ratio (NT - NO x 1st gear ratio) 150 rpm or more INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" z button: Shift up Press "←" button: Shift down Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SR and SL1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746 AND P0771) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0746 and P0771 are output Only P0771 is output A P0746, P0771 and other DTCs are output B z z HINT: If any other codes besides P0746 and P0771 are output, perform troubleshooting for those DTCs first. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* [Vehicle Condition] HINT: Operate the shift solenoid SLT and raise line pressure z z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that Result: LINE PRESSURE VALUE DTC OUTPUT IN PREVIOUS CHECK PROCEED TO Changed P0746 and P0771 A Changed P0771 B Not changed - C B INSPECT SHIFT SOLENOID VALVE SR C REPLACE SHIFT SOLENOID VALVE SLT A 3. INSPECT SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 4. INSPECT SHIFT SOLENOID VALVE SR REPLACE SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SR OK 5. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8F02MX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0748: Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shifting between 4th and 5th gear. P0748 (1-trip detection logic) z z z Output signal duty equals to 100%. (NOTE: SL1 output signal duty is less than 100% under normal condition.) z Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL1 circuit. The ECM commands gearshift by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting between 4th and 5th gears, if the ECM detects an open or short in the shift solenoid valve SL1 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0748: Shift solenoid valve SL1/Range check Required sensors/Components Shift solenoid valve SL1 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Battery voltage 10 V or more CPU commanded duty Less than 75% Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The shift solenoid valve SL1 is turned on/off normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL1) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 12 (SL1+) - 4 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 12 (SL1+) - Body ground 10 kΩ or higher 4 (SL1-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-19 (SL1+) - E5-18 (SL1-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-19 (SL1+) - Body ground 10 kΩ or higher E5-18 (SL1-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8J025X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0751: Shift Solenoid "A" Performance (Shift Solenoid Valve S1) (2007 4Runner) DTC P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0751 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S1 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S1. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0751: Related DTCs Shift solenoid valve S1/OFF malfunction Shift solenoid valve S1/ON malfunction Required sensors/Components (Main) Shift solenoid valve S1 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A) and (C): 0.4 sec. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OFF malfunction (B): Immediate Duration ON malfunction (A), (B) and (C): 0.4 sec. ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting OFF malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 8% or more 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) Current ECM selected gear 5th A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (C) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Either of the following conditions is met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (C) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (D) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (E) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, read the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z z This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 is turned on/off normally when the shift lever is in the D position: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0751) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0751" is output A "P0751" and other DTCs B HINT: If any other codes besides "P0751" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z z HINT: Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W80025X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0756: Shift Solenoid "B" Performance (Shift Solenoid Valve S2) (2007 4Runner) DTC P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0756 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S2 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0756: Related DTCs Shift solenoid valve S2/OFF malfunction Shift solenoid valve S2/ON malfunction Required sensors/Components (Main) Shift solenoid valve S2 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A), (B) and (C): 0.4 sec. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OFF malfunction (D): Immediate Duration ON malfunction (A) and (B): 0.4 sec. ON malfunction (C): 3 sec. ON malfunction (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting OFF malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B), (C) and (D) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (B) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (C) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (D) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Both of the following conditions are met: ON malfunction (A) or (B), and ON malfunction (C) or (D) ON malfunction (A) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (D) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0756) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0756 is output A P0756 and other DTCs B HINT: If any other codes besides P0756 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S2 (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE S2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C5V00IX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0776: Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0776 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SL2 remains open Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" of the shift solenoid valve SL2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/ON malfunction Required sensors/Components (Main) Shift solenoid valve SL2 Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous ON malfunction (A), (B) and (C): 0.4 sec. Duration ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 4th A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [ON malfunction] Both of the following conditions are met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed/Output speed 0.93 to 1.07 ON malfunction (D) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (E) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position. z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0776" is output A "P0776" and other DTCs B HINT: If any other codes besides "P0776" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z z HINT: Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8G02LX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0778: Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. P0778 . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL2 circuit while driving and shifting gears. (1-trip detection logic) z Output signal duty equals to 100%. (NOTE: SL2 output signal duty is less than 100% under normal condition.) z z z Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL2 circuit. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting gears, if the ECM detects an open or short in the shift solenoid valve SL2 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0778: Shift solenoid valve SL2/Range check Required sensors/Components Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TYPICAL ENABLING CONDITIONS P0115 - P0118 (ECT sensor) P0125 (Insufficient ETC for Closed Loop) The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) CPU commanded duty Less than 75% Battery voltage 10 V or more Ignition Switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL2) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 11 (SL2+) - 3 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 11 (SL2+) - Body ground 10 kΩ or higher 3 (SL2-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID SL2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-17 (SL2+) - E5-16 (SL2-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-17 (SL2+) - Body ground 10 kΩ or higher E5-16 (SL2-) - Body ground ↑ 3. INSPECT SHIFT SOLENOID SL2 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID SL2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000XP101WX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0781: 1-2 Shift (1-2 Shift Valve) (2007 4Runner) DTC P0781 1-2 Shift (1-2 Shift Valve) DESCRIPTION The 1-2 shift valve performs shifting to 1st gear and other gears. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0781 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SLT remains open or closed Valve body is blocked up or stuck (1-2 shift valve) Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates that the 1-2 shift valve in the valve body is locked in the direction the spring compresses. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF" and switching oil pressure to the valves in the valve body. The ECM calculates the "actual" transmission gear by comparing the signals from the input speed sensor A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (NT) and the output speed sensor (SP2). The ECM can detect many mechanical problems in the shift solenoids, valve body, and the transmission clutches, brakes, and gears. If the ECM detects that the actual gear position and the commanded gear position are different, it will illuminate the MIL and store the DTC . MONITOR STRATEGY Related DTCs P0781: Valve body/Rationality check Required sensors/Components (Main) Valve body Required sensors/Components (Related) Automatic transmission assembly, Speed sensor (NT), Speed sensor (NO), Vehicle speed sensor, Throttle position sensor Frequency of operation Continuous Condition (A) and (B): 0.4 sec. Duration Condition (C): 3 sec. Condition (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Condition (A) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) Condition (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) Condition (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) Condition (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: Condition (A), and Condition (B), (C) or (D) Condition (A) Turbine speed/Output speed 3.30 to 7.50 Condition (B) Turbine speed/Output speed 1.28 to 1.53 Condition (C) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) Condition (D) 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0781) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0781 is output A P0781 and other DTCs B HINT: If any other codes besides P0781 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. OK: Gear position changes in accordance with the tester command. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 4. CLEAR THE DTC AND RUNNING TEST (a) Clear the DTC, and check for the DTC again after conducting the " MONITOR DRIVE PATTERN FOR ECT TEST" . OK: No DTC code NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK END A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W83030X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0894: Transmission Component Slipping (2007 4Runner) DTC P0894 Transmission Component Slipping DTC P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *: The duty ratio is the ratio of the current ON time (A) to the total of the current ON and OFF time (A + B). Duty Ratio (%) = A / (A + B) x 100 DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0894 ECM detects a malfunction on SLT, S1, S2, SR, SL1, SL2 or 1-2 shift solenoid valve according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z z z z P2714 ECM detects a malfunction on SLT (ON side) according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION The ECM calculates the amount of heat absorbed by the friction material based on the difference in revolution (clutch slippage) between the turbine and output shaft. The ECM turns on the MIL and outputs this DTC when the amount of heat absorption exceeds the specified value. When the shift solenoid valve SLT, SL2, S1 or S2 remains on, or the shift solenoid valve SL1 or SR remains off, oil pressure goes down and clutch engagement force decreases. NOTICE: If you continue driving under these conditions, the clutch will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P0894: Automatic transmission slip malfunction P2714: Shift solenoid valve SLT/ON malfunction A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve SLT, Valve body, ATF temperature sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous P0894 ON malfunction (A): Immediate Duration P0894 ON malfunction (B): 0.4 sec. P2714: Immediate MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All The monitor will run whenever this DTC is not present. None Turbine speed sensor (NT) circuit Not circuit malfunction Output speed sensor (NO) circuit Not circuit malfunction TFT temperature sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT (Engine Coolant Temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric Throttle Control System) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° crankshaft angle or more Engine Starting Transfer range "High" *1 TFT temperature 10°C (50°F) or more Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 TYPICAL MALFUNCTION THRESHOLDS [P0894: ON malfunction] When either condition below is met: OFF malfunction (A) or (B) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Summation of C2 clutch heat generations Specified value Actual gear for SLT fail judgment Not determined [P2714: ON malfunction] One of the following conditions is met: ON malfunction (A), (B), (C), (D), (E), (F) or (G) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Shift solenoid valve S1 ON malfunction Detected ON malfunction (C) Shift solenoid valve S2 ON malfunction Detected ON malfunction (D) Shift solenoid valve SR OFF malfunction Detected ON malfunction (E) 1-2 shift valve malfunction Detected ON malfunction (F) Shift solenoid valve SL1 OFF malfunction Detected A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ON malfunction (G) Shift solenoid valve SL2 ON malfunction Detected INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTCS P0894 AND P2714) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0894 is output Only P0894 and P2714 are output A P0894, P2714 and other DTCs are output B z z HINT: If any other codes besides P0894 and P2714 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and HINT: z DIAGNOSTIC NOTE [Vehicle Condition] z OFF: Line pressure up (when Active Test Vehicle stopped A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... raise line pressure z "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG INSPECT SHIFT SOLENOID VALVE SLT OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Clear the DTC . (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (d) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. z z z z z (e) Compare the ECM gear shift command and the actual gear position. ECM GEAR SHIFT COMMAND 1ST 2ND 3RD 4TH 5TH Shift solenoid S1 Shift solenoid S2 Actual gear position under malfunction Shift solenoid SL2 Shift solenoid SR Stuck ON 1st 2nd 2nd 1st N*1 Stuck OFF 4th 3rd 3rd 4th 5th Stuck ON*2 2nd 2nd 3rd 3rd N*1 Stuck OFF*3 1st 1st 4th 4th 5th Stuck ON 1st 2nd 3rd 4th N*1 Stuck OFF 1st 2nd 3rd 4th 5th Stuck ON*4 1st 2nd 3rd 4th 5th Stuck OFF*5 1st PROCEED TO A B C D 2nd 3rd 4th 4th HINT: z z z z z z *1: Neutral *2: When shift solenoid S2 is stuck ON, the vehicle cannot drive in reverse. *3: When shift solenoid S2 is stuck OFF, the 4th to 5th upshift will have a large shift shock. Also, the 5th to 4th down-shift will have time lag. *4: Stuck ON condition can be determined by checking if shift shock has increased excessively. *5: When shift solenoid SR is stuck OFF, moving the shift lever from N to D will cause a large shift shock. Gear shift can be determined by paying attention to changes in rpm. OK: Gear position changes in accordance with the tester command. OK INSPECT SHIFT SOLENOID VALVE SLT B INSPECT SHIFT SOLENOID VALVE S2 C INSPECT SHIFT SOLENOID VALVE SL2 D INSPECT SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A 4. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S1 connector - Shift solenoid S1 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 6. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S1 INSPECT SHIFT SOLENOID VALVE S2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 8. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S2 INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL2 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 10. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL2 INSPECT SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 11. INSPECT SHIFT SOLENOID VALVE SL1 REPLACE SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 13. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL1 INSPECT SHIFT SOLENOID VALVE SLT A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SLT. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SLT - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SLT OK 14. INSPECT TRANSMISSION VALVE BODY ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 15. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W86029X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0973: Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) (2007 4Runner) DTC P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) DTC P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0973 . DTC DETECTION CONDITION ECM detects short in solenoid valve S1 circuit 2 times when solenoid valve S1 is operated (1-trip detection logic) TROUBLE AREA z z z P0974 ECM detects open in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S1 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S1 circuit. When the shift solenoid valve S1 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S1 circuit . MONITOR STRATEGY Related DTCs P0973: Shift solenoid valve S1/Range check (Low resistance) P0974: Shift solenoid valve S1/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve S1 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0973: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 ON P0974: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS P0973: Range check (Low resistance) Shift solenoid valve S1 resistance. 8 Ω or less P0974: Range check (High resistance) Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S1 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S1) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 8 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S1 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-11 (S1) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W87028X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0976: Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) (2007 4Runner) DTC P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) DTC P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0976 . DTC DETECTION CONDITION ECM detects short in solenoid valve S2 circuit 2 times when solenoid valve S2 is operated (1-trip detection logic) TROUBLE AREA z z z P0977 ECM detects open in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S2 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S2 circuit. When the shift solenoid valve S2 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S2 circuit . MONITOR STRATEGY Related DTCs P0976: Shift solenoid valve S2/Range check (Low resistance) P0977: Shift solenoid valve S2/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve S2 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0976: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 ON P0977: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS P0976: Range check (Low resistance) Shift solenoid valve S2 resistance 8 Ω or less P0977: Range check (High resistance) Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S2 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S2) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 15 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S2 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-10 (S2) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S2) - Solenoid Body (S2) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8H020X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0985: Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) (2007 4Runner) DTC P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) DTC P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0985 . DTC DETECTION CONDITION ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic) TROUBLE AREA z z z P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic) z z z Short in shift solenoid valve SR circuit Shift solenoid valve SR ECM Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve SR is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve SR circuit. When the shift solenoid valve SR is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve SR circuit . MONITOR STRATEGY Related DTCs P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve SR Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR ON Battery voltage 8 V or more Engine switch ON Starter OFF P0986: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR OFF Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance) Shift solenoid valve SR resistance 8 Ω or less P0986: Range check (High resistance) Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve SR Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... WIRING DIAGRAM INSPECTION PROCEDURE HINT: The shift solenoid valve SR turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SR) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 7 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE SR OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-9 (SR) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SR OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8A02NX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2716: Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) (2007 4Runner) DTC P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. *: Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100 (%) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... DTC NO. P2716 DTC DETECTION CONDITION Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detection logic). TROUBLE AREA z z z Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716: Shift solenoid valve SLT/Range check Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLT) from IC Fail (Open or short) Case 2: Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty. WIRING DIAGRAM Less than 100% A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLT) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 14 (SLT+) - 6 (SLT-) 5.0 to 5.6 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 14 (SLT+) - Body ground 10 kΩ or higher 6 (SLT-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLT OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-13 (SLT+) - E5-12 (SLT-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-13 (SLT+) - Body ground 10 kΩ or higher E5-12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OK 3. REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLT OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012XR00WX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2740: Transmission Fluid Temperature Sensor "B" Circuit (2007 4Runner) DTC P2740 Transmission Fluid Temperature Sensor "B" Circuit DTC P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input DTC P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input DESCRIPTION The No. 2 ATF temperature sensor is on the transmission, just in front of the oil cooler inlet pipeline. If the ECM detects an abnormally high ATF temperature near this sensor, it illuminates the warning light. HINT: z z The temperature of ATF easily rises when towing, climbing hills and in traffic, etc. If the No. 2 ATF temperature sensor becomes short-circuited, the signal that indicates the ATF temperature is 150°C (302°F) or higher is input in ECM. Vehicle conditions when the sensor is normal and when the sensor is short-circuited are indicated in the table below. NO. 2 ATF TEMPERATURE SENSOR STATE Sensor is normal DETECTION CONDITION SYMPTOM RECOVERY CONDITION ATF temperature more than 150°C (275°F) A/T OIL TEMP warning light remains ON ATF temperature less than 135°C (275°F)*2 ATF temperature more than 130°C (266°F) Shift point too high ATF temperature less than 110°C (230°F) Lock-up at 3rd gear*1 ATF temperature less than 110°C (230°F)*2 and engine coolant temperature more than 95°C (203°F) When the conditions (a) and (b) are satisfied. (a) ATF temperature more than 130°C (266°F) (b) Engine coolant temperature more than 95°C (203°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z Any conditions Sensor is shortcircuited z A/T OIL TEMP warning light remains ON Shift point too high Engine coolant Lock-up at 3rd temperature more than gear*1 95°C (203°F) Symptoms still occur Symptoms still occur HINT: *1: When ATF temperature is normal, transmission lock-up occurs in 5th gear with the shift lever in the D position, and 4th gear with the shift lever in the 4 position. *2: When ATF temperature is in the normal range, it decreases to less than 135°C (275°F) within 5 minutes with the shift lever in the P or N position in an idling state. DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 seconds when neither P2742 or P2743 are detected. (1-trip detection logic) (a) No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V). P2740 (b) No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V). HINT: z z z Open or short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Within 0.5 seconds, the malfunction switches from (a) to (b) or from (b) to (a). z P2742 No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V) for 0.5 seconds or more. (1-trip detection logic) z z No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V) when 15 minutes or more have passed after P2743 the engine start. DTC is detected for 0.5 seconds or more. (1-trip detection logic) MONITOR DESCRIPTION z z z Short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Open in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ATF temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 25 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will illuminate the MIL and store the DTC. HINT: z z z *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P2740: ATF temperature sensor/Range check (Fluttering) Related DTCs P2742: ATF temperature sensor/Range check (Low resistance) P2743: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None P2740, P2742: Range check (Fluttering, Low voltage) The typical enabling condition is not available. - P2743: Range check (High voltage) Time after engine start 15 minutes or more TYPICAL MALFUNCTION THRESHOLDS P2740: Range check (Fluttering) Less than 0.046 V TFT (Transmission fluid temperature) sensor voltage or More than 4.915 V P2742: Range check (Low voltage) TFT (Transmission fluid temperature) sensor voltage Less than 0.046 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... P2743: Range check (High voltage) TFT (Transmission fluid temperature) sensor voltage More than 4.915 V COMPONENT OPERATING RANGE TFT (Transmission fluid temperature) sensor Atmospheric temperature up to approximately 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4. 5. 6. 7. module) to the DLC3. Turn the ignition switch to the ON position. Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". According to the display on tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP2 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 2 value/ NORMAL CONDITION z Min.: -40°C (-40°F) Max.: 215°C (419° F) z After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold DIAGNOSTIC NOTE If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited HINT: { { When DTC P2742 is output and the intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P2743 is output and the intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO2 (OT2) and the body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit PROCEDURE 1. INSPECT TRANSMISSION WIRE (NO. 2 ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 1 (OT2-) - 9 (OT2+) 25 Ω to 156 kΩ 1 (OT2-) - Body ground 10 kΩ or higher 9 (OT2+) - Body ground 10 kΩ or higher HINT: If the resistance is outside the specified range of either ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20°C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... E5-32 (THO2) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-32 (THO2) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8D02EX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2757: Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, output speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU, valve body and torque converter clutch. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock-up remains ON z Shift solenoid valve SLU remains open or closed Valve body is blocked A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... in the lock-up OFF range. z (2-trip detection logic) z P2757 z Torque converter clutch Automatic transmission (clutch, brake or gear, etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on the turbine (input) speed sensor NT, output speed sensor SP2, engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to output shaft rpm (SP2). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid SLU. When the SLU is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve SLU or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. z z There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 70 rpm greater than input turbine speed.) There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) MONITOR STRATEGY P2757: Related DTCs Shift solenoid valve SLU/OFF malfunction Shift solenoid valve SLU/ON malfunction Required sensors/Components Shift solenoid valve SLU, Valve body, Vehicle speed sensor, Speed sensor (NT), Speed sensor (NO), Throttle position sensor Frequency of operation Continuous Duration OFF malfunction (A) 2 sec. OFF malfunction (B) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 0.4 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Torque converter clutch pressure control solenoid circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ECM selected gear 2nd or 3rd or 4th or 5th Vehicle speed 25 km/h (15.5 mph) or more Shift solenoid valve S1 circuit Not on malfunction Shift solenoid valve S2 circuit Not on malfunction Shift solenoid valve SL2 circuit Not on malfunction 1-2 shift valve circuit Not on malfunction Transfer neutral position switch OFF OFF malfunction (A) ECM lock-up command ON (SLU pressure: 513 kPa or more) Vehicle speed Less than 100 km/h (62.2 mph) OFF malfunction (B) ECM selected gear 2nd A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Varies with engine speed) ON malfunction ECM lock-up command OFF (SLU pressure: less than 4 kPa) Throttle valve opening angle 7% or more Vehicle speed Less than 29 km/h (18 mph) at 2nd gear (Varies with ECM selected gear) TYPICAL MALFUNCTION THRESHOLDS Both of the following condition are met: OFF malfunction (A) and (B) OFF malfunction (A) Engine speed - Turbine speed (NE - NT) 70 rpm or more OFF malfunction (B) Turbine speed/Output speed (NT/NO) Less than 3.30, or more than 7.50 ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2md detection; pending fault code ON Vehicle speed must be under 6.2mph (10 km/h) once before 2nd detection. Engine speed - Turbine speed (NE - NT) Less than 35 rpm INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on the tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic ON or OFF transmission to lock-up condition [Vehicle Condition] z z Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more HINT: z z This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. This test can be conducted with the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: z z When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off automatically.) PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2757) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P2757" is output A "P2757" and other DTCs B HINT: If any other codes besides "P2757" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK 3. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8902DX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2759: Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) DESCRIPTION The amount of current flow to the solenoid is controlled by the (*) duty ratio of the ECM output signal. The higher the duty ratio becomes, the higher the lock-up hydraulic pressure becomes during the lock-up operation. (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100(%). DTC NO. DTC DETECTION CONDITION P2759 TROUBLE AREA z Open or short is detected in shift solenoid valve SLU circuit for Open or short in shift solenoid valve SLU circuit A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1 second or more while driving (1-trip detection logic). z z Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or short in a shift solenoid valve (SLU) circuit is detected, the ECM determines there is a malfunction. The ECM will turn on the MIL and store this DTC. MONITOR STRATEGY Related DTCs P2759: Shift solenoid valve SLU/Range check Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLU) from IC Case 2: Fail (open or short) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLU) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 13 (SLU+) - 5 (SLU-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 13 (SLU+) - Body ground 10 kΩ or higher 5 (SLU-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLU OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-15 (SLU+) - E5-14 (SLU-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-15 (SLU+) - Body ground 10 kΩ or higher E5-14 (SLU-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 R Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W72042X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 L Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O7H01OX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PRECAUTION (2007 4Runner) PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY can not be completed by only disconnecting the battery cable. 1. The automatic transmission is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete the inspection, repair and reassembly before proceeding to the next component group as much as possible. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS 2. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. 3. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. 4. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. 5. Only recommended automatic transmission fluid or kerosene should be used for cleaning. 6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. 7. When disassembling a valve body, be sure to match each valve together with the corresponding spring. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 8. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. 9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. 10. All gaskets and rubber O-rings should be replaced with new ones. 11. Do not apply adhesive cements to gaskets and similar parts. 12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 13. When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. 14. Check thrust bearings and races for wear or damage. Replace them as necessary. 15. When working with FIPG material, you must observe the following: z z z z Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove any loose material. Clean both sealing surfaces with a non-residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 T Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7304AX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PROBLEM SYMPTOMS TABLE (2007 4Runner) PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical. If the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart SYMPTOM SUSPECTED AREA 1. Shift solenoid valve (S1) circuit *1 No up-shift (A particular gear, from 1st to 4th gear, is not 2. Shift solenoid valve (S2) circuit up-shifted) *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Engine coolant temp. sensor circuit *1 No up-shift (4th -> 5th) 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SL1) circuit *1 5. Shift solenoid valve (SL2) SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... circuit *1 6. Shift solenoid valve (SR) circuit *1 7. ECM 1. Engine coolant temp. sensor circuit *1 No up-shift (3rd -> 4th) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (2 - L) *1 No up-shift (1st -> 2nd) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Shift solenoid valve (SL1) circuit *1 No down-shift (5th -> 4th) 3. Shift solenoid valve (SL2) circuit *1 4. Shift solenoid valve (SR) circuit *1 5. ECM 1. Transmission control switch circuit (2 - L) *1 No down-shift (2nd -> 1st) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Shift solenoid valve (S1) circuit *1 No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. ATF temperature sensor circuit *1 No lock-up 2. Stop light switch circuit *1 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SLU) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... circuit *1 5. Engine coolant temp. sensor circuit *1 6. ECM No lock-up off 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. Shift solenoid valve (SLT) circuit *1 2. Speed sensor NT circuit *1 3. Speed sensor SP2 circuit *1 Shift point too high or too low 4. Throttle position sensor circuit *1 5. ATF temperature sensor circuit *1 6. ECM Up-shift to 5th from 4th while shift lever is in 4 position 1. Transmission control switch circuit (D - 4) *1 2. ECM Up-shift to 5th from 4th while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM Up-shift to 4th from 3rd while shift lever is in 3 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 3rd from 2nd while shift lever is in 2 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 2nd from 1st while shift lever is in L position 1. Transmission control switch circuit (2 - L) *1 2. ECM 1. Speed sensor NT circuit *1 Harsh engagement (N -> D) 2. Shift solenoid valve (SL1) circuit *1 3. Shift solenoid valve (SLT) circuit *1 4. ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. Speed sensor NT circuit *1 2. Speed sensor SP2 circuit *1 Harsh engagement (Lock-up) 3. Shift solenoid valve (SLU) circuit *1 4. ECM Harsh engagement (Any driving position) ECM 1. ATF temperature sensor No. 2 circuit 2. Engine coolant temp. sensor circuit *1 Poor acceleration 3. Shift solenoid valve (SLT) circuit *1 4. ECM No engine braking ECM No kick-down ECM Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. ATF temperature sensor No. 2 circuit AT Oil Temp. warning light remains on, Lock-up at 3rd gear and/or shift point too high 2. Engine coolant temp. sensor circuit 3. ECM 1. Park/neutral position switch circuit *1 Malfunction in shifting 2. ECM 2. Chapter 2: On-vehicle Repair SYMPTOM SUSPECTED AREA SEE PAGE 1. Transmission control cable Vehicle does not move with shift lever in any forward position and reverse position 2. Manual valve 3. Parking lock pawl 4. Off-vehicle repair matrix chart - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. Valve body assembly Vehicle does not move with shift lever in R position 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (1st -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (2nd -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (3rd -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (4th -> 5th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (5th -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (4th -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (3rd -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (2nd -> 1st) 2. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) No lock-up or No lock-up off 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (N -> D) 2. Valve body assembly 3. C1 accumulator 4. Off-vehicle repair matrix - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... chart 1. Shift solenoid valve (SLU) Harsh engagement (Lock-up) 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) 2. Shift solenoid valve (SLU) Harsh engagement (N -> R) 3. Valve body assembly 4. C3 accumulator 5. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) Harsh engagement (1st -> 2nd -> 3rd -> 4th -> 5th) 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Valve body assembly Harsh engagement (1st -> 2nd) 2. B3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (2nd -> 3rd) 2. C3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (3rd -> 4th) 2. C2 accumulator 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (4th -> 5th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... chart 1. Shift solenoid valve (SL1) Harsh engagement (5th -> 4th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Transmission control cable 2. Valve body assembly Slip or shudder (Forward and reverse) 3. Oil strainer 4. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (1st: L position) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (2nd: 2 position) 2. Off-vehicle repair matrix chart No kick-down Valve body assembly - 1. Shift solenoid valve (SLT) Shift point too high or too low 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Shift solenoid valve (SLT) Poor acceleration 2. Valve body assembly Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) 2. Valve body assembly 3. Chapter 3: Off-Vehicle Repair SYMPTOM SUSPECTED AREA 1. Rear planetary gear SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Vehicle does not move with shift lever in any forward position and reverse position unit 2. Torque converter clutch 1. Brake No. 4 (B4) Vehicle does not move with shift lever in R position 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) No up-shift (1st -> 2nd) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) No up-shift (2nd -> 3rd) Clutch No. 3 (C3) No up-shift (3rd -> 4th) Clutch No. 2 (C2) 1. Brake No. 1 (B1) No up-shift (4th -> 5th) No lock-up or No lock-up off 2. Clutch No. 1 (C1) Torque converter clutch 1. Clutch No. 1 (C1) Harsh engagement (N -> D) 2. One-way clutch No. 3 (F3) 1. Clutch No. 3 (C3) Harsh engagement (N -> R) 2. Brake No. 4 (B4) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) Harsh engagement (1 -> 2) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) Harsh engagement (2 -> 3) Clutch No. 3 (C3) Harsh engagement (3 -> 4) Clutch No. 2 (C2) 1. Brake No. 1 (B1) Harsh engagement (4 -> 5th) Harsh engagement (Lock-up) 2. Clutch No. 1 (C1) Torque converter clutch 1. One-way clutch No. 1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (F1) Slip or shudder (Forward and reverse: After warm-up) 2. Clutch No. 3 (C3) 3. Torque converter clutch Slip or shudder (Particular position: Just after engine starts) Torque converter clutch 1. Brake No. 4 (B4) Slip or shudder (R position) 2. One-way clutch No. 1 (F1) 3. Clutch No. 3 (C3) 1. Clutch No. 1 (C1) Slip or shudder (1st) 2. One-way clutch No. 3 (F3) 1. Clutch No.1 (C1) 2. Brake No. 3 (B3) Slip or shudder (2nd) 3. One-way clutch No. 1 (F1) 4. One-way clutch No. 2 (F2) 1. Clutch No. 1 (C1) Slip or shudder (3rd) 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Clutch No. 1 (C1) Slip or shudder (4th) 2. Clutch No. 2 (C2) 1. Clutch No. 2 (C2) Slip or shudder (5th) 2. Clutch No. 3 (C3) 3. Brake No. 1 (B1) No engine braking (1st - 4th: D position) Clutch No. 1 (C1) No engine braking (1st: L position) Brake No. 4 (B4) No engine braking (2nd: 2 position) Brake No. 2 (B2) No engine braking (3rd: 3 position) Brake No. 1 (B1) Poor acceleration (All positions) Torque converter clutch 1. Clutch No. 1 (C1) 2. Clutch No. 3 (C3) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. Brake No. 1 (B1) Poor acceleration (5th) 4. Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903VX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 47°C (117°F) or less and vehicle speed is at 30 mph (49 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W75042X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): SYSTEM DESCRIPTION (2007 4Runner) SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transmission) is an automatic transmission that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: z z Diagnostic function. Fail-safe function when a malfunction occurs. 2. OPERATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7D03MX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): SYSTEM DIAGRAM (2007 4Runner) SYSTEM DIAGRAM The configuration of the electronic control system in the A750E automatic transmission is as shown in the following chart. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7403OX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): TERMINALS OF ECM (2007 4Runner) TERMINALS OF ECM 1. ECM HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to inspected. The standard voltage between the terminals is shown under "Specific Condition". Use the illustration above as a reference for the ECM terminals. SYMBOLS (TERMINALS NO.) WIRING COLOR L (E7-9) - E1 (E61) B-L - BR ↑ ↑ 2 (E7-10) - E1 (E6-1) TERMINAL DESCRIPTION L shift position switch signal CONDITION SPECIFIED CONDITION IG switch ON and shift lever L position 10 to 14 V ↑ IG switch ON and shift lever except L position Below 1 V G-R - BR 2 shift position switch signal IG switch ON and shift lever 2 and L position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 2 and L position Below 1 V R (E7-11) - E1 (E6-1) R-Y - BR R shift position switch signal IG switch ON and shift lever R position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except R position Below 1 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... D (E7-21) - E1 (E6-1) V - BR D shift position switch signal IG switch ON and shift lever D and 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except D and 4 position Below 1 V 3 (E7-19) - E1 (E6-1) L - BR 3 shift position switch signal IG switch ON and shift lever 3 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 3 position Below 1 V 4 (E7-20) - E1 (E6-1) G - BR 4 shift position switch signal IG switch ON and shift lever 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 4 position Below 1 V STP (E8-15) - E1 (E6-1) G-Y - BR ↑ ↑ Stop light switch signal ↑ Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V Pulse generation SLU+ (E5-15) SLU- (E5-14) R-B - R-W SLU solenoid signal 5th (lock-up) gear S2 (E5-10) - E1 (E6-1) W-L - BR 2nd or 3rd gear 10 to 14 V ↑ ↑ 1st, 4th or 5th gear Below 1 V S1 (E5-11) - E1 (E6-1) GR - BR 1st or 2nd gear 10 to 14 V ↑ ↑ 3rd, 4th or 5th gear Below 1 V SLT+ (E5-13) SLT- (E5-12) P-L - BR ↑ ↑ SL1+ (E5-19) SL1- (E5-18) THO1 (E5-24) - E2 ↑ S1 solenoid signal ↑ LG-B - L-R SLT solenoid signal SR (E5-9) - E1 (E6-1) SL2+ (E5-17) SL2- (E5-16) S2 solenoid signal SR solenoid signal ↑ B-W - B-R SL2 solenoid signal G-B - B-Y Engine idle speed (See waveform 2) Pulse generation (See waveform 1) 5th gear 10 to 14 V 1st gear Below 1 V Engine idle speed SL1 solenoid signal Engine idle speed No. 1 ATF No. 1 ATF temperature: Pulse generation (See waveform 3) Pulse generation (See waveform 4) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (E4-28) THO2 (E5-32) - E2 (E4-28) SP2+ (E5-34) SP2- (E5-26) Y-G - BR temperature sensor signal L - BR No. 2 ATF temperature sensor signal R-L - L-Y Speed sensor (SP2) signal 115°C (239°F) or more No. 2 ATF temperature: 115°C (239°F) or more Vehicle speed 20 km/h (12 mph) Below 1.5 V Below 1.5 V Pulse generation (See waveform 6) Pulse generation NT+ (E5-35) - NT(E5-27) W-R - Y-R Speed sensor (NT) signal Engine idle speed STAR/NSW (E5-8) - E1 (E6-1) P - BR Park neutral switch signal IG switch ON and shift lever P and N position Below 2 V ↑ ↑ IG switch ON and shift lever except P and N position 10 to 14 V ↑ (a) Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (b) Waveform 2 Reference: Terminal SLU+ - SLU- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition 5th (lock-up) (c) Waveform 3 Reference: Terminal SL2+ - SL2- (See waveform 5) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (d) Waveform 4 Reference: Terminal SL1+ - SL1- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (e) Waveform 5 Reference: Terminal NT+ - NT- Tool setting 1 V/DIV., 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) (f) Waveform 6 Reference: Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV. Vehicle condition Vehicle speed 20 km/h (12 mph) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W78041X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): CHECK MODE PROCEDURE (2007 4Runner) CHECK MODE PROCEDURE 1. DESCRIPTION (a) Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 2. CHECK MODE PROCEDURE (a) Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF (b) Turn the engine switch off. (c) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (f) Change the ECM to check mode. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if:1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the engine switch is turned from on (IG) to on (ACC) or off. NOTICE: Before check mode, make notes of the DTCs and freeze frame data. (g) Start the engine. The MIL should turn off after the engine starts. (h) Perform "MONITOR DRIVE PATTERN" for the ECT test . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (Or, simulate the conditions of the malfunction described by the customer). (i) After simulating the malfunction conditions, use the intelligent tester diagnosis selector to check the DTC and freeze frame data. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7E046X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DATA LIST / ACTIVE TEST (2007 4Runner) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) NORMAL CONDITION Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) DIAGNOSTIC NOTE - Lock-up is Input shaft speed/ SPD(NT) z Min.: 0 rpm Max.: 12,750 rpm z ON (after warming up engine): Input turbine speed (NT) is equal to engine speed OFF (idling with shift lever on N): Input turbine speed Data is displayed in increments of 50 rpm A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (NT) is nearly equal to engine speed PNP SW [NSW] PNP switch status/ ON or OFF Shift lever is: z z On P and N: ON Not on P and N: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 Stop light switch STOP LIGHT status/ SW ON or OFF Brake pedal is z z Depressed: ON Released: OFF - Shift lever position is SHIFT ECM gear shift command/ z 1st, 2nd, 3rd, 4th or 5th z z z z REVERSE PNP switch status/ ON or OFF On D: 1st, 2nd, 3rd, 4th or 5th On 4: 1st, 2nd, 3rd or 4th On 3: 1st, 2nd or 3rd On 2: 1st or 2nd On L: 1st Shift lever is: z z On R: ON Not on R: OFF - When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 DRIVE PNP switch status/ ON or OFF Shift lever is: z z On D: ON Not on D: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... P0705 4TH/DRIVE PNP switch status/ ON or OFF Shift lever is: z z On 4: ON Not on 4: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 3RD PNP switch status/ ON or OFF Shift lever is: z z On 3: ON Not on 3: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 2ND PNP switch status/ ON or OFF Shift lever is: z z On 2: ON Not on 2: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 LOW PNP switch status/ ON or OFF Shift lever is: z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A/T OIL TEMP1 ATF temperature sensor No. 1 value/ Min.: -40°C (-40° F) z z Max.: 215°C (419° F) A/T OIL TEMP2 ATF temperature sensor No. 2 value/ Min.: -40°C (-40° F) LOCK UP ON or OFF z z SOLENOID (SLU) SOLENOID (SLT) Lock-up solenoid status/ ON or OFF Shift solenoid SLU status/ ON or OFF After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited Lock-up is z z LOCK UP SOL If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited cold Max.: 215°C (419° F) Lock up/ After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is Operating: ON Not operating: OFF - Lock-up solenoid is z z Operating: ON Not operating: OFF - Shift solenoid SLU is z z Shift solenoid SLT status/ z ON or OFF z Operating: ON Not operating: OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (e) Push the "ON" button of the intelligent tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE [Vehicle Condition] SOLENOID (SLU) Operate the shift solenoid SLU ON or OFF z z Engine stopped Shift lever P or N position ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure HINT: z z [Vehicle Condition] OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling [Vehicle Condition] SOLENOID (S1) Operate the shift solenoid S1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (S2) Operate the shift solenoid S2 ON or OFF z z Engine stopped Shift lever P or N position Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic transmission to lock-up condition [Vehicle Condition] ON or OFF z z SHIFT Operate shift solenoid valve and set each shift position by yourself z z Press "→" button: Shift up Press "←" button: Shift down Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less [Vehicle Condition] A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... SOLENOID (SR) Operate the shift solenoid SR ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL1) Operate the shift solenoid SL1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL2) Operate the shift solenoid SL2 ON or OFF z z Engine stopped Shift lever P or N position *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. as A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7I03ZX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DEFINITION OF TERMS (2007 4Runner) DEFINITION OF TERMS TERM DEFINITION Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Sequence of operation Required sensor/components Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. The sensors and components that are used by the ECM to detect malfunctions. The number of times that the ECM checks for malfunctions per driving cycle. "Once per driving cycle" means that the ECM detects malfunction only one Frequency of operation time during a single driving cycle. "Continuous" means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL illumination timing after a defect is detected. MIL operation "Immediately" means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. "2 driving cycle" means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W76046X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DIAGNOSIS SYSTEM (2007 4Runner) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (complying with SAE J1987). Various data output from the vehicle's ECM can then be read. (b) OBD II regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (1) The emission control system/components (2) The power train control components (which affect vehicle emissions) (3) The computer In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. (c) To check DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) of the vehicle. The intelligent tester displays DTCs, the freeze frame data and a variety of the engine data. The DTCs and freeze frame data can be erased with the intelligent tester . 2. NORMAL MODE AND CHECK MODE (a) The diagnosis system operates in "normal mode" during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available to technicians as an option. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunctions. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. 2 TRIP DETECTION LOGIC (a) When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate. 4. FREEZE FRAME DATA (a) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. (b) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 times before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. 5. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Terminal of DLC3 SYMBOLS (TERMINAL NO.) TERMINAL DESCRIPTION CONDITION SPECIFIED CONDITION SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) Body ground Chassis ground Always Below 1 Ω Always Below 1 Ω SG (5) - Body Signal ground ground BAT (16) Body ground Battery positive Always CANH (6) CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω HIGH-level Ignition 6 kΩ or CANH (6) Battery 9 to 14 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... positive CAN bus line switch OFF* higher CANH (6) CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. 6. CHECK BATTERY VOLTAGE Battery voltage: 11 to 14 V (a) If voltage is below 11 V, replace the battery before proceeding. 7. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch to the ON position. If the MIL does not illuminate, there is a problem in the MIL circuit . (b) When the engine is started, the MIL should turn off. 8. ALL READINESS (a) For this vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Enter the following menus: ENHANCED OBD II / MONITOR STATUS on the intelligent tester. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 S Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W71043X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DIAGNOSTIC TROUBLE CODE CHART (2007 4Runner) DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT: z z z *1: Comes on MIL (Malfunction Indicator Lamp) light up *2: "DTC stored" mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition. This DTC may be output when the clutch, brake and gear components etc. inside the automatic transmission are damaged. AUTOMATIC TRANSMISSION SYSTEM: DTC CODE P0705 DETECTION ITEM Transmission Range Sensor Circuit Malfunction (PRNDL Input) TROUBLE AREA MIL *1 1. Open or short in Comes park/neutral position switch on circuit MEMORY *2 DTC stored 2. Park/neutral position switch 3. ECM P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor No. 1 circuit Comes on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0711 Transmission Fluid Temperature Sensor "A" Performance Transmission wire (ATF temperature sensor No. 1) Comes on DTC stored P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor No. 1 circuit Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 1 circuit on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0717 Turbine Speed Sensor Circuit No Signal 1. Open or short in speed sensor (NT) circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Speed sensor (NT) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0722 Output Speed Sensor Circuit No Signal 1. Open or short in speed sensor (SP2) circuit 2. Speed sensor (SP2) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains closed 2. Shift solenoid valve SR remains open or closed 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. ECM P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) 1. Shift solenoid valve S1 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) 1. Shift solenoid valve S2 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) 1. Shift solenoid valve SR remains open or closed 2. Shift solenoid valve SL1 remains closed A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. ECM P0781 1-2 Shift (1-2 Shift Valve) 1. Valve body is blocked up or stuck (1-2 shift valve) 2. Automatic transmission (clutch, brake or gear, etc.) P0894 Transmission Component Slipping 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) 1. Short in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) 1. Open in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) 1. Short in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) 1. Open in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) 1. Short in shift solenoid valve SR circuit 2. Shift solenoid valve SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. ECM P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) 1. Open in shift solenoid valve SR circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 2 circuit on DTC stored 2. Shift solenoid valve SR 3. ECM P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. ECM P2740 Transmission Fluid Temperature Sensor "B" Circuit 1. Open or short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input 1. Short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) 1. Shift solenoid valve SLU remains open or closed Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transmission (clutch, brake or gear, etc.) 5. Line pressure is too low P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit 1. Open or short in shift solenoid valve SLU circuit A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Electrical (Shift Solenoid Valve SLU) 2. Shift solenoid valve SLU 3. ECM P2772 Transfer "L4" Switch Circuit 1. Short in transfer L4 position switch circuit 2. Four wheel drive control ECU 3. ECM Comes on DTC stored A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W77041X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): DTC CHECK / CLEAR (2007 4Runner) DTC CHECK / CLEAR 1. CHECK DTC (a) DTCs which are stored in the ECM can be displayed with the intelligent tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTC aren't stored if the ECM doesn't detect a malfunction during consecutive driving. However, the detected malfunction during once driving is stored as pending DTC. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch to the ON position. (3) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Confirm the DTCs and freeze frame data and then write them down. (5) Confirm the details of the DTCs . NOTICE: When simulating a symptom with the scan tool to check the DTCs, use normal mode. For codes on DIAGNOSTIC TROUBLE CODE CHART which are subject to "2-trip detection logic", perform the following actions. Turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM. 2. CLEAR DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... press YES. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O8L046X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): FAILSAFE CHART (2007 4Runner) FAIL-SAFE CHART 1. FAIL-SAFE CHART This function minimizes the loss of the ECT functions when a malfunction occurs in each sensor or solenoid. MALFUNCTION PART FUNCTION No. 1 ATF Temperature Sensor During a No. 1 ATF temperature sensor malfunction, up-shift to the 5th gear and flex lock-up clutch control are prohibited. Output Speed Sensor During an output speed sensor malfunction, shift control is effected through the (SP2) input speed sensor signal (NT). Shift Solenoid Valve S1, S2 and SR The current to the failed solenoid valve is cut off and control is effected by operating the other solenoid valves with normal operation. Shift control is effected depending on the failed solenoid as described in the table below. Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction, up-shift to the 5th gear is prohibited. Shift Solenoid Valve SLT During a solenoid valve SLT malfunction, the current to the solenoid valve is stopped. This stops line pressure optimal control, and shift shock increases. However, shifting is effected through normal clutch pressure control. Shift Solenoid Valve SLU During a solenoid valve SLU malfunction, the current to the solenoid valve is stopped. This stops lock-up control and flex lock-up control, and fuel economy decreases. Fail-safe function: If either of the shift solenoid valve circuits has an open or short failure, the ECM turns the other shift solenoid ON and OFF in order to shift into the gear positions shown in the table below. In case of a short circuit, the ECM stops sending current to the short circuit solenoid. Even if starting the engine again in the fail-safe mode, the gear position remains in the same position. HINT: z z z ↓: Condition in the electrical malfunction is shown above "↓". ↓: Condition in fail-safe mode is shown below "↓". E/B: Engine brake. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... POSITION R NORMAL S1 OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th 1st ON OFF OFF OFF ON ↓ OFF OFF 3rd D ↓ ON 2nd ON ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON OFF OFF 3rd ↓ OFF OFF 3rd E/B ↓ ON OFF ON 3rd 3 2 L 2nd ON D OFF OFF ON ↓ ON OFF ON OFF OFF ↓ OFF 3rd E/B 3rd E/B OFF ON OFF OFF OFF 3rd E/B OFF ON OFF OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON 1st OFF OFF OFF OFF ON 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st E/B ON OFF OFF OFF OFF 1st E/B OFF OFF OFF OFF OFF 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF POSITION R ON ↓ S2 OFF SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ OFF OFF OFF ON 2nd ON ON OFF OFF ON 4th OFF A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 4th OFF OFF OFF ON OFF 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ 2nd ON ON OFF OFF ON 3rd E/B OFF 3rd E/B OFF OFF ON OFF OFF ON OFF OFF OFF ↓ OFF 3rd E/B OFF OFF OFF OFF 3 ↓ OFF 3rd ON OFF 4th OFF OFF ON OFF ON 3rd OFF ↓ ON OFF OFF ON 3rd E/B 5th OFF OFF ON ON OFF ↓ OFF ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF OFF ON OFF 1st E/B ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF ON OFF OFF ON OFF ON OFF ↓ 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ON OFF ON OFF ↓ OFF 2nd OFF OFF ON ON OFF ON OFF OFF OFF OFF ON OFF ON OFF OFF ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF ↓ ↓ 2nd ON 1st E/B ON OFF OFF OFF OFF ON 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ↓ OFF ON ON OFF ↓ OFF OFF OFF ↓ ON OFF ON OFF ↓ OFF 2nd ON 4th ↓ OFF OFF L ↓ ON ON 5th ON OFF OFF 2 OFF OFF ON 1st OFF 4th ↓ ↓ ON OFF 3rd 1st ↓ OFF ON OFF ON ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF OFF ON ↓ OFF ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 5th OFF POSITION R D OFF ON ON OFF ↓ ↓ ↓ 2nd ON ON S1 S2 OFF OFF ↓ OFF S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R ON OFF OFF OFF ON 4th OFF OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON 4th OFF OFF OFF OFF ON ↓ ↓ OFF OFF OFF ON 4th OFF 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF ON 3rd ↓ ON OFF OFF OFF OFF ↓ 1st ON 3rd E/B OFF 3rd ON 1st E/B ON ↓ ↓ ↓ OFF 3rd OFF ↓ OFF OFF OFF OFF 3rd E/B OFF OFF ON OFF OFF OFF 3rd E/B OFF OFF OFF OFF OFF ↓ ↓ ON 3rd E/B 3 OFF OFF OFF OFF OFF OFF 3rd ↓ ON ON 4th OFF OFF ON OFF ON 3rd OFF OFF OFF OFF ↓ ON 1st E/B 5th OFF OFF ON ON OFF ↓ OFF OFF OFF 3rd 1st Fail 4th 2 Fail 4th OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON 1st OFF 1st E/B ↓ ↓ ON 1st OFF 1st E/B ON OFF OFF ON OFF ↓ ↓ OFF ON OFF ON OFF ON OFF OFF OFF ↓ ON OFF ↓ ↓ ↓ ON 1st ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st ↓ ON OFF OFF OFF ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1st E/B 5th OFF OFF ON ON 1st E/B OFF OFF OFF OFF Fail 4th OFF OFF ON OFF Fail 4th OFF OFF ON OFF L OFF OFF ON OFF ↓ ↓ 1st ON OFF 1st E/B ON OFF OFF 1st E/B ↓ ↓ ON OFF ON 1st OFF 1st E/B OFF ↓ ↓ ↓ ON 1st ON OFF OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st OFF ↓ OFF OFF ON ON OFF ON 1st E/B 5th OFF POSITION R ON ON OFF ↓ ↓ 1st ON OFF ↓ ↓ OFF ON S1 S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON ↓ OFF OFF 3rd ↓ ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF 3rd OFF ↓ 3rd OFF ON 4th OFF OFF OFF ↓ ↓ OFF ON ON OFF OFF ON 3 OFF S1 SR OFF 4th D OFF OFF OFF OFF ↓ ON 3rd OFF OFF OFF OFF ON ON ON ↓ 3rd OFF OFF OFF OFF ON 3rd E/B ↓ OFF ON OFF OFF 3rd 3rd OFF OFF ↓ OFF OFF ↓ ON ON OFF 3rd E/B ↓ ↓ ON 3rd ON 3rd ↓ ↓ OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ON ↓ A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ON 3rd E/B ↓ OFF OFF 3rd 1st ON ↓ OFF ON OFF OFF OFF ON ON OFF 3rd E/B ↓ ↓ ↓ OFF ON 3rd OFF ON 1st OFF OFF OFF OFF OFF OFF ON OFF ↓ ↓ OFF ON OFF ON 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF 2 ↓ OFF OFF OFF OFF OFF ON 1st E/B OFF ↓ OFF OFF OFF OFF 1st 1st ↓ OFF OFF 2nd 2nd 1st E/B OFF ↓ ON OFF ON OFF OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF ↓ 1st E/B OFF OFF OFF OFF ↓ 1st OFF 1st E/B OFF OFF OFF 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF L ↓ OFF OFF OFF OFF OFF ↓ OFF OFF 2nd ON 1st E/B OFF ↓ OFF OFF OFF OFF 2nd ↓ ON ON OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF ↓ ON OFF ON 1st E/B ↓ ↓ ↓ 1st 1st 1st ↓ ON ON OFF ON 1st E/B ↓ ↓ ↓ 1st ON OFF ↓ OFF 1st E/B OFF ↓ 1st A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W6Z047X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): HOW TO PROCEED WITH TROUBLESHOOTING (2007 4Runner) HOW TO PROCEED WITH TROUBLESHOOTING HINT: z z The ECM of this system is connected to the CAN and multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN and multiplex communication systems. *: Use the intelligent tester. 1. VEHICLE BROUGHT TO WORKSHOP NEXT 2. CUSTOMER PROBLEM ANALYSIS NEXT 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4. CONNECT INTELLIGENT TESTER TO DLC3* NEXT 5. CHECK AND CLEAR DTCS AND FREEZE FRAME DATA* A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Refer to the DTC CHECK/CLEAR . NEXT 6. VISUAL INSPECTION NEXT 7. SETTING CHECK MODE DIAGNOSIS* . (a) Refer to the CHECK MODE PROCEDURE NEXT 8. PROBLEM SYMPTOM CONFIRMATION (a) Refer to the ROAD TEST . Result: RESULT PROCEED TO Symptom does not occur A Symptom occurs B B GO TO STEP 10 A 9. SYMPTOM SIMULATION (a) Refer to the ELECTRONIC CIRCUIT INSPECTION PROCEDURE NEXT 10. DTC CHECK* . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Refer to the DTC CHECK / CLEAR . Result: RESULT PROCEED TO DTC is not output A DTC is output B B GO TO STEP 19 A 11. BASIC INSPECTION (a) Refer to the AUTOMATIC TRANSMISSION FLUID . (b) Refer to the PARK/NEUTRAL POSITION SWITCH . . (c) Refer to the SHIFT LEVER ASSEMBLY NG GO TO STEP 22 OK 12. MECHANICAL SYSTEM TEST . (a) Refer to the MECHANICAL SYSTEM TEST NG GO TO STEP 18 NG GO TO STEP 18 OK 13. HYDRAULIC TEST (a) Refer to the HYDRAULIC TEST . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 14. MANUAL SHIFTING TEST (a) Refer to the MANUAL SHIFTING TEST . NG GO TO STEP 17 OK 15. PROBLEM SYMPTOMS TABLE CHAPTER 1 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 20 OK 16. PROBLEM SYMPTOMS TABLE CHAPTER 2 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 18 OK 17. PROBLEM SYMPTOMS TABLE CHAPTER 3 (a) Refer to the PROBLEM SYMPTOMS TABLE . NEXT 18. PART INSPECTION NEXT GO TO STEP 22 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 19. DTC CHART (a) Refer to the DIAGNOSTIC TROUBLE CODE CHART . NEXT 20. CIRCUIT INSPECTION NEXT 21. IDENTIFICATION OF PROBLEM NEXT 22. REPAIR OR REPLACE NEXT 23. CONFIRMATION TEST NEXT END A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7B042X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): HYDRAULIC TEST (2007 4Runner) HYDRAULIC TEST 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: z z z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. Be careful to prevent SST hose from interfering with the exhaust pipe. This Check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. When conducting stall test, do not continue more than 5 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Turn the ignition switch off. (3) Lift the vehicle up. (4) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (5) Lower the vehicle. (6) Fully apply the parking brake and chock the 4 wheels. (7) Start the engine and check idling speed. (8) Keep your left foot pressing firmly on the brake pedal and shift into D position. (9) Measure the line pressure when the engine is idling. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (10) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (11) In the same manner, do the test in R position. Specified line pressure: CONDITION Idling D POSITION KPA R POSITION KPA (KGF/CM 2, PSI) (KGF/CM 2, PSI) 362 to 423 kPa 484 to 565 kPa (3.7 to 4.3 kgf/cm 2, 53 to 61 psi) (4.9 to 5.8 kgf/cm 2, 70 to 82 psi) 1,282 to 1,381 kPa Stall test 1,218 to 1,338 kPa 2 (13.1 to 14.1 kgf/cm , (12.4 to 13.6 kgf/cm 2, 186 to 200 psi) 177 to 194 psi) Evaluation: PROBLEM If the measured values at all position are higher POSSIBLE CAUSE z z If the measured values at all position are lower z z z If pressure is low in the D position only z z If pressure is low in the R position only z z z Shift solenoid valve (SLT) defective Regulator valve defective Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective D position circuit fluid leak Clutch No.1 (C 1) defective R position circuit fluid leak Clutch No.3 (C 3) defective Brake No.4 (B 4) defective A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03WX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7C044X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MANUAL SHIFTING TEST (2007 4Runner) MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transmission. If any abnormalities are found in the following test, the problem is in the transmission itself. z z (a) Disconnect the connector of the transmission wire. (b) Drive with the transmission wire disconnected. Shifting the shift lever to the L, 2, 3, 4 and D position to check whether the shifting condition changes the table below. SHIFT POSITION SHIFTING CONDITION L ←→ 2 No Shift (Not Change) 2 ←→ 3 Down Shift ←→ Up Shift 3 ←→ 4 Down Shift ←→ Up Shift 4 ←→ D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the gear position will be as follows: z z z z When the shift When the shift When the shift When the shift respectively. lever lever lever lever is is is is in in in in the the the the L or the 2 position, the gear is held in the 1st position. 3 position, the gear is held in the 3rd position. 4 or the D position, the gear is held in the 4th position. R or the P position, the gear is also in the R or the P position A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (c) Connect the connector of the transmission wire. (d) Clear the DTC . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7A044X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MECHANICAL SYSTEM TESTS (2007 4Runner) MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D position. NOTICE: z z z z z Driving test should be done on a paved road (a nonskid road). Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). Do not continuously run this test for longer than 5 seconds. To ensure safety, do this test in a wide, clear level area which provides good traction. The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,400 +- 150 rpm Evaluation: PROBLEM POSSIBLE CAUSE z z (a) Stall engine speed is low in D position Engine power output may be insufficient Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. z Line pressure is too low A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Stall engine speed is high in D position Clutch No. 1 (C 1) slipping One-way clutch No. 3 (F 3) not operating properly z z Improper fluid level z (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutch, and brake. NOTICE: z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). Be sure to allow 1 minute interval between tests. Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): PROBLEM N → D time lag is longer POSSIBLE CAUSE z z z z N → R time lag is longer z z z Line pressure is too low Clutch No.1 (C 1) worn One-way clutch No. 3 (F 3) not operating properly Line pressure is too low Clutch No. 3 (C 3) worn Brake No. 4 (B 4) worn One-way clutch No. 1 (F 1) not operating properly A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7K040X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): MONITOR DRIVE PATTERN (2007 4Runner) MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern.) HINT: Preparation for driving z z Warm up the engine sufficiently. (Engine coolant temperature is 60°C (140°F) or higher) Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction is not detected when the atmospheric temperature is less than -10°C (14°F)) Notice in driving z Drive the vehicle through all gears. z Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON). Repeat the above driving pattern three times or more. NOTICE: z z z The monitor status can be checked using the OBD II scan tool or intelligent tester. When using the intelligent tester, monitor status can be found in the "ENHANCED OBD II / DATA LIST" or under "CARB OBD II". In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8404EX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input) (2007 4Runner) DTC P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC NO. DTC DETECTION CONDITION P0705 TROUBLE AREA z Open or short in park/neutral position switch circuit Park/neutral position switch z ECM z (2-trip detection logic) MONITOR DESCRIPTION These DTCs indicate a problem with the park/neutral position switch and the wire harness in the park/neutral position switch circuit. The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position. The park/neutral position switch sends a signal to the ECM according to the shift position (P, R, N, D, 4, 3, 2 or L). The ECM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P0705: Park/neutral position switch/Verify switch input Required sensors/Components Park/neutral position switch Frequency of operation Continuous Condition (A) and (C) Duration 2 sec. Condition (B) 60 sec. MIL operation 2 driving cycles Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Engine switch ON Battery voltage 10.5 V or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A), (B) or (C) Condition (A) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (B) All of following conditions are met NSW switch OFF R switch OFF D switch OFF 3 switch OFF 2 switch OFF Condition (C) Both (i) and (ii) are met (i) One of following conditions is met NSW switch ON R switch ON (ii) One of following condition is met 4 switch ON L switch ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... COMPONENT OPERATING RANGE Park/neutral position switch The park/neutral position switch sends only one signal to the ECM. WIRING DIAGRAM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Shift lever is: PNP SW [NSW] PNP switch status/ z ON or OFF z When shift lever position displayed on intelligent On P and tester differs from actual position, adjustment of N: ON PNP switch or shift cable may be incorrect Not on P and N: OFF Shift lever is: REVERSE PNP switch status/ ON or OFF z z On R: ON Not on R: OFF Shift lever is: DRIVE PNP switch status/ ON or OFF z z On D: ON Not on D: OFF Shift lever is: 4TH/DRIVE PNP switch status/ ON or OFF z z On 4: ON Not on 4: OFF Shift lever is: When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3RD PNP switch status/ z ON or OFF z On 3: ON Not on 3: OFF Shift lever is: PNP switch status/ 2ND ON or OFF z z On 2: ON Not on 2: OFF Shift lever is: PNP switch status/ LOW ON or OFF z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect PROCEDURE 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω Except 2 and L ↑ 10 kΩ or higher NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 2. INSPECT SHIFT LOCK CONTROL ECU SUB-ASSEMBLY (TRANSMISSION CONTROL SWITCH) (a) Connect the park/neutral position switch connector. (b) Disconnect the shift lock control ECU connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION D 4 D 4 2 TESTER CONNECTION 9 - 2 (NSSD - ATD) 9 - 3 (NSSD - AT4) 10 - 5 (NSSL - AT2) SPECIFIED CONDITION Below 1 Ω 10 kΩ or higher 10 kΩ or higher Below 1 Ω Below 1 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... L 10 kΩ or higher 2 10 kΩ or higher 10 - 4 (NSSL - ATL) L NG Below 1 Ω REPLACE SHIFT LOCK CONTROL ECU SUBASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Connect the shift lock control ECU connector. (b) Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P and N E5-8 (NSW) - Body ground Below 2 V Except P and N ↑ 10 to 14 V R E7-11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D and 4 E7-21 (D) - Body ground 10 to 14 V Except D and 4 ↑ Below 1 V 3 E7-19 (3) - Body ground 10 to 14 V Except 3 ↑ Below 1 V 2 and L E7-10 (2) - Body ground 10 to 14 V Except 2 and L ↑ Below 1 V L E7-9 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *: The voltage will drop slightly due to the turning on of the back up light. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8503WX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0710: Transmission Fluid Temperature Sensor "A" Circuit (2007 4Runner) DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor No. 1 resistance is less than 79 Ω. P0710 z (b) ATF temperature sensor No. 1 resistance is more than 156 kΩ. z HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or z Open or short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM from (b) to (a) z P0712 ATF temperature sensor No. 1 resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic) z z z ATF temperature No. 1 sensor resistance is more than 156 kΩ P0713 when 15 minutes or more have elapsed after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic) z z Short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM Open in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω *1 or more than 156 kΩ *2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P0710: ATF temperature sensor/Range check (Chattering) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Related DTCs P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0712: Range check (Low resistance) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω or more than 156 kΩ P0712: Range check (Low resistance) TFT sensor resistance. P0713: Range check (High resistance) Less than 79 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TFT sensor resistance. More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor. Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on tester, read the "DATA LIST". A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal OIL and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150 °C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE 1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 2 (OT-) - 10 (OT+) 79 Ω to 156 kΩ 2 (OT-) - Body ground 10 kΩ or higher 10 (OT+) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with either the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20 °C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Z03LX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0711: Transmission Fluid Temperature Sensor "A" Performance (2007 4Runner) DTC P0711 Transmission Fluid Temperature Sensor "A" Performance DESCRIPTION . DTC NO. DTC DETECTION CONDITION TROUBLE AREA Both (a) and (b) are detected: (2-trip detection logic) P0711 (a) Intake air and engine coolant temps. are more than -10° Transmission wire (ATF C (14°F) at engine start temperature sensor No. 1) (b) After normal driving for over 22 min. and 9 km (6 mile) or more, ATF temp. is less than 20°C (68°F) MONITOR DESCRIPTION This DTC indicates that there is a problem with output from the automatic transmission fluid (ATF) temperature sensor and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault in the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 20°C (68°F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. MONITOR STRATEGY Related DTCs P0711: ATF temperature sensor/Rationality check Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 3 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None TFT sensor circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 21 min. and 40 sec. Driving distance after engine start 5.6 mile (9 km) or more IAT (12 sec. after engine start) -10°C (14°F) or more ECT (12 sec. after engine start) -10°C (14°F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (Transmission fluid temperature) Less than 20°C (60°F) (ATF temperature = -10°C (14°F) at engine start) (Conditions vary with ATF temperature at engine start) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0711" is output A "P0711" and other DTCs B HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. CHECK TRANSMISSION FLUID LEVEL OK: Automatic transmission fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Y01MX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0717: Turbine Speed Sensor Circuit No Signal (2007 4Runner) DTC P0717 Turbine Speed Sensor Circuit No Signal DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input revolution of transmission. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (SP2), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC NO. DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected for 5 secs. or more (1-trip detection logic) (a) Gear change is not performed P0717 (b) Gear position: 4th or 5th (c) T/M input shaft rpm: 300 rpm or less z Open or short in speed sensor (NT) circuit Speed sensor (NT) ECM z Automatic transmission (clutch, z (d) T/M output shaft rpm: 1,000 rpm or more (e) Park/neutral position switch: z NSW input signal is OFF z A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z z R input signal is OFF L input signal is OFF brake or gear, etc.) (f) Shift solenoid valves and park/neutral position switch are in normal operation Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NT- of the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 1 V/DIV, 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) MONITOR DESCRIPTION This DTC indicates that pulse is not output from the speed sensor NT (Turbine (input) speed sensor) or is output only little. The NT terminal of the ECM detects the revolving signal from speed sensor (NT) (input RPM). The ECM outputs a gearshift signal comparing the input speed sensor (NT) with the output speed sensor (SP2). While the vehicle is operating in the 4th or 5th gear position in the shift position of D, if the input shaft revolution is less than 300 rpm *1 although the output shaft revolution is more than 1,000 rpm or more *2 , the ECM detects the trouble, illuminates the MIL and stores the DTC. *1 : Pulse is not output or is irregularly output. *2 : The vehicle speed is approx. 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT)/Verify pulse input Required sensors/Components (Main) Speed sensor (NT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components (Related) Speed sensor (NC) Frequency of operation Continuous Duration 5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Shift change Shift change is completed and before starting next shift change operation ECM selected gear 4th or 5th Output shaft rpm 1,000 rpm or more NSW (STAR) switch OFF R switch OFF L switch OFF Engine Running Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Input speed is equal to engine speed when lock-up ON. WIRING DIAGRAM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Lock-up is Input shaft speed/ SPD(NT) Min.: 0 rpm z Max.: 12,750 rpm z ON (after warming up engine): Input Data is displayed in turbine speed (NT) is equal to engine increments of 50 rpm speed OFF (idling with shift lever on N): Input turbine speed (NT) is nearly equal to A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... engine speed HINT: z SPD(NT) is always 0 while driving: z Open or short in the sensor or circuit. SPD(NT) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (NT) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG SECURELY INSTALL SPEED SENSOR OR REPLACE SPEED SENSOR OK 2. INSPECT SPEED SENSOR (NT) (a) Disconnect the speed sensor connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (NT) OK 3. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-35 (NT+) - E5-27 (NT-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-35 (NT+) - Body ground 10 kΩ or higher E5-27 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012TD00VX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0722: Output Speed Sensor Circuit No Signal (2007 4Runner) DTC P0722 Output Speed Sensor Circuit No Signal DESCRIPTION The speed sensor SP2 detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the speed sensor SP2 coil as the parking gear mounted on the rear planetary gear assembly rotates, and this voltage is sent to the ECM. The parking gear on the rear planetary gear is used as the timing rotor for this sensor. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. DTC NO. P0722 DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected 500 times or more continuously (2-trip detection logic) (a) No signal from speed sensor (SP2) is input to ECM while 4 pulses of No. 1 vehicle speed sensor signal are sent z z Open or short in speed sensor (SP2) circuit Speed sensor (SP2) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Vehicle speed is 9 km/h (6 mph) or more for at least 4 sec. z z (c) Park/neutral position switch is OFF. ECM Automatic transmission assembly (clutch, brake or gear, etc.) (d) Transfer position is except neutral (4WD). Reference (Using an oscilloscope): Check the waveform between terminals SP2+ and SP2- of the ECM connector. Standard: Refer to the illustration. Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV Vehicle condition Vehicle speed 20 km/h (12 mph) MONITOR DESCRIPTION The output speed sensor SP2 monitors the output shaft speed. The ECM controls the gearshift point and the lock up timing based on the signals from the output speed sensor SP2 and throttle position sensor. If the ECM detects no signal from the output shaft speed sensor SP2 even while the vehicle is moving, it will conclude that is a malfunction of the output speed sensor SP2. The ECM will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0722 : Speed sensor SP2/Verify pulse input Required Sensors/Components Speed sensor SP2 Frequency of operation Continuous Duration 500 output shaft revolution MIL operation 2 driving cycles Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Vehicle speed sensor pulse input 4 Vehicle speed range (4 sec. or more) 9 km/h (5.59 mph) or more NSW switch OFF Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output speed sensor pulse input No input WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) - HINT: z SPD(SP2) is always 0 while driving: z Open or short in the sensor or circuit. SPD(SP2) value displayed on the tester is much lower than the actual vehicle speed: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (SP2) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG OK SECURELY INSTALL SENSOR OR REPLACE SENSOR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. INSPECT SPEED SENSOR (SP2) (a) Disconnect the speed sensor connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (SP2) OK 3. CHECK WIRE HARNESS AND CONNECTOR (SPEED SENSOR SP2 - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-34 (SP2+) - E5-26 (SP2-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-34 (SP2+) - Body ground 10 kΩ or higher E5-26 (SP2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8802YX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0724: Brake Switch "B" Circuit High (2007 4Runner) DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC NO. DTC DETECTION CONDITION The stop light switch remains ON even when the vehicle is driven in a P0724 STOP (less than 3 km/h (2 mph)) and GO (30 km/h (19 mph) or more) fashion 5 times. (2-trip detection logic). TROUBLE AREA z z z Short in stop light switch signal circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) five times for two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The stop light switch remains on during GO and STOP 5 times. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... GO and STOP is defined as follows; The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.63 mph (30 km/h) or more) Once STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Once Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM . INSPECTION PROCEDURE PROCEDURE 1. READ VALUE OF DATA LIST (STP SIGNAL) HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn on the tester. (e) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read the "DATA LIST". Standard: TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... STOP LIGHT SW Brake pedal is Stop light switch status/ ON or OFF Depressed: ON Released: OFF z z NOTICE: In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty or not. OK CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) NG 2. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Switch pin free 1-2 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher Switch pin free 3-4 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Install the stop light switch assembly. (b) Disconnect the ECM connector. (c) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage: CONDITION TESTER CONNECTION SPECIFIED CONDITION Brake pedal is depressed E8-15 (STP) - Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002SNB002X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0746: Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) DTC P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0746 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z z P0771 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z Shift solenoid valve SL1 remains closed Shift solenoid valve SR remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SR remains open or closed Shift solenoid valve SL1 remains closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates a stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SR and SL1. The ECM commands gear shifts by turning the shift solenoid valves ON/OFF. When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... MONITOR STRATEGY P0746: Shift solenoid valve SL1/OFF malfunction Related DTCs P0771: Shift solenoid valve SR/ON malfunction P0771: Shift solenoid valve SR/OFF malfunction Required sensors/Components (Main) Shift solenoid valve SL1 Shift solenoid valve SR Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous P0746 and P0771 OFF malfunction (A) and (B): 0.4 sec. Duration P0746 and P0771 OFF malfunction (C): Immediate P0771 ON malfunction: 0.15 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting P0746 and P0771: OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear 5th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) P0746 and P0771: OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more P0746 and P0771: OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th P0771: ON malfunction Current ECM selected gear 2nd Last ECM selected gear 1st Throttle valve opening angle (During transition from 1st to 2nd gear) 6.0% or more at 3,000 rpm (Vary with turbine speed) TYPICAL MALFUNCTION THRESHOLDS [P0746 and P0771: OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Not change as follow Turbine speed/Output speed 0.93 to 1.07 ↓ 0.65 to 0.79 OFF malfunction (C) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Output record from ECM for 4th → 5th upshifting Recorded [P0771: ON malfunction] 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON ON malfunction Turbine speed - Output speed x 1st gear ratio (NT - NO x 1st gear ratio) 150 rpm or more INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" z button: Shift up Press "←" button: Shift down Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SR and SL1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746 AND P0771) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0746 and P0771 are output Only P0771 is output A P0746, P0771 and other DTCs are output B z z HINT: If any other codes besides P0746 and P0771 are output, perform troubleshooting for those DTCs first. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* [Vehicle Condition] HINT: Operate the shift solenoid SLT and raise line pressure z z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that Result: LINE PRESSURE VALUE DTC OUTPUT IN PREVIOUS CHECK PROCEED TO Changed P0746 and P0771 A Changed P0771 B Not changed - C B INSPECT SHIFT SOLENOID VALVE SR C REPLACE SHIFT SOLENOID VALVE SLT A 3. INSPECT SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 4. INSPECT SHIFT SOLENOID VALVE SR REPLACE SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SR OK 5. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8F02KX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0748: Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shifting between 4th and 5th gear. P0748 (1-trip detection logic) z z z Output signal duty equals to 100%. (NOTE: SL1 output signal duty is less than 100% under normal condition.) z Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL1 circuit. The ECM commands gearshift by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting between 4th and 5th gears, if the ECM detects an open or short in the shift solenoid valve SL1 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0748: Shift solenoid valve SL1/Range check Required sensors/Components Shift solenoid valve SL1 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Battery voltage 10 V or more CPU commanded duty Less than 75% Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The shift solenoid valve SL1 is turned on/off normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL1) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 12 (SL1+) - 4 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 12 (SL1+) - Body ground 10 kΩ or higher 4 (SL1-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-19 (SL1+) - E5-18 (SL1-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-19 (SL1+) - Body ground 10 kΩ or higher E5-18 (SL1-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8J023X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0751: Shift Solenoid "A" Performance (Shift Solenoid Valve S1) (2007 4Runner) DTC P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0751 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S1 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S1. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0751: Related DTCs Shift solenoid valve S1/OFF malfunction Shift solenoid valve S1/ON malfunction Required sensors/Components (Main) Shift solenoid valve S1 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A) and (C): 0.4 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OFF malfunction (B): Immediate Duration ON malfunction (A), (B) and (C): 0.4 sec. ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 8% or more 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (C) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Either of the following conditions is met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (C) Turbine speed/Output speed ON malfunction (D) 1.91 to 2.35 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (E) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, read the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY SHIFT . TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z Press "→" z button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 is turned on/off normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0751) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0751" is output A "P0751" and other DTCs B HINT: If any other codes besides "P0751" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NOTICE: z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG OK 3. INSPECT SHIFT SOLENOID VALVE S1 REPLACE SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W80023X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0756: Shift Solenoid "B" Performance (Shift Solenoid Valve S2) (2007 4Runner) DTC P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0756 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S2 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0756: Related DTCs Shift solenoid valve S2/OFF malfunction Shift solenoid valve S2/ON malfunction Required sensors/Components (Main) Shift solenoid valve S2 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A), (B) and (C): 0.4 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OFF malfunction (D): Immediate Duration ON malfunction (A) and (B): 0.4 sec. ON malfunction (C): 3 sec. ON malfunction (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (D) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B), (C) and (D) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (B) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (C) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (D) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Both of the following conditions are met: ON malfunction (A) or (B), and ON malfunction (C) or (D) ON malfunction (A) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (B) Turbine speed/Output speed ON malfunction (C) 1.28 to 1.53 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (D) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY SHIFT TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z z Press "→" button: Shift up Press "←" button: Shift DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... down HINT: This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0756) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0756 is output A P0756 and other DTCs B HINT: If any other codes besides P0756 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S2 (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE S2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C5V00GX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0776: Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0776 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SL2 remains open Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" of the shift solenoid valve SL2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/ON malfunction Required sensors/Components (Main) Shift solenoid valve SL2 Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous ON malfunction (A), (B) and (C): 0.4 sec. Duration ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ON malfunction (B) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [ON malfunction] Both of the following conditions are met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed/Output speed ON malfunction (D) 0.93 to 1.07 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (E) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY SHIFT . TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z Press "→" z button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position. z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0776" is output A "P0776" and other DTCs B HINT: If any other codes besides "P0776" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NOTICE: z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG OK 3. INSPECT SHIFT SOLENOID VALVE SL2 REPLACE SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8G02JX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0778: Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. P0778 . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL2 circuit while driving and shifting gears. (1-trip detection logic) z Output signal duty equals to 100%. (NOTE: SL2 output signal duty is less than 100% under normal condition.) z z z Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL2 circuit. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting gears, if the ECM detects an open or short in the shift solenoid valve SL2 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0778: Shift solenoid valve SL2/Range check Required sensors/Components Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TYPICAL ENABLING CONDITIONS P0115 - P0118 (ECT sensor) P0125 (Insufficient ETC for Closed Loop) The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) CPU commanded duty Less than 75% Battery voltage 10 V or more Ignition Switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL2) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 11 (SL2+) - 3 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 11 (SL2+) - Body ground 10 kΩ or higher 3 (SL2-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID SL2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-17 (SL2+) - E5-16 (SL2-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-17 (SL2+) - Body ground 10 kΩ or higher E5-16 (SL2-) - Body ground ↑ 3. INSPECT SHIFT SOLENOID SL2 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID SL2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000XP101UX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0781: 1-2 Shift (1-2 Shift Valve) (2007 4Runner) DTC P0781 1-2 Shift (1-2 Shift Valve) DESCRIPTION The 1-2 shift valve performs shifting to 1st gear and other gears. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0781 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SLT remains open or closed Valve body is blocked up or stuck (1-2 shift valve) Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates that the 1-2 shift valve in the valve body is locked in the direction the spring compresses. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF" and switching oil pressure to the valves in the valve body. The ECM calculates the "actual" transmission gear by comparing the signals from the input speed sensor A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (NT) and the output speed sensor (SP2). The ECM can detect many mechanical problems in the shift solenoids, valve body, and the transmission clutches, brakes, and gears. If the ECM detects that the actual gear position and the commanded gear position are different, it will illuminate the MIL and store the DTC . MONITOR STRATEGY Related DTCs P0781: Valve body/Rationality check Required sensors/Components (Main) Valve body Required sensors/Components (Related) Automatic transmission assembly, Speed sensor (NT), Speed sensor (NO), Vehicle speed sensor, Throttle position sensor Frequency of operation Continuous Condition (A) and (B): 0.4 sec. Duration Condition (C): 3 sec. Condition (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 Condition (A) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) Condition (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Vary with engine speed) Condition (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) Condition (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: Condition (A), and Condition (B), (C) or (D) Condition (A) Turbine speed/Output speed Condition (B) 3.30 to 7.50 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Turbine speed/Output speed 1.28 to 1.53 Condition (C) Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) Condition (D) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0781) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0781 is output A P0781 and other DTCs B HINT: If any other codes besides P0781 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. HINT: PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. OK: Gear position changes in accordance with the tester command. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 4. CLEAR THE DTC AND RUNNING TEST (a) Clear the DTC, and check for the DTC again after conducting the " MONITOR DRIVE PATTERN FOR ECT TEST" . OK: No DTC code NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK END A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W83031X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0894: Transmission Component Slipping (2007 4Runner) DTC P0894 Transmission Component Slipping DTC P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: *: The duty ratio is the ratio of the current ON time (A) to the total of the current ON and OFF time (A + B). Duty Ratio (%) = A / (A + B) x 100 DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0894 ECM detects a malfunction on SLT, S1, S2, SR, SL1, SL2 or 1-2 shift solenoid valve according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z z z z P2714 ECM detects a malfunction on SLT (ON side) according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION The ECM calculates the amount of heat absorbed by the friction material based on the difference in revolution (clutch slippage) between the turbine and output shaft. The ECM turns on the MIL and outputs this DTC when the amount of heat absorption exceeds the specified value. When the shift solenoid valve SLT, SL2, S1 or S2 remains on, or the shift solenoid valve SL1 or SR remains off, oil pressure goes down and clutch engagement force decreases. NOTICE: If you continue driving under these conditions, the clutch will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P0894: Automatic transmission slip malfunction P2714: Shift solenoid valve SLT/ON malfunction A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve SLT, Valve body, ATF temperature sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous P0894 ON malfunction (A): Immediate Duration P0894 ON malfunction (B): 0.4 sec. P2714: Immediate MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All The monitor will run whenever this DTC is not present. None Turbine speed sensor (NT) circuit Not circuit malfunction Output speed sensor (NO) circuit Not circuit malfunction TFT temperature sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT (Engine Coolant Temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric Throttle Control System) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° crankshaft angle or more Engine Starting Transfer range "High" *1 TFT temperature 10°C (50°F) or more Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 TYPICAL MALFUNCTION THRESHOLDS [P0894: ON malfunction] When either condition below is met: OFF malfunction (A) or (B) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Summation of C2 clutch heat generations Specified value Actual gear for SLT fail judgment Not determined [P2714: ON malfunction] One of the following conditions is met: ON malfunction (A), (B), (C), (D), (E), (F) or (G) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Shift solenoid valve S1 ON malfunction Detected ON malfunction (C) Shift solenoid valve S2 ON malfunction Detected ON malfunction (D) Shift solenoid valve SR OFF malfunction Detected ON malfunction (E) 1-2 shift valve malfunction Detected ON malfunction (F) Shift solenoid valve SL1 OFF malfunction Detected A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ON malfunction (G) Shift solenoid valve SL2 ON malfunction Detected INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTCS P0894 AND P2714) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0894 is output Only P0894 and P2714 are output A P0894, P2714 and other DTCs are output B z z HINT: If any other codes besides P0894 and P2714 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and HINT: z DIAGNOSTIC NOTE [Vehicle Condition] z OFF: Line pressure up (when Active Test Vehicle stopped A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... raise line pressure z "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG INSPECT SHIFT SOLENOID VALVE SLT OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Clear the DTC . (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (d) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. z z z z z (e) Compare the ECM gear shift command and the actual gear position. ECM GEAR SHIFT COMMAND 1ST 2ND 3RD 4TH 5TH Shift solenoid S1 Shift solenoid S2 Actual gear position under malfunction Shift solenoid SL2 Shift solenoid SR Stuck ON 1st 2nd 2nd 1st N*1 Stuck OFF 4th 3rd 3rd 4th 5th Stuck ON*2 2nd 2nd 3rd 3rd N*1 Stuck OFF*3 1st 1st 4th 4th 5th Stuck ON 1st 2nd 3rd 4th N*1 Stuck OFF 1st 2nd 3rd 4th 5th Stuck ON*4 1st 2nd 3rd 4th 5th Stuck OFF*5 1st PROCEED TO A B C D 2nd 3rd 4th 4th HINT: z z z z z z *1: Neutral *2: When shift solenoid S2 is stuck ON, the vehicle cannot drive in reverse. *3: When shift solenoid S2 is stuck OFF, the 4th to 5th upshift will have a large shift shock. Also, the 5th to 4th down-shift will have time lag. *4: Stuck ON condition can be determined by checking if shift shock has increased excessively. *5: When shift solenoid SR is stuck OFF, moving the shift lever from N to D will cause a large shift shock. Gear shift can be determined by paying attention to changes in rpm. OK: Gear position changes in accordance with the tester command. OK INSPECT SHIFT SOLENOID VALVE SLT B INSPECT SHIFT SOLENOID VALVE S2 C INSPECT SHIFT SOLENOID VALVE SL2 D INSPECT SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A 4. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S1 connector - Shift solenoid S1 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 6. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S1 INSPECT SHIFT SOLENOID VALVE S2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 8. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S2 INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL2 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 10. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL2 INSPECT SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 11. INSPECT SHIFT SOLENOID VALVE SL1 REPLACE SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 13. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL1 INSPECT SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SLT. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SLT - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SLT OK 14. INSPECT TRANSMISSION VALVE BODY ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 15. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W86027X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0973: Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) (2007 4Runner) DTC P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) DTC P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0973 . DTC DETECTION CONDITION ECM detects short in solenoid valve S1 circuit 2 times when solenoid valve S1 is operated (1-trip detection logic) TROUBLE AREA z z z P0974 ECM detects open in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S1 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S1 circuit. When the shift solenoid valve S1 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S1 circuit . MONITOR STRATEGY Related DTCs P0973: Shift solenoid valve S1/Range check (Low resistance) P0974: Shift solenoid valve S1/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve S1 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0973: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 ON P0974: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS P0973: Range check (Low resistance) Shift solenoid valve S1 resistance. 8 Ω or less P0974: Range check (High resistance) Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S1 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S1) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 8 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S1 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-11 (S1) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W87026X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0976: Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) (2007 4Runner) DTC P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) DTC P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0976 . DTC DETECTION CONDITION ECM detects short in solenoid valve S2 circuit 2 times when solenoid valve S2 is operated (1-trip detection logic) TROUBLE AREA z z z P0977 ECM detects open in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S2 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S2 circuit. When the shift solenoid valve S2 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S2 circuit . MONITOR STRATEGY Related DTCs P0976: Shift solenoid valve S2/Range check (Low resistance) P0977: Shift solenoid valve S2/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve S2 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0976: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 ON P0977: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS P0976: Range check (Low resistance) Shift solenoid valve S2 resistance 8 Ω or less P0977: Range check (High resistance) Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S2 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S2) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 15 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S2 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-10 (S2) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S2) - Solenoid Body (S2) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8H01YX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P0985: Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) (2007 4Runner) DTC P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) DTC P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0985 . DTC DETECTION CONDITION ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic) TROUBLE AREA z z z P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic) z z z Short in shift solenoid valve SR circuit Shift solenoid valve SR ECM Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve SR is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve SR circuit. When the shift solenoid valve SR is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve SR circuit . MONITOR STRATEGY Related DTCs P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Required sensors/Components Shift solenoid valve SR Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR ON Battery voltage 8 V or more Engine switch ON Starter OFF P0986: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR OFF Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance) Shift solenoid valve SR resistance 8 Ω or less P0986: Range check (High resistance) Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve SR Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... WIRING DIAGRAM INSPECTION PROCEDURE HINT: The shift solenoid valve SR turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SR) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 7 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE SR OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-9 (SR) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SR OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8A02LX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2716: Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) (2007 4Runner) DTC P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. *: Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100 (%) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... DTC NO. P2716 DTC DETECTION CONDITION Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detection logic). TROUBLE AREA z z z Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716: Shift solenoid valve SLT/Range check Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLT) from IC Fail (Open or short) Case 2: Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty. WIRING DIAGRAM Less than 100% A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLT) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 14 (SLT+) - 6 (SLT-) 5.0 to 5.6 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 14 (SLT+) - Body ground 10 kΩ or higher 6 (SLT-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLT OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-13 (SLT+) - E5-12 (SLT-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-13 (SLT+) - Body ground 10 kΩ or higher E5-12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... OK 3. REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLT OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012XR00UX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2740: Transmission Fluid Temperature Sensor "B" Circuit (2007 4Runner) DTC P2740 Transmission Fluid Temperature Sensor "B" Circuit DTC P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input DTC P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input DESCRIPTION The No. 2 ATF temperature sensor is on the transmission, just in front of the oil cooler inlet pipeline. If the ECM detects an abnormally high ATF temperature near this sensor, it illuminates the warning light. HINT: z z The temperature of ATF easily rises when towing, climbing hills and in traffic, etc. If the No. 2 ATF temperature sensor becomes short-circuited, the signal that indicates the ATF temperature is 150°C (302°F) or higher is input in ECM. Vehicle conditions when the sensor is normal and when the sensor is short-circuited are indicated in the table below. NO. 2 ATF TEMPERATURE SENSOR STATE Sensor is normal DETECTION CONDITION SYMPTOM RECOVERY CONDITION ATF temperature more than 150°C (275°F) A/T OIL TEMP warning light remains ON ATF temperature less than 135°C (275°F)*2 ATF temperature more than 130°C (266°F) Shift point too high ATF temperature less than 110°C (230°F) Lock-up at 3rd gear*1 ATF temperature less than 110°C (230°F)*2 and engine coolant temperature more than 95°C (203°F) When the conditions (a) and (b) are satisfied. (a) ATF temperature more than 130°C (266°F) (b) Engine coolant temperature more than 95°C (203°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z Any conditions Sensor is shortcircuited z A/T OIL TEMP warning light remains ON Shift point too high Engine coolant Lock-up at 3rd temperature more than gear*1 95°C (203°F) Symptoms still occur Symptoms still occur HINT: *1: When ATF temperature is normal, transmission lock-up occurs in 5th gear with the shift lever in the D position, and 4th gear with the shift lever in the 4 position. *2: When ATF temperature is in the normal range, it decreases to less than 135°C (275°F) within 5 minutes with the shift lever in the P or N position in an idling state. DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 seconds when neither P2742 or P2743 are detected. (1-trip detection logic) (a) No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V). P2740 (b) No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V). HINT: z z z Open or short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Within 0.5 seconds, the malfunction switches from (a) to (b) or from (b) to (a). z P2742 No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V) for 0.5 seconds or more. (1-trip detection logic) z z No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V) when 15 minutes or more have passed after P2743 the engine start. DTC is detected for 0.5 seconds or more. (1-trip detection logic) MONITOR DESCRIPTION z z z Short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Open in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ATF temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 25 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will illuminate the MIL and store the DTC. HINT: z z z *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P2740: ATF temperature sensor/Range check (Fluttering) Related DTCs P2742: ATF temperature sensor/Range check (Low resistance) P2743: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None P2740, P2742: Range check (Fluttering, Low voltage) The typical enabling condition is not available. - P2743: Range check (High voltage) Time after engine start 15 minutes or more TYPICAL MALFUNCTION THRESHOLDS P2740: Range check (Fluttering) Less than 0.046 V TFT (Transmission fluid temperature) sensor voltage or More than 4.915 V P2742: Range check (Low voltage) TFT (Transmission fluid temperature) sensor voltage Less than 0.046 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... P2743: Range check (High voltage) TFT (Transmission fluid temperature) sensor voltage More than 4.915 V COMPONENT OPERATING RANGE TFT (Transmission fluid temperature) sensor Atmospheric temperature up to approximately 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4. 5. 6. 7. module) to the DLC3. Turn the ignition switch to the ON position. Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". According to the display on tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP2 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 2 value/ NORMAL CONDITION z Min.: -40°C (-40°F) Max.: 215°C (419° F) z After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold DIAGNOSTIC NOTE If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited HINT: { { When DTC P2742 is output and the intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P2743 is output and the intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO2 (OT2) and the body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit PROCEDURE 1. INSPECT TRANSMISSION WIRE (NO. 2 ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 1 (OT2-) - 9 (OT2+) 25 Ω to 156 kΩ 1 (OT2-) - Body ground 10 kΩ or higher 9 (OT2+) - Body ground 10 kΩ or higher HINT: If the resistance is outside the specified range of either ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20°C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... E5-32 (THO2) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-32 (THO2) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8D02CX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2757: Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, output speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU, valve body and torque converter clutch. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock-up remains ON z Shift solenoid valve SLU remains open or closed Valve body is blocked A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... in the lock-up OFF range. z (2-trip detection logic) z P2757 z Torque converter clutch Automatic transmission (clutch, brake or gear, etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on the turbine (input) speed sensor NT, output speed sensor SP2, engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to output shaft rpm (SP2). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid SLU. When the SLU is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve SLU or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. z z There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 70 rpm greater than input turbine speed.) There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) MONITOR STRATEGY P2757: Related DTCs Shift solenoid valve SLU/OFF malfunction Shift solenoid valve SLU/ON malfunction Required sensors/Components Shift solenoid valve SLU, Valve body, Vehicle speed sensor, Speed sensor (NT), Speed sensor (NO), Throttle position sensor Frequency of operation Continuous Duration OFF malfunction (A) 2 sec. OFF malfunction (B) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 0.4 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Torque converter clutch pressure control solenoid circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ECM selected gear 2nd or 3rd or 4th or 5th Vehicle speed 25 km/h (15.5 mph) or more Shift solenoid valve S1 circuit Not on malfunction Shift solenoid valve S2 circuit Not on malfunction Shift solenoid valve SL2 circuit Not on malfunction 1-2 shift valve circuit Not on malfunction Transfer neutral position switch OFF Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) ECM lock-up command ON (SLU pressure: 513 kPa or more) Vehicle speed Less than 100 km/h (62.2 mph) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 6.5% or more at 2,000 rpm (Varies with engine speed) ON malfunction ECM lock-up command OFF (SLU pressure: less than 4 kPa) Throttle valve opening angle 7% or more Vehicle speed Less than 29 km/h (18 mph) at 2nd gear (Varies with ECM selected gear) TYPICAL MALFUNCTION THRESHOLDS Both of the following condition are met: OFF malfunction (A) and (B) OFF malfunction (A) Engine speed - Turbine speed (NE - NT) 70 rpm or more OFF malfunction (B) Turbine speed/Output speed (NT/NO) Less than 3.30, or more than 7.50 ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2md detection; pending fault code ON Vehicle speed must be under 6.2mph (10 km/h) once before 2nd detection. Engine speed - Turbine speed (NE - NT) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Less than 35 rpm A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on the tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic ON or OFF transmission to lock-up condition [Vehicle Condition] z z Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more HINT: z z This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. This test can be conducted with the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... HINT: When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off automatically.) z z PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2757) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P2757" is output A "P2757" and other DTCs B HINT: If any other codes besides "P2757" are output, perform troubleshooting for those DTCs first. B A 2. INSPECT SHIFT SOLENOID VALVE SLU GO TO DTC CHART A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (a) Remove the shift solenoid valve SLU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK 3. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG OK REPLACE TRANSMISSION VALVE BODY ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8902BX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2759: Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) DESCRIPTION The amount of current flow to the solenoid is controlled by the (*) duty ratio of the ECM output signal. The higher the duty ratio becomes, the higher the lock-up hydraulic pressure becomes during the lock-up operation. (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100(%). DTC NO. DTC DETECTION CONDITION P2759 TROUBLE AREA z Open or short is detected in shift solenoid valve SLU circuit for Open or short in shift solenoid valve SLU circuit A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 1 second or more while driving (1-trip detection logic). z z Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or short in a shift solenoid valve (SLU) circuit is detected, the ECM determines there is a malfunction. The ECM will turn on the MIL and store this DTC. MONITOR STRATEGY Related DTCs P2759: Shift solenoid valve SLU/Range check Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLU) from IC Case 2: Fail (open or short) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLU) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 13 (SLU+) - 5 (SLU-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 13 (SLU+) - Body ground 10 kΩ or higher 5 (SLU-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLU OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-15 (SLU+) - E5-14 (SLU-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-15 (SLU+) - Body ground 10 kΩ or higher E5-14 (SLU-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C4J009X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): P2772: Four Wheel Drive (4WD) Low Switch Circuit Range / Performance (2007 4Runner) DTC P2772 Four Wheel Drive (4WD) Low Switch Circuit Range / Performance DESCRIPTION The ECM detects the signal from the transfer L4 position switch. This DTC indicates that the transfer L4 position switch remains on. DTC NO. P2772 DTC DETECTION CONDITION Transfer L4 position switch remains ON while vehicle is running under following conditions for 1.8 seconds or more (1-trip detection logic) (a) Output shaft speed between 1,000 and 3,000 rpm (b) Transfer shift position is H TROUBLE AREA z z z Short in transfer L4 position switch circuit Four wheel drive control ECU ECM MONITOR DESCRIPTION The ECM monitors the transfer-case L4 position switch to determine when the transfer-case L4 gear is engaged. If the transfer-case L4 gears remain engaged under the following conditions, the ECM will conclude that there is a malfunction of the L4 position switch: z z z z L4 switch indicated that the L4 transfer-case gears are engaged. Transfer-case shifter is in the "H" position. Transfer-case output shaft rpm is between 1,000 and 3,000 rpm. The specified time period has elapsed. If all of the above conditions are detected, the ECM will conclude that there is a malfunction of the L4 switch, and illuminate the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2772: Transfer L4 position switch/ON malfunction Required sensors/Components Transfer L4 position switch Frequency of operation Continuous Duration ON malfunction (A): 1.8 sec. ON malfunction (B): 0.5 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS All: Output speed sensor circuit Not circuit malfunction Vehicle speed sensor circuit Not circuit malfunction Transfer neutral position switch OFF ON malfunction (A) Output speed (Transfer output speed) 1,000 to 3,000 rpm ON malfunction (B) Output speed (Transfer output speed) 143 rpm or more TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: ON malfunction (A) and (B) ON malfunction (A) L4 switch ON ON malfunction (B) Actual transfer gear ratio Transfer input speed/Transfer output speed WIRING DIAGRAM 0.9 to 1.1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TERMINAL VOLTAGE (4WD ECU - ECM) (a) Disconnect the four wheel drive control ECU connector. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: TESTER CONNECTION SPECIFIED CONDITION F9-24 (L4) - Body ground 10 to 14 V OK CHECK AND REPLACE FOUR WHEEL DRIVE CONTROL ECU A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... NG 2. INSPECT TERMINAL VOLTAGE (ECM - 4WD ECU) (a) Turn the ignition switch ON. (b) Measure the voltage according to the value(s) in the table below. Standard voltage: TESTER CONNECTION SPECIFIED CONDITION E6-13 (L4) - Body ground 10 to 14 V OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 R Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W72040X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 L Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O7H01MX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PRECAUTION (2007 4Runner) PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY can not be completed by only disconnecting the battery cable. 1. The automatic transmission is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete the inspection, repair and reassembly before proceeding to the next component group as much as possible. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS 2. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. 3. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. 4. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. 5. Only recommended automatic transmission fluid or kerosene should be used for cleaning. 6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. 7. When disassembling a valve body, be sure to match each valve together with the corresponding spring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 8. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. 9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. 10. All gaskets and rubber O-rings should be replaced with new ones. 11. Do not apply adhesive cements to gaskets and similar parts. 12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 13. When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. 14. Check thrust bearings and races for wear or damage. Replace them as necessary. 15. When working with FIPG material, you must observe the following: z z z z Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove any loose material. Clean both sealing surfaces with a non-residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 T Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W73048X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): PROBLEM SYMPTOMS TABLE (2007 4Runner) PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical. If the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart SYMPTOM SUSPECTED AREA 1. Shift solenoid valve (S1) circuit *1 No up-shift (A particular gear, from 1st to 4th gear, is not 2. Shift solenoid valve (S2) circuit up-shifted) *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Engine coolant temp. sensor circuit *1 No up-shift (4th -> 5th) 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SL1) circuit *1 5. Shift solenoid valve (SL2) SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... circuit *1 6. Shift solenoid valve (SR) circuit *1 7. ECM 1. Engine coolant temp. sensor circuit *1 No up-shift (3rd -> 4th) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (2 - L) *1 No up-shift (1st -> 2nd) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Shift solenoid valve (SL1) circuit *1 No down-shift (5th -> 4th) 3. Shift solenoid valve (SL2) circuit *1 4. Shift solenoid valve (SR) circuit *1 5. ECM 1. Transmission control switch circuit (2 - L) *1 No down-shift (2nd -> 1st) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Shift solenoid valve (S1) circuit *1 No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. ATF temperature sensor circuit *1 2. Transfer L4 position switch circuit *1 3. Stop light switch circuit *1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 4. Speed sensor NT circuit *1 No lock-up 5. Shift solenoid valve (SLU) circuit *1 6. Engine coolant temp. sensor circuit *1 7. ECM No lock-up off 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. Shift solenoid valve (SLT) circuit *1 2. Speed sensor NT circuit *1 3. Speed sensor SP2 circuit *1 Shift point too high or too low 4. Throttle position sensor circuit *1 5. ATF temperature sensor circuit *1 6. Transfer L4 position switch circuit *1 7. ECM Up-shift to 5th from 4th while shift lever is in 4 position 1. Transmission control switch circuit (D - 4) *1 2. ECM Up-shift to 5th from 4th while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM Up-shift to 4th from 3rd while shift lever is in 3 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 3rd from 2nd while shift lever is in 2 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 2nd from 1st while shift lever is in L position 1. Transmission control switch circuit (2 - L) *1 2. ECM 1. Speed sensor NT circuit *1 2. Shift solenoid valve (SL1) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... circuit *1 Harsh engagement (N -> D) 3. Shift solenoid valve (SLT) circuit *1 4. ECM 1. Speed sensor NT circuit *1 2. Speed sensor SP2 circuit *1 Harsh engagement (Lock-up) 3. Shift solenoid valve (SLU) circuit *1 4. ECM Harsh engagement (Any driving position) ECM 1. ATF temperature sensor No. 2 circuit 2. Engine coolant temp. sensor circuit *1 Poor acceleration 3. Shift solenoid valve (SLT) circuit *1 4. ECM No engine braking ECM No kick-down ECM Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. ATF temperature sensor No. 2 circuit AT Oil Temp. warning light remains on, Lock-up at 3rd gear and/or shift point too high 2. Engine coolant temp. sensor circuit 3. ECM 1. Park/neutral position switch circuit *1 Malfunction in shifting 2. ECM 2. Chapter 2: On-vehicle Repair SYMPTOM SUSPECTED AREA 1. Transmission control cable SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 2. Manual valve Vehicle does not move with shift lever in any forward position and reverse position 3. Parking lock pawl 4. Off-vehicle repair matrix chart - 1. Valve body assembly Vehicle does not move with shift lever in R position 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (1st -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (2nd -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (3rd -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (4th -> 5th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (5th -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (4th -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (3rd -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (2nd -> 1st) 2. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) No lock-up or No lock-up off 2. Valve body assembly 3. Off-vehicle repair matrix chart 1. Shift solenoid valve - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (SL1) 2. Valve body assembly Harsh engagement (N -> D) 3. C1 accumulator 4. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) Harsh engagement (Lock-up) 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) 2. Shift solenoid valve (SLU) Harsh engagement (N -> R) 3. Valve body assembly 4. C3 accumulator 5. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) Harsh engagement (1st -> 2nd -> 3rd -> 4th -> 5th) 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Valve body assembly Harsh engagement (1st -> 2nd) 2. B3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (2nd -> 3rd) 2. C3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (3rd -> 4th) 2. C2 accumulator 3. Off-vehicle repair matrix chart 1. Shift solenoid valve - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (SL1) 2. Shift solenoid valve (SL2) Harsh engagement (4th -> 5th) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (5th -> 4th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Transmission control cable 2. Valve body assembly Slip or shudder (Forward and reverse) 3. Oil strainer 4. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (1st: L position) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (2nd: 2 position) 2. Off-vehicle repair matrix chart No kick-down Valve body assembly 1. Shift solenoid valve (SLT) Shift point too high or too low 2. Shift solenoid valve (SL1) 3. Valve body assembly Poor acceleration 1. Shift solenoid valve (SLT) 2. Valve body assembly Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) 2. Valve body assembly - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... 3. Chapter 3: Off-Vehicle Repair SYMPTOM Vehicle does not move with shift lever in any forward position and reverse position SUSPECTED AREA 1. Rear planetary gear unit 2. Torque converter clutch 1. Brake No. 4 (B4) Vehicle does not move with shift lever in R position 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) No up-shift (1st -> 2nd) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) No up-shift (2nd -> 3rd) Clutch No. 3 (C3) No up-shift (3rd -> 4th) Clutch No. 2 (C2) 1. Brake No. 1 (B1) No up-shift (4th -> 5th) No lock-up or No lock-up off 2. Clutch No. 1 (C1) Torque converter clutch 1. Clutch No. 1 (C1) Harsh engagement (N -> D) 2. One-way clutch No. 3 (F3) 1. Clutch No. 3 (C3) Harsh engagement (N -> R) 2. Brake No. 4 (B4) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) Harsh engagement (1 -> 2) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) Harsh engagement (2 -> 3) Clutch No. 3 (C3) Harsh engagement (3 -> 4) Clutch No. 2 (C2) 1. Brake No. 1 (B1) SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Harsh engagement (4 -> 5th) 2. Clutch No. 1 (C1) Harsh engagement (Lock-up) Torque converter clutch 1. One-way clutch No. 1 (F1) Slip or shudder (Forward and reverse: After warm-up) 2. Clutch No. 3 (C3) 3. Torque converter clutch Slip or shudder (Particular position: Just after engine starts) Torque converter clutch 1. Brake No. 4 (B4) Slip or shudder (R position) 2. One-way clutch No. 1 (F1) 3. Clutch No. 3 (C3) 1. Clutch No. 1 (C1) Slip or shudder (1st) 2. One-way clutch No. 3 (F3) 1. Clutch No.1 (C1) 2. Brake No. 3 (B3) Slip or shudder (2nd) 3. One-way clutch No. 1 (F1) 4. One-way clutch No. 2 (F2) 1. Clutch No. 1 (C1) Slip or shudder (3rd) 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Clutch No. 1 (C1) Slip or shudder (4th) 2. Clutch No. 2 (C2) 1. Clutch No. 2 (C2) Slip or shudder (5th) 2. Clutch No. 3 (C3) 3. Brake No. 1 (B1) No engine braking (1st - 4th: D position) Clutch No. 1 (C1) No engine braking (1st: L position) Brake No. 4 (B4) No engine braking (2nd: 2 position) Brake No. 2 (B2) No engine braking (3rd: 3 position) Brake No. 1 (B1) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Poor acceleration (All positions) Torque converter clutch 1. Clutch No. 1 (C1) 2. Clutch No. 3 (C3) Poor acceleration (5th) 3. Brake No. 1 (B1) 4. Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903TX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 47°C (117°F) or less and vehicle speed is at 30 mph (49 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W75040X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): SYSTEM DESCRIPTION (2007 4Runner) SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transmission) is an automatic transmission that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: z z Diagnostic function. Fail-safe function when a malfunction occurs. 2. OPERATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7D03KX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): SYSTEM DIAGRAM (2007 4Runner) SYSTEM DIAGRAM The configuration of the electronic control system in the A750F automatic transmission is as shown in the following chart. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7403MX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE): TERMINALS OF ECM (2007 4Runner) TERMINALS OF ECM 1. ECM HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to inspected. The standard voltage between the terminals is shown under "Specific Condition". Use the illustration above as a reference for the ECM terminals. SYMBOLS (TERMINALS NO.) WIRING COLOR TERMINAL DESCRIPTION L4 (E6-13) - E1 (E6-1) W-L - BR Transfer L position switch signal ↑ ↑ L (E7-9) - E1 (E61) B-L - BR ↑ ↑ 2 (E7-10) - E1 (E6-1) ↑ CONDITION SPECIFIED CONDITION IG switch ON and Transfer L position Below 1 V IG switch ON and Transfer except L position 10 to 14 V IG switch ON and shift lever L position 10 to 14 V ↑ IG switch ON and shift lever except L position Below 1 V G-R - BR 2 shift position switch signal IG switch ON and shift lever 2 and L position 10 to 14 V ↑ ↑ IG switch ON and shift lever except 2 and L position Below 1 V ↑ L shift position switch signal A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... R (E7-11) - E1 (E6-1) R-Y - BR R shift position switch signal IG switch ON and shift lever R position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except R position Below 1 V D (E7-21) - E1 (E6-1) V - BR D shift position switch signal IG switch ON and shift lever D and 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except D and 4 position Below 1 V 3 (E7-19) - E1 (E6-1) L - BR 3 shift position switch signal IG switch ON and shift lever 3 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 3 position Below 1 V 4 (E7-20) - E1 (E6-1) G - BR 4 shift position switch signal IG switch ON and shift lever 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 4 position Below 1 V STP (E8-15) - E1 (E6-1) G-Y - BR ↑ ↑ Stop light switch signal ↑ Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V Pulse generation SLU+ (E5-15) SLU- (E5-14) R-B - R-W SLU solenoid signal 5th (lock-up) gear S2 (E5-10) - E1 (E6-1) W-L - BR 2nd or 3rd gear 10 to 14 V ↑ ↑ 1st, 4th or 5th gear Below 1 V S1 (E5-11) - E1 (E6-1) GR - BR 1st or 2nd gear 10 to 14 V ↑ ↑ 3rd, 4th or 5th gear Below 1 V SLT+ (E5-13) SLT- (E5-12) ↑ S1 solenoid signal ↑ LG-B - L-R SLT solenoid signal SR (E5-9) - E1 (E6-1) P-L - BR ↑ ↑ SL2+ (E5-17) SL2- (E5-16) S2 solenoid signal SR solenoid signal ↑ B-W - B-R SL2 solenoid signal Engine idle speed (See waveform 2) Pulse generation (See waveform 1) 5th gear 10 to 14 V 1st gear Below 1 V Engine idle speed Pulse generation (See waveform 3) Pulse A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... generation SL1+ (E5-19) SL1- (E5-18) G-B - B-Y SL1 solenoid signal Engine idle speed THO1 (E5-24) - E2 (E4-28) Y-G - BR No. 1 ATF temperature sensor signal No. 1 ATF temperature: 115°C (239°F) or more Below 1.5 V THO2 (E5-32) - E2 (E4-28) L - BR No. 2 ATF temperature sensor signal No. 2 ATF temperature: 115°C (239°F) or more Below 1.5 V SP2+ (E5-34) SP2- (E5-26) R-L - L-Y Speed sensor (SP2) signal Vehicle speed 20 km/h (12 mph) (See waveform 4) Pulse generation (See waveform 6) Pulse generation NT+ (E5-35) - NT(E5-27) W-R - Y-R Speed sensor (NT) signal Engine idle speed STAR/NSW (E5-8) - E1 (E6-1) P - BR Park neutral switch signal IG switch ON and shift lever P and N position Below 2 V ↑ ↑ IG switch ON and shift lever except P and N position 10 to 14 V ↑ (a) Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (b) Waveform 2 Reference: Terminal SLU+ - SLU- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition 5th (lock-up) (c) Waveform 3 (See waveform 5) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 1GR-FE)... Reference: Terminal SL2+ - SL2- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (d) Waveform 4 Reference: Terminal SL1+ - SL1- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (e) Waveform 5 Reference: Terminal NT+ - NT- Tool setting 1 V/DIV., 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) (f) Waveform 6 Reference: Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV. Vehicle condition Vehicle speed 20 km/h (12 mph) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W78044X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): CHECK MODE PROCEDURE (2007 4Runner) CHECK MODE PROCEDURE 1. DESCRIPTION (a) Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 2. CHECK MODE PROCEDURE (a) Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF (b) Turn the engine switch off. (c) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (f) Change the ECM to check mode. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if:1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the engine switch is turned from on (IG) to on (ACC) or off. NOTICE: Before check mode, make notes of the DTCs and freeze frame data. (g) Start the engine. The MIL should turn off after the engine starts. (h) Perform "MONITOR DRIVE PATTERN" for the ECT test . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (Or, simulate the conditions of the malfunction described by the customer). (i) After simulating the malfunction conditions, use the intelligent tester diagnosis selector to check the DTC and freeze frame data. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7E049X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DATA LIST / ACTIVE TEST (2007 4Runner) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) NORMAL CONDITION Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) DIAGNOSTIC NOTE - Lock-up is Input shaft speed/ SPD(NT) z Min.: 0 rpm Max.: 12,750 rpm z ON (after warming up engine): Input turbine speed (NT) is equal to engine speed OFF (idling with shift lever on N): Input turbine speed Data is displayed in increments of 50 rpm A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (NT) is nearly equal to engine speed PNP SW [NSW] PNP switch status/ ON or OFF Shift lever is: z z On P and N: ON Not on P and N: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 Stop light switch STOP LIGHT status/ SW ON or OFF Brake pedal is z z Depressed: ON Released: OFF - Shift lever position is SHIFT ECM gear shift command/ z 1st, 2nd, 3rd, 4th or 5th z z z z REVERSE PNP switch status/ ON or OFF On D: 1st, 2nd, 3rd, 4th or 5th On 4: 1st, 2nd, 3rd or 4th On 3: 1st, 2nd or 3rd On 2: 1st or 2nd On L: 1st Shift lever is: z z On R: ON Not on R: OFF - When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 DRIVE PNP switch status/ ON or OFF Shift lever is: z z On D: ON Not on D: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... P0705 4TH/DRIVE PNP switch status/ ON or OFF Shift lever is: z z On 4: ON Not on 4: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 3RD PNP switch status/ ON or OFF Shift lever is: z z On 3: ON Not on 3: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 2ND PNP switch status/ ON or OFF Shift lever is: z z On 2: ON Not on 2: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 LOW PNP switch status/ ON or OFF Shift lever is: z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A/T OIL TEMP1 ATF temperature sensor No. 1 value/ Min.: -40°C (-40° F) z z Max.: 215°C (419° F) A/T OIL TEMP2 ATF temperature sensor No. 2 value/ Min.: -40°C (-40° F) LOCK UP ON or OFF z z SOLENOID (SLU) SOLENOID (SLT) Lock-up solenoid status/ ON or OFF Shift solenoid SLU status/ ON or OFF After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited Lock-up is z z LOCK UP SOL If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited cold Max.: 215°C (419° F) Lock up/ After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is Operating: ON Not operating: OFF - Lock-up solenoid is z z Operating: ON Not operating: OFF - Shift solenoid SLU is z z Shift solenoid SLT status/ z ON or OFF z Operating: ON Not operating: OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (e) Push the "ON" button of the intelligent tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE [Vehicle Condition] SOLENOID (SLU) Operate the shift solenoid SLU ON or OFF z z Engine stopped Shift lever P or N position ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure HINT: z z [Vehicle Condition] OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling [Vehicle Condition] SOLENOID (S1) Operate the shift solenoid S1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (S2) Operate the shift solenoid S2 ON or OFF z z Engine stopped Shift lever P or N position Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic transmission to lock-up condition [Vehicle Condition] ON or OFF z z SHIFT Operate shift solenoid valve and set each shift position by yourself z z Press "→" button: Shift up Press "←" button: Shift down Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less [Vehicle Condition] A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... SOLENOID (SR) Operate the shift solenoid SR ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL1) Operate the shift solenoid SL1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL2) Operate the shift solenoid SL2 ON or OFF z z Engine stopped Shift lever P or N position *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. as A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7I042X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DEFINITION OF TERMS (2007 4Runner) DEFINITION OF TERMS TERM DEFINITION Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Sequence of operation Required sensor/components Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. The sensors and components that are used by the ECM to detect malfunctions. The number of times that the ECM checks for malfunctions per driving cycle. "Once per driving cycle" means that the ECM detects malfunction only one Frequency of operation time during a single driving cycle. "Continuous" means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL illumination timing after a defect is detected. MIL operation "Immediately" means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. "2 driving cycle" means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W76049X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DIAGNOSIS SYSTEM (2007 4Runner) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (complying with SAE J1987). Various data output from the vehicle's ECM can then be read. (b) OBD II regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (1) The emission control system/components (2) The power train control components (which affect vehicle emissions) (3) The computer In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. (c) To check DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) of the vehicle. The intelligent tester displays DTCs, the freeze frame data and a variety of the engine data. The DTCs and freeze frame data can be erased with the intelligent tester . 2. NORMAL MODE AND CHECK MODE (a) The diagnosis system operates in "normal mode" during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available to technicians as an option. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunctions. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. 2 TRIP DETECTION LOGIC (a) When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate. 4. FREEZE FRAME DATA (a) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. (b) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 times before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. 5. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Terminal of DLC3 SYMBOLS (TERMINAL NO.) TERMINAL DESCRIPTION CONDITION SPECIFIED CONDITION SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) Body ground Chassis ground Always Below 1 Ω Always Below 1 Ω SG (5) - Body Signal ground ground BAT (16) Body ground Battery positive Always CANH (6) CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω HIGH-level Ignition 6 kΩ or CANH (6) Battery 9 to 14 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... positive CAN bus line switch OFF* higher CANH (6) CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. 6. CHECK BATTERY VOLTAGE Battery voltage: 11 to 14 V (a) If voltage is below 11 V, replace the battery before proceeding. 7. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch to the ON position. If the MIL does not illuminate, there is a problem in the MIL circuit . (b) When the engine is started, the MIL should turn off. 8. ALL READINESS (a) For this vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Enter the following menus: ENHANCED OBD II / MONITOR STATUS on the intelligent tester. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 S Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W71046X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DIAGNOSTIC TROUBLE CODE CHART (2007 4Runner) DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed in the table below and proceed to the page given. HINT: z z z *1: "Comes on" means that the MIL will illuminate. *2: "DTC stored" means that the ECM memorizes the malfunction code if the DTC detection condition(s) are met. These DTCs may be output when the clutch, brake and gear components, etc., inside the automatic transmission are damaged. AUTOMATIC TRANSMISSION SYSTEM: DTC CODE P0705 DETECTION ITEM Transmission Range Sensor Circuit Malfunction (PRNDL Input) TROUBLE AREA MIL *1 1. Open or short in Comes park/neutral position switch on circuit MEMORY *2 DTC stored 2. Park/neutral position switch 3. ECM P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor No. 1 circuit Comes on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0711 Transmission Fluid Temperature Sensor "A" Performance Transmission wire (ATF temperature sensor No. 1) Comes on DTC stored P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor No. 1 circuit Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 1 circuit on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0717 Turbine Speed Sensor Circuit No Signal 1. Open or short in speed sensor (NT) circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Speed sensor (NT) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0722 Output Speed Sensor Circuit No Signal 1. Open or short in speed sensor (SP2) circuit 2. Speed sensor (SP2) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains closed 2. Shift solenoid valve SR remains open or closed 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. ECM P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) 1. Shift solenoid valve S1 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) 1. Shift solenoid valve S2 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) 1. Shift solenoid valve SR remains open or closed 2. Shift solenoid valve SL1 remains closed A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. ECM P0781 1-2 Shift (1-2 Shift Valve) 1. Valve body is blocked up or stuck (1-2 shift valve) 2. Automatic transmission (clutch, brake or gear, etc.) P0894 Transmission Component Slipping 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) 1. Short in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) 1. Open in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) 1. Short in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) 1. Open in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) 1. Short in shift solenoid valve SR circuit 2. Shift solenoid valve SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. ECM P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) 1. Open in shift solenoid valve SR circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 2 circuit on DTC stored 2. Shift solenoid valve SR 3. ECM P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. ECM P2740 Transmission Fluid Temperature Sensor "B" Circuit 1. Open or short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input 1. Short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) 1. Shift solenoid valve SLU remains open or closed Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transmission (clutch, brake or gear, etc.) 5. Line pressure is too low P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit 1. Open or short in shift solenoid valve SLU circuit A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Electrical (Shift Solenoid Valve SLU) 2. Shift solenoid valve SLU 3. ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W77044X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DTC CHECK / CLEAR (2007 4Runner) DTC CHECK / CLEAR 1. CHECK DTC (a) DTCs which are stored in the ECM can be displayed with the intelligent tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTC aren't stored if the ECM doesn't detect a malfunction during consecutive driving. However, the detected malfunction during once driving is stored as pending DTC. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch to the ON position. (3) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Confirm the DTCs and freeze frame data and then write them down. (5) Confirm the details of the DTCs . NOTICE: When simulating a symptom with the scan tool to check the DTCs, use normal mode. For codes on DIAGNOSTIC TROUBLE CODE CHART which are subject to "2-trip detection logic", perform the following actions. Turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM. 2. CLEAR DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... press YES. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O8L049X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): FAILSAFE CHART (2007 4Runner) FAIL-SAFE CHART 1. FAIL-SAFE CHART This function minimizes the loss of the ECT functions when a malfunction occurs in each sensor or solenoid. MALFUNCTION PART FUNCTION No. 1 ATF Temperature Sensor During a No. 1 ATF temperature sensor malfunction, up-shift to the 5th gear and flex lock-up clutch control are prohibited. Output Speed Sensor During an output speed sensor malfunction, shift control is effected through the (SP2) input speed sensor signal (NT). Shift Solenoid Valve S1, S2 and SR The current to the failed solenoid valve is cut off and control is effected by operating the other solenoid valves with normal operation. Shift control is effected depending on the failed solenoid as described in the table below. Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction, up-shift to the 5th gear is prohibited. Shift Solenoid Valve SLT During a solenoid valve SLT malfunction, the current to the solenoid valve is stopped. This stops line pressure optimal control, and shift shock increases. However, shifting is effected through normal clutch pressure control. Shift Solenoid Valve SLU During a solenoid valve SLU malfunction, the current to the solenoid valve is stopped. This stops lock-up control and flex lock-up control, and fuel economy decreases. Fail-safe function: If either of the shift solenoid valve circuits has an open or short failure, the ECM turns the other shift solenoid ON and OFF in order to shift into the gear positions shown in the table below. In case of a short circuit, the ECM stops sending current to the short circuit solenoid. Even if starting the engine again in the fail-safe mode, the gear position remains in the same position. HINT: z z z ↓: Condition in the electrical malfunction is shown above "↓". ↓: Condition in fail-safe mode is shown below "↓". E/B: Engine brake. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... POSITION R NORMAL S1 OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th 1st ON OFF OFF OFF ON ↓ OFF OFF 3rd D ↓ ON 2nd ON ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON OFF OFF 3rd ↓ OFF OFF 3rd E/B ↓ ON OFF ON 3rd 3 2 L 2nd ON D OFF OFF ON ↓ ON OFF ON OFF OFF ↓ OFF 3rd E/B 3rd E/B OFF ON OFF OFF OFF 3rd E/B OFF ON OFF OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON 1st OFF OFF OFF OFF ON 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st E/B ON OFF OFF OFF OFF 1st E/B OFF OFF OFF OFF OFF 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF POSITION R ON ↓ S2 OFF SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ OFF OFF OFF ON 2nd ON ON OFF OFF ON 4th OFF A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 4th OFF OFF OFF ON OFF 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ 2nd ON ON OFF OFF ON 3rd E/B OFF 3rd E/B OFF OFF ON OFF OFF ON OFF OFF OFF ↓ OFF 3rd E/B OFF OFF OFF OFF 3 ↓ OFF 3rd ON OFF 4th OFF OFF ON OFF ON 3rd OFF ↓ ON OFF OFF ON 3rd E/B 5th OFF OFF ON ON OFF ↓ OFF ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF OFF ON OFF 1st E/B ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF ON OFF OFF ON OFF ON OFF ↓ 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ON OFF ON OFF ↓ OFF 2nd OFF OFF ON ON OFF ON OFF OFF OFF OFF ON OFF ON OFF OFF ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF ↓ ↓ 2nd ON 1st E/B ON OFF OFF OFF OFF ON 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ↓ OFF ON ON OFF ↓ OFF OFF OFF ↓ ON OFF ON OFF ↓ OFF 2nd ON 4th ↓ OFF OFF L ↓ ON ON 5th ON OFF OFF 2 OFF OFF ON 1st OFF 4th ↓ ↓ ON OFF 3rd 1st ↓ OFF ON OFF ON ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF OFF ON ↓ OFF ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 5th OFF POSITION R D OFF ON ON OFF ↓ ↓ ↓ 2nd ON ON S1 S2 OFF OFF ↓ OFF S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R ON OFF OFF OFF ON 4th OFF OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON 4th OFF OFF OFF OFF ON ↓ ↓ OFF OFF OFF ON 4th OFF 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF ON 3rd ↓ ON OFF OFF OFF OFF ↓ 1st ON 3rd E/B OFF 3rd ON 1st E/B ON ↓ ↓ ↓ OFF 3rd OFF ↓ OFF OFF OFF OFF 3rd E/B OFF OFF ON OFF OFF OFF 3rd E/B OFF OFF OFF OFF OFF ↓ ↓ ON 3rd E/B 3 OFF OFF OFF OFF OFF OFF 3rd ↓ ON ON 4th OFF OFF ON OFF ON 3rd OFF OFF OFF OFF ↓ ON 1st E/B 5th OFF OFF ON ON OFF ↓ OFF OFF OFF 3rd 1st Fail 4th 2 Fail 4th OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON 1st OFF 1st E/B ↓ ↓ ON 1st OFF 1st E/B ON OFF OFF ON OFF ↓ ↓ OFF ON OFF ON OFF ON OFF OFF OFF ↓ ON OFF ↓ ↓ ↓ ON 1st ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st ↓ ON OFF OFF OFF ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1st E/B 5th OFF OFF ON ON 1st E/B OFF OFF OFF OFF Fail 4th OFF OFF ON OFF Fail 4th OFF OFF ON OFF L OFF OFF ON OFF ↓ ↓ 1st ON OFF 1st E/B ON OFF OFF 1st E/B ↓ ↓ ON OFF ON 1st OFF 1st E/B OFF ↓ ↓ ↓ ON 1st ON OFF OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st OFF ↓ OFF OFF ON ON OFF ON 1st E/B 5th OFF POSITION R ON ON OFF ↓ ↓ 1st ON OFF ↓ ↓ OFF ON S1 S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON ↓ OFF OFF 3rd ↓ ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF 3rd OFF ↓ 3rd OFF ON 4th OFF OFF OFF ↓ ↓ OFF ON ON OFF OFF ON 3 OFF S1 SR OFF 4th D OFF OFF OFF OFF ↓ ON 3rd OFF OFF OFF OFF ON ON ON ↓ 3rd OFF OFF OFF OFF ON 3rd E/B ↓ OFF ON OFF OFF 3rd 3rd OFF OFF ↓ OFF OFF ↓ ON ON OFF 3rd E/B ↓ ↓ ON 3rd ON 3rd ↓ ↓ OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ON ↓ A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ON 3rd E/B ↓ OFF OFF 3rd 1st ON ↓ OFF ON OFF OFF OFF ON ON OFF 3rd E/B ↓ ↓ ↓ OFF ON 3rd OFF ON 1st OFF OFF OFF OFF OFF OFF ON OFF ↓ ↓ OFF ON OFF ON 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF 2 ↓ OFF OFF OFF OFF OFF ON 1st E/B OFF ↓ OFF OFF OFF OFF 1st 1st ↓ OFF OFF 2nd 2nd 1st E/B OFF ↓ ON OFF ON OFF OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF ↓ 1st E/B OFF OFF OFF OFF ↓ 1st OFF 1st E/B OFF OFF OFF 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF L ↓ OFF OFF OFF OFF OFF ↓ OFF OFF 2nd ON 1st E/B OFF ↓ OFF OFF OFF OFF 2nd ↓ ON ON OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF ↓ ON OFF ON 1st E/B ↓ ↓ ↓ 1st 1st 1st ↓ ON ON OFF ON 1st E/B ↓ ↓ ↓ 1st ON OFF ↓ OFF 1st E/B OFF ↓ 1st A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W6Z04AX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): HOW TO PROCEED WITH TROUBLESHOOTING (2007 4Runner) HOW TO PROCEED WITH TROUBLESHOOTING HINT: z z The ECM of this system is connected to the CAN and multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN and multiplex communication systems. *: Use the intelligent tester. 1. VEHICLE BROUGHT TO WORKSHOP NEXT 2. CUSTOMER PROBLEM ANALYSIS NEXT 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4. CONNECT INTELLIGENT TESTER TO DLC3* NEXT 5. CHECK AND CLEAR DTCS AND FREEZE FRAME DATA* A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Refer to the DTC CHECK/CLEAR . NEXT 6. VISUAL INSPECTION NEXT 7. SETTING CHECK MODE DIAGNOSIS* . (a) Refer to the CHECK MODE PROCEDURE NEXT 8. PROBLEM SYMPTOM CONFIRMATION (a) Refer to the ROAD TEST . Result: RESULT PROCEED TO Symptom does not occur A Symptom occurs B B GO TO STEP 10 A 9. SYMPTOM SIMULATION (a) Refer to the ELECTRONIC CIRCUIT INSPECTION PROCEDURE NEXT 10. DTC CHECK* . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Refer to the DTC CHECK / CLEAR . Result: RESULT PROCEED TO DTC is not output A DTC is output B B GO TO STEP 19 A 11. BASIC INSPECTION (a) Refer to the AUTOMATIC TRANSMISSION FLUID . (b) Refer to the PARK/NEUTRAL POSITION SWITCH . . (c) Refer to the SHIFT LEVER ASSEMBLY NG GO TO STEP 22 OK 12. MECHANICAL SYSTEM TEST . (a) Refer to the MECHANICAL SYSTEM TEST NG GO TO STEP 18 NG GO TO STEP 18 OK 13. HYDRAULIC TEST (a) Refer to the HYDRAULIC TEST . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 14. MANUAL SHIFTING TEST (a) Refer to the MANUAL SHIFTING TEST . NG GO TO STEP 17 OK 15. PROBLEM SYMPTOMS TABLE CHAPTER 1 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 20 OK 16. PROBLEM SYMPTOMS TABLE CHAPTER 2 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 18 OK 17. PROBLEM SYMPTOMS TABLE CHAPTER 3 (a) Refer to the PROBLEM SYMPTOMS TABLE . NEXT 18. PART INSPECTION NEXT GO TO STEP 22 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 19. DTC CHART (a) Refer to the DIAGNOSTIC TROUBLE CODE CHART . NEXT 20. CIRCUIT INSPECTION NEXT 21. IDENTIFICATION OF PROBLEM NEXT 22. REPAIR OR REPLACE NEXT 23. CONFIRMATION TEST NEXT END A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7B045X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): HYDRAULIC TEST (2007 4Runner) HYDRAULIC TEST 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: z z z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. Be careful to prevent SST hose from interfering with the exhaust pipe. This Check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. When conducting stall test, do not continue more than 5 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Turn the ignition switch off. (3) Lift the vehicle up. (4) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (5) Lower the vehicle. (6) Fully apply the parking brake and chock the 4 wheels. (7) Start the engine and check idling speed. (8) Keep your left foot pressing firmly on the brake pedal and shift into D position. (9) Measure the line pressure when the engine is idling. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (10) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (11) In the same manner, do the test in R position. Specified line pressure: CONDITION Idling D POSITION KPA R POSITION KPA (KGF/CM 2, PSI) (KGF/CM 2, PSI) 362 to 420 kPa 500 to 580 kPa (3.7 to 4.2 kgf/cm 2, 53 to 59 psi) (5.1 to 5.9 kgf/cm 2, 73 to 84 psi) 1,360 to 1,460 kPa Stall test 1,295 to 1,415 kPa 2 (13.8 to 14.9 kgf/cm , (13.2 to 14.4 kgf/cm 2, 196 to 212 psi) 188 to 205 psi) Evaluation: PROBLEM If the measured values at all position are higher POSSIBLE CAUSE z z If the measured values at all position are lower z z z If pressure is low in the D position only z z If pressure is low in the R position only z z z Shift solenoid valve (SLT) defective Regulator valve defective Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective D position circuit fluid leak Clutch No.1 (C 1) defective R position circuit fluid leak Clutch No.3 (C 3) defective Brake No.4 (B 4) defective A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03ZX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7C047X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MANUAL SHIFTING TEST (2007 4Runner) MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transmission. If any abnormalities are found in the following test, the problem is in the transmission itself. z z (a) Disconnect the connector of the transmission wire. (b) Drive with the transmission wire disconnected. Shifting the shift lever to the L, 2, 3, 4 and D position to check whether the shifting condition changes the table below. SHIFT POSITION SHIFTING CONDITION L ←→ 2 No Shift (Not Change) 2 ←→ 3 Down Shift ←→ Up Shift 3 ←→ 4 Down Shift ←→ Up Shift 4 ←→ D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the gear position will be as follows: z z z z When the shift When the shift When the shift When the shift respectively. lever lever lever lever is is is is in in in in the the the the L or the 2 position, the gear is held in the 1st position. 3 position, the gear is held in the 3rd position. 4 or the D position, the gear is held in the 4th position. R or the P position, the gear is also in the R or the P position A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (c) Connect the connector of the transmission wire. (d) Clear the DTC . A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7A047X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MECHANICAL SYSTEM TESTS (2007 4Runner) MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D position. NOTICE: z z z z z Driving test should be done on a paved road (a nonskid road). Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). Do not continuously run this test for longer than 5 seconds. To ensure safety, do this test in a wide, clear level area which provides good traction. The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,150 +- 150 rpm Evaluation: PROBLEM POSSIBLE CAUSE z z (a) Stall engine speed is low in D position Engine power output may be insufficient Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. z Line pressure is too low A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Stall engine speed is high in D position Clutch No. 1 (C 1) slipping One-way clutch No. 3 (F 3) not operating properly z z Improper fluid level z (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutch, and brake. NOTICE: z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). Be sure to allow 1 minute interval between tests. Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): PROBLEM N → D time lag is longer POSSIBLE CAUSE z z z z N → R time lag is longer z z z Line pressure is too low Clutch No.1 (C 1) worn One-way clutch No. 3 (F 3) not operating properly Line pressure is too low Clutch No. 3 (C 3) worn Brake No. 4 (B 4) worn One-way clutch No. 1 (F 1) not operating properly A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7K043X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MONITOR DRIVE PATTERN (2007 4Runner) MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern.) HINT: Preparation for driving z z Warm up the engine sufficiently. (Engine coolant temperature is 60°C (140°F) or higher) Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction is not detected when the atmospheric temperature is less than -10°C (14°F)) Notice in driving z Drive the vehicle through all gears. z Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON). Repeat the above driving pattern three times or more. NOTICE: z z z The monitor status can be checked using the OBD II scan tool or intelligent tester. When using the intelligent tester, monitor status can be found in the "ENHANCED OBD II / DATA LIST" or under "CARB OBD II". In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8404HX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input) (2007 4Runner) DTC P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC NO. DTC DETECTION CONDITION P0705 TROUBLE AREA z Open or short in park/neutral position switch circuit Park/neutral position switch z ECM z (2-trip detection logic) MONITOR DESCRIPTION These DTCs indicate a problem with the park/neutral position switch and the wire harness in the park/neutral position switch circuit. The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position. The park/neutral position switch sends a signal to the ECM according to the shift position (P, R, N, D, 4, 3, 2 or L). The ECM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P0705: Park/neutral position switch/Verify switch input Required sensors/Components Park/neutral position switch Frequency of operation Continuous Condition (A) and (C) Duration 2 sec. Condition (B) 60 sec. MIL operation 2 driving cycles Sequence of operation None A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Engine switch ON Battery voltage 10.5 V or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A), (B) or (C) Condition (A) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (B) All of following conditions are met NSW switch OFF R switch OFF D switch OFF 3 switch OFF 2 switch OFF Condition (C) Both (i) and (ii) are met (i) One of following conditions is met NSW switch ON R switch ON (ii) One of following condition is met 4 switch ON L switch ON A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... COMPONENT OPERATING RANGE Park/neutral position switch The park/neutral position switch sends only one signal to the ECM. WIRING DIAGRAM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Shift lever is: PNP SW [NSW] PNP switch status/ z ON or OFF z When shift lever position displayed on intelligent On P and tester differs from actual position, adjustment of N: ON PNP switch or shift cable may be incorrect Not on P and N: OFF Shift lever is: REVERSE PNP switch status/ ON or OFF z z On R: ON Not on R: OFF Shift lever is: DRIVE PNP switch status/ ON or OFF z z On D: ON Not on D: OFF Shift lever is: 4TH/DRIVE PNP switch status/ ON or OFF z z On 4: ON Not on 4: OFF Shift lever is: When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3RD PNP switch status/ z ON or OFF z On 3: ON Not on 3: OFF Shift lever is: PNP switch status/ 2ND ON or OFF z z On 2: ON Not on 2: OFF Shift lever is: PNP switch status/ LOW ON or OFF z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect PROCEDURE 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω Except 2 and L ↑ 10 kΩ or higher NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 2. INSPECT SHIFT LOCK CONTROL ECU SUB-ASSEMBLY (TRANSMISSION CONTROL SWITCH) (a) Connect the park/neutral position switch connector. (b) Disconnect the shift lock control ECU connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION D 4 D 4 2 TESTER CONNECTION 9 - 2 (NSSD - ATD) 9 - 3 (NSSD - AT4) 10 - 5 (NSSL - AT2) SPECIFIED CONDITION Below 1 Ω 10 kΩ or higher 10 kΩ or higher Below 1 Ω Below 1 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... L 10 kΩ or higher 2 10 kΩ or higher 10 - 4 (NSSL - ATL) L NG Below 1 Ω REPLACE SHIFT LOCK CONTROL ECU SUBASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Connect the shift lock control ECU connector. (b) Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P and N E5-8 (NSW) - Body ground Below 2 V Except P and N ↑ 10 to 14 V R E7-11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D and 4 E7-21 (D) - Body ground 10 to 14 V Except D and 4 ↑ Below 1 V 3 E7-19 (3) - Body ground 10 to 14 V Except 3 ↑ Below 1 V 2 and L E7-10 (2) - Body ground 10 to 14 V Except 2 and L ↑ Below 1 V L E7-9 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *: The voltage will drop slightly due to the turning on of the back up light. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8503ZX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0710: Transmission Fluid Temperature Sensor "A" Circuit (2007 4Runner) DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor No. 1 resistance is less than 79 Ω. P0710 z (b) ATF temperature sensor No. 1 resistance is more than 156 kΩ. z HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or z Open or short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM from (b) to (a) z P0712 ATF temperature sensor No. 1 resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic) z z z ATF temperature No. 1 sensor resistance is more than 156 kΩ P0713 when 15 minutes or more have elapsed after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic) z z Short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM Open in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω *1 or more than 156 kΩ *2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P0710: ATF temperature sensor/Range check (Chattering) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Related DTCs P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0712: Range check (Low resistance) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω or more than 156 kΩ P0712: Range check (Low resistance) TFT sensor resistance. P0713: Range check (High resistance) Less than 79 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TFT sensor resistance. More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor. Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on tester, read the "DATA LIST". A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal OIL and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150 °C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE 1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 2 (OT-) - 10 (OT+) 79 Ω to 156 kΩ 2 (OT-) - Body ground 10 kΩ or higher 10 (OT+) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with either the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20 °C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Z03OX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0711: Transmission Fluid Temperature Sensor "A" Performance (2007 4Runner) DTC P0711 Transmission Fluid Temperature Sensor "A" Performance DESCRIPTION . DTC NO. DTC DETECTION CONDITION TROUBLE AREA Both (a) and (b) are detected: (2-trip detection logic) P0711 (a) Intake air and engine coolant temps. are more than -10° Transmission wire (ATF C (14°F) at engine start temperature sensor No. 1) (b) After normal driving for over 22 min. and 9 km (6 mile) or more, ATF temp. is less than 10°C (50°F) MONITOR DESCRIPTION This DTC indicates that there is a problem with output from the automatic transmission fluid (ATF) temperature sensor and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault in the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 10°C (50°F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. MONITOR STRATEGY Related DTCs P0711: ATF temperature sensor/Rationality check Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 3 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None TFT sensor circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 21 min. and 40 sec. Driving distance after engine start 5.6 mile (9 km) or more IAT (12 sec. after engine start) -10°C (14°F) or more ECT (12 sec. after engine start) -10°C (14°F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (Transmission fluid temperature) Less than 10°C (50°F) (ATF temperature = -10°C (14°F) at engine start) (Conditions vary with ATF temperature at engine start) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0711" is output A "P0711" and other DTCs B HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. CHECK TRANSMISSION FLUID LEVEL OK: Automatic transmission fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Y01PX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0717: Turbine Speed Sensor Circuit No Signal (2007 4Runner) DTC P0717 Turbine Speed Sensor Circuit No Signal DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input revolution of transmission. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (SP2), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC NO. DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected for 5 secs. or more (1-trip detection logic) (a) Gear change is not performed P0717 (b) Gear position: 4th or 5th (c) T/M input shaft rpm: 300 rpm or less z Open or short in speed sensor (NT) circuit Speed sensor (NT) ECM z Automatic transmission (clutch, z (d) T/M output shaft rpm: 1,000 rpm or more (e) Park/neutral position switch: z NSW input signal is OFF z A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z R input signal is OFF L input signal is OFF brake or gear, etc.) (f) Shift solenoid valves and park/neutral position switch are in normal operation Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NT- of the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 1 V/DIV, 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) MONITOR DESCRIPTION This DTC indicates that pulse is not output from the speed sensor NT (Turbine (input) speed sensor) or is output only little. The NT terminal of the ECM detects the revolving signal from speed sensor (NT) (input RPM). The ECM outputs a gearshift signal comparing the input speed sensor (NT) with the output speed sensor (SP2). While the vehicle is operating in the 4th or 5th gear position in the shift position of D, if the input shaft revolution is less than 300 rpm *1 although the output shaft revolution is more than 1,000 rpm or more *2 , the ECM detects the trouble, illuminates the MIL and stores the DTC. *1 : Pulse is not output or is irregularly output. *2 : The vehicle speed is approx. 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT)/Verify pulse input Required sensors/Components (Main) Speed sensor (NT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components (Related) Speed sensor (NC) Frequency of operation Continuous Duration 5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Shift change Shift change is completed and before starting next shift change operation ECM selected gear 4th or 5th Output shaft rpm 1,000 rpm or more NSW (STAR) switch OFF R switch OFF L switch OFF Engine Running Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Input speed is equal to engine speed when lock-up ON. WIRING DIAGRAM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Lock-up is Input shaft speed/ SPD(NT) Min.: 0 rpm z Max.: 12,750 rpm z ON (after warming up engine): Input Data is displayed in turbine speed (NT) is equal to engine increments of 50 rpm speed OFF (idling with shift lever on N): Input turbine speed (NT) is nearly equal to A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... engine speed HINT: z SPD(NT) is always 0 while driving: z Open or short in the sensor or circuit. SPD(NT) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (NT) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG SECURELY INSTALL SPEED SENSOR OR REPLACE SPEED SENSOR OK 2. INSPECT SPEED SENSOR (NT) (a) Disconnect the speed sensor connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (NT) OK 3. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-35 (NT+) - E5-27 (NT-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-35 (NT+) - Body ground 10 kΩ or higher E5-27 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012TD00YX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0722: Output Speed Sensor Circuit No Signal (2007 4Runner) DTC P0722 Output Speed Sensor Circuit No Signal DESCRIPTION The speed sensor SP2 detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the speed sensor SP2 coil as the parking gear mounted on the rear planetary gear assembly rotates, and this voltage is sent to the ECM. The parking gear on the rear planetary gear is used as the timing rotor for this sensor. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. DTC NO. P0722 DTC DETECTION CONDITION All conditions below are detected 500 times or more continuously (2-trip detection logic) (a) No signal from speed sensor (SP2) is input to ECM while 4 pulses of No. 1 vehicle speed sensor signal are sent TROUBLE AREA z Open or short in speed sensor (SP2) circuit Speed sensor (SP2) z ECM z A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Vehicle speed is 9 km/h (6 mph) or more for at least 4 sec. z Automatic transmission assembly (clutch, brake or gear, etc.) (c) Park/neutral position switch is OFF. Reference (Using an oscilloscope): Check the waveform between terminals SP2+ and SP2- of the ECM connector. Standard: Refer to the illustration. Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV Vehicle condition Vehicle speed 20 km/h (12 mph) MONITOR DESCRIPTION The output speed sensor SP2 monitors the output shaft speed. The ECM controls the gearshift point and the lock up timing based on the signals from the output speed sensor SP2 and throttle position sensor. If the ECM detects no signal from the output shaft speed sensor SP2 even while the vehicle is moving, it will conclude that is a malfunction of the output speed sensor SP2. The ECM will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0722 : Speed sensor SP2/Verify pulse input Required Sensors/Components Speed sensor SP2 Frequency of operation Continuous Duration 5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Vehicle speed range (4 sec. or more) 9 km/h (5.59 mph) or more Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output speed sensor signal No signal WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) - HINT: z SPD(SP2) is always 0 while driving: z Open or short in the sensor or circuit. SPD(SP2) value displayed on the tester is much lower than the actual vehicle speed: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (SP2) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG OK 2. INSPECT SPEED SENSOR (SP2) SECURELY INSTALL SENSOR OR REPLACE SENSOR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Disconnect the speed sensor connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (SP2) OK 3. CHECK WIRE HARNESS AND CONNECTOR (SPEED SENSOR SP2 - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-34 (SP2+) - E5-26 (SP2-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-34 (SP2+) - Body ground 10 kΩ or higher E5-26 (SP2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W88031X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0724: Brake Switch "B" Circuit High (2007 4Runner) DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC NO. DTC DETECTION CONDITION The stop light switch remains ON even when the vehicle is driven in a P0724 STOP (less than 3 km/h (2 mph)) and GO (30 km/h (19 mph) or more) fashion 5 times. (2-trip detection logic). TROUBLE AREA z z z Short in stop light switch signal circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) five times for two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The stop light switch remains on during GO and STOP 5 times. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... GO and STOP is defined as follows; The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.63 mph (30 km/h) or more) Once STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Once Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM . INSPECTION PROCEDURE PROCEDURE 1. READ VALUE OF DATA LIST (STP SIGNAL) HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn on the tester. (e) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read the "DATA LIST". Standard: TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... STOP LIGHT SW Brake pedal is Stop light switch status/ ON or OFF Depressed: ON Released: OFF z z NOTICE: In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty or not. OK CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) NG 2. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Switch pin free 1-2 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher Switch pin free 3-4 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Install the stop light switch assembly. (b) Disconnect the ECM connector. (c) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage: CONDITION TESTER CONNECTION SPECIFIED CONDITION Brake pedal is depressed E8-15 (STP) - Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002SNB000X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0746: Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) DTC P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0746 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z z P0771 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z Shift solenoid valve SL1 remains closed Shift solenoid valve SR remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SR remains open or closed Shift solenoid valve SL1 remains closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates a stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SR and SL1. The ECM commands gear shifts by turning the shift solenoid valves ON/OFF. When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... MONITOR STRATEGY P0746: Shift solenoid valve SL1/OFF malfunction Related DTCs P0771: Shift solenoid valve SR/ON malfunction P0771: Shift solenoid valve SR/OFF malfunction Required sensors/Components (Main) Shift solenoid valve SL1 Shift solenoid valve SR Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous P0746 and P0771 OFF malfunction (A) and (B): 0.4 sec. Duration P0746 and P0771 OFF malfunction (C): Immediate P0771 ON malfunction: 0.15 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting P0746 and P0771: OFF malfunction (A) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear 5th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) P0746 and P0771: OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more P0746 and P0771: OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th P0771: ON malfunction Current ECM selected gear 2nd Last ECM selected gear 1st Throttle valve opening angle (During transition from 1st to 2nd gear) 6.5% or more at 3,000 rpm (Vary with turbine speed) TYPICAL MALFUNCTION THRESHOLDS [P0746 and P0771: OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Not change as follow Turbine speed/Output speed 0.93 to 1.07 ↓ 0.65 to 0.79 OFF malfunction (C) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Output record from ECM for 4th → 5th upshifting Recorded [P0771: ON malfunction] 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON ON malfunction Turbine speed - Output speed x 1st gear ratio (NT - NO x 1st gear ratio) 150 rpm or more INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" z button: Shift up Press "←" button: Shift down Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SR and SL1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746 AND P0771) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0746 and P0771 are output Only P0771 is output A P0746, P0771 and other DTCs are output B z z HINT: If any other codes besides P0746 and P0771 are output, perform troubleshooting for those DTCs first. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* [Vehicle Condition] HINT: Operate the shift solenoid SLT and raise line pressure z z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that Result: LINE PRESSURE VALUE DTC OUTPUT IN PREVIOUS CHECK PROCEED TO Changed P0746 and P0771 A Changed P0771 B Not changed - C B INSPECT SHIFT SOLENOID VALVE SR C REPLACE SHIFT SOLENOID VALVE SLT A 3. INSPECT SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 4. INSPECT SHIFT SOLENOID VALVE SR REPLACE SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SR OK 5. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8F02NX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0748: Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shifting between 4th and 5th gear. P0748 (1-trip detection logic) z z z Output signal duty equals to 100%. (NOTE: SL1 output signal duty is less than 100% under normal condition.) z Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL1 circuit. The ECM commands gearshift by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting between 4th and 5th gears, if the ECM detects an open or short in the shift solenoid valve SL1 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0748: Shift solenoid valve SL1/Range check Required sensors/Components Shift solenoid valve SL1 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Battery voltage 10 V or more CPU commanded duty Less than 75% Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve SL1 is turned on/off normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL1) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 12 (SL1+) - 4 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 12 (SL1+) - Body ground 10 kΩ or higher 4 (SL1-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID VALVE SL1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-19 (SL1+) - E5-18 (SL1-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-19 (SL1+) - Body ground 10 kΩ or higher E5-18 (SL1-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8J026X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0751: Shift Solenoid "A" Performance (Shift Solenoid Valve S1) (2007 4Runner) DTC P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0751 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S1 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S1. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0751: Related DTCs Shift solenoid valve S1/OFF malfunction Shift solenoid valve S1/ON malfunction Required sensors/Components (Main) Shift solenoid valve S1 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A) and (C): 0.4 sec. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OFF malfunction (B): Immediate Duration ON malfunction (A), (B) and (C): 0.4 sec. ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting OFF malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 8% or more 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) Current ECM selected gear 5th A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (C) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Either of the following conditions is met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (C) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (D) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (E) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, read the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve S1 is turned on/off normally when the shift lever is in the D position: z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0751) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0751" is output A "P0751" and other DTCs B HINT: If any other codes besides "P0751" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z z HINT: Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W80026X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0756: Shift Solenoid "B" Performance (Shift Solenoid Valve S2) (2007 4Runner) DTC P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0756 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S2 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0756: Related DTCs Shift solenoid valve S2/OFF malfunction Shift solenoid valve S2/ON malfunction Required sensors/Components (Main) Shift solenoid valve S2 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A), (B) and (C): 0.4 sec. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OFF malfunction (D): Immediate Duration ON malfunction (A) and (B): 0.4 sec. ON malfunction (C): 3 sec. ON malfunction (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting OFF malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B), (C) and (D) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (B) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (C) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (D) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Both of the following conditions are met: ON malfunction (A) or (B), and ON malfunction (C) or (D) ON malfunction (A) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (D) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0756) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0756 is output A P0756 and other DTCs B HINT: If any other codes besides P0756 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* HINT: Operate the shift solenoid SLT and raise z OFF: Line pressure up (when Active Test line pressure "LINE PRESS UP" is performed, ECM commands SLT solenoid to turn OFF) z ON: No action (normal operation) [Vehicle Condition] z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S2 (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE S2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C5V00JX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0776: Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0776 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SL2 remains open Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" of the shift solenoid valve SL2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/ON malfunction Required sensors/Components (Main) Shift solenoid valve SL2 Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous ON malfunction (A), (B) and (C): 0.4 sec. Duration ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 4th A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [ON malfunction] Both of the following conditions are met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed/Output speed 0.93 to 1.07 ON malfunction (D) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) 1,000 rpm or more ON malfunction (E) Turbine speed - Output speed x 5th gear ratio (NT - NO x 5th gear ratio) 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position. z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0776" is output A "P0776" and other DTCs B HINT: If any other codes besides "P0776" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z z HINT: Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8G02MX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0778: Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. P0778 . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL2 circuit while driving and shifting gears. (1-trip detection logic) z Output signal duty equals to 100%. (NOTE: SL2 output signal duty is less than 100% under normal condition.) z z z Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL2 circuit. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting gears, if the ECM detects an open or short in the shift solenoid valve SL2 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0778: Shift solenoid valve SL2/Range check Required sensors/Components Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TYPICAL ENABLING CONDITIONS P0115 - P0118 (ECT sensor) P0125 (Insufficient ETC for Closed Loop) The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) CPU commanded duty Less than 75% Battery voltage 10 V or more Ignition Switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL2) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 11 (SL2+) - 3 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 11 (SL2+) - Body ground 10 kΩ or higher 3 (SL2-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID SL2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-17 (SL2+) - E5-16 (SL2-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-17 (SL2+) - Body ground 10 kΩ or higher E5-16 (SL2-) - Body ground ↑ 3. INSPECT SHIFT SOLENOID SL2 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID SL2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000XP101XX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0781: 1-2 Shift (1-2 Shift Valve) (2007 4Runner) DTC P0781 1-2 Shift (1-2 Shift Valve) DESCRIPTION The 1-2 shift valve performs shifting to 1st gear and other gears. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0781 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SLT remains open or closed Valve body is blocked up or stuck (1-2 shift valve) Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates that the 1-2 shift valve in the valve body is locked in the direction the spring compresses. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF" and switching oil pressure to the valves in the valve body. The ECM calculates the "actual" transmission gear by comparing the signals from the input speed sensor A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (NT) and the output speed sensor (SP2). The ECM can detect many mechanical problems in the shift solenoids, valve body, and the transmission clutches, brakes, and gears. If the ECM detects that the actual gear position and the commanded gear position are different, it will illuminate the MIL and store the DTC . MONITOR STRATEGY Related DTCs P0781: Valve body/Rationality check Required sensors/Components (Main) Valve body Required sensors/Components (Related) Automatic transmission assembly, Speed sensor (NT), Speed sensor (NO), Vehicle speed sensor, Throttle position sensor Frequency of operation Continuous Condition (A) and (B): 0.4 sec. Duration Condition (C): 3 sec. Condition (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Condition (A) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) Condition (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) Condition (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) Condition (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: Condition (A), and Condition (B), (C) or (D) Condition (A) Turbine speed/Output speed 3.30 to 7.50 Condition (B) Turbine speed/Output speed 1.28 to 1.53 Condition (C) Turbine speed - Output speed x 4th gear ratio (NT - NO x 4th gear ratio) Condition (D) 1,000 rpm or more A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0781) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0781 is output A P0781 and other DTCs B HINT: If any other codes besides P0781 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. OK: Gear position changes in accordance with the tester command. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* HINT: Operate the shift solenoid SLT and raise z OFF: Line pressure up (when Active Test line pressure "LINE PRESS UP" is performed, ECM commands SLT solenoid to turn OFF) z ON: No action (normal operation) [Vehicle Condition] z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 4. CLEAR THE DTC AND RUNNING TEST (a) Clear the DTC, and check for the DTC again after conducting the " MONITOR DRIVE PATTERN FOR ECT TEST" . OK: No DTC code NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK END A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8302RX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0894: Transmission Component Slipping (2007 4Runner) DTC P0894 Transmission Component Slipping DTC P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *: The duty ratio is the ratio of the current ON time (A) to the total of the current ON and OFF time (A + B). Duty Ratio (%) = A / (A + B) x 100 DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0894 ECM detects a malfunction on SLT, S1, S2, SR, SL1, SL2 or 1-2 shift solenoid valve according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z z z z P2714 ECM detects a malfunction on SLT (ON side) according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION The ECM calculates the amount of heat absorbed by the friction material based on the difference in revolution (clutch slippage) between the turbine and output shaft. The ECM turns on the MIL and outputs this DTC when the amount of heat absorption exceeds the specified value. When the shift solenoid valve SLT, SL2, S1 or S2 remains on, or the shift solenoid valve SL1 or SR remains off, oil pressure goes down and clutch engagement force decreases. NOTICE: If you continue driving under these conditions, the clutch will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P0894: Automatic transmission slip malfunction P2714: Shift solenoid valve SLT/ON malfunction A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve SLT, Valve body, ATF temperature sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous P0894 ON malfunction (A): Immediate Duration P0894 ON malfunction (B): 0.4 sec. P2714: Immediate MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All The monitor will run whenever this DTC is not present. None Turbine speed sensor (NT) circuit Not circuit malfunction Output speed sensor (NO) circuit Not circuit malfunction TFT temperature sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT (Engine Coolant Temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric Throttle Control System) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° crankshaft angle or more Engine Starting Transfer range "High" *1 TFT temperature 10°C (50°F) or more Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 TYPICAL MALFUNCTION THRESHOLDS [P0894: ON malfunction] When either condition below is met: OFF malfunction (A) or (B) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Summation of C2 clutch heat generations Specified value Actual gear for SLT fail judgment Not determined [P2714: ON malfunction] One of the following conditions is met: ON malfunction (A), (B), (C), (D), (E), (F) or (G) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Shift solenoid valve S1 ON malfunction Detected ON malfunction (C) Shift solenoid valve S2 ON malfunction Detected ON malfunction (D) Shift solenoid valve SR OFF malfunction Detected ON malfunction (E) 1-2 shift valve malfunction Detected ON malfunction (F) Shift solenoid valve SL1 OFF malfunction Detected A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ON malfunction (G) Shift solenoid valve SL2 ON malfunction Detected INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTCS P0894 AND P2714) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0894 is output Only P0894 and P2714 are output A P0894, P2714 and other DTCs are output B z z HINT: If any other codes besides P0894 and P2714 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and HINT: z DIAGNOSTIC NOTE [Vehicle Condition] z OFF: Line pressure up (when Active Test Vehicle stopped A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... raise line pressure z "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG INSPECT SHIFT SOLENOID VALVE SLT OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Clear the DTC . (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (d) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. z z z z z (e) Compare the ECM gear shift command and the actual gear position. ECM GEAR SHIFT COMMAND 1ST 2ND 3RD 4TH 5TH Shift solenoid S1 Shift solenoid S2 Actual gear position under malfunction Shift solenoid SL2 Shift solenoid SR Stuck ON 1st 2nd 2nd 1st N*1 Stuck OFF 4th 3rd 3rd 4th 5th Stuck ON*2 2nd 2nd 3rd 3rd N*1 Stuck OFF*3 1st 1st 4th 4th 5th Stuck ON 1st 2nd 3rd 4th N*1 Stuck OFF 1st 2nd 3rd 4th 5th Stuck ON*4 1st 2nd 3rd 4th 5th Stuck OFF*5 1st PROCEED TO A B C D 2nd 3rd 4th 4th HINT: z z z z z z *1: Neutral *2: When shift solenoid S2 is stuck ON, the vehicle cannot drive in reverse. *3: When shift solenoid S2 is stuck OFF, the 4th to 5th upshift will have a large shift shock. Also, the 5th to 4th down-shift will have time lag. *4: Stuck ON condition can be determined by checking if shift shock has increased excessively. *5: When shift solenoid SR is stuck OFF, moving the shift lever from N to D will cause a large shift shock. Gear shift can be determined by paying attention to changes in rpm. OK: Gear position changes in accordance with the tester command. OK INSPECT SHIFT SOLENOID VALVE SLT B INSPECT SHIFT SOLENOID VALVE S2 C INSPECT SHIFT SOLENOID VALVE SL2 D INSPECT SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A 4. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S1 connector - Shift solenoid S1 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 6. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S1 INSPECT SHIFT SOLENOID VALVE S2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 8. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S2 INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL2 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 10. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL2 INSPECT SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 11. INSPECT SHIFT SOLENOID VALVE SL1 REPLACE SHIFT SOLENOID VALVE SR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 13. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL1 INSPECT SHIFT SOLENOID VALVE SLT A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SLT. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SLT - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SLT OK 14. INSPECT TRANSMISSION VALVE BODY ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 15. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8602AX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0973: Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) (2007 4Runner) DTC P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) DTC P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0973 . DTC DETECTION CONDITION ECM detects short in solenoid valve S1 circuit 2 times when solenoid valve S1 is operated (1-trip detection logic) TROUBLE AREA z z z P0974 ECM detects open in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S1 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S1 circuit. When the shift solenoid valve S1 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S1 circuit . MONITOR STRATEGY Related DTCs P0973: Shift solenoid valve S1/Range check (Low resistance) P0974: Shift solenoid valve S1/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve S1 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0973: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 ON P0974: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS P0973: Range check (Low resistance) Shift solenoid valve S1 resistance. 8 Ω or less P0974: Range check (High resistance) Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S1 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S1) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 8 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S1 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-11 (S1) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W87029X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0976: Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) (2007 4Runner) DTC P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) DTC P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0976 . DTC DETECTION CONDITION ECM detects short in solenoid valve S2 circuit 2 times when solenoid valve S2 is operated (1-trip detection logic) TROUBLE AREA z z z P0977 ECM detects open in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S2 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S2 circuit. When the shift solenoid valve S2 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S2 circuit . MONITOR STRATEGY Related DTCs P0976: Shift solenoid valve S2/Range check (Low resistance) P0977: Shift solenoid valve S2/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve S2 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0976: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 ON P0977: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS P0976: Range check (Low resistance) Shift solenoid valve S2 resistance 8 Ω or less P0977: Range check (High resistance) Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S2 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S2) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 15 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S2 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-10 (S2) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S2 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S2) - Solenoid Body (S2) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8H021X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0985: Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) (2007 4Runner) DTC P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) DTC P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0985 . DTC DETECTION CONDITION ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic) TROUBLE AREA z z z P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic) z z z Short in shift solenoid valve SR circuit Shift solenoid valve SR ECM Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve SR is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve SR circuit. When the shift solenoid valve SR is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve SR circuit . MONITOR STRATEGY Related DTCs P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve SR Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR ON Battery voltage 8 V or more Engine switch ON Starter OFF P0986: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR OFF Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance) Shift solenoid valve SR resistance 8 Ω or less P0986: Range check (High resistance) Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve SR Resistance: 11 to 15 Ω at 20°C (68°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... WIRING DIAGRAM INSPECTION PROCEDURE HINT: The shift solenoid valve SR turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SR) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 7 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE SR OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-9 (SR) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SR OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8A02OX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2716: Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) (2007 4Runner) DTC P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. *: Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100 (%) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... DTC NO. P2716 DTC DETECTION CONDITION Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detection logic). TROUBLE AREA z z z Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716: Shift solenoid valve SLT/Range check Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLT) from IC Fail (Open or short) Case 2: Hybrid IC status WIRING DIAGRAM Fail A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLT) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 14 (SLT+) - 6 (SLT-) 5.0 to 5.6 Ω A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 14 (SLT+) - Body ground 10 kΩ or higher 6 (SLT-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLT OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-13 (SLT+) - E5-12 (SLT-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-13 (SLT+) - Body ground 10 kΩ or higher E5-12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OK 3. REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLT OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012XR00XX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2740: Transmission Fluid Temperature Sensor "B" Circuit (2007 4Runner) DTC P2740 Transmission Fluid Temperature Sensor "B" Circuit DTC P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input DTC P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input DESCRIPTION The No. 2 ATF temperature sensor is on the transmission, just in front of the oil cooler inlet pipeline. If the ECM detects an abnormally high ATF temperature near this sensor, it illuminates the warning light. HINT: z z The temperature of ATF easily rises when towing, climbing hills and in traffic, etc. If the No. 2 ATF temperature sensor becomes short-circuited, the signal that indicates the ATF temperature is 150°C (302°F) or higher is input in ECM. Vehicle conditions when the sensor is normal and when the sensor is short-circuited are indicated in the table below. NO. 2 ATF TEMPERATURE SENSOR STATE Sensor is normal DETECTION CONDITION SYMPTOM RECOVERY CONDITION ATF temperature more than 150°C (275°F) A/T OIL TEMP warning light remains ON ATF temperature less than 135°C (275°F)*2 ATF temperature more than 130°C (266°F) Shift point too high ATF temperature less than 110°C (230°F) Lock-up at 3rd gear*1 ATF temperature less than 110°C (230°F)*2 and engine coolant temperature more than 95°C (203°F) When the conditions (a) and (b) are satisfied. (a) ATF temperature more than 130°C (266°F) (b) Engine coolant temperature more than 95°C (203°F) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z Any conditions Sensor is shortcircuited z A/T OIL TEMP warning light remains ON Shift point too high Engine coolant Lock-up at 3rd temperature more than gear*1 95°C (203°F) Symptoms still occur Symptoms still occur HINT: *1: When ATF temperature is normal, transmission lock-up occurs in 5th gear with the shift lever in the D position, and 4th gear with the shift lever in the 4 position. *2: When ATF temperature is in the normal range, it decreases to less than 135°C (275°F) within 5 minutes with the shift lever in the P or N position in an idling state. DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 seconds when neither P2742 or P2743 are detected. (1-trip detection logic) (a) No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V). P2740 (b) No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V). HINT: z z z Open or short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Within 0.5 seconds, the malfunction switches from (a) to (b) or from (b) to (a). z P2742 No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V) for 0.5 seconds or more. (1-trip detection logic) z z No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V) when 15 minutes or more have passed after P2743 the engine start. DTC is detected for 0.5 seconds or more. (1-trip detection logic) MONITOR DESCRIPTION z z z Short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Open in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ATF temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 25 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will illuminate the MIL and store the DTC. HINT: z z z *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P2740: ATF temperature sensor/Range check (Fluttering) Related DTCs P2742: ATF temperature sensor/Range check (Low resistance) P2743: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None P2740, P2742: Range check (Fluttering, Low voltage) The typical enabling condition is not available. - P2743: Range check (High voltage) Time after engine start 15 minutes or more TYPICAL MALFUNCTION THRESHOLDS P2740: Range check (Fluttering) Less than 0.046 V TFT (Transmission fluid temperature) sensor voltage or More than 4.915 V P2742: Range check (Low voltage) TFT (Transmission fluid temperature) sensor voltage Less than 0.046 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... P2743: Range check (High voltage) TFT (Transmission fluid temperature) sensor voltage More than 4.915 V COMPONENT OPERATING RANGE TFT (Transmission fluid temperature) sensor Atmospheric temperature up to approximately 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4. 5. 6. 7. module) to the DLC3. Turn the ignition switch to the ON position. Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". According to the display on tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP2 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 2 value/ NORMAL CONDITION z Min.: -40°C (-40°F) Max.: 215°C (419° F) z After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold DIAGNOSTIC NOTE If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited HINT: { { When DTC P2742 is output and the intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P2743 is output and the intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO2 (OT2) and the body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit PROCEDURE 1. INSPECT TRANSMISSION WIRE (NO. 2 ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 1 (OT2-) - 9 (OT2+) 25 Ω to 156 kΩ 1 (OT2-) - Body ground 10 kΩ or higher 9 (OT2+) - Body ground 10 kΩ or higher HINT: If the resistance is outside the specified range of either ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20°C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... E5-32 (THO2) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-32 (THO2) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8D02FX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2757: Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, output speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU, valve body and torque converter clutch. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock-up remains ON z Shift solenoid valve SLU remains open or closed Valve body is blocked A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... in the lock-up OFF range. z (2-trip detection logic) z P2757 z Torque converter clutch Automatic transmission (clutch, brake or gear, etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on the turbine (input) speed sensor NT, output speed sensor SP2, engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to output shaft rpm (SP2). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid SLU. When the SLU is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve SLU or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. z z There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 70 rpm greater than input turbine speed.) There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) MONITOR STRATEGY P2757: Related DTCs Shift solenoid valve SLU/OFF malfunction Shift solenoid valve SLU/ON malfunction Required sensors/Components Shift solenoid valve SLU, Valve body, Vehicle speed sensor, Speed sensor (NT), Speed sensor (NO), Throttle position sensor Frequency of operation Continuous Duration OFF malfunction (A) 2 sec. OFF malfunction (B) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 0.4 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Torque converter clutch pressure control solenoid circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ECM selected gear 2nd or 3rd or 4th or 5th Vehicle speed 25 km/h (15.5 mph) or more Shift solenoid valve S1 circuit Not on malfunction Shift solenoid valve S2 circuit Not on malfunction Shift solenoid valve SL2 circuit Not on malfunction 1-2 shift valve circuit Not on malfunction Transfer neutral position switch OFF OFF malfunction (A) ECM lock-up command ON (SLU pressure: 513 kPa or more) Vehicle speed Less than 100 km/h (62.2 mph) OFF malfunction (B) ECM selected gear 2nd A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Varies with engine speed) ON malfunction ECM lock-up command OFF (SLU pressure: less than 4 kPa) Throttle valve opening angle 9% or more Vehicle speed Less than 29 km/h (18 mph) at 2nd gear (Varies with ECM selected gear) TYPICAL MALFUNCTION THRESHOLDS Both of the following condition are met: OFF malfunction (A) and (B) OFF malfunction (A) Engine speed - Turbine speed (NE - NT) 70 rpm or more OFF malfunction (B) Turbine speed/Output speed (NT/NO) Less than 3.30, or more than 7.50 ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2md detection; pending fault code ON Vehicle speed must be under 6.2mph (10 km/h) once before 2nd detection. Engine speed - Turbine speed (NE - NT) Less than 35 rpm INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on the tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic ON or OFF transmission to lock-up condition [Vehicle Condition] z z Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more HINT: z z This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. This test can be conducted with the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: z z When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off automatically.) PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2757) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P2757" is output A "P2757" and other DTCs B HINT: If any other codes besides "P2757" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK 3. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 4. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8902EX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2759: Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) DESCRIPTION The amount of current flow to the solenoid is controlled by the (*) duty ratio of the ECM output signal. The higher the duty ratio becomes, the higher the lock-up hydraulic pressure becomes during the lock-up operation. (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100(%). DTC NO. DTC DETECTION CONDITION P2759 TROUBLE AREA z Open or short is detected in shift solenoid valve SLU circuit for Open or short in shift solenoid valve SLU circuit A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1 second or more while driving (1-trip detection logic). z z Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or short in a shift solenoid valve (SLU) circuit is detected, the ECM determines there is a malfunction. The ECM will turn on the MIL and store this DTC. MONITOR STRATEGY Related DTCs P2759: Shift solenoid valve SLU/Range check Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLU) from IC Case 2: Fail (open or short) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLU) (a) Disconnect the transmission wire connector from the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 13 (SLU+) - 5 (SLU-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 13 (SLU+) - Body ground 10 kΩ or higher 5 (SLU-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLU OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-15 (SLU+) - E5-14 (SLU-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-15 (SLU+) - Body ground 10 kΩ or higher E5-14 (SLU-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK REPAIR OR REPLACE TRANSMISSION WIRE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 R Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W72043X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 L Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O7H01PX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PRECAUTION (2007 4Runner) PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY can not be completed by only disconnecting the battery cable. 1. The automatic transmission is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete the inspection, repair and reassembly before proceeding to the next component group as much as possible. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS 2. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. 3. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. 4. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. 5. Only recommended automatic transmission fluid or kerosene should be used for cleaning. 6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. 7. When disassembling a valve body, be sure to match each valve together with the corresponding spring. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 8. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. 9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. 10. All gaskets and rubber O-rings should be replaced with new ones. 11. Do not apply adhesive cements to gaskets and similar parts. 12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 13. When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. 14. Check thrust bearings and races for wear or damage. Replace them as necessary. 15. When working with FIPG material, you must observe the following: z z z z Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove any loose material. Clean both sealing surfaces with a non-residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 T Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7304BX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PROBLEM SYMPTOMS TABLE (2007 4Runner) PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical. If the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart SYMPTOM SUSPECTED AREA 1. Shift solenoid valve (S1) circuit *1 No up-shift (A particular gear, from 1st to 4th gear, is not 2. Shift solenoid valve (S2) circuit up-shifted) *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Engine coolant temp. sensor circuit *1 No up-shift (4th -> 5th) 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SL1) circuit *1 5. Shift solenoid valve (SL2) SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... circuit *1 6. Shift solenoid valve (SR) circuit *1 7. ECM 1. Engine coolant temp. sensor circuit *1 No up-shift (3rd -> 4th) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (2 - L) *1 No up-shift (1st -> 2nd) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Shift solenoid valve (SL1) circuit *1 No down-shift (5th -> 4th) 3. Shift solenoid valve (SL2) circuit *1 4. Shift solenoid valve (SR) circuit *1 5. ECM 1. Transmission control switch circuit (2 - L) *1 No down-shift (2nd -> 1st) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Shift solenoid valve (S1) circuit *1 No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. ATF temperature sensor circuit *1 No lock-up 2. Stop light switch circuit *1 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SLU) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... circuit *1 5. Engine coolant temp. sensor circuit *1 6. ECM No lock-up off 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. Shift solenoid valve (SLT) circuit *1 2. Speed sensor NT circuit *1 3. Speed sensor SP2 circuit *1 Shift point too high or too low 4. Throttle position sensor circuit *1 5. ATF temperature sensor circuit *1 6. ECM Up-shift to 5th from 4th while shift lever is in 4 position 1. Transmission control switch circuit (D - 4) *1 2. ECM Up-shift to 5th from 4th while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM Up-shift to 4th from 3rd while shift lever is in 3 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 3rd from 2nd while shift lever is in 2 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 2nd from 1st while shift lever is in L position 1. Transmission control switch circuit (2 - L) *1 2. ECM 1. Speed sensor NT circuit *1 Harsh engagement (N -> D) 2. Shift solenoid valve (SL1) circuit *1 3. Shift solenoid valve (SLT) circuit *1 4. ECM A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1. Speed sensor NT circuit *1 2. Speed sensor SP2 circuit *1 Harsh engagement (Lock-up) 3. Shift solenoid valve (SLU) circuit *1 4. ECM Harsh engagement (Any driving position) ECM 1. ATF temperature sensor No. 2 circuit 2. Engine coolant temp. sensor circuit *1 Poor acceleration 3. Shift solenoid valve (SLT) circuit *1 4. ECM No engine braking ECM No kick-down ECM Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. ATF temperature sensor No. 2 circuit AT Oil Temp. warning light remains on, Lock-up at 3rd gear and/or shift point too high 2. Engine coolant temp. sensor circuit 3. ECM 1. Park/neutral position switch circuit *1 Malfunction in shifting 2. ECM 2. Chapter 2: On-vehicle Repair SYMPTOM SUSPECTED AREA SEE PAGE 1. Transmission control cable Vehicle does not move with shift lever in any forward position and reverse position 2. Manual valve 3. Parking lock pawl 4. Off-vehicle repair matrix chart - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1. Valve body assembly Vehicle does not move with shift lever in R position 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (1st -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (2nd -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (3rd -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (4th -> 5th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (5th -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (4th -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (3rd -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (2nd -> 1st) 2. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) No lock-up or No lock-up off 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (N -> D) 2. Valve body assembly 3. C1 accumulator 4. Off-vehicle repair matrix - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... chart 1. Shift solenoid valve (SLU) Harsh engagement (Lock-up) 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) 2. Shift solenoid valve (SLU) Harsh engagement (N -> R) 3. Valve body assembly 4. C3 accumulator 5. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) Harsh engagement (1st -> 2nd -> 3rd -> 4th -> 5th) 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Valve body assembly Harsh engagement (1st -> 2nd) 2. B3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (2nd -> 3rd) 2. C3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (3rd -> 4th) 2. C2 accumulator 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (4th -> 5th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix - A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... chart 1. Shift solenoid valve (SL1) Harsh engagement (5th -> 4th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Transmission control cable 2. Valve body assembly Slip or shudder (Forward and reverse) 3. Oil strainer 4. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (1st: L position) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (2nd: 2 position) 2. Off-vehicle repair matrix chart No kick-down Valve body assembly - 1. Shift solenoid valve (SLT) Shift point too high or too low 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Shift solenoid valve (SLT) Poor acceleration 2. Valve body assembly Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) 2. Valve body assembly 3. Chapter 3: Off-Vehicle Repair SYMPTOM SUSPECTED AREA 1. Rear planetary gear SEE PAGE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Vehicle does not move with shift lever in any forward position and reverse position unit 2. Torque converter clutch 1. Brake No. 4 (B4) Vehicle does not move with shift lever in R position 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) No up-shift (1st -> 2nd) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) No up-shift (2nd -> 3rd) Clutch No. 3 (C3) No up-shift (3rd -> 4th) Clutch No. 2 (C2) 1. Brake No. 1 (B1) No up-shift (4th -> 5th) No lock-up or No lock-up off 2. Clutch No. 1 (C1) Torque converter clutch 1. Clutch No. 1 (C1) Harsh engagement (N -> D) 2. One-way clutch No. 3 (F3) 1. Clutch No. 3 (C3) Harsh engagement (N -> R) 2. Brake No. 4 (B4) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) Harsh engagement (1 -> 2) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) Harsh engagement (2 -> 3) Clutch No. 3 (C3) Harsh engagement (3 -> 4) Clutch No. 2 (C2) 1. Brake No. 1 (B1) Harsh engagement (4 -> 5th) Harsh engagement (Lock-up) 2. Clutch No. 1 (C1) Torque converter clutch 1. One-way clutch No. 1 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (F1) Slip or shudder (Forward and reverse: After warm-up) 2. Clutch No. 3 (C3) 3. Torque converter clutch Slip or shudder (Particular position: Just after engine starts) Torque converter clutch 1. Brake No. 4 (B4) Slip or shudder (R position) 2. One-way clutch No. 1 (F1) 3. Clutch No. 3 (C3) 1. Clutch No. 1 (C1) Slip or shudder (1st) 2. One-way clutch No. 3 (F3) 1. Clutch No.1 (C1) 2. Brake No. 3 (B3) Slip or shudder (2nd) 3. One-way clutch No. 1 (F1) 4. One-way clutch No. 2 (F2) 1. Clutch No. 1 (C1) Slip or shudder (3rd) 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Clutch No. 1 (C1) Slip or shudder (4th) 2. Clutch No. 2 (C2) 1. Clutch No. 2 (C2) Slip or shudder (5th) 2. Clutch No. 3 (C3) 3. Brake No. 1 (B1) No engine braking (1st - 4th: D position) Clutch No. 1 (C1) No engine braking (1st: L position) Brake No. 4 (B4) No engine braking (2nd: 2 position) Brake No. 2 (B2) No engine braking (3rd: 3 position) Brake No. 1 (B1) Poor acceleration (All positions) Torque converter clutch 1. Clutch No. 1 (C1) 2. Clutch No. 3 (C3) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. Brake No. 1 (B1) Poor acceleration (5th) 4. Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903WX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 40°C (104°F) or less and vehicle speed is at 28 mph (45 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W75043X Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): SYSTEM DESCRIPTION (2007 4Runner) SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transmission) is an automatic transmission that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: z z Diagnostic function. Fail-safe function when a malfunction occurs. 2. OPERATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7D03NX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): SYSTEM DIAGRAM (2007 4Runner) SYSTEM DIAGRAM The configuration of the electronic control system in the A750E automatic transmission is as shown in the following chart. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7403PX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): TERMINALS OF ECM (2007 4Runner) TERMINALS OF ECM 1. ECM HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to inspected. The standard voltage between the terminals is shown under "Specific Condition". Use the illustration above as a reference for the ECM terminals. SYMBOLS (TERMINALS NO.) WIRING COLOR L (E7-9) - E1 (E61) B-L - W-B ↑ ↑ 2 (E7-10) - E1 (E6-1) TERMINAL DESCRIPTION L shift position switch signal CONDITION SPECIFIED CONDITION IG switch ON and shift lever L position 10 to 14 V ↑ IG switch ON and shift lever except L position Below 1 V G-R - W-B 2 shift position switch signal IG switch ON and shift lever 2 and L position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 2 and L position Below 1 V R (E7-11) - E1 (E6-1) R-Y - W-B R shift position switch signal IG switch ON and shift lever R position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except R position Below 1 V A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... D (E7-21) - E1 (E6-1) V - W-B D shift position switch signal IG switch ON and shift lever D and 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except D and 4 position Below 1 V 3 (E7-19) - E1 (E6-1) L - W-B 3 shift position switch signal IG switch ON and shift lever 3 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 3 position Below 1 V 4 (E7-20) - E1 (E6-1) G - W-B 4 shift position switch signal IG switch ON and shift lever 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 4 position Below 1 V STP (E8-15) - E1 (E6-1) G-Y - W-B ↑ ↑ Stop light switch signal ↑ Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V Pulse generation SLU+ (E5-15) SLU- (E5-14) R-B - R-W SLU solenoid signal 5th (lock-up) gear S2 (E5-10) - E1 (E6-1) W-L - W-B S2 solenoid signal 2nd or 3rd gear 10 to 14 V 1st, 4th or 5th gear Below 1 V 1st or 2nd gear 10 to 14 V 3rd, 4th or 5th gear Below 1 V ↑ ↑ S1 (E5-11) - E1 (E6-1) GR - W-B ↑ ↑ ↑ S1 solenoid signal ↑ (See waveform 2) Pulse generation SLT+ (E5-13) SLT- (E5-12) LG-B - L-R SLT solenoid signal Engine idle speed SR (E5-9) - E1 (E6-1) P-L - W-B 5th gear 10 to 14 V ↑ ↑ 1st gear Below 1 V SL2+ (E5-17) SL2- (E5-16) SL1+ (E5-19) SL1- (E5-18) THO1 (E5-24) - E2 SR solenoid signal ↑ B-W - B-R SL2 solenoid signal G-B - B-Y Engine idle speed SL1 solenoid signal Engine idle speed No. 1 ATF No. 1 ATF temperature: (See waveform 1) Pulse generation (See waveform 3) Pulse generation (See waveform 4) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (E4-28) THO2 (E5-32) - E2 (E4-28) SP2+ (E5-34) SP2- (E5-26) Y-G - BR temperature sensor signal L - BR No. 2 ATF temperature sensor signal L-Y - R-L Speed sensor (SP2) signal 115°C (239°F) or more No. 2 ATF temperature: 115°C (239°F) or more Vehicle speed 20 km/h (12 mph) Below 1.5 V Below 1.5 V Pulse generation (See waveform 6) Pulse generation NT+ (E5-35) - NT(E5-27) Y-R - W-R Speed sensor (NT) signal Engine idle speed STAR/NSW (E5-8) - E1 (E6-1) P - W-B Park neutral switch signal IG switch ON and shift lever P and N position Below 2 V ↑ ↑ IG switch ON and shift lever except P and N position 10 to 14 V ↑ (a) Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (b) Waveform 2 Reference: Terminal SLU+ - SLU- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition 5th (lock-up) (c) Waveform 3 Reference: Terminal SL2+ - SL2- (See waveform 5) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (d) Waveform 4 Reference: Terminal SL1+ - SL1- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (e) Waveform 5 Reference: Terminal NT+ - NT- Tool setting 1 V/DIV., 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) (f) Waveform 6 Reference: Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV. Vehicle condition Vehicle speed 20 km/h (12 mph) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W78042X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): CHECK MODE PROCEDURE (2007 4Runner) CHECK MODE PROCEDURE 1. DESCRIPTION (a) Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. In check mode, DTCs are detected with 1-trip detection logic. 2. CHECK MODE PROCEDURE (a) Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF (b) Turn the engine switch off. (c) Connect the intelligent tester together with the Controller Area Network Vehicle Interface Module (CAN VIM) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (f) Change the ECM to check mode. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if:1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the engine switch is turned from on (IG) to on (ACC) or off. NOTICE: Before check mode, make notes of the DTCs and freeze frame data. (g) Start the engine. The MIL should turn off after the engine starts. (h) Perform "MONITOR DRIVE PATTERN" for the ECT test . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (Or, simulate the conditions of the malfunction described by the customer). (i) After simulating the malfunction conditions, use the intelligent tester diagnosis selector to check the DTC and freeze frame data. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7E047X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DATA LIST / ACTIVE TEST (2007 4Runner) DATA LIST / ACTIVE TEST 1. DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) NORMAL CONDITION Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) DIAGNOSTIC NOTE - Lock-up is Input shaft speed/ SPD(NT) z Min.: 0 rpm Max.: 12,750 rpm z ON (after warming up engine): Input turbine speed (NT) is equal to engine speed OFF (idling with shift lever on N): Input turbine speed Data is displayed in increments of 50 rpm A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (NT) is nearly equal to engine speed PNP SW [NSW] PNP switch status/ ON or OFF Shift lever is: z z On P and N: ON Not on P and N: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 Stop light switch STOP LIGHT status/ SW ON or OFF Brake pedal is z z Depressed: ON Released: OFF - Shift lever position is SHIFT ECM gear shift command/ z 1st, 2nd, 3rd, 4th or 5th z z z z REVERSE PNP switch status/ ON or OFF On D: 1st, 2nd, 3rd, 4th or 5th On 4: 1st, 2nd, 3rd or 4th On 3: 1st, 2nd or 3rd On 2: 1st or 2nd On L: 1st Shift lever is: z z On R: ON Not on R: OFF - When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 DRIVE PNP switch status/ ON or OFF Shift lever is: z z On D: ON Not on D: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... P0705 4TH/DRIVE PNP switch status/ ON or OFF Shift lever is: z z On 4: ON Not on 4: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 3RD PNP switch status/ ON or OFF Shift lever is: z z On 3: ON Not on 3: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 2ND PNP switch status/ ON or OFF Shift lever is: z z On 2: ON Not on 2: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 LOW PNP switch status/ ON or OFF Shift lever is: z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect HINT: When failure still occurs even after adjusting these parts, refer to DTC P0705 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A/T OIL TEMP1 ATF temperature sensor No. 1 value/ Min.: -40°C (-40° F) z z Max.: 215°C (419° F) A/T OIL TEMP2 ATF temperature sensor No. 2 value/ Min.: -40°C (-40° F) LOCK UP ON or OFF z z SOLENOID (SLU) SOLENOID (SLT) Lock-up solenoid status/ ON or OFF Shift solenoid SLU status/ ON or OFF After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited Lock-up is z z LOCK UP SOL If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited cold Max.: 215°C (419° F) Lock up/ After stall test: Approximately 80°C (176° F) Equal to ambient temperature while engine is Operating: ON Not operating: OFF - Lock-up solenoid is z z Operating: ON Not operating: OFF - Shift solenoid SLU is z z Shift solenoid SLT status/ z ON or OFF z Operating: ON Not operating: OFF Accelerator pedal is depressed: OFF Accelerator pedal is released: ON - - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (e) Push the "ON" button of the intelligent tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE [Vehicle Condition] SOLENOID (SLU) Operate the shift solenoid SLU ON or OFF z z Engine stopped Shift lever P or N position ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure HINT: z z [Vehicle Condition] OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling [Vehicle Condition] SOLENOID (S1) Operate the shift solenoid S1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (S2) Operate the shift solenoid S2 ON or OFF z z Engine stopped Shift lever P or N position Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic transmission to lock-up condition [Vehicle Condition] ON or OFF z z SHIFT Operate shift solenoid valve and set each shift position by yourself z z Press "→" button: Shift up Press "←" button: Shift down Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less [Vehicle Condition] A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... SOLENOID (SR) Operate the shift solenoid SR ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL1) Operate the shift solenoid SL1 ON or OFF z z Engine stopped Shift lever P or N position [Vehicle Condition] SOLENOID (SL2) Operate the shift solenoid SL2 ON or OFF z z Engine stopped Shift lever P or N position *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. as A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7I040X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DEFINITION OF TERMS (2007 4Runner) DEFINITION OF TERMS TERM DEFINITION Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs Group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Sequence of operation Required sensor/components Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. The sensors and components that are used by the ECM to detect malfunctions. The number of times that the ECM checks for malfunctions per driving cycle. "Once per driving cycle" means that the ECM detects malfunction only one Frequency of operation time during a single driving cycle. "Continuous" means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL illumination timing after a defect is detected. MIL operation "Immediately" means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. "2 driving cycle" means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W76047X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DIAGNOSIS SYSTEM (2007 4Runner) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (complying with SAE J1987). Various data output from the vehicle's ECM can then be read. (b) OBD II regulations require that the vehicle's on-board computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (1) The emission control system/components (2) The power train control components (which affect vehicle emissions) (3) The computer In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. (c) To check DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) of the vehicle. The intelligent tester displays DTCs, the freeze frame data and a variety of the engine data. The DTCs and freeze frame data can be erased with the intelligent tester . 2. NORMAL MODE AND CHECK MODE (a) The diagnosis system operates in "normal mode" during normal vehicle use. In normal mode, "2 trip detection logic" is used to ensure accurate detection of malfunctions. "Check mode" is also available to technicians as an option. In check mode, "1 trip detection logic" is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent malfunctions. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. 2 TRIP DETECTION LOGIC (a) When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate. 4. FREEZE FRAME DATA (a) The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up or not, whether the air/fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction. (b) The intelligent tester displays freeze frame data recorded at five different points: 1) 3 times before the DTC is set, 2) once when the DTC is set, and 3) once after the DTC is set. The data can be used to simulate the vehicle's condition around the time of the malfunction. The data may be helpful in determining the cause of a malfunction. It may also be helpful in determining whether a DTC is being caused by a temporary malfunction. 5. DATA LINK CONNECTOR 3 (DLC3) (a) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Terminal of DLC3 SYMBOLS (TERMINAL NO.) TERMINAL DESCRIPTION CONDITION SPECIFIED CONDITION SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) Body ground Chassis ground Always Below 1 Ω Always Below 1 Ω SG (5) - Body Signal ground ground BAT (16) Body ground Battery positive Always CANH (6) CANL (14) CAN bus line Ignition switch OFF* 54 to 69 Ω HIGH-level Ignition 6 kΩ or CANH (6) Battery 9 to 14 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... positive CAN bus line switch OFF* higher CANH (6) CG (4) HIGH-level CAN bus line Ignition switch OFF* 200 Ω or higher CANL (14) Battery positive LOW-level CAN bus line Ignition switch OFF* 6 kΩ or higher CANL (14) CG (4) LOW-level CAN bus line Ignition switch OFF* 200 Ω or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch ON and attempt to use the tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. 6. CHECK BATTERY VOLTAGE Battery voltage: 11 to 14 V (a) If voltage is below 11 V, replace the battery before proceeding. 7. CHECK MIL (a) Check that the MIL illuminates when turning the ignition switch to the ON position. If the MIL does not illuminate, there is a problem in the MIL circuit . (b) When the engine is started, the MIL should turn off. 8. ALL READINESS (a) For this vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been complete, readiness codes are set. Enter the following menus: ENHANCED OBD II / MONITOR STATUS on the intelligent tester. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 S Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W71044X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DIAGNOSTIC TROUBLE CODE CHART (2007 4Runner) DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT: z z z *1: Comes on MIL (Malfunction Indicator Lamp) light up *2: "DTC stored" mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition. This DTC may be output when the clutch, brake and gear components etc. inside the automatic transmission are damaged. AUTOMATIC TRANSMISSION SYSTEM: DTC CODE P0705 DETECTION ITEM Transmission Range Sensor Circuit Malfunction (PRNDL Input) TROUBLE AREA MIL *1 1. Open or short in Comes park/neutral position switch on circuit MEMORY *2 DTC stored 2. Park/neutral position switch 3. ECM P0710 Transmission Fluid Temperature Sensor "A" Circuit 1. Open or short in ATF temperature sensor No. 1 circuit Comes on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0711 Transmission Fluid Temperature Sensor "A" Performance Transmission wire (ATF temperature sensor No. 1) Comes on DTC stored P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input 1. Short in ATF temperature sensor No. 1 circuit Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 1 circuit on DTC stored 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. Transmission wire (ATF temperature sensor No. 1) 3. ECM P0717 Turbine Speed Sensor Circuit No Signal 1. Open or short in speed sensor (NT) circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Speed sensor (NT) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0722 Output Speed Sensor Circuit No Signal 1. Open or short in speed sensor (SP2) circuit 2. Speed sensor (SP2) 3. ECM 4. Automatic transmission (clutch, brake or gear, etc.) P0724 Brake Switch "B" Circuit High 1. Short in stop light switch signal circuit 2. Stop light switch 3. ECM P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) 1. Shift solenoid valve SL1 remains closed 2. Shift solenoid valve SR remains open or closed 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) 1. Open or short in shift solenoid valve SL1 circuit 2. Shift solenoid valve SL1 3. ECM P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) 1. Shift solenoid valve S1 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) 1. Shift solenoid valve S2 remains open or closed 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) 1. Shift solenoid valve SR remains open or closed 2. Shift solenoid valve SL1 remains closed A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. Valve body is blocked 4. Automatic transmission (clutch, brake or gear, etc.) P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) 1. Shift solenoid valve SL2 remains open Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Automatic transmission (clutch, brake or gear, etc.) P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) 1. Open or short in shift solenoid valve SL2 circuit 2. Shift solenoid valve SL2 3. ECM P0781 1-2 Shift (1-2 Shift Valve) 1. Valve body is blocked up or stuck (1-2 shift valve) 2. Automatic transmission (clutch, brake or gear, etc.) P0894 Transmission Component Slipping 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) 1. Short in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) 1. Open in shift solenoid valve S1 circuit 2. Shift solenoid valve S1 3. ECM P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) 1. Short in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) 1. Open in shift solenoid valve S2 circuit 2. Shift solenoid valve S2 3. ECM P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) 1. Short in shift solenoid valve SR circuit 2. Shift solenoid valve SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. ECM P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) 1. Open in shift solenoid valve SR circuit Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored Comes on DTC stored 1. Open in ATF temperature Comes sensor No. 2 circuit on DTC stored 2. Shift solenoid valve SR 3. ECM P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) 1. Shift solenoid valve SLT remains open or closed 2. Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 3. 1-2 shift valve is stuck 4. Valve body is blocked 5. Automatic transmission (clutch, brake or gear, etc.) P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) 1. Open or short in shift solenoid valve SLT circuit 2. Shift solenoid valve SLT 3. ECM P2740 Transmission Fluid Temperature Sensor "B" Circuit 1. Open or short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input 1. Short in ATF temperature sensor No. 2 circuit 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input 2. Transmission wire (ATF temperature sensor No. 2) 3. ECM P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) 1. Shift solenoid valve SLU remains open or closed Comes on DTC stored Comes on DTC stored 2. Valve body is blocked 3. Torque converter clutch 4. Automatic transmission (clutch, brake or gear, etc.) 5. Line pressure is too low P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit 1. Open or short in shift solenoid valve SLU circuit A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Electrical (Shift Solenoid Valve SLU) 2. Shift solenoid valve SLU 3. ECM P2772 Transfer "L4" Switch Circuit 1. Short in transfer L4 position switch circuit 2. Four wheel drive control ECU 3. ECM Comes on DTC stored A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W77042X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): DTC CHECK / CLEAR (2007 4Runner) DTC CHECK / CLEAR 1. CHECK DTC (a) DTCs which are stored in the ECM can be displayed with the intelligent tester or generic OBD II scan tool. These scan tools can display pending DTCs and current DTCs. Some DTC aren't stored if the ECM doesn't detect a malfunction during consecutive driving. However, the detected malfunction during once driving is stored as pending DTC. (1) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the Data Link Connector 3 (DLC3). (2) Turn the ignition switch to the ON position. (3) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES (or PENDING CODE). (4) Confirm the DTCs and freeze frame data and then write them down. (5) Confirm the details of the DTCs . NOTICE: When simulating a symptom with the scan tool to check the DTCs, use normal mode. For codes on DIAGNOSTIC TROUBLE CODE CHART which are subject to "2-trip detection logic", perform the following actions. Turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM. 2. CLEAR DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch to the ON position. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES and A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... press YES. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O8L047X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): FAILSAFE CHART (2007 4Runner) FAIL-SAFE CHART 1. FAIL-SAFE CHART This function minimizes the loss of the ECT functions when a malfunction occurs in each sensor or solenoid. MALFUNCTION PART FUNCTION No. 1 ATF Temperature Sensor During a No. 1 ATF temperature sensor malfunction, up-shift to the 5th gear and flex lock-up clutch control are prohibited. Output Speed Sensor During an output speed sensor malfunction, shift control is effected through the (SP2) input speed sensor signal (NT). Shift Solenoid Valve S1, S2 and SR The current to the failed solenoid valve is cut off and control is effected by operating the other solenoid valves with normal operation. Shift control is effected depending on the failed solenoid as described in the table below. Shift Solenoid Valve SL1 and SL2 During a solenoid valve SL1 or SL2 malfunction, up-shift to the 5th gear is prohibited. Shift Solenoid Valve SLT During a solenoid valve SLT malfunction, the current to the solenoid valve is stopped. This stops line pressure optimal control, and shift shock increases. However, shifting is effected through normal clutch pressure control. Shift Solenoid Valve SLU During a solenoid valve SLU malfunction, the current to the solenoid valve is stopped. This stops lock-up control and flex lock-up control, and fuel economy decreases. Fail-safe function: If either of the shift solenoid valve circuits has an open or short failure, the ECM turns the other shift solenoid ON and OFF in order to shift into the gear positions shown in the table below. In case of a short circuit, the ECM stops sending current to the short circuit solenoid. Even if starting the engine again in the fail-safe mode, the gear position remains in the same position. HINT: z z z ↓: Condition in the electrical malfunction is shown above "↓". ↓: Condition in fail-safe mode is shown below "↓". E/B: Engine brake. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... POSITION R NORMAL S1 OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th 1st ON OFF OFF OFF ON ↓ OFF OFF 3rd D ↓ ON 2nd ON ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON OFF OFF 3rd ↓ OFF OFF 3rd E/B ↓ ON OFF ON 3rd 3 2 L 2nd ON D OFF OFF ON ↓ ON OFF ON OFF OFF ↓ OFF 3rd E/B 3rd E/B OFF ON OFF OFF OFF 3rd E/B OFF ON OFF OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st ON OFF OFF OFF ON 1st OFF OFF OFF OFF ON 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 1st E/B ON OFF OFF OFF OFF 1st E/B OFF OFF OFF OFF OFF 2nd E/B ON ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 3rd E/B OFF ON ON OFF OFF 4th OFF OFF ON OFF ON 4th OFF OFF ON OFF ON 5th OFF OFF ON ON OFF 5th OFF OFF ON ON OFF POSITION R ON ↓ S2 OFF SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R ON OFF OFF OFF ON R ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ OFF OFF OFF ON 2nd ON ON OFF OFF ON 4th OFF A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 5th OFF OFF ON ON OFF 4th OFF OFF OFF ON OFF 1st ON OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON ↓ ↓ 2nd ON ON OFF OFF ON 3rd E/B OFF 3rd E/B OFF OFF ON OFF OFF ON OFF OFF OFF ↓ OFF 3rd E/B OFF OFF OFF OFF 3 ↓ OFF 3rd ON OFF 4th OFF OFF ON OFF ON 3rd OFF ↓ ON OFF OFF ON 3rd E/B 5th OFF OFF ON ON OFF ↓ OFF ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF OFF ON OFF 1st E/B ON 2nd E/B ON ↓ ↓ 4th OFF Fail 4th OFF OFF OFF ON OFF OFF ON OFF ON OFF ↓ 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ON OFF ON OFF ↓ OFF 2nd OFF OFF ON ON OFF ON OFF OFF OFF OFF ON OFF ON OFF OFF ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF ↓ ↓ 2nd ON 1st E/B ON OFF OFF OFF OFF ON 2nd ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF ↓ OFF ON ON OFF ↓ OFF OFF OFF ↓ ON OFF ON OFF ↓ OFF 2nd ON 4th ↓ OFF OFF L ↓ ON ON 5th ON OFF OFF 2 OFF OFF ON 1st OFF 4th ↓ ↓ ON OFF 3rd 1st ↓ OFF ON OFF ON ↓ ON 1st OFF OFF ↓ ↓ ↓ 2nd ON ON 1st E/B OFF OFF ON ↓ OFF ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 5th OFF POSITION R D OFF ON ON OFF ↓ ↓ ↓ 2nd ON ON S1 S2 OFF OFF ↓ OFF S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R ON OFF OFF OFF ON 4th OFF OFF OFF OFF ON 1st ON OFF OFF OFF ON 1st ON 4th OFF OFF OFF OFF ON ↓ ↓ OFF OFF OFF ON 4th OFF 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF 5th OFF OFF ON ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF ON 3rd ↓ ON OFF OFF OFF OFF ↓ 1st ON 3rd E/B OFF 3rd ON 1st E/B ON ↓ ↓ ↓ OFF 3rd OFF ↓ OFF OFF OFF OFF 3rd E/B OFF OFF ON OFF OFF OFF 3rd E/B OFF OFF OFF OFF OFF ↓ ↓ ON 3rd E/B 3 OFF OFF OFF OFF OFF OFF 3rd ↓ ON ON 4th OFF OFF ON OFF ON 3rd OFF OFF OFF OFF ↓ ON 1st E/B 5th OFF OFF ON ON OFF ↓ OFF OFF OFF 3rd 1st Fail 4th 2 Fail 4th OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON 1st OFF 1st E/B ↓ ↓ ON 1st OFF 1st E/B ON OFF OFF ON OFF ↓ ↓ OFF ON OFF ON OFF ON OFF OFF OFF ↓ ON OFF ↓ ↓ ↓ ON 1st ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st ↓ ON OFF OFF OFF ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1st E/B 5th OFF OFF ON ON 1st E/B OFF OFF OFF OFF Fail 4th OFF OFF ON OFF Fail 4th OFF OFF ON OFF L OFF OFF ON OFF ↓ ↓ 1st ON OFF 1st E/B ON OFF OFF 1st E/B ↓ ↓ ON OFF ON 1st OFF 1st E/B OFF ↓ ↓ ↓ ON 1st ON OFF OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ↓ ON OFF 4th OFF OFF ON OFF ON 1st OFF ↓ OFF OFF ON ON OFF ON 1st E/B 5th OFF POSITION R ON ON OFF ↓ ↓ 1st ON OFF ↓ ↓ OFF ON S1 S2 SR OFF GEAR S1 S2 SR SL1 SL2 GEAR S1 S2 SR SL1 SL2 R OFF OFF OFF OFF ON R OFF OFF OFF OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON ↓ OFF OFF 3rd ↓ ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 3rd OFF ON OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON 4th OFF OFF OFF OFF ON ON OFF ON OFF 4th OFF OFF OFF ↓ ↓ OFF ON OFF 3rd OFF ↓ 3rd OFF ON 4th OFF OFF OFF ↓ ↓ OFF ON ON OFF OFF ON 3 OFF S1 SR OFF 4th D OFF OFF OFF OFF ↓ ON 3rd OFF OFF OFF OFF ON ON ON ↓ 3rd OFF OFF OFF OFF ON 3rd E/B ↓ OFF ON OFF OFF 3rd 3rd OFF OFF ↓ OFF OFF ↓ ON ON OFF 3rd E/B ↓ ↓ ON 3rd ON 3rd ↓ ↓ OFF OFF OFF OFF OFF ↓ ON OFF OFF OFF OFF ON ↓ A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ON 3rd E/B ↓ OFF OFF 3rd 1st ON ↓ OFF ON OFF OFF OFF ON ON OFF 3rd E/B ↓ ↓ ↓ OFF ON 3rd OFF ON 1st OFF OFF OFF OFF OFF OFF ON OFF ↓ ↓ OFF ON OFF ON 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF 2 ↓ OFF OFF OFF OFF OFF ON 1st E/B OFF ↓ OFF OFF OFF OFF 1st 1st ↓ OFF OFF 2nd 2nd 1st E/B OFF ↓ ON OFF ON OFF OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF OFF OFF ↓ 1st E/B OFF OFF OFF OFF ↓ 1st OFF 1st E/B OFF OFF OFF 1st E/B 2nd 2nd OFF OFF ON ON OFF OFF OFF OFF OFF OFF L ↓ OFF OFF OFF OFF OFF ↓ OFF OFF 2nd ON 1st E/B OFF ↓ OFF OFF OFF OFF 2nd ↓ ON ON OFF ↓ 1st OFF OFF OFF OFF OFF OFF OFF ON ON OFF ↓ ↓ OFF ON OFF OFF OFF ↓ ON OFF ON 1st E/B ↓ ↓ ↓ 1st 1st 1st ↓ ON ON OFF ON 1st E/B ↓ ↓ ↓ 1st ON OFF ↓ OFF 1st E/B OFF ↓ 1st A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W6Z048X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): HOW TO PROCEED WITH TROUBLESHOOTING (2007 4Runner) HOW TO PROCEED WITH TROUBLESHOOTING HINT: z z The ECM of this system is connected to the CAN and multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN and multiplex communication systems. *: Use the intelligent tester. 1. VEHICLE BROUGHT TO WORKSHOP NEXT 2. CUSTOMER PROBLEM ANALYSIS NEXT 3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4. CONNECT INTELLIGENT TESTER TO DLC3* NEXT 5. CHECK AND CLEAR DTCS AND FREEZE FRAME DATA* A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Refer to the DTC CHECK/CLEAR . NEXT 6. VISUAL INSPECTION NEXT 7. SETTING CHECK MODE DIAGNOSIS* . (a) Refer to the CHECK MODE PROCEDURE NEXT 8. PROBLEM SYMPTOM CONFIRMATION (a) Refer to the ROAD TEST . Result: RESULT PROCEED TO Symptom does not occur A Symptom occurs B B GO TO STEP 10 A 9. SYMPTOM SIMULATION (a) Refer to the ELECTRONIC CIRCUIT INSPECTION PROCEDURE NEXT 10. DTC CHECK* . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Refer to the DTC CHECK / CLEAR . Result: RESULT PROCEED TO DTC is not output A DTC is output B B GO TO STEP 19 A 11. BASIC INSPECTION (a) Refer to the AUTOMATIC TRANSMISSION FLUID . (b) Refer to the PARK/NEUTRAL POSITION SWITCH . . (c) Refer to the SHIFT LEVER ASSEMBLY NG GO TO STEP 22 OK 12. MECHANICAL SYSTEM TEST . (a) Refer to the MECHANICAL SYSTEM TEST NG GO TO STEP 18 NG GO TO STEP 18 OK 13. HYDRAULIC TEST (a) Refer to the HYDRAULIC TEST . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 14. MANUAL SHIFTING TEST (a) Refer to the MANUAL SHIFTING TEST . NG GO TO STEP 17 OK 15. PROBLEM SYMPTOMS TABLE CHAPTER 1 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 20 OK 16. PROBLEM SYMPTOMS TABLE CHAPTER 2 . (a) Refer to the PROBLEM SYMPTOMS TABLE NG GO TO STEP 18 OK 17. PROBLEM SYMPTOMS TABLE CHAPTER 3 (a) Refer to the PROBLEM SYMPTOMS TABLE . NEXT 18. PART INSPECTION NEXT GO TO STEP 22 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 19. DTC CHART (a) Refer to the DIAGNOSTIC TROUBLE CODE CHART . NEXT 20. CIRCUIT INSPECTION NEXT 21. IDENTIFICATION OF PROBLEM NEXT 22. REPAIR OR REPLACE NEXT 23. CONFIRMATION TEST NEXT END A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7B043X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): HYDRAULIC TEST (2007 4Runner) HYDRAULIC TEST 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE: z z z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. Be careful to prevent SST hose from interfering with the exhaust pipe. This Check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. When conducting stall test, do not continue more than 5 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Turn the ignition switch off. (3) Lift the vehicle up. (4) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (5) Lower the vehicle. (6) Fully apply the parking brake and chock the 4 wheels. (7) Start the engine and check idling speed. (8) Keep your left foot pressing firmly on the brake pedal and shift into D position. (9) Measure the line pressure when the engine is idling. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (10) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (11) In the same manner, do the test in R position. Specified line pressure: CONDITION Idling D POSITION KPA R POSITION KPA (KGF/CM 2, PSI) (KGF/CM 2, PSI) 362 to 420 kPa 500 to 580 kPa (3.7 to 4.2 kgf/cm 2, 53 to 59 psi) (5.1 to 5.9 kgf/cm 2, 73 to 84 psi) 1,360 to 1,460 kPa Stall test 1,295 to 1,415 kPa 2 (13.8 to 14.9 kgf/cm , (13.2 to 14.4 kgf/cm 2, 196 to 212 psi) 188 to 205 psi) Evaluation: PROBLEM If the measured values at all position are higher POSSIBLE CAUSE z z If the measured values at all position are lower z z z If pressure is low in the D position only z z If pressure is low in the R position only z z z Shift solenoid valve (SLT) defective Regulator valve defective Shift solenoid valve (SLT) defective Regulator valve defective Oil pump defective D position circuit fluid leak Clutch No.1 (C 1) defective R position circuit fluid leak Clutch No.3 (C 3) defective Brake No.4 (B 4) defective A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03XX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7C045X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MANUAL SHIFTING TEST (2007 4Runner) MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transmission. If any abnormalities are found in the following test, the problem is in the transmission itself. z z (a) Disconnect the connector of the transmission wire. (b) Drive with the transmission wire disconnected. Shifting the shift lever to the L, 2, 3, 4 and D position to check whether the shifting condition changes the table below. SHIFT POSITION SHIFTING CONDITION L ←→ 2 No Shift (Not Change) 2 ←→ 3 Down Shift ←→ Up Shift 3 ←→ 4 Down Shift ←→ Up Shift 4 ←→ D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the gear position will be as follows: z z z z When the shift When the shift When the shift When the shift respectively. lever lever lever lever is is is is in in in in the the the the L or the 2 position, the gear is held in the 1st position. 3 position, the gear is held in the 3rd position. 4 or the D position, the gear is held in the 4th position. R or the P position, the gear is also in the R or the P position A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (c) Connect the connector of the transmission wire. (d) Clear the DTC . A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7A045X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MECHANICAL SYSTEM TESTS (2007 4Runner) MECHANICAL SYSTEM TESTS 1. PERFORM MECHANICAL SYSTEM TESTS (a) Measure the stall speed. The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D position. NOTICE: z z z z z Driving test should be done on a paved road (a nonskid road). Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F). Do not continuously run this test for longer than 5 seconds. To ensure safety, do this test in a wide, clear level area which provides good traction. The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,150 +- 150 rpm Evaluation: PROBLEM POSSIBLE CAUSE z z (a) Stall engine speed is low in D position Engine power output may be insufficient Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. z Line pressure is too low A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Stall engine speed is high in D position Clutch No. 1 (C 1) slipping One-way clutch No. 3 (F 3) not operating properly z z Improper fluid level z (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the clutch, and brake. NOTICE: z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F). Be sure to allow 1 minute interval between tests. Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an intelligent tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): PROBLEM N → D time lag is longer POSSIBLE CAUSE z z z z N → R time lag is longer z z z Line pressure is too low Clutch No.1 (C 1) worn One-way clutch No. 3 (F 3) not operating properly Line pressure is too low Clutch No. 3 (C 3) worn Brake No. 4 (B 4) worn One-way clutch No. 1 (F 1) not operating properly A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7K041X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): MONITOR DRIVE PATTERN (2007 4Runner) MONITOR DRIVE PATTERN 1. MONITOR DRIVE PATTERN FOR ECT TEST (a) Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern.) HINT: Preparation for driving z z Warm up the engine sufficiently. (Engine coolant temperature is 60°C (140°F) or higher) Drive the vehicle when the atmospheric temperature is -10°C (14°F) or higher. (Malfunction is not detected when the atmospheric temperature is less than -10°C (14°F)) Notice in driving z Drive the vehicle through all gears. z Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON). Repeat the above driving pattern three times or more. NOTICE: z z z The monitor status can be checked using the OBD II scan tool or intelligent tester. When using the intelligent tester, monitor status can be found in the "ENHANCED OBD II / DATA LIST" or under "CARB OBD II". In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors), the drive pattern can be resumed and, in most cases, the monitor can be completed. Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8404FX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0705: Transmission Range Sensor Circuit Malfunction (PRNDL Input) (2007 4Runner) DTC P0705 Transmission Range Sensor Circuit Malfunction (PRNDL Input) DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC NO. DTC DETECTION CONDITION P0705 TROUBLE AREA z Open or short in park/neutral position switch circuit Park/neutral position switch z ECM z (2-trip detection logic) MONITOR DESCRIPTION These DTCs indicate a problem with the park/neutral position switch and the wire harness in the park/neutral position switch circuit. The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the shift lever is in the P or N position. The park/neutral position switch sends a signal to the ECM according to the shift position (P, R, N, D, 4, 3, 2 or L). The ECM determines that there is a problem with the switch or related parts if it receives more than 1 position signal simultaneously. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P0705: Park/neutral position switch/Verify switch input Required sensors/Components Park/neutral position switch Frequency of operation Continuous Condition (A) and (C) Duration 2 sec. Condition (B) 60 sec. MIL operation 2 driving cycles Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Engine switch ON Battery voltage 10.5 V or more TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A), (B) or (C) Condition (A) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON Condition (B) All of following conditions are met NSW switch OFF R switch OFF D switch OFF 3 switch OFF 2 switch OFF Condition (C) Both (i) and (ii) are met (i) One of following conditions is met NSW switch ON R switch ON (ii) One of following condition is met 4 switch ON L switch ON A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... COMPONENT OPERATING RANGE Park/neutral position switch The park/neutral position switch sends only one signal to the ECM. WIRING DIAGRAM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Shift lever is: PNP SW [NSW] PNP switch status/ z ON or OFF z When shift lever position displayed on intelligent On P and tester differs from actual position, adjustment of N: ON PNP switch or shift cable may be incorrect Not on P and N: OFF Shift lever is: REVERSE PNP switch status/ ON or OFF z z On R: ON Not on R: OFF Shift lever is: DRIVE PNP switch status/ ON or OFF z z On D: ON Not on D: OFF Shift lever is: 4TH/DRIVE PNP switch status/ ON or OFF z z On 4: ON Not on 4: OFF Shift lever is: When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3RD PNP switch status/ z ON or OFF z On 3: ON Not on 3: OFF Shift lever is: PNP switch status/ 2ND ON or OFF z z On 2: ON Not on 2: OFF Shift lever is: PNP switch status/ LOW ON or OFF z z On L: ON Not on L: OFF When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect When shift lever position displayed on intelligent tester differs from actual position, adjustment of PNP switch or shift cable may be incorrect PROCEDURE 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω Except 2 and L ↑ 10 kΩ or higher NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY OK 2. INSPECT SHIFT LOCK CONTROL ECU SUB-ASSEMBLY (TRANSMISSION CONTROL SWITCH) (a) Connect the park/neutral position switch connector. (b) Disconnect the shift lock control ECU connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION D 4 D 4 2 TESTER CONNECTION 9 - 2 (NSSD - ATD) 9 - 3 (NSSD - AT4) 10 - 5 (NSSL - AT2) SPECIFIED CONDITION Below 1 Ω 10 kΩ or higher 10 kΩ or higher Below 1 Ω Below 1 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... L 10 kΩ or higher 2 10 kΩ or higher 10 - 4 (NSSL - ATL) L NG Below 1 Ω REPLACE SHIFT LOCK CONTROL ECU SUBASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH - ECM) (a) Connect the shift lock control ECU connector. (b) Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Standard voltage: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P and N E5-8 (NSW) - Body ground Below 2 V Except P and N ↑ 10 to 14 V R E7-11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D and 4 E7-21 (D) - Body ground 10 to 14 V Except D and 4 ↑ Below 1 V 3 E7-19 (3) - Body ground 10 to 14 V Except 3 ↑ Below 1 V 2 and L E7-10 (2) - Body ground 10 to 14 V Except 2 and L ↑ Below 1 V L E7-9 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *: The voltage will drop slightly due to the turning on of the back up light. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8503XX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0710: Transmission Fluid Temperature Sensor "A" Circuit (2007 4Runner) DTC P0710 Transmission Fluid Temperature Sensor "A" Circuit DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low Input DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High Input DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 sec. when neither P0712 nor P0713 is detected (1-trip detection logic) (a) ATF temperature sensor No. 1 resistance is less than 79 Ω. P0710 z (b) ATF temperature sensor No. 1 resistance is more than 156 kΩ. z HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or z Open or short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM from (b) to (a) z P0712 ATF temperature sensor No. 1 resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic) z z z ATF temperature No. 1 sensor resistance is more than 156 kΩ P0713 when 15 minutes or more have elapsed after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic) z z Short in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM Open in ATF temperature sensor No. 1 circuit Transmission wire (ATF temperature sensor No. 1) ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω *1 or more than 156 kΩ *2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P0710: ATF temperature sensor/Range check (Chattering) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Related DTCs P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0710: Range check (Chattering) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0712: Range check (Low resistance) The monitor will run whenever this DTC is not present. None The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. None Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω or more than 156 kΩ P0712: Range check (Low resistance) TFT sensor resistance. P0713: Range check (High resistance) Less than 79 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TFT sensor resistance. More than 156 kΩ COMPONENT OPERATING RANGE TFT sensor. Atmospheric temperature to approx. 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on tester, read the "DATA LIST". A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal OIL and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150 °C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE 1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 2 (OT-) - 10 (OT+) 79 Ω to 156 kΩ 2 (OT-) - Body ground 10 kΩ or higher 10 (OT+) - Body ground 10 kΩ or higher HINT: If the resistance is out of the specified range with either the ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20 °C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-24 (THO1) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Z03MX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0711: Transmission Fluid Temperature Sensor "A" Performance (2007 4Runner) DTC P0711 Transmission Fluid Temperature Sensor "A" Performance DESCRIPTION . DTC NO. DTC DETECTION CONDITION TROUBLE AREA Both (a) and (b) are detected: (2-trip detection logic) P0711 (a) Intake air and engine coolant temps. are more than -10° Transmission wire (ATF C (14°F) at engine start temperature sensor No. 1) (b) After normal driving for over 22 min. and 9 km (6 mile) or more, ATF temp. is less than 10°C (50°F) MONITOR DESCRIPTION This DTC indicates that there is a problem with output from the automatic transmission fluid (ATF) temperature sensor and that the sensor itself is defective. The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault in the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 10°C (50°F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. MONITOR STRATEGY Related DTCs P0711: ATF temperature sensor/Rationality check Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 3 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None TFT sensor circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 21 min. and 40 sec. Driving distance after engine start 5.6 mile (9 km) or more IAT (12 sec. after engine start) -10°C (14°F) or more ECT (12 sec. after engine start) -10°C (14°F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (Transmission fluid temperature) Less than 10°C (50°F) (ATF temperature = -10°C (14°F) at engine start) (Conditions vary with ATF temperature at engine start) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP1 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 1 value/ Min.: -40°C (-40°F) Max.: 215°C (419°F) z z NORMAL CONDITION DIAGNOSTIC NOTE After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 1 circuit is opened or short circuited HINT: When DTC P0712 is output and OBD II scan tool or intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P0713 is output and OBD II scan tool or intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO1 (OT) and body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. PROCEDURE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0711) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0711" is output A "P0711" and other DTCs B HINT: If any other codes besides "P0711" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. CHECK TRANSMISSION FLUID LEVEL OK: Automatic transmission fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7Y01NX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0717: Turbine Speed Sensor Circuit No Signal (2007 4Runner) DTC P0717 Turbine Speed Sensor Circuit No Signal DESCRIPTION This sensor detects the rotation speed of the turbine which shows the input revolution of transmission. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (SP2), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC NO. DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected for 5 secs. or more (1-trip detection logic) (a) Gear change is not performed P0717 (b) Gear position: 4th or 5th (c) T/M input shaft rpm: 300 rpm or less z Open or short in speed sensor (NT) circuit Speed sensor (NT) ECM z Automatic transmission (clutch, z (d) T/M output shaft rpm: 1,000 rpm or more (e) Park/neutral position switch: z NSW input signal is OFF z A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z R input signal is OFF L input signal is OFF brake or gear, etc.) (f) Shift solenoid valves and park/neutral position switch are in normal operation Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NT- of the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 1 V/DIV, 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) MONITOR DESCRIPTION This DTC indicates that pulse is not output from the speed sensor NT (Turbine (input) speed sensor) or is output only little. The NT terminal of the ECM detects the revolving signal from speed sensor (NT) (input RPM). The ECM outputs a gearshift signal comparing the input speed sensor (NT) with the output speed sensor (SP2). While the vehicle is operating in the 4th or 5th gear position in the shift position of D, if the input shaft revolution is less than 300 rpm *1 although the output shaft revolution is more than 1,000 rpm or more *2 , the ECM detects the trouble, illuminates the MIL and stores the DTC. *1 : Pulse is not output or is irregularly output. *2 : The vehicle speed is approx. 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs P0717: Speed sensor (NT)/Verify pulse input Required sensors/Components (Main) Speed sensor (NT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components (Related) Speed sensor (NC) Frequency of operation Continuous Duration 5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Shift change Shift change is completed and before starting next shift change operation ECM selected gear 4th or 5th Output shaft rpm 1,000 rpm or more NSW (STAR) switch OFF R switch OFF L switch OFF Engine Running Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Input speed is equal to engine speed when lock-up ON. WIRING DIAGRAM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Lock-up is Input shaft speed/ SPD(NT) Min.: 0 rpm z Max.: 12,750 rpm z ON (after warming up engine): Input Data is displayed in turbine speed (NT) is equal to engine increments of 50 rpm speed OFF (idling with shift lever on N): Input turbine speed (NT) is nearly equal to A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... engine speed HINT: z SPD(NT) is always 0 while driving: z Open or short in the sensor or circuit. SPD(NT) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (NT) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG SECURELY INSTALL SPEED SENSOR OR REPLACE SPEED SENSOR OK 2. INSPECT SPEED SENSOR (NT) (a) Disconnect the speed sensor connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (NT) OK 3. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-35 (NT+) - E5-27 (NT-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-35 (NT+) - Body ground 10 kΩ or higher E5-27 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012TD00WX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0722: Output Speed Sensor Circuit No Signal (2007 4Runner) DTC P0722 Output Speed Sensor Circuit No Signal DESCRIPTION The speed sensor SP2 detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the speed sensor SP2 coil as the parking gear mounted on the rear planetary gear assembly rotates, and this voltage is sent to the ECM. The parking gear on the rear planetary gear is used as the timing rotor for this sensor. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. DTC NO. P0722 DTC DETECTION CONDITION TROUBLE AREA All conditions below are detected 500 times or more continuously (1-trip detection logic) (a) No signal from speed sensor (SP2) is input to ECM while 4 pulses of No. 1 vehicle speed sensor signal are sent z z Open or short in speed sensor (SP2) circuit Speed sensor (SP2) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Vehicle speed is 9 km/h (6 mph) or more for at least 4 sec. z z (c) Park/neutral position switch is OFF. ECM Automatic transmission assembly (clutch, brake or gear, etc.) (d) Transfer position is except neutral (4WD). Reference (Using an oscilloscope): Check the waveform between terminals SP2+ and SP2- of the ECM connector. Standard: Refer to the illustration. Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV Vehicle condition Vehicle speed 20 km/h (12 mph) MONITOR DESCRIPTION The output speed sensor SP2 monitors the output shaft speed. The ECM controls the gearshift point and the lock up timing based on the signals from the output speed sensor SP2 and throttle position sensor. If the ECM detects no signal from the output shaft speed sensor SP2 even while the vehicle is moving, it will conclude that is a malfunction of the output speed sensor SP2. The ECM will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0722 : Speed sensor SP2/Verify pulse input Required Sensors/Components Speed sensor SP2 Frequency of operation Continuous Duration 5 sec. MIL operation 2 driving cycles Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 (Trans solenoid (range)) Vehicle speed range (4 sec. or more) 9 km/h (5.59 mph) or more Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output speed sensor signal No signal WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch off. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (g) According to the display on the tester, read the "DATA LIST". TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION DIAGNOSTIC NOTE Output shaft speed/ SPD(SP2) Min.: 0 km/h (0 mph) Max.: 255 km/h (158 mph) Vehicle stopped: 0 km/h (0 mph) (output shaft speed is equal to vehicle speed) - HINT: z SPD(SP2) is always 0 while driving: z Open or short in the sensor or circuit. SPD(SP2) value displayed on the tester is much lower than the actual vehicle speed: Sensor trouble, improper installation, or intermittent connection trouble of the circuit. PROCEDURE 1. INSPECT SPEED SENSOR INSTALLATION (a) Check the speed sensor (SP2) installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transmission case. NG OK 2. INSPECT SPEED SENSOR (SP2) SECURELY INSTALL SENSOR OR REPLACE SENSOR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Disconnect the speed sensor connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω NG REPLACE SPEED SENSOR (SP2) OK 3. CHECK WIRE HARNESS AND CONNECTOR (SPEED SENSOR SP2 - ECM) (a) Connect the speed sensor connector. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-34 (SP2+) - E5-26 (SP2-) 560 to 680 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-34 (SP2+) - Body ground 10 kΩ or higher E5-26 (SP2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8802ZX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0724: Brake Switch "B" Circuit High (2007 4Runner) DTC P0724 Brake Switch "B" Circuit High DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC NO. DTC DETECTION CONDITION The stop light switch remains ON even when the vehicle is driven in a P0724 STOP (less than 3 km/h (2 mph)) and GO (30 km/h (19 mph) or more) fashion 5 times. (2-trip detection logic). TROUBLE AREA z z z Short in stop light switch signal circuit Stop light switch ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) five times for two driving cycles in order to detect a malfunction. MONITOR STRATEGY Related DTCs P0724: Stop light switch/Range check/Rationality Required sensors/Components Stop light switch, Vehicle speed sensor Frequency of operation Continuous Duration GO and STOP 5 times MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The stop light switch remains on during GO and STOP 5 times. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... GO and STOP is defined as follows; The monitor will run whenever this DTC is not present. None GO: (Vehicle speed is 18.63 mph (30 km/h) or more) Once STOP: (Vehicle speed is less than 1.86 mph (3 km/h)) Once Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times WIRING DIAGRAM . INSPECTION PROCEDURE PROCEDURE 1. READ VALUE OF DATA LIST (STP SIGNAL) HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn on the tester. (e) Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". (f) According to the display on the tester, read the "DATA LIST". Standard: TESTER DISPLAY MEASUREMENT ITEM/RANGE NORMAL CONDITION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... STOP LIGHT SW Brake pedal is Stop light switch status/ ON or OFF Depressed: ON Released: OFF z z NOTICE: In the table above, the conditions listed under "Normal Condition" are reference conditions. Do not depend solely on these reference conditions when deciding whether a part is faulty or not. OK CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) NG 2. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Switch pin free 1-2 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher Switch pin free 3-4 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK 3. CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - ECM) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Install the stop light switch assembly. (b) Disconnect the ECM connector. (c) Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard voltage: CONDITION TESTER CONNECTION SPECIFIED CONDITION Brake pedal is depressed E8-15 (STP) - Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002SNB003X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0746: Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0746 Pressure Control Solenoid "A" Performance (Shift Solenoid Valve SL1) DTC P0771 Shift Solenoid "E" Performance (Shift Solenoid Valve SR) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0746 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z z P0771 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z z Shift solenoid valve SL1 remains closed Shift solenoid valve SR remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SR remains open or closed Shift solenoid valve SL1 remains closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates a stuck ON malfunction or stuck OFF malfunction of the shift solenoid valve SR and SL1. The ECM commands gear shifts by turning the shift solenoid valves ON/OFF. When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... MONITOR STRATEGY P0746: Shift solenoid valve SL1/OFF malfunction Related DTCs P0771: Shift solenoid valve SR/ON malfunction P0771: Shift solenoid valve SR/OFF malfunction Required sensors/Components (Main) Shift solenoid valve SL1 Shift solenoid valve SR Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous P0746 and P0771 OFF malfunction (A) and (B): 0.4 sec. Duration P0746 and P0771 OFF malfunction (C): Immediate P0771 ON malfunction: 0.15 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting P0746 and P0771: OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear 5th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) P0746 and P0771: OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more P0746 and P0771: OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th P0771: ON malfunction Current ECM selected gear 2nd Last ECM selected gear 1st Throttle valve opening angle (During transition from 1st to 2nd gear) 6.5% or more at 3,000 rpm (Vary with turbine speed) TYPICAL MALFUNCTION THRESHOLDS [P0746 and P0771: OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Not change as follow Turbine speed/Output speed 0.93 to 1.07 ↓ 0.65 to 0.79 OFF malfunction (C) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Output record from ECM for 4th → 5th upshifting Recorded [P0771: ON malfunction] 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON ON malfunction Turbine speed - Output speed x 1st gear ratio (NT - NO x 1st gear ratio) 150 rpm or more INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Operate shift solenoid valve and set each shift position by yourself SHIFT z Press "→" z button: Shift up Press "←" button: Shift down Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SR and SL1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0746 AND P0771) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0746 and P0771 are output Only P0771 is output A P0746, P0771 and other DTCs are output B z z HINT: If any other codes besides P0746 and P0771 are output, perform troubleshooting for those DTCs first. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* [Vehicle Condition] HINT: Operate the shift solenoid SLT and raise line pressure z z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that Result: LINE PRESSURE VALUE DTC OUTPUT IN PREVIOUS CHECK PROCEED TO Changed P0746 and P0771 A Changed P0771 B Not changed - C B INSPECT SHIFT SOLENOID VALVE SR C REPLACE SHIFT SOLENOID VALVE SLT A 3. INSPECT SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 4. INSPECT SHIFT SOLENOID VALVE SR REPLACE SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SR OK 5. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8F02LX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0748: Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) (2007 4Runner) DTC P0748 Pressure Control Solenoid "A" Electrical (Shift Solenoid Valve SL1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL1 circuit while driving and shifting between 4th and 5th gear. P0748 (1-trip detection logic) z z z Output signal duty equals to 100%. (NOTE: SL1 output signal duty is less than 100% under normal condition.) z Open or short in shift solenoid valve SL1 circuit Shift solenoid valve SL1 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL1 circuit. The ECM commands gearshift by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting between 4th and 5th gears, if the ECM detects an open or short in the shift solenoid valve SL1 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0748: Shift solenoid valve SL1/Range check Required sensors/Components Shift solenoid valve SL1 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. None Battery voltage 10 V or more CPU commanded duty Less than 75% Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve SL1 is turned on/off normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL1 OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL1) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 12 (SL1+) - 4 (SL1-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 12 (SL1+) - Body ground 10 kΩ or higher 4 (SL1-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID VALVE SL1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-19 (SL1+) - E5-18 (SL1-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-19 (SL1+) - Body ground 10 kΩ or higher E5-18 (SL1-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8J024X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0751: Shift Solenoid "A" Performance (Shift Solenoid Valve S1) (2007 4Runner) DTC P0751 Shift Solenoid "A" Performance (Shift Solenoid Valve S1) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0751 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S1 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S1. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0751: Related DTCs Shift solenoid valve S1/OFF malfunction Shift solenoid valve S1/ON malfunction Required sensors/Components (Main) Shift solenoid valve S1 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A) and (C): 0.4 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OFF malfunction (B): Immediate Duration ON malfunction (A), (B) and (C): 0.4 sec. ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 8% or more 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time for ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B) and (C) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 0.93 to 1.07 OFF malfunction (B) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (C) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Either of the following conditions is met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (C) Turbine speed/Output speed ON malfunction (D) 1.91 to 2.35 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (E) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, read the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY SHIFT . TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z Press "→" z button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 is turned on/off normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0751) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0751" is output A "P0751" and other DTCs B HINT: If any other codes besides "P0751" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NOTICE: z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG OK 3. INSPECT SHIFT SOLENOID VALVE S1 REPLACE SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W80024X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0756: Shift Solenoid "B" Performance (Shift Solenoid Valve S2) (2007 4Runner) DTC P0756 Shift Solenoid "B" Performance (Shift Solenoid Valve S2) DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0756 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve S2 remains open or closed Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" or "stuck OFF malfunction" of the shift solenoid valve S2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY P0756: Related DTCs Shift solenoid valve S2/OFF malfunction Shift solenoid valve S2/ON malfunction Required sensors/Components (Main) Shift solenoid valve S2 Required sensors/Components (Related) Vehicle speed sensor, Throttle position sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous OFF malfunction (A), (B) and (C): 0.4 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OFF malfunction (D): Immediate Duration ON malfunction (A) and (B): 0.4 sec. ON malfunction (C): 3 sec. ON malfunction (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) OFF malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Continuous time of ECM selecting 4th gear 2 sec. or more Actual gear when ECM selected 4th gear 4th OFF malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (D) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [OFF malfunction] All of the following conditions are met: OFF malfunction (A), (B), (C) and (D) 2 detections are necessary per driving cycle 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (B) Turbine speed/Output speed 3.30 to 7.50 OFF malfunction (C) Turbine speed/Output speed 0.65 to 0.79 OFF malfunction (D) Output record from ECM for 4th → 5th upshifting Recorded [ON malfunction] Both of the following conditions are met: ON malfunction (A) or (B), and ON malfunction (C) or (D) ON malfunction (A) Turbine speed/Output speed 1.91 to 2.35 ON malfunction (B) Turbine speed/Output speed ON malfunction (C) 1.28 to 1.53 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (D) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem . ECM TESTER DISPLAY SHIFT TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z z Press "→" button: Shift up Press "←" button: Shift DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... down HINT: This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0756) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0756 is output A P0756 and other DTCs B HINT: If any other codes besides P0756 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG REPLACE SHIFT SOLENOID VALVE SLT OK 3. INSPECT SHIFT SOLENOID VALVE S2 (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE S2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C5V00HX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0776: Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0776 Pressure Control Solenoid "B" Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the output shaft speed sensor and input speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transmission (clutch, brake or gear, etc.). DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0776 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SL2 remains open Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates "stuck ON malfunction" of the shift solenoid valve SL2. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs P0776: Shift solenoid valve SL2/ON malfunction Required sensors/Components (Main) Shift solenoid valve SL2 Required sensors/Components (Related) Speed sensor (NT), Speed sensor (NO), Crankshaft position sensor (NE) Frequency of operation Continuous ON malfunction (A), (B) and (C): 0.4 sec. Duration ON malfunction (D): 3 sec. ON malfunction (E): 0.5 sec. MIL operation 2 driving cycles A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Sequence of operation None TYPICAL ENABLING CONDITIONS All: P0115 - P0118 (ECT sensor) The monitor will run whenever this DTC is not present. P0125 (Insufficient ECT for Closed Loop) P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 ON malfunction (A) ECM selected gear 1st Vehicle speed 2 to 40 km/h (1.2 to 24.9 mph) Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ON malfunction (B) ECM selected gear 3rd Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (C) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) ON malfunction (D) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) ON malfunction (E) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS [ON malfunction] Both of the following conditions are met: ON malfunction (A) Turbine speed/Output speed 3.30 to 7.50 ON malfunction (B) Turbine speed/Output speed 1.28 to 1.53 ON malfunction (C) Turbine speed/Output speed ON malfunction (D) 0.93 to 1.07 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) ON malfunction (E) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SHIFT". (g) According to the display on the tester, perform the "ACTIVE TEST". HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY SHIFT . TEST PART Operate shift solenoid valve and set each shift position by yourself CONTROL RANGE z Press "→" z button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shiftings must be performed with the accelerator pedal released. The 5th to 4th down-shiftings must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position. z z z z z z ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0776) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the ignition switch to the ON position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P0776" is output A "P0776" and other DTCs B HINT: If any other codes besides "P0776" are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NOTICE: z z z z Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature: 50 to 80°C (122 to 176°F) Be careful to prevent SST hose from interfering with the exhaust pipe. This check must be conducted after checking and adjusting engine. Perform under condition that A/C is OFF. HINT: Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch OFF. (b) Lift the vehicle up. (c) Remove the test plug on the transmission case center right side and connect SST. (d) Lower the vehicle. (e) Fully apply the parking brake and chock the 4 wheels. (f) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (g) Start the engine. (h) Warm up the ATF (Automatic Transmission Fluid). A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (i) Measure the line pressure when the engine is idling. (j) Turn on the tester. (k) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST / SOLENOID (SLT)". (l) Follow the instructions on the tester and perform the ACTIVE TEST. (m) Measure the line pressure with SST. TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling *: "SOLENOID(SLT)" in the ACTIVE TEST is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the HYDRAULIC TEST as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. OK: The line pressure changes as specified when performing the ACTIVE TEST. NG OK 3. INSPECT SHIFT SOLENOID VALVE SL2 REPLACE SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SL2 OK 4. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8G02KX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0778: Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) (2007 4Runner) DTC P0778 Pressure Control Solenoid "B" Electrical (Shift Solenoid Valve SL2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly DTC NO. P0778 . DTC DETECTION CONDITION TROUBLE AREA The ECM checks for an open or short in the shift solenoid valve SL2 circuit while driving and shifting gears. (1-trip detection logic) z Output signal duty equals to 100%. (NOTE: SL2 output signal duty is less than 100% under normal condition.) z z z Open or short in shift solenoid valve SL2 circuit Shift solenoid valve SL2 ECM MONITOR DESCRIPTION This DTC indicates an open or short in the shift solenoid valve SL2 circuit. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition "ON/OFF". (In case of an open or short circuit, the ECM stops sending current to the circuit.) While driving and shifting gears, if the ECM detects an open or short in the shift solenoid valve SL2 circuit, the ECM determines there is a malfunction . MONITOR STRATEGY Related DTCs P0778: Shift solenoid valve SL2/Range check Required sensors/Components Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TYPICAL ENABLING CONDITIONS P0115 - P0118 (ECT sensor) P0125 (Insufficient ETC for Closed Loop) The monitor will run whenever this DTC is not present. P0500 (VSS) P0748 - P0798 (Trans solenoid (range)) CPU commanded duty Less than 75% Battery voltage 10 V or more Ignition Switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty WIRING DIAGRAM INSPECTION PROCEDURE HINT: Less than 100% A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... The shift solenoid valve SL2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SL2 ON ON ON ON OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (SL2) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 11 (SL2+) - 3 (SL2-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 11 (SL2+) - Body ground 10 kΩ or higher 3 (SL2-) - Body ground ↑ NG OK INSPECT SHIFT SOLENOID SL2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-17 (SL2+) - E5-16 (SL2-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-17 (SL2+) - Body ground 10 kΩ or higher E5-16 (SL2-) - Body ground ↑ 3. INSPECT SHIFT SOLENOID SL2 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID SL2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000XP101VX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0781: 1-2 Shift (1-2 Shift Valve) (2007 4Runner) DTC P0781 1-2 Shift (1-2 Shift Valve) DESCRIPTION The 1-2 shift valve performs shifting to 1st gear and other gears. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0781 The gear required by the ECM does not match the actual gear when driving (2-trip detection logic) z z Shift solenoid valve SLT remains open or closed Valve body is blocked up or stuck (1-2 shift valve) Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION This DTC indicates that the 1-2 shift valve in the valve body is locked in the direction the spring compresses. The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF" and switching oil pressure to the valves in the valve body. The ECM calculates the "actual" transmission gear by comparing the signals from the input speed sensor A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (NT) and the output speed sensor (SP2). The ECM can detect many mechanical problems in the shift solenoids, valve body, and the transmission clutches, brakes, and gears. If the ECM detects that the actual gear position and the commanded gear position are different, it will illuminate the MIL and store the DTC . MONITOR STRATEGY Related DTCs P0781: Valve body/Rationality check Required sensors/Components (Main) Valve body Required sensors/Components (Related) Automatic transmission assembly, Speed sensor (NT), Speed sensor (NO), Vehicle speed sensor, Throttle position sensor Frequency of operation Continuous Condition (A) and (B): 0.4 sec. Duration Condition (C): 3 sec. Condition (D): 0.5 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction ECT (Engine coolant temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 Condition (A) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) Condition (B) ECM selected gear 4th Vehicle speed 2 km/h (1.2 mph) or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Vary with engine speed) Condition (C) Current ECM selected gear 5th Last ECM selected gear 4th Vehicle speed (During transition from 4th to 5th gear) Less than 100 km/h (62.2 mph) Condition (D) ECM selected gear Engine speed - Turbine speed (NE - NT) (After transition from 4th to 5th gear) Vehicle speed (After transition from 4th to 5th gear) 5th 150 rpm or less Less than 100 km/h (62.2 mph) TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: Condition (A), and Condition (B), (C) or (D) Condition (A) Turbine speed/Output speed Condition (B) 3.30 to 7.50 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Turbine speed/Output speed 1.28 to 1.53 Condition (C) Turbine speed - Output speed x 4th gear ratio 1,000 rpm or more (NT - NO x 4th gear ratio) Condition (D) Turbine speed - Output speed x 5th gear ratio 1,000 rpm or more (NT - NO x 5th gear ratio) INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P0781) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0781 is output A P0781 and other DTCs B HINT: If any other codes besides P0781 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. HINT: PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (d) Turn the ignition switch ON. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem TESTER DISPLAY . TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less HINT: z z z z z This test can be conducted when the vehicle speed is 31 mph (50 km/h) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. OK: Gear position changes in accordance with the tester command. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and raise line pressure [Vehicle Condition] HINT: z z OFF: Line pressure up (when Active Test "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z z Vehicle stopped Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. REPLACE SHIFT SOLENOID VALVE SLT OK 4. CLEAR THE DTC AND RUNNING TEST (a) Clear the DTC, and check for the DTC again after conducting the " MONITOR DRIVE PATTERN FOR ECT TEST" . OK: No DTC code NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK END A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W83032X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0894: Transmission Component Slipping (2007 4Runner) DTC P0894 Transmission Component Slipping DTC P2714 Pressure Control Solenoid "D" Performance (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: *: The duty ratio is the ratio of the current ON time (A) to the total of the current ON and OFF time (A + B). Duty Ratio (%) = A / (A + B) x 100 DTC NO. DTC DETECTION CONDITION TROUBLE AREA z P0894 ECM detects a malfunction on SLT, S1, S2, SR, SL1, SL2 or 1-2 shift solenoid valve according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z z z z P2714 ECM detects a malfunction on SLT (ON side) according to the revolution difference of the turbine and the output shaft, and also by the oil pressure. (2-trip detection logic) z z z Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) Shift solenoid valve SLT remains open or closed Shift solenoid valve S1, S2, SR, SL1 or SL2 remains open or closed 1-2 shift valve is stuck Valve body is blocked Automatic transmission (clutch, brake or gear, etc.) MONITOR DESCRIPTION The ECM calculates the amount of heat absorbed by the friction material based on the difference in revolution (clutch slippage) between the turbine and output shaft. The ECM turns on the MIL and outputs this DTC when the amount of heat absorption exceeds the specified value. When the shift solenoid valve SLT, SL2, S1 or S2 remains on, or the shift solenoid valve SL1 or SR remains off, oil pressure goes down and clutch engagement force decreases. NOTICE: If you continue driving under these conditions, the clutch will burn out and the vehicle will no longer be drivable. MONITOR STRATEGY Related DTCs P0894: Automatic transmission slip malfunction P2714: Shift solenoid valve SLT/ON malfunction A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve SLT, Valve body, ATF temperature sensor, Speed sensor (NT), Speed sensor (NO) Frequency of operation Continuous P0894 ON malfunction (A): Immediate Duration P0894 ON malfunction (B): 0.4 sec. P2714: Immediate MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All The monitor will run whenever this DTC is not present. None Turbine speed sensor (NT) circuit Not circuit malfunction Output speed sensor (NO) circuit Not circuit malfunction TFT temperature sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SLT circuit Not circuit malfunction ECT (Engine Coolant Temperature) sensor circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric Throttle Control System) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° crankshaft angle or more Engine Starting Transfer range "High" *1 TFT temperature 10°C (50°F) or more Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Transfer output speed 143 rpm or more NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 TYPICAL MALFUNCTION THRESHOLDS [P0894: ON malfunction] When either condition below is met: OFF malfunction (A) or (B) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Summation of C2 clutch heat generations Specified value Actual gear for SLT fail judgment Not determined [P2714: ON malfunction] One of the following conditions is met: ON malfunction (A), (B), (C), (D), (E), (F) or (G) ON malfunction (A) Summation of C1 clutch heat generations Specified value ON malfunction (B) Shift solenoid valve S1 ON malfunction Detected ON malfunction (C) Shift solenoid valve S2 ON malfunction Detected ON malfunction (D) Shift solenoid valve SR OFF malfunction Detected ON malfunction (E) 1-2 shift valve malfunction Detected ON malfunction (F) Shift solenoid valve SL1 OFF malfunction Detected A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ON malfunction (G) Shift solenoid valve SL2 ON malfunction Detected INSPECTION PROCEDURE PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTCS P0894 AND P2714) (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the ignition switch ON and push the intelligent tester main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the DTCs using the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only P0894 is output Only P0894 and P2714 are output A P0894, P2714 and other DTCs are output B z z HINT: If any other codes besides P0894 and P2714 are output, perform troubleshooting for those DTCs first. B GO TO DTC CHART A 2. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SHIFT SOLENOID VALVE SLT) NOTICE: z z z Perform the test at the normal operating ATF temperature: 50 to 80°C (122 to 176°F). Be careful to prevent SST's hose from interfering with the exhaust pipe. Perform the test with the A/C OFF. HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Remove the test plug on the transmission case center right side and connect SST. SST: 09992-00095 09992-00231 09992-00271 (b) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (c) Start the engine and warm it up. (d) Measure the line pressure with SST. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (g) Follow the instructions on the tester and perform the ACTIVE TEST. (h) Measure the line pressure with SST. ECM TESTER DISPLAY TEST PART CONTROL RANGE ON or OFF SOLENOID (SLT)* Operate the shift solenoid SLT and HINT: z DIAGNOSTIC NOTE [Vehicle Condition] z OFF: Line pressure up (when Active Test Vehicle stopped A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... raise line pressure z "SOLENOID(SLT)" is performed, ECM commands SLT solenoid to turn OFF) ON: No action (normal operation) z Engine: idling HINT: *: SOLENOID(SLT) in the Active Test is performed to check the line pressure changes by connecting SST to the automatic transmission, which is used in the Hydraulic Test the pressure values in the Active Test and Hydraulic Test are different. as well. Please note that OK: The line pressure changes as specified when performing the ACTIVE TEST. NG INSPECT SHIFT SOLENOID VALVE SLT OK 3. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (RUNNING TEST) NOTICE: This test should always be performed with at least 2 people. (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Clear the DTC . (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST. (d) Perform the ACTIVE TEST using the intelligent tester. HINT: While driving, the shift position can be forcibly changed with the intelligent tester. ECM TESTER DISPLAY TEST PART CONTROL RANGE z SHIFT Operate shift solenoid valve and set each shift position by yourself z Press "→" button: Shift up Press "←" button: Shift down DIAGNOSTIC NOTE Possible to check operation of shift solenoid valves [Vehicle Condition] 50 km/h (30 mph) or less A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The 4th to 5th up-shift must be performed with the accelerator pedal released. The 5th to 4th down-shift must be performed with the accelerator pedal released. Do not operate the accelerator pedal for at least 2 seconds after shifting and do not shift successively. The shift position commanded by the ECM is shown in the DATA LIST (SHIFT) display on the intelligent tester. z z z z z (e) Compare the ECM gear shift command and the actual gear position. ECM GEAR SHIFT COMMAND 1ST 2ND 3RD 4TH 5TH Shift solenoid S1 Shift solenoid S2 Actual gear position under malfunction Shift solenoid SL2 Shift solenoid SR Stuck ON 1st 2nd 2nd 1st N*1 Stuck OFF 4th 3rd 3rd 4th 5th Stuck ON*2 2nd 2nd 3rd 3rd N*1 Stuck OFF*3 1st 1st 4th 4th 5th Stuck ON 1st 2nd 3rd 4th N*1 Stuck OFF 1st 2nd 3rd 4th 5th Stuck ON*4 1st 2nd 3rd 4th 5th Stuck OFF*5 1st PROCEED TO A B C D 2nd 3rd 4th 4th HINT: z z z z z z *1: Neutral *2: When shift solenoid S2 is stuck ON, the vehicle cannot drive in reverse. *3: When shift solenoid S2 is stuck OFF, the 4th to 5th upshift will have a large shift shock. Also, the 5th to 4th down-shift will have time lag. *4: Stuck ON condition can be determined by checking if shift shock has increased excessively. *5: When shift solenoid SR is stuck OFF, moving the shift lever from N to D will cause a large shift shock. Gear shift can be determined by paying attention to changes in rpm. OK: Gear position changes in accordance with the tester command. OK INSPECT SHIFT SOLENOID VALVE SLT B INSPECT SHIFT SOLENOID VALVE S2 C INSPECT SHIFT SOLENOID VALVE SL2 D INSPECT SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A 4. INSPECT SHIFT SOLENOID VALVE S1 (a) Remove the shift solenoid valve S1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S1 connector - Shift solenoid S1 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 6. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S1 INSPECT SHIFT SOLENOID VALVE S2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid S2 connector - Shift solenoid S2 body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 8. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE S2 INSPECT SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL2 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 10. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL2 INSPECT SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SR. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Shift solenoid SR connector - Shift solenoid SR body 20°C (68°F) SPECIFIED CONDITION 11 to 15 Ω (c) Connect the battery's positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG OK 11. INSPECT SHIFT SOLENOID VALVE SL1 REPLACE SHIFT SOLENOID VALVE SR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SL1. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SL1 - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. 13. OK INSPECT TRANSMISSION VALVE BODY ASSEMBLY NG REPLACE SHIFT SOLENOID VALVE SL1 INSPECT SHIFT SOLENOID VALVE SLT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SLT. (b) Measure the resistance of the solenoid value. Standard resistance: TESTER CONNECTION CONDITION Terminal 1 of the shift solenoid valve SLT - terminal 2 20°C (68°F) SPECIFIED CONDITION 5.0 to 5.6 Ω (c) Connect the battery's positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector. Then check that the valve moves and makes an operating noise. (d) Check the operating noise of the solenoid valve. OK: Solenoid makes operating noise. NG REPLACE SHIFT SOLENOID VALVE SLT OK 14. INSPECT TRANSMISSION VALVE BODY ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Check the transmission valve body assembly. OK: There are no foreign objects on each valve. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSEMBLY OK 15. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W86028X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0973: Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) (2007 4Runner) DTC P0973 Shift Solenoid "A" Control Circuit Low (Shift Solenoid Valve S1) DTC P0974 Shift Solenoid "A" Control Circuit High (Shift Solenoid Valve S1) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0973 . DTC DETECTION CONDITION ECM detects short in solenoid valve S1 circuit 2 times when solenoid valve S1 is operated (1-trip detection logic) TROUBLE AREA z z z P0974 ECM detects open in solenoid valve S1 circuit 2 times when solenoid valve S1 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM Open in shift solenoid valve S1 circuit Shift solenoid valve S1 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S1 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S1 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S1 circuit. When the shift solenoid valve S1 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S1 circuit . MONITOR STRATEGY Related DTCs P0973: Shift solenoid valve S1/Range check (Low resistance) P0974: Shift solenoid valve S1/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve S1 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0973: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 ON P0974: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S1 OFF TYPICAL MALFUNCTION THRESHOLDS P0973: Range check (Low resistance) Shift solenoid valve S1 resistance. 8 Ω or less P0974: Range check (High resistance) Shift solenoid valve S1 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S1 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S1 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S1 ON ON OFF OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S1) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 8 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S1 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-11 (S1) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S1. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S1) - Solenoid Body (S1) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S1 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W87027X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0976: Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) (2007 4Runner) DTC P0976 Shift Solenoid "B" Control Circuit Low (Shift Solenoid Valve S2) DTC P0977 Shift Solenoid "B" Control Circuit High (Shift Solenoid Valve S2) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0976 . DTC DETECTION CONDITION ECM detects short in solenoid valve S2 circuit 2 times when solenoid valve S2 is operated (1-trip detection logic) TROUBLE AREA z z z P0977 ECM detects open in solenoid valve S2 circuit 2 times when solenoid valve S2 is not operated (1-trip detection logic) z z z Short in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM Open in shift solenoid valve S2 circuit Shift solenoid valve S2 ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve S2 circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve S2 is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve S2 circuit. When the shift solenoid valve S2 is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve S2 circuit . MONITOR STRATEGY Related DTCs P0976: Shift solenoid valve S2/Range check (Low resistance) P0977: Shift solenoid valve S2/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve S2 Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0976: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 ON P0977: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve S2 OFF TYPICAL MALFUNCTION THRESHOLDS P0976: Range check (Low resistance) Shift solenoid valve S2 resistance 8 Ω or less P0977: Range check (High resistance) Shift solenoid valve S2 resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve S2 WIRING DIAGRAM Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE HINT: The shift solenoid valve S2 turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve S2 OFF ON ON OFF OFF PROCEDURE 1. INSPECT TRANSMISSION WIRE (S2) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 15 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE S2 OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-10 (S2) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE S2 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve S2. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (S2) - Solenoid Body (S2) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE S2 OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8H01ZX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P0985: Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) (2007 4Runner) DTC P0985 Shift Solenoid "E" Control Circuit Low (Shift Solenoid Valve SR) DTC P0986 Shift Solenoid "E" Control Circuit High (Shift Solenoid Valve SR) DESCRIPTION Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, S1, S2 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly. (In case of an open or short circuit, the ECM stops sending current to the circuit.) Fail safe function DTC NO. P0985 . DTC DETECTION CONDITION ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic) TROUBLE AREA z z z P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic) z z z Short in shift solenoid valve SR circuit Shift solenoid valve SR ECM Open in shift solenoid valve SR circuit Shift solenoid valve SR ECM MONITOR DESCRIPTION These DTCs indicate an open or short in the shift solenoid valve SR circuit. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. When the shift solenoid valve SR is on, if resistance is 8 Ω or less, the ECM determines there is a short in the shift solenoid valve SR circuit. When the shift solenoid valve SR is off, if resistance is 100 kΩ or more, the ECM determines there is an open in the shift solenoid valve SR circuit . MONITOR STRATEGY Related DTCs P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Required sensors/Components Shift solenoid valve SR Frequency of operation Continuous Duration 0.128 seconds or more MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR ON Battery voltage 8 V or more Engine switch ON Starter OFF P0986: Range check (High resistance) The monitor will run whenever this DTC is not present. None Shift solenoid valve SR OFF Battery voltage 8 V or more Engine switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance) Shift solenoid valve SR resistance 8 Ω or less P0986: Range check (High resistance) Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Shift solenoid valve SR Resistance: 11 to 15 Ω at 20°C (68°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... WIRING DIAGRAM INSPECTION PROCEDURE HINT: The shift solenoid valve SR turns ON/OFF normally when the shift lever is in the D position: ECM gear shift command 1st 2nd 3rd 4th 5th Shift solenoid valve SR OFF OFF OFF OFF ON PROCEDURE 1. INSPECT TRANSMISSION WIRE (SR) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 7 - Body ground 11 to 15 Ω NG INSPECT SHIFT SOLENOID VALVE SR OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission connector to the transmission. (b) Disconnect the connector from the ECM. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-9 (SR) - Body ground 3. 11 to 15 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect the positive (+) lead to the terminal of the solenoid connector, and the negative (-) lead to the solenoid body. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SR OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8A02MX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2716: Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) (2007 4Runner) DTC P2716 Pressure Control Solenoid "D" Electrical (Shift Solenoid Valve SLT) DESCRIPTION The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty ratio* of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. *: Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100 (%) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... DTC NO. P2716 DTC DETECTION CONDITION Open or short is detected in shift solenoid valve SLT circuit for 1 second or more while driving (1-trip detection logic). TROUBLE AREA z z z Open or short in shift solenoid valve SLT circuit Shift solenoid valve SLT ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716: Shift solenoid valve SLT/Range check Required sensors/Components Shift solenoid valve SLT Frequency of operation Continuous A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLT) from IC Fail (Open or short) Case 2: Hybrid IC status WIRING DIAGRAM Fail A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLT) (a) Disconnect the transmission wire connector from the transmission. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 14 (SLT+) - 6 (SLT-) 5.0 to 5.6 Ω A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 14 (SLT+) - Body ground 10 kΩ or higher 6 (SLT-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLT OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-13 (SLT+) - E5-12 (SLT-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-13 (SLT+) - Body ground 10 kΩ or higher E5-12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... OK 3. REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLT (a) Remove the shift solenoid valve SLT. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLT OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000012XR00VX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2740: Transmission Fluid Temperature Sensor "B" Circuit (2007 4Runner) DTC P2740 Transmission Fluid Temperature Sensor "B" Circuit DTC P2742 Transmission Fluid Temperature Sensor "B" Circuit Low Input DTC P2743 Transmission Fluid Temperature Sensor "B" Circuit High Input DESCRIPTION The No. 2 ATF temperature sensor is on the transmission, just in front of the oil cooler inlet pipeline. If the ECM detects an abnormally high ATF temperature near this sensor, it illuminates the warning light. HINT: z z The temperature of ATF easily rises when towing, climbing hills and in traffic, etc. If the No. 2 ATF temperature sensor becomes short-circuited, the signal that indicates the ATF temperature is 150°C (302°F) or higher is input in ECM. Vehicle conditions when the sensor is normal and when the sensor is short-circuited are indicated in the table below. NO. 2 ATF TEMPERATURE SENSOR STATE Sensor is normal DETECTION CONDITION SYMPTOM RECOVERY CONDITION ATF temperature more than 150°C (275°F) A/T OIL TEMP warning light remains ON ATF temperature less than 135°C (275°F)*2 ATF temperature more than 130°C (266°F) Shift point too high ATF temperature less than 110°C (230°F) Lock-up at 3rd gear*1 ATF temperature less than 110°C (230°F)*2 and engine coolant temperature more than 95°C (203°F) When the conditions (a) and (b) are satisfied. (a) ATF temperature more than 130°C (266°F) (b) Engine coolant temperature more than 95°C (203°F) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z Any conditions Sensor is shortcircuited z A/T OIL TEMP warning light remains ON Shift point too high Engine coolant Lock-up at 3rd temperature more than gear*1 95°C (203°F) Symptoms still occur Symptoms still occur HINT: *1: When ATF temperature is normal, transmission lock-up occurs in 5th gear with the shift lever in the D position, and 4th gear with the shift lever in the 4 position. *2: When ATF temperature is in the normal range, it decreases to less than 135°C (275°F) within 5 minutes with the shift lever in the P or N position in an idling state. DTC NO. DTC DETECTION CONDITION TROUBLE AREA (a) and (b) are detected momentarily within 0.5 seconds when neither P2742 or P2743 are detected. (1-trip detection logic) (a) No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V). P2740 (b) No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V). HINT: z z z Open or short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Within 0.5 seconds, the malfunction switches from (a) to (b) or from (b) to (a). z P2742 No. 2 ATF temperature sensor resistance is less than 25 Ω (0.046 V) for 0.5 seconds or more. (1-trip detection logic) z z No. 2 ATF temperature sensor resistance is more than 156 kΩ (4.915 V) when 15 minutes or more have passed after P2743 the engine start. DTC is detected for 0.5 seconds or more. (1-trip detection logic) MONITOR DESCRIPTION z z z Short in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM Open in No. 2 ATF temperature sensor circuit No. 2 ATF temperature sensor ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ATF temperature sensor converts ATF temperature into an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an open or short in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 25 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will illuminate the MIL and store the DTC. HINT: z z z *1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature. *2: -40°C (-40°F) is indicated regardless of the actual ATF temperature. The ATF temperature can be checked on the intelligent tester display. MONITOR STRATEGY P2740: ATF temperature sensor/Range check (Fluttering) Related DTCs P2742: ATF temperature sensor/Range check (Low resistance) P2743: ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None P2740, P2742: Range check (Fluttering, Low voltage) The typical enabling condition is not available. - P2743: Range check (High voltage) Time after engine start 15 minutes or more TYPICAL MALFUNCTION THRESHOLDS P2740: Range check (Fluttering) Less than 0.046 V TFT (Transmission fluid temperature) sensor voltage or More than 4.915 V P2742: Range check (Low voltage) TFT (Transmission fluid temperature) sensor voltage Less than 0.046 V A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... P2743: Range check (High voltage) TFT (Transmission fluid temperature) sensor voltage More than 4.915 V COMPONENT OPERATING RANGE TFT (Transmission fluid temperature) sensor Atmospheric temperature up to approximately 130°C (266°F) WIRING DIAGRAM INSPECTION PROCEDURE 1. DATA LIST HINT: According to the DATA LIST displayed by the intelligent tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. 1. Warm up the engine. 2. Turn the ignition switch off. 3. Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4. 5. 6. 7. module) to the DLC3. Turn the ignition switch to the ON position. Turn on the tester. Select the item "DIAGNOSIS / OBD/MOBD / ECT / DATA LIST". According to the display on tester, read the "DATA LIST". TESTER DISPLAY A/T OIL TEMP2 MEASUREMENT ITEM/RANGE ATF temperature sensor No. 2 value/ NORMAL CONDITION z Min.: -40°C (-40°F) Max.: 215°C (419° F) z After stall test: Approximately 80°C (176°F) Equal to ambient temperature while engine is cold DIAGNOSTIC NOTE If value is -40°C (-40°F) or 215°C (419°F), ATF temperature sensor No. 2 circuit is opened or short circuited HINT: { { When DTC P2742 is output and the intelligent tester output is 150°C (302°F) or more, there is a short circuit. When DTC P2743 is output and the intelligent tester output is -40°C (-40°F), there is an open circuit. Measure the resistance between terminal THO2 (OT2) and the body ground. TEMPERATURE DISPLAYED MALFUNCTION -40°C (-40°F) Open circuit 150°C (302°F) or more Short circuit PROCEDURE 1. INSPECT TRANSMISSION WIRE (NO. 2 ATF TEMPERATURE SENSOR) (a) Disconnect the transmission wire connector. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 1 (OT2-) - 9 (OT2+) 25 Ω to 156 kΩ 1 (OT2-) - Body ground 10 kΩ or higher 9 (OT2+) - Body ground 10 kΩ or higher HINT: If the resistance is outside the specified range of either ATF temperature shown in the table below, the driveability of the vehicle may decrease. Standard resistance: ATF TEMPERATURE SPECIFIED CONDITION 20°C (68°F) 3 to 4 kΩ 110°C (230°F) 0.22 to 0.28 kΩ NG REPAIR OR REPLACE TRANSMISSION WIRE OK 2. CHECK WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... E5-32 (THO2) - E4-28 (E2) 79 Ω to 156 kΩ (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check or short): TESTER CONNECTION SPECIFIED CONDITION E5-32 (THO2) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8D02DX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2757: Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2757 Torque Converter Clutch Pressure Control Solenoid Performance (Shift Solenoid Valve SLU) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, output speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve SLU, valve body and torque converter clutch. DTC NO. DTC DETECTION CONDITION TROUBLE AREA z Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock-up remains ON z Shift solenoid valve SLU remains open or closed Valve body is blocked A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... in the lock-up OFF range. z (2-trip detection logic) z P2757 z Torque converter clutch Automatic transmission (clutch, brake or gear, etc.) Line pressure is too low MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on the turbine (input) speed sensor NT, output speed sensor SP2, engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to output shaft rpm (SP2). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid SLU. When the SLU is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve SLU or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. z z There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 70 rpm greater than input turbine speed.) There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) MONITOR STRATEGY P2757: Related DTCs Shift solenoid valve SLU/OFF malfunction Shift solenoid valve SLU/ON malfunction Required sensors/Components Shift solenoid valve SLU, Valve body, Vehicle speed sensor, Speed sensor (NT), Speed sensor (NO), Throttle position sensor Frequency of operation Continuous Duration OFF malfunction (A) 2 sec. OFF malfunction (B) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 0.4 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The following items are common to all conditions below. The monitor will run whenever this DTC is not present. None Turbine speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Torque converter clutch pressure control solenoid circuit Not circuit malfunction KCS sensor circuit Not circuit malfunction ETCS (Electric throttle control system) Not system down Transmission range "D" ECT 40°C (104°F) or more Spark advance from Max. retard timing by KCS control 0° CA or more Engine Starting ECM selected gear 2nd or 3rd or 4th or 5th Vehicle speed 25 km/h (15.5 mph) or more Shift solenoid valve S1 circuit Not on malfunction Shift solenoid valve S2 circuit Not on malfunction Shift solenoid valve SL2 circuit Not on malfunction 1-2 shift valve circuit Not on malfunction Transfer neutral position switch OFF Transfer range "High" *1 Transfer range "HIGH" *1 (This condition is applied only 4WD) *1: Following conditions met Vehicle speed sensor circuit Not circuit malfunction Output shaft speed sensor circuit Not circuit malfunction Transfer output speed 143 rpm or more A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NO/NOtf (Transfer input speed/Transfer output speed) 0.9 to 1.1 OFF malfunction (A) ECM lock-up command ON (SLU pressure: 513 kPa or more) Vehicle speed Less than 100 km/h (62.2 mph) OFF malfunction (B) ECM selected gear 2nd Vehicle speed 2 km/h (1.2 mph) or more Output speed 2nd → 1st down shift point or more Throttle valve opening angle 7.0% or more at 2,000 rpm (Varies with engine speed) ON malfunction ECM lock-up command OFF (SLU pressure: less than 4 kPa) Throttle valve opening angle 9% or more Vehicle speed Less than 29 km/h (18 mph) at 2nd gear (Varies with ECM selected gear) TYPICAL MALFUNCTION THRESHOLDS Both of the following condition are met: OFF malfunction (A) and (B) OFF malfunction (A) Engine speed - Turbine speed (NE - NT) 70 rpm or more OFF malfunction (B) Turbine speed/Output speed (NT/NO) Less than 3.30, or more than 7.50 ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2md detection; pending fault code ON Vehicle speed must be under 6.2mph (10 km/h) once before 2nd detection. Engine speed - Turbine speed (NE - NT) INSPECTION PROCEDURE 1. ACTIVE TEST HINT: Less than 35 rpm A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Performing the ACTIVE TEST using the intelligent tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the intelligent tester together with the CAN VIM (controller area network vehicle interface module) to the DLC3. (d) Turn the ignition switch to the ON position. (e) Turn on the tester. (f) Select the item "DIAGNOSIS / OBD/MOBD / ECT / ACTIVE TEST". (g) According to the display on the tester, perform the "ACTIVE TEST". TESTER DISPLAY TEST PART CONTROL RANGE DIAGNOSTIC NOTE Possible to check shift solenoid valve SLU operation LOCK UP Control shift solenoid SLU to set automatic ON or OFF transmission to lock-up condition [Vehicle Condition] z z Throttle valve opening angle: Less than 35% Vehicle speed: 60 km/h (36 mph) or more HINT: z z This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. This test can be conducted with the 5th gear. (h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... HINT: When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off automatically.) z z PROCEDURE 1. CHECK OTHER DTCS OUTPUT (IN ADDITION TO DTC P2757) (a) Connect the OBD II scan tool or the intelligent tester to the DLC3. (b) Turn the engine switch on (IG) position and push the OBD II scan tool or the intelligent tester main switch ON. (c) When you use intelligent tester: Select the item "DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES". (d) Read the DTCs using the OBD II scan tool or the intelligent tester. Result: DISPLAY (DTC OUTPUT) PROCEED TO Only "P2757" is output A "P2757" and other DTCs B HINT: If any other codes besides "P2757" are output, perform troubleshooting for those DTCs first. B A 2. INSPECT SHIFT SOLENOID VALVE SLU GO TO DTC CHART A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (a) Remove the shift solenoid valve SLU. (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK 3. INSPECT TRANSMISSION VALVE BODY ASSEMBLY OK: There are no foreign objects on each valve. NG OK REPLACE TRANSMISSION VALVE BODY ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Check the torque converter clutch assembly . OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSEMBLY OK REPAIR OR REPLACE AUTOMATIC TRANSMISSION ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W8902CX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2759: Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) (2007 4Runner) DTC P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical (Shift Solenoid Valve SLU) DESCRIPTION The amount of current flow to the solenoid is controlled by the (*) duty ratio of the ECM output signal. The higher the duty ratio becomes, the higher the lock-up hydraulic pressure becomes during the lock-up operation. (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio = A/(A+B) x 100(%). DTC NO. DTC DETECTION CONDITION P2759 TROUBLE AREA z Open or short is detected in shift solenoid valve SLU circuit for Open or short in shift solenoid valve SLU circuit A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 1 second or more while driving (1-trip detection logic). z z Shift solenoid valve SLU ECM MONITOR DESCRIPTION When an open or short in a shift solenoid valve (SLU) circuit is detected, the ECM determines there is a malfunction. The ECM will turn on the MIL and store this DTC. MONITOR STRATEGY Related DTCs P2759: Shift solenoid valve SLU/Range check Required sensors/Components Shift solenoid valve SLU Frequency of operation Continuous Duration 1 sec. MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present. None Case 1: Solenoid current cut status Not cut Battery voltage 11 V or more Ignition switch ON Starter OFF Case 2: Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Case 1: Solenoid status (SLU) from IC Case 2: Fail (open or short) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Hybrid IC status Fail COMPONENT OPERATING RANGE Output signal duty Less than 100% WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 1. INSPECT TRANSMISSION WIRE (SLU) (a) Disconnect the transmission wire connector from the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 13 (SLU+) - 5 (SLU-) 5.0 to 5.6 Ω (c) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION 13 (SLU+) - Body ground 10 kΩ or higher 5 (SLU-) - Body ground ↑ NG INSPECT SHIFT SOLENOID VALVE SLU OK 2. CHECK HARNESS AND CONNECTOR (TRANSMISSION WIRE - ECM) (a) Connect the transmission wire connector to the transmission. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Disconnect the ECM connector. (c) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) E5-15 (SLU+) - E5-14 (SLU-) 5.0 to 5.6 Ω (d) Measure the resistance according to the value(s) in the table below. Standard resistance (Check for short): TESTER CONNECTION SPECIFIED CONDITION E5-15 (SLU+) - Body ground 10 kΩ or higher E5-14 (SLU-) - Body ground ↑ 3. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE ECM INSPECT SHIFT SOLENOID VALVE SLU (a) Remove the shift solenoid valve SLU. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (b) Measure the resistance according to the value(s) in the table below. Standard resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 5.0 to 5.6 Ω (c) Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating sound. NG REPLACE SHIFT SOLENOID VALVE SLU OK REPAIR OR REPLACE TRANSMISSION WIRE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 C Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002C4J00AX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): P2772: Four Wheel Drive (4WD) Low Switch Circuit Range / Performance (2007 4Runner) DTC P2772 Four Wheel Drive (4WD) Low Switch Circuit Range / Performance DESCRIPTION The ECM detects the signal from the transfer L4 position switch. This DTC indicates that the transfer L4 position switch remains on. DTC NO. P2772 DTC DETECTION CONDITION Transfer L4 position switch remains ON while vehicle is running under following conditions for 1.8 seconds or more (1-trip detection logic) (a) Output shaft speed between 1,000 and 3,000 rpm (b) Transfer shift position is H TROUBLE AREA z z z Short in transfer L4 position switch circuit Four wheel drive control ECU ECM MONITOR DESCRIPTION The ECM monitors the transfer-case L4 position switch to determine when the transfer-case L4 gear is engaged. If the transfer-case L4 gears remain engaged under the following conditions, the ECM will conclude that there is a malfunction of the L4 position switch: z z z z L4 switch indicated that the L4 transfer-case gears are engaged. Transfer-case shifter is in the "H" position. Transfer-case output shaft rpm is between 1,000 and 3,000 rpm. The specified time period has elapsed. If all of the above conditions are detected, the ECM will conclude that there is a malfunction of the L4 switch, and illuminate the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2772: Transfer L4 position switch/ON malfunction Required sensors/Components Transfer L4 position switch Frequency of operation Continuous Duration ON malfunction (A): 1.8 sec. ON malfunction (B): 0.5 sec. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS All: Output speed sensor circuit Not circuit malfunction Vehicle speed sensor circuit Not circuit malfunction Transfer neutral position switch OFF ON malfunction (A) Output speed (Transfer output speed) 1,000 to 3,000 rpm ON malfunction (B) Output speed (Transfer output speed) 143 rpm or more TYPICAL MALFUNCTION THRESHOLDS Both of the following conditions are met: ON malfunction (A) and (B) ON malfunction (A) L4 switch ON ON malfunction (B) Actual transfer gear ratio Transfer input speed/Transfer output speed WIRING DIAGRAM 0.9 to 1.1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... INSPECTION PROCEDURE PROCEDURE 1. INSPECT TERMINAL VOLTAGE (4WD ECU - ECM) (a) Disconnect the four wheel drive control ECU connector. (b) Turn the ignition switch ON. (c) Measure the voltage according to the value(s) in the table below. Standard voltage: TESTER CONNECTION SPECIFIED CONDITION F9-24 (L4) - Body ground 10 to 14 V OK CHECK AND REPLACE FOUR WHEEL DRIVE CONTROL ECU A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... NG 2. INSPECT TERMINAL VOLTAGE (ECM - 4WD ECU) (a) Turn the ignition switch ON. (b) Measure the voltage according to the value(s) in the table below. Standard voltage: TESTER CONNECTION SPECIFIED CONDITION E6-13 (L4) - Body ground 10 to 14 V OK REPAIR OR REPLACE HARNESS OR CONNECTOR NG REPLACE ECM A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 R Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W72041X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PARTS LOCATION (2007 4Runner) PARTS LOCATION ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 L Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000O7H01NX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PRECAUTION (2007 4Runner) PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM . HINT: RESET MEMORY can not be completed by only disconnecting the battery cable. 1. The automatic transmission is composed of highly precision-finished parts which need careful inspection before reassembly. Even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion caused by similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. Complete the inspection, repair and reassembly before proceeding to the next component group as much as possible. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because some parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended: ATF WS 2. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. 3. Dry all parts with compressed air. Never use a shop rag or a piece of cloth to dry them. 4. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene in your face. 5. Only recommended automatic transmission fluid or kerosene should be used for cleaning. 6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repair, and reassembly. 7. When disassembling a valve body, be sure to match each valve together with the corresponding spring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 8. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. 9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. 10. All gaskets and rubber O-rings should be replaced with new ones. 11. Do not apply adhesive cements to gaskets and similar parts. 12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 13. When replacing a worn bushing, the sub-assembly containing the bushing must also be replaced. 14. Check thrust bearings and races for wear or damage. Replace them as necessary. 15. When working with FIPG material, you must observe the following: z z z z Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove any loose material. Clean both sealing surfaces with a non-residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7F03XX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): INITIALIZATION (2007 4Runner) INITIALIZATION 1. RESET MEMORY NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM. The RESET MEMORY can be performed only with the Intelligent tester. z z HINT: The ECM memorizes the condition that the ECT controls the automatic transmission assembly and engine assembly according to those characteristics. Therefore, when the automatic transmission assembly, engine assembly, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the engine switch off. (b) Connect the intelligent tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Turn the intelligent tester main switch on. (e) Select the item "DIAGNOSIS / ENHANCED OBD II". (f) Perform the reset memory procedure from the ENGINE menu. CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST earlier. HINT: The ECM is learned by performing the ROAD TEST. (1) Tester menu flow: described A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903UX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 40°C (104°F) or less and vehicle speed is at 28 mph (45 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Last Modified: 4-26-2007 1.6 F Service Category: General Section: Specifications Model Year: 2007 Model: 4Runner Doc ID: RM000002E14001X Title: SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4Runner) SERVICE DATA 2UZ-FE: Engine idling D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) Line pressure (Wheel locked) Engine stall revolution Time lag R position 495 to 576 kPa (5.0 to 5.9 kgf*cm 2, 71 to 84 psi) AT stall (Throttle valve fully open) D position 1,235 to 1,332 kPa (12.6 to 13.6 kgf*cm 2, 179 to 193 psi) R position 1,229 to 1,350 kPa (12.5 to 13.8 kgf*cm 2, 178 to 196 psi) D position 2,200 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully open) 4 → 5 186 to 200 km/h (116 to 124 mph) 5 → 4 181 to 194 km/h (112 to 121 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully close) 4 → 5 50 to 56 km/h (31 to 35 mph) 5 → 4 26 to 31 km/h (16 to 19 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 4 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully close) 5 → 4 198 to 212 km/h (122 to 132 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 3 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) (Throttle valve fully open) 4 → 3 139 to 151 km/h (86 to 94 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 2 position 1 → 2 52 to 64 km/h (32 to 40 mph) (Throttle valve fully open) 3 → 2 92 to 103 km/h (57 to 64 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) L position 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 72 to 79 km/h (45 to 49 mph) Lock-up OFF 65 to 71 km/h (40 to 44 mph) 4 position 4th gear Lock-up ON 117 to 125 km/h (73 to 78 mph) Lock-up OFF 110 to 117 km/h (68 to 73 mph) 1GR-FE: Engine idling Line pressure (Wheel locked) D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) R position 484 to 565 kPa (4.9 to 5.8 kgf*cm 2, 70 to 82 psi) AT stall (Throttle valve fully opened) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Engine stall revolution Time lag D position 1,282 to 1,381 kPa (13.1 to 14.1 kgf*cm 2, 186 to 200 psi) R position 1,218 to 1,338 kPa (12.4 to 13.6 kgf*cm 2, 177 to 194 psi) D positions 2,400 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 4 → 5 179 to 189 km/h (111 to 117 mph) 5 → 4 171 to 182 km/h (106 to 113 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) (Throttle valve fully close) 4 → 5 46 to 51 km/h (29 to 32 mph) 5 → 4 27 to 33 km/h (17 to 21 mph) 4 position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 5 → 4 191 to 202 km/h (119 to 126 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 3 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 2 → 3 97 to 106 km/h (60 to 66 mph) 4 → 3 133 to 143 km/h (83 to 88 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 2 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 3 → 2 88 to 98 km/h (55 to 61 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) L position (Throttle valve fully open) Lock-up point 2 → 1 42 to 48 km/h (26 to 30 mph) Throttle valve opening 5% D position 5th gear Lock-up ON 57 to 63 km/h (35 to 39 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) 4 position 4th gear Lock-up ON 69 to 74 km/h (43 to 46 mph) Lock-up OFF 61 to 67 km/h (38 to 42 mph) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 T Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W73049X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): PROBLEM SYMPTOMS TABLE (2007 4Runner) PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Refer to the table below when the trouble cause is considered to be electrical. If the instruction "Proceed to next circuit inspection shown on matrix chart" is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart SYMPTOM SUSPECTED AREA 1. Shift solenoid valve (S1) circuit *1 No up-shift (A particular gear, from 1st to 4th gear, is not 2. Shift solenoid valve (S2) circuit up-shifted) *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Engine coolant temp. sensor circuit *1 No up-shift (4th -> 5th) 3. Speed sensor NT circuit *1 4. Shift solenoid valve (SL1) circuit *1 5. Shift solenoid valve (SL2) SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... circuit *1 6. Shift solenoid valve (SR) circuit *1 7. ECM 1. Engine coolant temp. sensor circuit *1 No up-shift (3rd -> 4th) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (2 - L) *1 No up-shift (1st -> 2nd) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Transmission control switch circuit (D - 4) *1 2. Shift solenoid valve (SL1) circuit *1 No down-shift (5th -> 4th) 3. Shift solenoid valve (SL2) circuit *1 4. Shift solenoid valve (SR) circuit *1 5. ECM 1. Transmission control switch circuit (2 - L) *1 No down-shift (2nd -> 1st) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. Shift solenoid valve (S1) circuit *1 No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) 2. Shift solenoid valve (S2) circuit *1 3. ECM 1. ATF temperature sensor circuit *1 2. Transfer L4 position switch circuit *1 3. Stop light switch circuit *1 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 4. Speed sensor NT circuit *1 No lock-up 5. Shift solenoid valve (SLU) circuit *1 6. Engine coolant temp. sensor circuit *1 7. ECM No lock-up off 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. Shift solenoid valve (SLT) circuit *1 2. Speed sensor NT circuit *1 3. Speed sensor SP2 circuit *1 Shift point too high or too low 4. Throttle position sensor circuit *1 5. ATF temperature sensor circuit *1 6. Transfer L4 position switch circuit *1 7. ECM Up-shift to 5th from 4th while shift lever is in 4 position 1. Transmission control switch circuit (D - 4) *1 2. ECM Up-shift to 5th from 4th while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM Up-shift to 4th from 3rd while shift lever is in 3 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 3rd from 2nd while shift lever is in 2 position 1. Park/neutral position switch circuit *1 2. ECM Up-shift to 2nd from 1st while shift lever is in L position 1. Transmission control switch circuit (2 - L) *1 2. ECM 1. Speed sensor NT circuit *1 2. Shift solenoid valve (SL1) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... circuit *1 Harsh engagement (N -> D) 3. Shift solenoid valve (SLT) circuit *1 4. ECM 1. Speed sensor NT circuit *1 2. Speed sensor SP2 circuit *1 Harsh engagement (Lock-up) 3. Shift solenoid valve (SLU) circuit *1 4. ECM Harsh engagement (Any driving position) ECM 1. ATF temperature sensor No. 2 circuit 2. Engine coolant temp. sensor circuit *1 Poor acceleration 3. Shift solenoid valve (SLT) circuit *1 4. ECM No engine braking ECM No kick-down ECM Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) circuit *1 2. ECM 1. ATF temperature sensor No. 2 circuit AT Oil Temp. warning light remains on, Lock-up at 3rd gear and/or shift point too high 2. Engine coolant temp. sensor circuit 3. ECM 1. Park/neutral position switch circuit *1 Malfunction in shifting 2. ECM 2. Chapter 2: On-vehicle Repair SYMPTOM SUSPECTED AREA 1. Transmission control cable SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 2. Manual valve Vehicle does not move with shift lever in any forward position and reverse position 3. Parking lock pawl 4. Off-vehicle repair matrix chart - 1. Valve body assembly Vehicle does not move with shift lever in R position 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (1st -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (2nd -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (3rd -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No up-shift (4th -> 5th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (5th -> 4th) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (4th -> 3rd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (3rd -> 2nd) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No down-shift (2nd -> 1st) 2. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) No lock-up or No lock-up off 2. Valve body assembly 3. Off-vehicle repair matrix chart 1. Shift solenoid valve - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (SL1) 2. Valve body assembly Harsh engagement (N -> D) 3. C1 accumulator 4. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLU) Harsh engagement (Lock-up) 2. Valve body assembly 3. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) 2. Shift solenoid valve (SLU) Harsh engagement (N -> R) 3. Valve body assembly 4. C3 accumulator 5. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SLT) Harsh engagement (1st -> 2nd -> 3rd -> 4th -> 5th) 2. Shift solenoid valve (SL1) 3. Valve body assembly 1. Valve body assembly Harsh engagement (1st -> 2nd) 2. B3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (2nd -> 3rd) 2. C3 accumulator 3. Off-vehicle repair matrix chart - 1. Valve body assembly Harsh engagement (3rd -> 4th) 2. C2 accumulator 3. Off-vehicle repair matrix chart 1. Shift solenoid valve - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (SL1) 2. Shift solenoid valve (SL2) Harsh engagement (4th -> 5th) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Shift solenoid valve (SL1) Harsh engagement (5th -> 4th) 2. Shift solenoid valve (SL2) 3. Valve body assembly 4. Off-vehicle repair matrix chart - 1. Transmission control cable 2. Valve body assembly Slip or shudder (Forward and reverse) 3. Oil strainer 4. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (1st: L position) 2. Off-vehicle repair matrix chart - 1. Valve body assembly No engine braking (2nd: 2 position) 2. Off-vehicle repair matrix chart No kick-down Valve body assembly 1. Shift solenoid valve (SLT) Shift point too high or too low 2. Shift solenoid valve (SL1) 3. Valve body assembly Poor acceleration 1. Shift solenoid valve (SLT) 2. Valve body assembly Engine stalls when starting off or stopping 1. Shift solenoid valve (SLU) 2. Valve body assembly - A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... 3. Chapter 3: Off-Vehicle Repair SYMPTOM Vehicle does not move with shift lever in any forward position and reverse position SUSPECTED AREA 1. Rear planetary gear unit 2. Torque converter clutch 1. Brake No. 4 (B4) Vehicle does not move with shift lever in R position 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) No up-shift (1st -> 2nd) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) No up-shift (2nd -> 3rd) Clutch No. 3 (C3) No up-shift (3rd -> 4th) Clutch No. 2 (C2) 1. Brake No. 1 (B1) No up-shift (4th -> 5th) No lock-up or No lock-up off 2. Clutch No. 1 (C1) Torque converter clutch 1. Clutch No. 1 (C1) Harsh engagement (N -> D) 2. One-way clutch No. 3 (F3) 1. Clutch No. 3 (C3) Harsh engagement (N -> R) 2. Brake No. 4 (B4) 3. One-way clutch No. 1 (F1) 1. Brake No. 3 (B3) Harsh engagement (1 -> 2) 2. One-way clutch No. 1 (F1) 3. One-way clutch No. 2 (F2) Harsh engagement (2 -> 3) Clutch No. 3 (C3) Harsh engagement (3 -> 4) Clutch No. 2 (C2) 1. Brake No. 1 (B1) SEE PAGE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Harsh engagement (4 -> 5th) 2. Clutch No. 1 (C1) Harsh engagement (Lock-up) Torque converter clutch 1. One-way clutch No. 1 (F1) Slip or shudder (Forward and reverse: After warm-up) 2. Clutch No. 3 (C3) 3. Torque converter clutch Slip or shudder (Particular position: Just after engine starts) Torque converter clutch 1. Brake No. 4 (B4) Slip or shudder (R position) 2. One-way clutch No. 1 (F1) 3. Clutch No. 3 (C3) 1. Clutch No. 1 (C1) Slip or shudder (1st) 2. One-way clutch No. 3 (F3) 1. Clutch No.1 (C1) 2. Brake No. 3 (B3) Slip or shudder (2nd) 3. One-way clutch No. 1 (F1) 4. One-way clutch No. 2 (F2) 1. Clutch No. 1 (C1) Slip or shudder (3rd) 2. Clutch No. 3 (C3) 3. One-way clutch No. 1 (F1) 1. Clutch No. 1 (C1) Slip or shudder (4th) 2. Clutch No. 2 (C2) 1. Clutch No. 2 (C2) Slip or shudder (5th) 2. Clutch No. 3 (C3) 3. Brake No. 1 (B1) No engine braking (1st - 4th: D position) Clutch No. 1 (C1) No engine braking (1st: L position) Brake No. 4 (B4) No engine braking (2nd: 2 position) Brake No. 2 (B2) No engine braking (3rd: 3 position) Brake No. 1 (B1) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Poor acceleration (All positions) Torque converter clutch 1. Clutch No. 1 (C1) 2. Clutch No. 3 (C3) Poor acceleration (5th) 3. Brake No. 1 (B1) 4. Front planetary gear unit Engine stalls when starting off or stopping Torque converter clutch A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7903UX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): ROAD TEST (2007 4Runner) ROAD TEST 1. PROBLEM SYMPTOM CONFIRMATION (a) Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transmission does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the normal operating ATF temperature of 50 to 80°C (122 to 176°F). (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts take place at the shift point shown in the automatic shift schedule . HINT: 5th Gear Up-shift Prohibition Control z Engine coolant temperature is 55°C (131°F) or less and vehicle speed is at 32 mph (51 km/h) or less. 4th Gear Up-shift Prohibition Control z Engine coolant temperature is 40°C (104°F) or less and vehicle speed is at 28 mph (45 km/h) or less. 5th Gear Lock-up Prohibition Control z z z Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check for shift shock and slippage. Check for shock and slippage at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5 up-shifts. (3) Check for abnormal noise and vibration. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and also check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule . (5) Check for abnormal shock and slippage at kick-down. (6) Check the lock-up mechanism. z z Drive in the D position (5th gear), at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (b) 4 (O/D OFF) position test: Shift into the 4 (O/D OFF) position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3, and 3 → 4 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: z z There is no 5th up-shift in the 4 position. 4th Gear Lock-up Prohibition Control { { { Brake pedal is depressed. Accelerator pedal is released. Engine coolant temperature is 60°C (140°F) or less. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (4) Check the lock-up mechanism. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... z z Drive in the 4 position and 4th gear, at a steady speed (lock-up ON). Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT: If there is a sudden increase in engine speed, there is no lock-up. (c) 3 position test Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shifts take place and that the shift point conforms to the automatic shift schedule . HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While driving in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule . HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While driving in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While driving in the L position, check that there is no up-shift to 2nd gear. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... (2) Check engine braking. While driving in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (f) R position test Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test, ensure that the test area is free from people and obstruction. (g) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 D Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W75041X Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): SYSTEM DESCRIPTION (2007 4Runner) SYSTEM DESCRIPTION 1. SYSTEM DESCRIPTION (a) The ECT (Electronic controlled automatic transmission) is an automatic transmission that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: z z Diagnostic function. Fail-safe function when a malfunction occurs. 2. OPERATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7D03LX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): SYSTEM DIAGRAM (2007 4Runner) SYSTEM DIAGRAM The configuration of the electronic control system in the A750F automatic transmission is as shown in the following chart. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Last Modified: 4-26-2007 1.6 U Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000000W7403NX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE): TERMINALS OF ECM (2007 4Runner) TERMINALS OF ECM 1. ECM HINT: Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to inspected. The standard voltage between the terminals is shown under "Specific Condition". Use the illustration above as a reference for the ECM terminals. SYMBOLS (TERMINALS NO.) WIRING COLOR L4 (E6-13) - E1 (E6-1) W-L - W-B ↑ ↑ L (E7-9) - E1 (E61) B-L - W-B ↑ ↑ 2 (E7-10) - E1 (E6-1) ↑ TERMINAL DESCRIPTION Transfer L position switch signal CONDITION SPECIFIED CONDITION IG switch ON and Transfer L position Below 1 V IG switch ON and Transfer except L position 10 to 14 V IG switch ON and shift lever L position 10 to 14 V ↑ IG switch ON and shift lever except L position Below 1 V G-R - W-B 2 shift position switch signal IG switch ON and shift lever 2 and L position 10 to 14 V ↑ ↑ IG switch ON and shift lever except 2 and L position Below 1 V ↑ L shift position switch signal A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... R (E7-11) - E1 (E6-1) R-Y - W-B R shift position switch signal IG switch ON and shift lever R position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except R position Below 1 V D (E7-21) - E1 (E6-1) V - W-B D shift position switch signal IG switch ON and shift lever D and 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except D and 4 position Below 1 V 3 (E7-19) - E1 (E6-1) L - W-B 3 shift position switch signal IG switch ON and shift lever 3 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 3 position Below 1 V 4 (E7-20) - E1 (E6-1) G - W-B 4 shift position switch signal IG switch ON and shift lever 4 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 4 position Below 1 V STP (E8-15) - E1 (E6-1) G-Y - W-B ↑ ↑ Stop light switch signal ↑ Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V Pulse generation SLU+ (E5-15) SLU- (E5-14) R-B - R-W SLU solenoid signal 5th (lock-up) gear S2 (E5-10) - E1 (E6-1) W-L - W-B S2 solenoid signal 2nd or 3rd gear 10 to 14 V 1st, 4th or 5th gear Below 1 V 1st or 2nd gear 10 to 14 V 3rd, 4th or 5th gear Below 1 V ↑ ↑ S1 (E5-11) - E1 (E6-1) GR - W-B ↑ ↑ ↑ S1 solenoid signal ↑ (See waveform 2) Pulse generation SLT+ (E5-13) SLT- (E5-12) LG-B - L-R SLT solenoid signal Engine idle speed SR (E5-9) - E1 (E6-1) P-L - W-B 5th gear 10 to 14 V ↑ ↑ 1st gear Below 1 V SL2+ (E5-17) SL2- (E5-16) SR solenoid signal ↑ B-W - B-R SL2 solenoid signal Engine idle speed (See waveform 1) Pulse generation (See waveform 3) Pulse A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... generation SL1+ (E5-19) SL1- (E5-18) G-B - B-Y SL1 solenoid signal Engine idle speed THO1 (E5-24) - E2 (E4-28) Y-G - BR No. 1 ATF temperature sensor signal No. 1 ATF temperature: 115°C (239°F) or more Below 1.5 V THO2 (E5-32) - E2 (E4-28) L - BR No. 2 ATF temperature sensor signal No. 2 ATF temperature: 115°C (239°F) or more Below 1.5 V SP2+ (E5-34) SP2- (E5-26) L-Y - R-L Speed sensor (SP2) signal Vehicle speed 20 km/h (12 mph) (See waveform 4) Pulse generation (See waveform 6) Pulse generation NT+ (E5-35) - NT(E5-27) Y-R - W-R Speed sensor (NT) signal Engine idle speed STAR/NSW (E5-8) - E1 (E6-1) P - W-B Park neutral switch signal IG switch ON and shift lever P and N position Below 2 V ↑ ↑ IG switch ON and shift lever except P and N position 10 to 14 V ↑ (a) Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (b) Waveform 2 Reference: Terminal SLU+ - SLU- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition 5th (lock-up) (c) Waveform 3 (See waveform 5) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM (for 2UZ-FE)... Reference: Terminal SL2+ - SL2- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (d) Waveform 4 Reference: Terminal SL1+ - SL1- Tool setting 5 V/DIV., 1 ms./DIV. Vehicle condition Engine idle speed (e) Waveform 5 Reference: Terminal NT+ - NT- Tool setting 1 V/DIV., 2 ms./DIV. Vehicle condition Engine idle speed (P or N position) (f) Waveform 6 Reference: Terminal SP2+ - SP2- Tool setting 2 V/DIV., 20 ms./DIV. Vehicle condition Vehicle speed 20 km/h (12 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Last Modified: 4-26-2007 1.6 F Service Category: General Section: Specifications Model Year: 2007 Model: 4Runner Doc ID: RM000002E14001X Title: SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4Runner) SERVICE DATA 2UZ-FE: Engine idling D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) Line pressure (Wheel locked) Engine stall revolution Time lag R position 495 to 576 kPa (5.0 to 5.9 kgf*cm 2, 71 to 84 psi) AT stall (Throttle valve fully open) D position 1,235 to 1,332 kPa (12.6 to 13.6 kgf*cm 2, 179 to 193 psi) R position 1,229 to 1,350 kPa (12.5 to 13.8 kgf*cm 2, 178 to 196 psi) D position 2,200 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully open) 4 → 5 186 to 200 km/h (116 to 124 mph) 5 → 4 181 to 194 km/h (112 to 121 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully close) 4 → 5 50 to 56 km/h (31 to 35 mph) 5 → 4 26 to 31 km/h (16 to 19 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 4 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) 3 → 4 138 to 154 km/h (86 to 96 mph) (Throttle valve fully close) 5 → 4 198 to 212 km/h (122 to 132 mph) 4 → 3 126 to 139 km/h (78 to 86 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 3 position 1 → 2 52 to 64 km/h (32 to 40 mph) 2 → 3 97 to 108 km/h (60 to 67 mph) (Throttle valve fully open) 4 → 3 139 to 151 km/h (86 to 94 mph) 3 → 2 85 to 93 km/h (53 to 58 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) 2 position 1 → 2 52 to 64 km/h (32 to 40 mph) (Throttle valve fully open) 3 → 2 92 to 103 km/h (57 to 64 mph) 2 → 1 40 to 46 km/h (25 to 29 mph) L position 2 → 1 40 to 46 km/h (25 to 29 mph) (Throttle valve fully open) Lock-up point Throttle valve opening 5% D position 5th gear Lock-up ON 72 to 79 km/h (45 to 49 mph) Lock-up OFF 65 to 71 km/h (40 to 44 mph) 4 position 4th gear Lock-up ON 117 to 125 km/h (73 to 78 mph) Lock-up OFF 110 to 117 km/h (68 to 73 mph) 1GR-FE: Engine idling Line pressure (Wheel locked) D position 362 to 423 kPa (3.7 to 4.3 kgf*cm 2, 53 to 61 psi) R position 484 to 565 kPa (4.9 to 5.8 kgf*cm 2, 70 to 82 psi) AT stall (Throttle valve fully opened) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... Engine stall revolution Time lag D position 1,282 to 1,381 kPa (13.1 to 14.1 kgf*cm 2, 186 to 200 psi) R position 1,218 to 1,338 kPa (12.4 to 13.6 kgf*cm 2, 177 to 194 psi) D positions 2,400 +- 150 rpm N → D position Less than 1.2 seconds N → R position Less than 1.5 seconds Engine idle speed (A/C OFF) N position 700 +- 50 rpm Drive plate runout Max. 0.20 mm (0.0079 in.) Torque converter runout Max. 0.30 mm (0.0118 in.) Torque converter clutch installation distance More than 17.1 mm (0.673 in.) Shift schedule D position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 4 → 5 179 to 189 km/h (111 to 117 mph) 5 → 4 171 to 182 km/h (106 to 113 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) (Throttle valve fully close) 4 → 5 46 to 51 km/h (29 to 32 mph) 5 → 4 27 to 33 km/h (17 to 21 mph) 4 position 1 → 2 50 to 61 km/h (31 to 38 mph) 2 → 3 97 to 106 km/h (60 to 66 mph) 3 → 4 140 to 154 km/h (87 to 96 mph) (Throttle valve fully open) 5 → 4 191 to 202 km/h (119 to 126 mph) 4 → 3 125 to 134 km/h (78 to 83 mph) 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 3 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 2 → 3 97 to 106 km/h (60 to 66 mph) 4 → 3 133 to 143 km/h (83 to 88 mph) SERVICE SPECIFICATIONS: A750F AUTOMATIC TRANSMISSION: SERVICE DATA (2007 4... 3 → 2 83 to 89 km/h (52 to 55 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) 2 position 1 → 2 50 to 61 km/h (31 to 38 mph) (Throttle valve fully open) 3 → 2 88 to 98 km/h (55 to 61 mph) 2 → 1 39 to 44 km/h (24 to 27 mph) L position (Throttle valve fully open) Lock-up point 2 → 1 42 to 48 km/h (26 to 30 mph) Throttle valve opening 5% D position 5th gear Lock-up ON 57 to 63 km/h (35 to 39 mph) Lock-up OFF 50 to 55 km/h (31 to 34 mph) 4 position 4th gear Lock-up ON 69 to 74 km/h (43 to 46 mph) Lock-up OFF 61 to 67 km/h (38 to 42 mph) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EY00SX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS (2007 4Runner COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... 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ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EZ00SX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH (a) Remove the nut, washer and control shaft lever LH. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Using a screwdriver, pry out the lock washer. (b) Remove the nut, lock washer and bolt. (c) Remove the park/neutral position switch. 3. REMOVE OIL COOLER TUBE UNION (a) Remove the 2 oil cooler tube unions. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the O-ring from the oil cooler tube union. 4. REMOVE SPEED SENSOR (a) Remove the 2 bolts and 2 speed sensor. (b) Remove the O-ring from each sensor. 5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE (a) Remove the 3 bolts. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the breather tube. (c) Remove the O-ring from each tube. 6. REMOVE AUTOMATIC TRANSMISSION HOUSING (a) Remove the 10 bolts. (b) Remove the transmission housing. 7. REMOVE EXTENSION HOUSING SUB-ASSEMBLY (a) Remove the 6 bolts. (b) Remove the extension housing assembly. HINT: Use a brass bar and hammer to remove the extension housing assembly. (c) Remove the gasket from the extension housing assembly. (d) Using a snap ring expander, remove the snap ring. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (e) Remove the thrust needle roller bearing and 2 bearing races. 8. REMOVE EXTENSION HOUSING DUST DEFLECTOR (a) Using a brass bar and hammer, remove the extension housing dust deflector. 9. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL (a) Using SST, tap out the oil seal. SST: 09308-00010 10. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY (a) Install the transmission case on the overhaul attachment. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 11. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the pan. (a) Remove the drain plug and 20 bolts. 12. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Turn over the transmission. (b) Remove the 4 bolts holding the valve body oil strainer assembly to the valve body. (c) Remove the O-ring form the valve body oil strainer assembly. 14. REMOVE TRANSMISSION WIRE (a) Remove the ATF temperature sensor. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the bolt and clamp. (c) Disconnect the 7 connectors from the shift solenoid valves. (d) Remove the bolt from the case. (e) Pull the transmission wire out of the transmission case. (f) Remove the O-ring from the transmission wire. 15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts. (b) Remove the valve body assembly. 16. REMOVE TRANSAXLE CASE GASKET (a) Remove the 3 transaxle case gaskets. 17. REMOVE BRAKE DRUM GASKET A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the 3 brake drum gaskets. 18. REMOVE CHECK BALL BODY (a) Remove the check ball body and spring. 19. REMOVE C-2 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the C2 accumulator piston and spring. (b) Remove the 2 O-rings from the piston. NOTICE: Be careful as the C-3 and B-3 accumulator piston may jump out. 20. REMOVE B-3 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... B3 accumulator piston and spring. (b) Remove the 2 O-rings from the piston. NOTICE: Be careful as the C-3 accumulator piston may jump out. 21. REMOVE C-3 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the C3 accumulator piston and 2 spring. (b) Remove the 2 O-rings from the piston. 22. REMOVE C-1 ACCUMULATOR VALVE (a) Remove the C-1 accumulator valve and 2 springs. 23. REMOVE PARKING LOCK PAWL BRACKET A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the 3 bolts and parking lock pawl bracket. 24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY (a) Disconnect the parking lock rod from the manual valve lever. 25. REMOVE PARKING LOCK PAWL SHAFT (a) Pull out the parking lock pawl shaft from the front side, and then remove the lock pawl and spring. (b) Remove the E-ring from the shaft. 26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY (a) Using a hammer and screwdriver, cut off the spacer and remove it from the shaft. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Using a pin punch and hammer, tap out the spring pin. HINT: Slowly drive out the spring pin so that it does not fall into the transmission case. (c) Pull the manual valve lever shaft out through the case, and remove the manual valve lever. 27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using a screwdriver, remove the 2 oil seals. 28. REMOVE OIL PUMP ASSEMBLY (a) Remove the 10 bolts holding the oil pump from the transmission case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Using SST, remove the oil pump. SST: 09350-30020 09350-07020 (c) Remove the No. 1 thrust bearing race from the front oil pump. 29. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Remove the clutch drum and input shaft drum assembly from the transmission case. (b) Remove the clutch drum thrust washer and thrust needle roller bearing. 30. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 31. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY (a) Remove the No. 2 1-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly. 32. REMOVE NO. 3 BRAKE SNAP RING (a) Using a screwdriver, remove the No. 3 brake snap ring from the case. 33. REMOVE NO. 3 BRAKE DISC (a) Remove the flange and cushion plate the 4 discs and the 4 plates from the case. 34. INSPECT NO. 3 BRAKE DISC 35. REMOVE 2ND BRAKE PISTON HOLE SNAP RING (a) Using SST, remove the snap ring. SST: 09350-30020 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 09350-07060 36. REMOVE 1-WAY CLUTCH ASSEMBLY (a) Remove the 1-way clutch assembly and the No. 1 planetary carrier thrust washer from the case. 37. REMOVE 2ND BRAKE CYLINDER (a) Remove the 2nd brake cylinder from the case. 38. REMOVE 2ND BRAKE PISTON (a) Using SST and a press, remove the snap ring. SST: 09351-40010 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston. (c) Remove the 2 O-rings from the 2nd brake piston. 39. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 40. REMOVE FRONT PLANETARY GEAR ASSEMBLY (a) Remove the front planetary gear assembly and the 1 way clutch inner race from the case. (b) Remove the thrust needle roller bearing, the No. 3 thrust bearing race and the No. 2 planetary carrier thrust washer from the front planetary gear assembly. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 41. INSPECT FRONT PLANETARY GEAR ASSEMBLY 42. INSPECT 1-WAY CLUTCH ASSEMBLY 43. REMOVE FRONT PLANETARY RING GEAR (a) Remove the front planetary ring gear and bearing from the transmission case. 44. REMOVE CENTER PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring. (b) Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear. 45. REMOVE NO. 1 BRAKE DISC A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the flange, 3 discs and 3 plates from the case. 46. INSPECT NO. 1 BRAKE DISC 47. REMOVE BRAKE PISTON RETURN SPRING SNAP RING (a) Using a screwdriver, remove the brake piston return spring snap ring from the case. 48. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Remove the brake piston return spring and No. 1 the brake piston with the No. 1 brake cylinder from the transmission case. 49. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 50. REMOVE NO. 1 BRAKE PISTON (a) Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the transmission case to remove the No. 1 brake piston. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the 2 O-rings from the No. 1 brake piston. 51. REMOVE NO. 2 BRAKE DISC (a) Using a screwdriver, remove the snap ring from the case. (b) Remove the flange, the brake piston return spring, the 3 discs and the 3 plates from the case. 52. INSPECT NO. 2 BRAKE DISC 53. INSPECT NO.2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 54. REMOVE NO. 2 BRAKE PISTON (a) Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the transmission case to remove the No. 2 brake piston. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the 2 O-rings from the No. 2 brake piston. 55. REMOVE CENTER PLANETARY GEAR ASSEMBLY (a) Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the case. 56. INSPECT CENTER PLANETARY GEAR ASSEMBLY 57. REMOVE INTERMEDIATE SHAFT (a) Using a screwdriver, remove the snap ring from the case. (b) Remove the intermediate shaft with the No. 3 1- way clutch assembly from the case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 58. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY 59. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY (a) Remove the No. 3 1-way clutch assembly and the 1 way clutch inner race from the intermediate shaft. 60. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (a) Remove the No. 8 thrust bearing race, thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft. 61. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 62. INSPECT INTERMEDIATE SHAFT 63. REMOVE BRAKE PLATE STOPPER SPRING A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the brake plate stopper spring from the case. 64. REMOVE NO. 4 BRAKE DISC (a) Remove the 7 plates, the 8 discs and the 2 flanges from the case. 65. INSPECT NO. 4 BRAKE DISC 66. REMOVE REAR PLANETARY GEAR ASSEMBLY (a) Remove the rear planetary gear assembly from the case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the No. 9 thrust bearing race and the thrust needle roller bearing from the rear planetary gear assembly. (c) Remove the thrust needle roller bearing from the case. 67. INSPECT REAR PLANETARY GEAR ASSEMBLY 68. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the spring retainer and compress the brake return spring. SST: 09350-30020 09350-07050 (b) Using SST, remove the snap ring and the brake return spring. SST: 09350-30020 09350-07070 69. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 70. REMOVE 1ST AND REVERSE BRAKE PISTON (a) Hold the 1st and reverse brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... transmission case to remove the 1st and reverse brake piston. HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the O-ring from 1st and reverse brake piston. 71. REMOVE BRAKE REACTION SLEEVE (a) Using SST, remove the reaction sleeve. SST: 09350-30020 09350-07080 (b) Remove the O-ring from the reaction sleeve. 72. REMOVE NO. 4 BRAKE PISTON (a) Using SST, remove the No. 4 brake piston. SST: 09350-30020 09350-07090 (b) Remove the 2 O-rings from the No. 4 piston. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EX00TX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (a) Remove the magnets, and use them to collect steel particles. (b) Carefully lock at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. z z Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY (a) Hold the Reverse clutch hub and turn the No. 2 1-way clutch assembly. (b) The No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise. 3. INSPECT NO. 3 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 4. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 15.72 mm (0.619 in.) 5. INSPECT FRONT PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the front planetary pinion gear thrust clearance. Standard clearance: 0.2 to 0.60 mm (0.008 to 0.024 in.) Maximum clearance 0.65 mm (0.026 in.) If the clearance is greater than the maximum, replace the front planetary gear assembly. (b) Using a cylinder gauge, measure the inside diameter of the front planetary gear bushing. Maximum inside diameter: 57.48 mm (2.263 in.) If the inside diameter is greater than the maximum, replace the front planetary gear. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... 6. INSPECT 1-WAY CLUTCH ASSEMBLY (a) Install the 1-way clutch assembly to the 1-way clutch inner race. (b) Hold the 1-way clutch inner race and turn the 1-way clutch assembly. (c) Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise. (d) Remove the 1-way clutch assembly from the 1-way clutch inner race. 7. INSPECT NO. 1 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 8. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 17.05 mm (0.671 in.) 9. INSPECT NO. 2 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 10. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.45 mm (0.687 in.) 11. INSPECT CENTER PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the center planetary gear pinion thrust clearance. Standard clearance: 0.12 to 0.68 mm (0.005 to 0.027 in.) Maximum clearance 0.73 mm (0.029 in.) If the clearance is greater than the maximum, replace the center planetary gear assembly. 12. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY (a) Hold the rear planetary ring gear flange sub-assembly turn the 1-way clutch assembly. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... (b) Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise. 13. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the rear planetary ring gear bushing. Maximum inside diameter: 32.175 mm (1.267 in.) If the inside diameter is greater than the maximum, replace the rear planetary ring gear. 14. INSPECT INTERMEDIATE SHAFT (a) Using a dial indicator, check the intermediate shaft runout. Maximum runout: 0.08 mm (0.003 in.) NOTICE: If the bend exceeds the specification, replace the intermediate shaft with anew one. (b) Using a micrometer, check the outer diameter of the intermediate shaft positions shown in the diagram. Standard diameter: A 25.962 to 25.975 mm (1.022 to 1.023 in.) B 25.962 to 25.975 mm (1.022 to 1.023 in.) C 32.062 to 32.075 mm (1.262 to 1.263 in.) D 32.062 to 32.075 mm (1.262 to 1.263 in.) Minimum diameter: A 25.912 mm (1.020 in.) B 25.912 mm (1.020in.) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... C 32.012 mm (1.260 in.) D 32.012 mm (1.260 in.) NOTICE: If the outer diameter is outside the standard, replace the intermediate shaft with the new one. 15. INSPECT NO. 4 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 16. INSPECT REAR PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the rear planetary gear pinion thrust clearance. Standard clearance: 0.2 to 0.6 mm (0.008 to 0.024 in.) Maximum clearance 0.65 mm (0.026 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. (b) Using a dial indicator, measure the inside diameter of A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... the rear planetary gear bushing. Maximum inside diameter: 20.075 mm (0.790 in.) If the inside diameter is greater than the maximum, replace the rear planetary gear assembly. 17. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 23.74 mm (0.935 in.) 18. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (a) Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case. 19. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON (a) Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (... (b) Using a feeler gauge, measure the B3 bearing pack clearance between the snap ring and flange. Piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 in.) If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange. HINT: There are 4 different thicknesses for the flange. 20. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION (a) Check the operating sound while applying compressed air into the oil holes indicated in the illustration. HINT: When inspecting the O/D direct clutch, check with the C3 accumulator piston holes indicated in the illustration. HINT: If there is no sound, disassembly and check the installation condition of the parts. z z z z z z z No. No. No. No. No. No. No. 2 3 1 3 1 2 4 clutch (C2) clutch (C3) clutch (C1) brake (B1) brake (B1) brake (B2) brake (B4) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013F000SX Title: A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY (2007 4Runner) REASSEMBLY 1. BEARING POSITION (a) Check bearing position. Bearing diameter: MARK FRONT RACE DIAMETER THRUST BEARING DIAMETER REAR RACE DIAMETER A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... INSIDE / OUTSIDE INSIDE / OUTSIDE INSIDE / OUTSIDE A 73.6 mm (2.898 in.) / 102.0 mm (4.016 in.) 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) - B 38.0 mm (1.496 in.) / 57.0 mm (2.244 in.) 43.4 mm (1.709 in.) / 58.3 mm (2.295 in.) - C - 55.7 mm (2.193 in.) / 76.4 mm (3.008 in.) 53.7 mm (2.114 in.) / 74.0 mm (2.913 in.) D 33.4 mm (1.315 in.) / 49.0 mm (1.929 in.) 32.1 mm (1.264 in.) / 49.35 mm (1.943 in.) 32.1 mm (1.264 in.)/ 49.0 mm (1.929 in.) E - 21.5 mm(0.847 in.) / 40.8 mm (1.606 in.) - F 48.5 mm (1.909 in.) / 62.7 mm (2.469 in.) 45.9 mm (1.807 in.) / 64.0 mm (2.520 in.) - 2. INSTALL NO. 4 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve. (b) Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston. (c) Install the No. 4 brake piston to the reaction sleeve. 3. INSTALL BRAKE REACTION SLEEVE (a) Coat a new O-ring with ATF, and install it to the reaction sleeve. (b) With the No. 1brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... NOTICE: Be careful not to damage the O-rings. 4. INSTALL 1ST AND REVERSE BRAKE PISTON (a) Coat a new O-ring with ATF. (b) Install the O-ring on the 1st and reverse brake piston. (c) With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case. NOTICE: Be careful not to damage the O-ring. (d) Place the piston return spring onto the No. 4 brake piston. 5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the spring retainer, and compress the return spring. SST: 09350-30020 09350-07050 (b) Using SST, install the snap ring. SST: 09350-30020 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07070 6. INSTALL REAR PLANETARY GEAR ASSEMBLY (a) Install the thrust needle roller bearing. Thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 45.9 mm (1.807 in.) 64.0 mm (2.520 in.) (b) Install the thrust needle roller bearing. (c) Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear. Bearing and race diameter: ITEM INSIDE OUTSIDE Bearing 21.5 mm (0.847 in.) 40.8 mm (1.606 in.) Race 48.5 mm (1.909 in.) 62.7 mm (2.469 in.) (d) Install the rear planetary gear assembly. 7. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case. (b) Using vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average. NOTICE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case. HINT: Length A = 36.35 to 37.09 mm (1.431 to 1.460 in.) (c) Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average. HINT: Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.010 to 0.071 in.) HINT: Length B = 36.04 to 37.14 mm (1.419 to 1.462 in.) Pack clearance: 0.8 to 1.1 mm (0.031 to 0.043 in.) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (d) If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard. H thickness: NO. THICKNESS NO. THICKNESS 0 0 mm (0 in.) 8 0.8 mm (0.031 in.) 2 0.2 mm(0.008 in.) 10 1.0 mm (0.039 in.) 4 0.4 mm (0.016 in.) 12 1.2 mm (0.047 in.) 6 0.6 mm (0.024 in.) 14 1.4 mm (0.055 in.) 8. INSTALL NO. 4 BRAKE DISC (a) Install the 7 plates, the 8 discs and the 2 flanges. Install in order: F - D - P - D - P - D- P - D -P - D - P - D - P - D - P - D - F HINT: P = Plate, D = Disc, F = Flange 9. INSTALL BRAKE PLATE STOPPER SPRING (a) Install the brake plate stopper spring. 10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft. Bearing and race diameter: ITEM INSIDE OUTSIDE No. 7 thrust bearing race 33.4 mm (1.315 in.) 49.0 mm (1.929 in.) Thrust needle roller bearing 32.1 mm (1.264 in.) 49.35 mm (1.943 in.) No. 8 thrust bearing race 32.1 mm (1.264 in.) 49.0 mm (1.929 in.) 11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY (a) Install the No. 3 1-way clutch assembly and 1-way clutch inner race to the intermediate shaft. 12. INSTALL INTERMEDIATE SHAFT (a) Install the intermediate shaft with the No. 3 1-way clutch assembly to the case. (b) Using SST, install the snap ring. SST: 09350-30020 09350-07050 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07060 13. INSTALL CENTER PLANETARY GEAR ASSEMBLY (a) Install the center planetary gear assembly and planetary sun gear to the case. (b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear. Race diameter: ITEM INSIDE OUTSIDE Race 53.7 mm (2.114 in.) 74.0 m (2.913 in.) 14. INSTALL NO. 2 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston. (b) Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands. (c) Install the No. 2 brake piston to the case. 15. INSTALL NO, 2 BRAKE DISC A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install flange, 3 plates, 3 discs and brake piston return spring. Install in order: F-P-S-P-D-P-D HINT: P = Plate, D = Disc, F = Flange (b) Using SST and press, install the No. 2 brake spring snap ring. SST: 09351-40010 16. INSTALL NO. 1 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston. (b) Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands. 17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Install the brake piston return spring and the No. 1 brake piston with No. 1 brake cylinder on the transmission case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING (a) Using SST and a press, install the brake piston return spring snap ring. SST: 09351-40010 19. INSTALL NO. 1 BRAKE DISC (a) Install the 3 plates, 3 discs and flange. Install in order: F-D-P-D-P-D-P-D-P-D-P-D HINT: P = Plate, D = Disc, F = Flange 20. INSTALL CENTER PLANETARY RING GEAR (a) Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear. (b) Using a screwdriver, install the snap ring. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 21. INSTALL FRONT PLANETARY RING GEAR (a) Install the front planetary ring gear and the thrust needle roller bearing on the case. Thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 55.7 mm (2.193 in.) 76.4 mm (3.008 in.) 22. INSTALL FRONT PLANETARY GEAR ASSEMBLY (a) Install the thrust needle roller bearing and the thrust washer. (b) Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear. Thrust needle roller bearing and race diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 43.4 mm (1.709 in.) 58.3 mm (2.295 in.) Race 38.0 mm (1.496 in.) 57.0 mm (2.244 in.) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (c) Install the front planetary gear assembly and 1-way clutch inner race from the case. 23. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON (a) Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case. (b) Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange. Piston stroke: 0.42 to 0.72 mm (0.017 to 0.028 in.) If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange. HINT: There are 4 different thicknesses for the flange. Flange thickness: 24. INSTALL 2ND BRAKE PISTON NO. THICKNESS NO. THICKNESS 0 2.0 mm (0.079 in.) 2 2.4 mm (0.094 in.) 1 2.2 mm (0.087 in.) 3 2.6 mm (0.102 in.) A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat 2 new O-rings with ATF, and install them to the 2nd brake piston. (b) Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands. (c) Using SST and press, install the snap ring. SST: 09351-40010 NOTICE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw. 25. INSTALL 2ND BRAKE CYLINDER (a) Install the 2nd brake cylinder fro the case. 26. INSTALL 1-WAY CLUTCH ASSEMBLY (a) Install the 1-way clutch assembly and thrust washer to the case. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING (a) Using SST, install the snap ring. SST: 09350-30020 09350-07060 28. INSTALL NO. 3 BRAKE DISC (a) Install the 2 flanges, the 4 discs, the 4 plates and cushion plate on the case. Install in order: F-D-P-D-P-D-P-D-P-C HINT: P = Plate, D = Disc, F = Flange C = Cushion 29. INSTALL NO. 3 BRAKE SNAP RING (a) Using a screwdriver, install the snap ring. 30. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY (a) Coat the race with petroleum jelly and install it onto the A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... No. 2 clutch drum thrust washer. (b) Install the No. 2 1-way clutch assembly washer. 31. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Install the thrust needle roller bearing. (b) Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly. Thrust needle roller bearing and diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 71.9 mm (2.831 in.) 85.6 mm (3.370 in.) Race 73.6 mm (2.898 in.) 102.0 mm (4.016 in.) (c) Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case. 32. INSTALL OIL PUMP ASSEMBLY A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the No. 1 thrust bearing race to the front oil pump Thrust bearing race diameter: ITEM INSIDE OUTSIDE Race 74.2 mm (2.921 in.) 87.74 mm (3.454 in.) (b) Coat a new O-ring with ATF, and install it around the oil pump assembly. (c) Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case. (d) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum. NOTICE: Do not push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum. (e) Install the 10 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) 33. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using SST, drive in 2 new oil seals. SST: 09350-30020 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07110 (b) Coat the oil seal lips with MP grease. 34. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION 35. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY (a) Install a new spacer to the manual valve lever. (b) Install the manual valve lever shaft to the transmission case through the manual valve lever. (c) Using a hammer, tap in a new spring pin. (d) Align the manual valve lever indentation with the spacer hole, and stake them together with the punch. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (e) Make sure the shaft rotates smoothly. 36. INSTALL PARKING LOCK PAWL SHAFT (a) Install the E-ring to the shaft. (b) Install the parking lock pawl, shaft and spring. 37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY (a) Connect the parking lock rod to the manual valve lever. 38. INSTALL PARKING LOCK PAWL BRACKET (a) Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... Torque: 7.4 N·m (75 kgf·cm, 65 in·lbf) (b) Shift the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked up by the lock pawl. 39. INSTALL C-1 ACCUMULATOR VALVE (a) Coat a new O-ring with ATF, and install it to the piston. (b) Install the spring and accumulator valve to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-1 Inner C-1 Outer 40. INSTALL C-3 ACCUMULATOR PISTON 30.40 mm (1.197 in.) 11.40 mm (0.449 in.) 48.76 mm (1.920 in.) 16.60 mm (0.654 in.) Pink Light green A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat a new O-ring with ATF, and install it to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-3 Inner C-3 Outer 44.0 mm (1.732 in.) 14.0 mm (0.551 in.) 73.35 mm (2.888 in.) 19.90 mm (0.784 in.) Yellow Red 41. INSTALL B-3 ACCUMULATOR PISTON (a) Coat 2 new O-rings with ATF, and install them to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER B-3 42. INSTALL C-2 ACCUMULATOR PISTON 70.5 mm (2.776 in.) 19.7 mm (0.776 in.) Purple A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat 2 new O-rings with ATF, and install them to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-2 62.0 mm (2.441 in.) 15.9 mm (03626 in.) 43. INSTALL CHECK BALL BODY (a) Install the check ball body and the spring. 44. INSTALL BRAKE DRUM GASKET (a) Install the 3 brake drum gaskets. 45. INSTALL TRANSAXLE CASE GASKET White A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the 3 transaxle case gaskets. 46. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Align the groove of the manual valve with the pin of the lever. (b) Install the 19 bolts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: 25 mm (0.98 in.) for bolt A 36 mm (1.42 in.) for bolt B 47. INSTALL TRANSMISSION WIRE (a) Install a new O-ring to the transmission wire. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (b) Install the transmission wire harness. (c) Install the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (d) Connect the solenoid connector. (e) Connect the 7 solenoid connectors. (f) Install the ATF temperature sensor. (g) Install the clamp and the 2 bolts. Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: 36 mm (1.42 in.) for bolt A 12 mm (0.47 in.) for bolt B Sensor wire harness: WIRE HARNESS COLOR for linear control Orange for oil temp warning light Blue 48. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF, and install them to the valve body oil strainer assembly. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (b) Install the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 49. INSTALL TRANSMISSION OIL CLEANER MAGNET (a) Install the 4 transmission oil cleaner magnets. 50. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (a) Install a new gasket on the oil pan. (b) Install the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) (c) Install the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 51. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL (a) Using SST and a hammer, tap in a new oil seal. SST: 09710-30050 SST: 09950-70010 09951-07100 52. INSTALL EXTENSION HOUSING DUST DEFLECTOR (a) Using SST and a hammer, tap in a new extension housing dust deflector. SST: 09223-15020 SST: 09950-70010 09951-07100 A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 53. INSTALL EXTENSION HOUSING SUB-ASSEMBLY (a) Install the thrust needle roller bearing and the 2 bearing races. (b) Using a snap ring expander, install the snap ring. (c) Using feeler gauge, measure the clearance between the snap ring and the race. Clearance: 0.05 to 0.33 mm (0.002 to 0.013 in.) If the Clearance is still standard, select another race. HINT: There are 6 different thickness for the race. Race thickness: NO. THICKNESS NO. THICKNESS 1 3.7 mm (0.146 in.) 4 4.0 mm (0.158 in.) 2 3.8 mm (0.150 in.) 5 4.1 mm (0.161 in.) 3 3.9 mm (0.154in.) 5 4.2 mm (0.165 in.) (d) Install the gasket to the extension housing. HINT: Take care not to drop the gasket. A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (e) Clean the threads of the bolts and the case with white gasoline. (f) Apply FIPG to the extension housing. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent (g) Install the extension housing with new 6 bolts. Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) HINT: z z Each bolt length is indicated below. Bolt length: 45 mm (1.722 in.) for bolt A 35 mm (1.378 in.) for bolt B 54. INSTALL AUTOMATIC TRANSMISSION HOUSING (a) Clean the threads of the bolts and the case with white gasoline. (b) Install the transmission housing with the 10 bolts. Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) Torque: 57 N·m (581 kgf·cm, 42 ft·lbf) Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: Bolt A: 14 mm Bolt B: 17 mm Bolt C: 14 mm 55. INSTALL AUTOMATIC TRANSAXLE BREATHER TUBE A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install a new O-ring to the breather tube. (b) Install the breather tube with the 3 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) 56. INSTALL SPEED SENSOR (a) Coat 2 new O-rings with ATF, and install it to the speed sensor. (b) Install the 2 speed sensor. (c) Install the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) 57. INSTALL OIL COOLER TUBE UNION (a) Coat a new O-ring with ATF, and install it to oil cooler A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... tube union. (b) Install the oil cooler tube union. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 58. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt. (b) Install a new lock washer and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf) (c) Push the control shaft rearward as much as possible. (d) Return the control shaft lever 2 notches to the N position. (e) Align the neutral basic line with the switch groove as A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... shown in the illustration, and tighten the adjusting bolt. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (f) Using a screwdriver, bend the tabs of the lock washer. HINT: Bend at least 2 of the lock washer tabs. 59. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH (a) Install the washer and the nut to the control shaft lever LH. Torque: 16 N·m (163 kgf·cm, 12 ft·lbf) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EY00RX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS (2007 4Runner COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... 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ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: COMPONENTS... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EZ00RX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH (a) Remove the nut, washer and control shaft lever LH. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Using a screwdriver, pry out the lock washer. (b) Remove the nut, lock washer and bolt. (c) Remove the park/neutral position switch. 3. REMOVE OIL COOLER TUBE UNION (a) Remove the 2 oil cooler tube unions. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the O-ring from the oil cooler tube union. 4. REMOVE SPEED SENSOR (a) Remove the 2 bolts and 2 speed sensor. (b) Remove the O-ring from each sensor. 5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE (a) Remove the 2bolts. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the breather tube. (c) Remove the O-ring from each tube. 6. REMOVE AUTOMATIC TRANSMISSION HOUSING (a) Remove the 10 bolts. (b) Remove the transmission housing. 7. REMOVE TRANSMISSION CASE ADAPTER SUB-ASSEMBLY (a) Remove the 8 bolts. (b) Remove the transmission case adapter assembly. HINT: Use a brass bar and a hammer to remove the extension housing assembly. (c) Remove the gasket from the transmission case adapter adapter assembly. 8. REMOVE TRANSMISSION CASE ADAPTER OIL SEAL (a) Using a screwdriver, pry out the oil seal. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY (a) Install the transmission case on the overhaul attachment. 10. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the pan. (a) Remove the drain plug and 20 bolts. 11. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Turn over the transmission. (b) Remove the 4 bolts holding the valve body oil strainer assembly to the valve body. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (c) Remove the O-ring form the valve body oil strainer assembly. 13. REMOVE TRANSMISSION WIRE (a) Remove the ATF temperature sensor. (b) Remove the bolt and clamp. (c) Disconnect the 7 connectors from the shift solenoid valves. (d) Remove the bolt from the case. (e) Pull the transmission wire out of the transmission case. (f) Remove the O-ring from the transmission wire. 14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts. (b) Remove the valve body assembly. 15. REMOVE TRANSAXLE CASE GASKET A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the 3 transaxle case gaskets. 16. REMOVE BRAKE DRUM GASKET (a) Remove the 3 brake drum gaskets. 17. REMOVE CHECK BALL BODY (a) Remove the check ball body and spring. 18. REMOVE C-2 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the C2 accumulator piston and spring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the 2 O-rings from the piston. NOTICE: Be careful as the C-3 and B-3 accumulator piston may jump out. 19. REMOVE B-3 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the B3 accumulator piston and spring. (b) Remove the 2 O-rings from the piston. NOTICE: Be careful as the C-3 accumulator piston may jump out. 20. REMOVE C-3 ACCUMULATOR PISTON (a) Applying compressed air to the oil hole, and remove the C3 accumulator piston and 2 spring. (b) Remove the 2 O-rings from the piston. 21. REMOVE C-1 ACCUMULATOR VALVE (a) Remove the C-1 accumulator valve and 2 springs. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 22. REMOVE PARKING LOCK PAWL BRACKET (a) Remove the 3 bolts and parking lock pawl bracket. 23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY (a) Disconnect the parking lock rod from the manual valve lever. 24. REMOVE PARKING LOCK PAWL SHAFT (a) Pull out the parking lock pawl shaft from the front side, and then remove the lock pawl and spring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the E-ring from the shaft. 25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY (a) Using a hammer and screwdriver, cut off the spacer and remove it from the shaft. (b) Using a pin punch and hammer, tap out the spring pin. HINT: Slowly drive out the spring pin so that it does not fall into the transmission case. (c) Pull the manual valve lever shaft out through the case, and remove the manual valve lever. 26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using a screwdriver, remove the 2 oil seals. 27. REMOVE OIL PUMP ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the 10 bolts holding the oil pump from the transmission case. (b) Using SST, remove the oil pump. SST: 09350-30020 09350-07020 (c) Remove the No. 1 thrust bearing race from the front oil pump. 28. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Remove the clutch drum and input shaft drum assembly from the transmission case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the clutch drum thrust washer and thrust needle roller bearing. 29. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY 30. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY (a) Remove the No. 2 1-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly. 31. REMOVE NO. 3 BRAKE SNAP RING (a) Using a screwdriver, remove the No. 3 brake snap ring from the case. 32. REMOVE NO. 3 BRAKE DISC (a) Remove the flange and cushion plate the 4 discs and the 4 plates from the case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 33. INSPECT NO. 3 BRAKE DISC 34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING (a) Using SST, remove the snap ring. SST: 09350-30020 09350-07060 35. REMOVE 1-WAY CLUTCH ASSEMBLY (a) Remove the 1-way clutch assembly and the No. 1 planetary carrier thrust washer from the case. 36. REMOVE 2ND BRAKE CYLINDER (a) Remove the 2nd brake cylinder from the case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 37. REMOVE 2ND BRAKE PISTON (a) Using SST and a press, remove the snap ring. SST: 09351-40010 (b) Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston. (c) Remove the 2 O-rings from the 2nd brake piston. 38. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 39. REMOVE FRONT PLANETARY GEAR ASSEMBLY (a) Remove the front planetary gear assembly and the 1 way clutch inner race from the case. (b) Remove the thrust needle roller bearing, the No. 3 thrust bearing race and the No. 2 planetary carrier thrust washer from the front planetary gear assembly. 40. INSPECT FRONT PLANETARY GEAR ASSEMBLY 41. INSPECT 1-WAY CLUTCH ASSEMBLY 42. REMOVE FRONT PLANETARY RING GEAR (a) Remove the front planetary ring gear and bearing from the transmission case. 43. REMOVE CENTER PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear. 44. REMOVE NO. 1 BRAKE DISC (a) Remove the flange, 3 discs and 3 plates from the case. 45. INSPECT NO. 1 BRAKE DISC 46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING (a) Using a screwdriver, remove the brake piston return spring snap ring from the case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 47. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Remove the brake piston return spring and No. 1 the brake piston with the No. 1 brake cylinder from the transmission case. 48. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 49. REMOVE NO. 1 BRAKE PISTON (a) Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the transmission case to remove the No. 1 brake piston. HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the 2 O-rings from the No. 1 brake piston. 50. REMOVE NO. 2 BRAKE DISC (a) Using a screwdriver, remove the snap ring from the case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (b) Remove the flange, the brake piston return spring, the 3 discs and the 3 plates from the case. 51. INSPECT NO. 2 BRAKE DISC 52. INSPECT NO.2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 53. REMOVE NO. 2 BRAKE PISTON (a) Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the transmission case to remove the No. 2 brake piston. HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the 2 O-rings from the No. 2 brake piston. 54. REMOVE CENTER PLANETARY GEAR ASSEMBLY (a) Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the case. 55. INSPECT CENTER PLANETARY GEAR ASSEMBLY 56. REMOVE INTERMEDIATE SHAFT A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Using a screwdriver, remove the snap ring from the case. (b) Remove the intermediate shaft with the No. 3 1- way clutch assembly from the case. 57. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY 58. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY (a) Remove the No. 3 1-way clutch assembly and the 1 way clutch inner race from the intermediate shaft. 59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (a) Remove the No. 8 thrust bearing race, thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... 60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 61. INSPECT INTERMEDIATE SHAFT 62. REMOVE BRAKE PLATE STOPPER SPRING (a) Remove the brake plate stopper spring from the case. 63. REMOVE NO. 4 BRAKE DISC (a) Remove the 7 plates, the 8 discs and the 2 flanges from the case. 64. INSPECT NO. 4 BRAKE DISC 65. REMOVE REAR PLANETARY GEAR ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... (a) Remove the rear planetary gear assembly from the case. (b) Remove the No. 9 thrust bearing race and the thrust needle roller bearing from the rear planetary gear assembly. (c) Remove the thrust needle roller bearing from the case. 66. INSPECT REAR PLANETARY GEAR ASSEMBLY 67. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the spring retainer and compress the brake return spring. SST: 09350-30020 09350-07050 (b) Using SST, remove the snap ring and the brake return spring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... SST: 09350-30020 09350-07070 68. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 69. REMOVE 1ST AND REVERSE BRAKE PISTON (a) Hold the 1st and reverse brake piston and apply compressed air (392 kPa, 4 kgf/cm 2, 57 psi) to the transmission case to remove the 1st and reverse brake piston. HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers. (b) Remove the O-ring from 1st and reverse brake piston. 70. REMOVE BRAKE REACTION SLEEVE (a) Using SST, remove the reaction sleeve. SST: 09350-30020 09350-07080 (b) Remove the O-ring from the reaction sleeve. 71. REMOVE NO. 4 BRAKE PISTON (a) Using SST, remove the No. 4 brake piston. SST: 09350-30020 09350-07090 (b) Remove the 2 O-rings from the No. 4 piston. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBL... A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013EX00SX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (a) Remove the magnets, and use them to collect steel particles. (b) Carefully lock at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. z z Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY (a) Hold the Reverse clutch hub and turn the No. 2 1-way clutch assembly. (b) The No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise. 3. INSPECT NO. 3 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 4. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 15.72 mm (0.619 in.) 5. INSPECT FRONT PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the front planetary pinion gear thrust clearance. Standard clearance: 0.2 to 0.60 mm (0.008 to 0.024 in.) Maximum clearance 0.65 mm (0.026 in.) If the clearance is greater than the maximum, replace the front planetary gear assembly. (b) Using a cylinder gauge, measure the inside diameter of the front planetary gear bushing. Maximum inside diameter: 57.48 mm (2.263 in.) If the inside diameter is greater than the maximum, replace the front planetary gear. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... 6. INSPECT 1-WAY CLUTCH ASSEMBLY (a) Install the 1-way clutch assembly to the 1-way clutch inner race. (b) Hold the 1-way clutch inner race and turn the 1-way clutch assembly. (c) Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise. (d) Remove the 1-way clutch assembly from the 1-way clutch inner race. 7. INSPECT NO. 1 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 8. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 17.05 mm (0.671 in.) 9. INSPECT NO. 2 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 10. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.45 mm (0.687 in.) 11. INSPECT CENTER PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the center planetary gear pinion thrust clearance. Standard clearance: 0.12 to 0.68 mm (0.005 to 0.027 in.) Maximum clearance 0.73 mm (0.029 in.) If the clearance is greater than the maximum, replace the center planetary gear assembly. 12. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY (a) Hold the rear planetary ring gear flange sub-assembly turn the 1-way clutch assembly. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... (b) Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise. 13. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the rear planetary ring gear bushing. Maximum inside diameter: 32.175 mm (1.267 in.) If the inside diameter is greater than the maximum, replace the rear planetary ring gear. 14. INSPECT INTERMEDIATE SHAFT (a) Using a dial indicator, check the intermediate shaft runout. Maximum runout: 0.08 mm (0.003 in.) NOTICE: If the bend exceeds the specification, replace the intermediate shaft with anew one. (b) Using a micrometer, check the outer diameter of the intermediate shaft positions shown in the diagram. Standard diameter: A 25.962 to 25.975 mm (1.022 to 1.023 in.) B 25.962 to 25.975 mm (1.022 to 1.023 in.) C 32.062 to 32.075 mm (1.262 to 1.263 in.) D 32.062 to 32.075 mm (1.262 to 1.263 in.) Minimum diameter: A 25.912 mm (1.020 in.) B 25.912 mm (1.020in.) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... C 32.012 mm (1.260 in.) D 32.012 mm (1.260 in.) NOTICE: If the outer diameter is outside the standard, replace the intermediate shaft with the new one. 15. INSPECT NO. 4 BRAKE DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 16. INSPECT REAR PLANETARY GEAR ASSEMBLY (a) Using a feeler gauge, measure the rear planetary gear pinion thrust clearance. Standard clearance: 0.2 to 0.6 mm (0.008 to 0.024 in.) Maximum clearance 0.65 mm (0.026 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. (b) Using a dial indicator, measure the inside diameter of A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... the rear planetary gear bushing. Maximum inside diameter: 20.075 mm (0.790 in.) If the inside diameter is greater than the maximum, replace the rear planetary gear assembly. 17. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 23.74 mm (0.935 in.) 18. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (a) Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case. 19. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON (a) Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: INSPECTION (2... (b) Using a feeler gauge, measure the B3 bearing pack clearance between the snap ring and flange. Piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 in.) If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange. HINT: There are 4 different thicknesses for the flange. 20. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION (a) Check the operating sound while applying compressed air into the oil holes indicated in the illustration. HINT: When inspecting the O/D direct clutch, check with the C3 accumulator piston holes indicated in the illustration. HINT: If there is no sound, disassembly and check the installation condition of the parts. z z z z z z z No. No. No. No. No. No. No. 2 3 1 3 1 2 4 clutch (C2) clutch (C3) clutch (C1) brake (B1) brake (B1) brake (B2) brake (B4) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000013F000RX Title: A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY (2007 4Runner) REASSEMBLY 1. BEARING POSITION (a) Check bearing position. Bearing diameter: MARK FRONT RACE DIAMETER THRUST BEARING DIAMETER REAR RACE DIAMETER A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... INSIDE / OUTSIDE INSIDE / OUTSIDE INSIDE / OUTSIDE A 73.6 mm (2.898 in.) / 102.0 mm (4.016 in.) 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) - B 38.0 mm (1.496 in.) / 57.0 mm (2.244 in.) 43.4 mm (1.709 in.) / 58.3 mm (2.295 in.) - C - 55.7 mm (2.193 in.) / 76.4 mm (3.008 in.) 53.7 mm (2.114 in.) / 74.0 mm (2.913 in.) D 33.4 mm (1.315 in.) / 49.0 mm (1.929 in.) 32.1 mm (1.264 in.) / 49.35 mm (1.943 in.) 32.1 mm (1.264 in.)/ 49.0 mm (1.929 in.) E - 21.5 mm(0.847 in.) / 40.8 mm (1.606 in.) - F 48.5 mm (1.909 in.) / 62.7 mm (2.469 in.) 45.9 mm (1.807 in.) / 64.0 mm (2.520 in.) - 2. INSTALL NO. 4 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve. (b) Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston. (c) Install the No. 4 brake piston to the reaction sleeve. 3. INSTALL BRAKE REACTION SLEEVE (a) Coat a new O-ring with ATF, and install it to the reaction sleeve. (b) With the No. 1brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... NOTICE: Be careful not to damage the O-rings. 4. INSTALL 1ST AND REVERSE BRAKE PISTON (a) Coat a new O-ring with ATF. (b) Install the O-ring on the 1st and reverse brake piston. (c) With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case. NOTICE: Be careful not to damage the O-ring. (d) Place the piston return spring onto the No. 4 brake piston. 5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (a) Place SST on the spring retainer, and compress the return spring. SST: 09350-30020 09350-07050 (b) Using SST, install the snap ring. SST: 09350-30020 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07070 6. INSTALL REAR PLANETARY GEAR ASSEMBLY (a) Install the thrust needle roller bearing. Thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 45.9 mm (1.807 in.) 64.0 mm (2.520 in.) (b) Install the thrust needle roller bearing. (c) Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear. Bearing and race diameter: ITEM INSIDE OUTSIDE Bearing 21.5 mm (0.847 in.) 40.8 mm (1.606 in.) Race 48.5 mm (1.909 in.) 62.7 mm (2.469 in.) (d) Install the rear planetary gear assembly. 7. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case. (b) Using vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average. NOTICE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case. HINT: Length A = 36.35 to 37.09 mm (1.431 to 1.460 in.) (c) Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average. HINT: Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.010 to 0.071 in.) HINT: Length B = 36.04 to 37.14 mm (1.419 to 1.462 in.) Pack clearance: 0.8 to 1.1 mm (0.031 to 0.043 in.) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (d) If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard. H thickness: NO. THICKNESS NO. THICKNESS 0 0 mm (0 in.) 8 0.8 mm (0.031 in.) 2 0.2 mm(0.008 in.) 10 1.0 mm (0.039 in.) 4 0.4 mm (0.016 in.) 12 1.2 mm (0.047 in.) 6 0.6 mm (0.024 in.) 14 1.4 mm (0.055 in.) 8. INSTALL NO. 4 BRAKE DISC (a) Install the 7 plates, the 8 discs and the 2 flanges. Install in order: F - D - P - D - P - D- P - D -P - D - P - D - P - D - P - D - F HINT: P = Plate, D = Disc, F = Flange 9. INSTALL BRAKE PLATE STOPPER SPRING (a) Install the brake plate stopper spring. 10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft. Bearing and race diameter: ITEM INSIDE OUTSIDE No. 7 thrust bearing race 33.4 mm (1.315 in.) 49.0 mm (1.929 in.) Thrust needle roller bearing 32.1 mm (1.264 in.) 49.35 mm (1.943 in.) No. 8 thrust bearing race 32.1 mm (1.264 in.) 49.0 mm (1.929 in.) 11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY (a) Install the No. 3 1-way clutch assembly and 1-way clutch inner race to the intermediate shaft. 12. INSTALL INTERMEDIATE SHAFT (a) Install the intermediate shaft with the No. 3 1-way clutch assembly to the case. (b) Using SST, install the snap ring. SST: 09350-30020 09350-07050 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07060 13. INSTALL CENTER PLANETARY GEAR ASSEMBLY (a) Install the center planetary gear assembly and planetary sun gear to the case. (b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear. Race diameter: ITEM INSIDE OUTSIDE Race 53.7 mm (2.114 in.) 74.0 m (2.913 in.) 14. INSTALL NO. 2 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston. (b) Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands. (c) Install the No. 2 brake piston to the case. 15. INSTALL NO, 2 BRAKE DISC A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install flange, 3 plates, 3 discs and brake piston return spring. Install in order: F-P-S-P-D-P-D HINT: P = Plate, D = Disc, F = Flange (b) Using SST and press, install the No. 2 brake spring snap ring. SST: 09351-40010 16. INSTALL NO. 1 BRAKE PISTON (a) Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston. (b) Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands. 17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (a) Install the brake piston return spring and the No. 1 brake piston with No. 1 brake cylinder on the transmission case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING (a) Using SST and a press, install the brake piston return spring snap ring. SST: 09351-40010 19. INSTALL NO. 1 BRAKE DISC (a) Install the 3 plates, 3 discs and flange. Install in order: F-D-P-D-P-D-P-D-P-D-P-D HINT: P = Plate, D = Disc, F = Flange 20. INSTALL CENTER PLANETARY RING GEAR (a) Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear. (b) Using a screwdriver, install the snap ring. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 21. INSTALL FRONT PLANETARY RING GEAR (a) Install the front planetary ring gear and the thrust needle roller bearing on the case. Thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 55.7 mm (2.193 in.) 76.4 mm (3.008 in.) 22. INSTALL FRONT PLANETARY GEAR ASSEMBLY (a) Install the thrust needle roller bearing and the thrust washer. (b) Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear. Thrust needle roller bearing and race diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 43.4 mm (1.709 in.) 58.3 mm (2.295 in.) Race 38.0 mm (1.496 in.) 57.0 mm (2.244 in.) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (c) Install the front planetary gear assembly and 1-way clutch inner race from the case. 23. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON (a) Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case. (b) Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange. Piston stroke: 0.42 to 0.72 mm (0.017 to 0.028 in.) If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange. HINT: There are 4 different thicknesses for the flange. Flange thickness: 24. INSTALL 2ND BRAKE PISTON NO. THICKNESS NO. THICKNESS 0 2.0 mm (0.079 in.) 2 2.4 mm (0.094 in.) 1 2.2 mm (0.087 in.) 3 2.6 mm (0.102 in.) A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat 2 new O-rings with ATF, and install them to the 2nd brake piston. (b) Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands. (c) Using SST and press, install the snap ring. SST: 09351-40010 NOTICE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw. 25. INSTALL 2ND BRAKE CYLINDER (a) Install the 2nd brake cylinder fro the case. 26. INSTALL 1-WAY CLUTCH ASSEMBLY (a) Install the 1-way clutch assembly and thrust washer to the case. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING (a) Using SST, install the snap ring. SST: 09350-30020 09350-07060 28. INSTALL NO. 3 BRAKE DISC (a) Install the 2 flanges, the 4 discs, the 4 plates and cushion plate on the case. Install in order: F-D-P-D-P-D-P-D-P-C HINT: P = Plate, D = Disc, F = Flange C = Cushion 29. INSTALL NO. 3 BRAKE SNAP RING (a) Using a screwdriver, install the snap ring. 30. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY (a) Coat the race with petroleum jelly and install it onto the A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... No. 2 clutch drum thrust washer. (b) Install the No. 2 1-way clutch assembly washer. 31. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Install the thrust needle roller bearing. (b) Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly. Thrust needle roller bearing and diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 71.9 mm (2.831 in.) 85.6 mm (3.370 in.) Race 73.6 mm (2.898 in.) 102.0 mm (4.016 in.) (c) Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case. 32. INSTALL OIL PUMP ASSEMBLY A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the No. 1 thrust bearing race to the front oil pump Thrust bearing race diameter: ITEM INSIDE OUTSIDE Race 74.2 mm (2.921 in.) 87.74 mm (3.454 in.) (b) Coat a new O-ring with ATF, and install it around the oil pump assembly. (c) Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case. (d) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum. NOTICE: Do not push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum. (e) Install the 10 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) 33. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL (a) Using SST, drive in 2 new oil seals. SST: 09350-30020 A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... 09350-07110 (b) Coat the oil seal lips with MP grease. 34. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION 35. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY (a) Install a new spacer to the manual valve lever. (b) Install the manual valve lever shaft to the transmission case through the manual valve lever. (c) Using a hammer, tap in a new spring pin. (d) Align the manual valve lever indentation with the spacer hole, and stake them together with the punch. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (e) Make sure the shaft rotates smoothly. 36. INSTALL PARKING LOCK PAWL SHAFT (a) Install the E-ring to the shaft. (b) Install the parking lock pawl, shaft and spring. 37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY (a) Connect the parking lock rod to the manual valve lever. 38. INSTALL PARKING LOCK PAWL BRACKET (a) Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... Torque: 7.4 N·m (75 kgf·cm, 65 in·lbf) (b) Shift the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked up by the lock pawl. 39. INSTALL C-1 ACCUMULATOR VALVE (a) Coat a new O-ring with ATF, and install it to the piston. (b) Install the spring and accumulator valve to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-1 Inner C-1 Outer 40. INSTALL C-3 ACCUMULATOR PISTON 30.40 mm (1.197 in.) 11.40 mm (0.449 in.) 48.76 mm (1.920 in.) 16.60 mm (0.654 in.) Pink Light green A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat a new O-ring with ATF, and install it to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-3 Inner C-3 Outer 44.0 mm (1.732 in.) 14.0 mm (0.551 in.) 73.35 mm (2.888 in.) 19.90 mm (0.784 in.) Yellow Red 41. INSTALL B-3 ACCUMULATOR PISTON (a) Coat 2 new O-rings with ATF, and install them to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER B-3 42. INSTALL C-2 ACCUMULATOR PISTON 70.5 mm (2.776 in.) 19.7 mm (0.776 in.) Purple A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Coat 2 new O-rings with ATF, and install them to the piston. (b) Install the spring and accumulator piston to the hole. Accumulator spring: SPRING FREE LENGTH COLOR OUTER DIAMETER C-2 62.0 mm (2.441 in.) 15.9 mm (03626 in.) 43. INSTALL CHECK BALL BODY (a) Install the check ball body and the spring. 44. INSTALL BRAKE DRUM GASKET (a) Install the 3 brake drum gaskets. 45. INSTALL TRANSAXLE CASE GASKET White A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install the 3 transaxle case gaskets. 46. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Align the groove of the manual valve with the pin of the lever. (b) Install the 19 bolts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: 25 mm (0.98 in.) for bolt A 36 mm (1.42 in.) for bolt B 47. INSTALL TRANSMISSION WIRE (a) Install a new O-ring to the transmission wire. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (b) Install the transmission wire harness. (c) Install the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (d) Connect the solenoid connector. (e) Connect the 7 solenoid connectors. (f) Install the ATF temperature sensor. (g) Install the clamp and the 2 bolts. Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: 36 mm (1.42 in.) for bolt A 12 mm (0.47 in.) for bolt B Sensor wire harness: WIRE HARNESS COLOR for linear control Orange for oil temp warning light Blue 48. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Coat a new O-ring with ATF, and install them to the valve body oil strainer assembly. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (b) Install the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 49. INSTALL TRANSMISSION OIL CLEANER MAGNET (a) Install the 4 transmission oil cleaner magnets. 50. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (a) Install a new gasket on the oil pan. (b) Install the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) (c) Install the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 51. INSTALL TRANSMISSION CASE ADAPTER OIL SEAL (a) Using SST and a hammer, tap in a new oil seal. SST: 09226-10010 52. INSTALL TRANSMISSION CASE ADAPTER SUB-ASSEMBLY (a) Apply seal packing or equivalent to the 8 bolts. Seal breadth: 1.0 to 1.5 mm (0.4 to 0.06 in.) Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent. A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (b) Install the transmission case adapter sub-assembly with the 8 bolts. Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 50 mm (1.969 in.) for bolt A 45 mm (1.772 in.) for bolt B 53. INSTALL AUTOMATIC TRANSMISSION HOUSING (a) Clean the threads of the bolts and the case with white gasoline. (b) Install the transmission housing with the 10 bolts. Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) Torque: 57 N·m (581 kgf·cm, 42 ft·lbf) Torque: 34 N·m (345 kgf·cm, 25 ft·lbf) HINT: z z Each bolt length is indicated bellow. Bolt length: Bolt A: 14 mm Bolt B: 17 mm Bolt C: 14 mm 54. INSTALL AUTOMATIC TRANSAXLE BREATHER TUBE A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... (a) Install a new O-ring to the breather tube. (b) Install the breather tube with the 3 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) 55. INSTALL SPEED SENSOR (a) Coat 2 new O-rings with ATF, and install it to the speed sensor. (b) Install the 2 speed sensor. (c) Install the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) 56. INSTALL OIL COOLER TUBE UNION (a) Coat a new O-ring with ATF, and install it to oil cooler A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... tube union. (b) Install the oil cooler tube union. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 57. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt. (b) Install a new lock washer and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf) (c) Push the control shaft rearward as much as possible. (d) Return the control shaft lever 2 notches to the N position. (e) Align the neutral basic line with the switch groove as A750F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY ... shown in the illustration, and tighten the adjusting bolt. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (f) Using a screwdriver, bend the tabs of the lock washer. HINT: Bend at least 2 of the lock washer tabs. 58. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH (a) Install the washer and the nut to the control shaft lever LH. Torque: 16 N·m (163 kgf·cm, 12 ft·lbf) A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FC00SX Title: A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FD00TX Title: A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. FIX CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft assembly onto the oil pump. 2. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Using a screwdriver, remove the snap ring. (b) Remove the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion, plate reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the clutch drum. 3. REMOVE REVERSE CLUTCH REACTION SLEEVE A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (a) Remove the reverse clutch reaction sleeve from the reverse clutch hub. 4. REMOVE REAR CLUTCH DISC (a) Remove the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs from the reverse clutch hub. 5. INSPECT REAR CLUTCH DISC 6. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 7. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Remove the forward clutch hub sub-assembly from the clutch drum. (b) Remove the 2 thrust needle roller bearings from the forward clutch hub. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 8. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY 9. REMOVE MULTIPLE DISC CLUTCH HUB (a) Remove the multiple disc clutch hub from the clutch drum. (b) Remove the No. 2 thrust bearing race and input shaft thrust bearing race rear from the multiple disc clutch hub. 10. REMOVE INPUT SHAFT ASSEMBLY (a) Remove the thrust needle roller bearing from the clutch drum. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (b) Remove the input shaft assembly from the clutch drum. 11. REMOVE INPUT SHAFT OIL SEAL RING (a) Remove the 3 oil seal rings from the input shaft. 12. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC (a) Using a screwdriver, remove the hole snap ring A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (b) Remove the 2 flanges, 6 discs and 5 plates from the input shaft. 13. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 14. REMOVE NO. 1 CLUTCH BALANCER (a) Place SST on the No. 1 clutch balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 09350-07070 (b) Remove the No. 1 clutch balancer and forward clutch return spring from the input shaft assembly. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (c) Remove the O-ring from the No. 1 clutch balancer. 15. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 16. REMOVE FORWARD CLUTCH PISTON (a) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the input shaft to remove the forward clutch piston. (b) Remove the 2 O-rings from the forward clutch piston. 17. REMOVE REVERSE CLUTCH FLANGE (a) Remove the reverse clutch flange from the clutch drum. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 18. REMOVE DIRECT CLUTCH DISK (a) Using a screwdriver, remove the 2 hole snap rings from the clutch drum. (b) Remove the reverse clutch flange, 6 plates and 5 discs from the clutch drum. 19. INSPECT DIRECT CLUTCH DISK 20. REMOVE NO. 3 CLUTCH BALANCER (a) Place SST on the No. 3 clutch balancer, and compress the return spring with a press. SST: 09387-00070 SST: 09350-30020 09350-07070 A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 21. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Remove the reverse clutch return spring and O-ring from the reverse clutch piston. 22. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 23. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY (a) Remove the reverse clutch piston, sub-assembly from the clutch drum. (b) Remove the O-ring from the reverse clutch piston. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (c) Remove the O-ring from the clutch drum. 24. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY (a) Place SST on the direct clutch piston, and compress the return spring with a press. SST: 09320-89010 SST: 09350-30020 09350-07070 (b) Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum. (c) Remove the O-ring from the clutch drum. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (d) Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch piston. (e) Remove the 2 O-rings from the direct clutch piston. 25. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FB00SX Title: A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT REAR CLUTCH DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 2. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing. Standard drum bushing: 35.812 to 35.837 mm (1.4099 to 1.4109 in.) Maximum drum bushing: 35.887 mm (1.4129 in.) If the inside diameter is greater than the maximum, replace the reverse clutch hub. 3. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the forward clutch hub bushing. Standard drum bushing: 26.037 to 26. 062 mm (1.0251 to 1.0261 in.) Maximum drum bushing: 26.112 mm (1.0280 in.) If the inside diameter is greater than the maximum, replace the forward clutch hub. 4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 5. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.053 in.) 6. INSPECT DIRECT CLUTCH DISK (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 7. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 21.04 mm (0.828 in.) A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... 8. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 19.51 mm (0.768 in.) 9. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (a) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average. Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) NOTICE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.) HINT: Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: NO. THICKNESS NO. THICKNESS 0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.) 1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.) 2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.) A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... 3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.) 4 3.4 mm (0.134 in.) - - 10. INSPECT PACK CLEARANCE OF REVERSE CLUTCH (a) Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm 2, 57 psi) from the oil hole as shown in the illustration, and calculate the average. Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) NOTICE: Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.) Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.) Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... No. Thickness No. Thickness 0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.) 1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.) 2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.) 3 3.1 mm (0.122 in.) 9 3.7 mm (0.146 in.) 4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.) 5 3.3 mm (0.130 in.) - 11. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (a) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at boths end across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average. Standard pack clearance: 0.6 to 0.9 mm (0.024 to 0.354 in.) NOTICE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.) HINT: Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: NO. THICKNESS NO. THICKNESS 0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.) 1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.) 2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.) 3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.) 4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.) 5 3.5 mm (0.138 in.) - A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FE00SX Title: A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY (a) Coat 2 new O-rings with ATF, and install them in the direct clutch piston. (b) Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston. (c) Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly. (d) Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (e) Place SST on the direct clutch piston, and compress the return spring with a press. SST: 09320-89010 SST: 09350-30020 09350-07070 (f) Install the snap ring with a snap ring expander. NOTICE: z z z Be sure the end gap of the snap ring is not aligned with the spring retainer claw. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (g) Set the end gap of the snap ring in the piston as shown in the illustration. 2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it on the clutch drum. (b) Coat a new O-ring with ATF, and install it on the reverse A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... clutch piston. (c) Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands. 3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it on the reverse clutch piston. (b) Install the reverse clutch return spring onto the reverse clutch piston. 4. INSTALL NO. 3 CLUTCH BALANCER (a) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press. SST: 09387-00070 SST: 09350-30020 09350-07070 A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the snap ring with a snap ring expander. (c) Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTICE: z z Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (d) Set the end gap of the snap ring in the piston as shown in the illustration. 5. INSTALL DIRECT CLUTCH DISK (a) Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum. Install in order: P-P-D-P-D-P-D-P-D-P-D-P-D-F HINT: P = Plate, D = Disc, F = Flange (b) Using a screwdriver, install the 2 hole snap rings on the clutch drum. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... 6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 7. INSTALL REVERSE CLUTCH FLANGE (a) Install the reverse clutch flange to the clutch drum. 8. INSTALL REVERSE CLUTCH REACTION SLEEVE (a) Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub. (b) Using a screwdriver, install the hole snap ring. 9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH 10. REMOVE REVERSE CLUTCH REACTION SLEEVE A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Using a screwdriver, remove the snap ring from the clutch drum. (b) Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub. 11. INSTALL FORWARD CLUTCH PISTON (a) Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston. 12. INSTALL NO. 1 CLUTCH BALANCER (a) Coat a new O-ring with ATF and install it on the No. 1 clutch balancer. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the No. 1 clutch balancer and forward clutch return spring sub-assembly. NOTICE: Be careful not to damage the O-ring. (c) Place SST on the No. 1 clutch balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 09350-07070 (d) Install the snap ring with a snap ring expander. (e) Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTICE: z z Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (f) Set the end gap of the snap ring in the piston as shown in the illustration. 13. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly. Install in order: F- D - P - D - P - D - P - D - P - D - P - D - P - D - F HINT: P = Plate, D = Disc, F = Flange (b) Using a screwdriver, install the hole snap ring. 14. INSTALL INPUT SHAFT OIL SEAL RING (a) Coat the 3 oil seal rings with ATF. (b) Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove. NOTICE: Do not over-spread the ring ends. A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... HINT: After installing the oil seal rings, check that they rotate smoothly. 15. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 16. INSTALL INPUT SHAFT ASSEMBLY (a) Install the input shaft assembly to the clutch drum. (b) Install the thrust needle roller bearing to the clutch drum. Standard thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 21.3 mm (0.839 in.) 41.1 mm (1.618 in.) 17. INSTALL MULTIPLE DISC CLUTCH HUB (a) Install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub. Standard bearing and race diameter: ITEM INSIDE OUTSIDE No. 2 Thrust bearing race 38.4 mm (1.512 in.) 63.0 mm (2.480 in.) Input shaft bearing race rear 22.6 mm (0.890 in.) 60.0 mm (2.362 in.) A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the multiple disc clutch hub to the clutch drum. 18. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Install the 2 thrust needle roller bearings to the forward clutch hub. Standard bearing and race diameter: ITEM INSIDE OUTSIDE Bearing A 42.5 mm (1.673 in.) 61.2 mm (2.409 in.) Bearing B 33.3 mm (1.311 in.) 56.6 mm (2.228 in.) (b) Install the forward clutch hub sub-assembly to the clutch drum. 19. INSTALL REAR CLUTCH DISC (a) Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub. Install in order: D-P-D-P-D-P-D-P-D-F HINT: P = Plate, D = Disc, F = Flange 20. INSTALL REVERSE CLUTCH REACTION SLEEVE A750E AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Install the reverse clutch reaction sleeve to the reverse clutch hub. 21. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum. (b) Using a screwdriver, install the snap ring on the clutch drum and input shaft. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FC00RX Title: A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: C... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FD00SX Title: A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. FIX CLUTCH DRUM AND INPUT SHAFT ASSEMBLY (a) Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft assembly onto the oil pump. 2. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Using a screwdriver, remove the snap ring. (b) Remove the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion, plate reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the clutch drum. 3. REMOVE REVERSE CLUTCH REACTION SLEEVE A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (a) Remove the reverse clutch reaction sleeve from the reverse clutch hub. 4. REMOVE REAR CLUTCH DISC (a) Remove the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs from the reverse clutch hub. 5. INSPECT REAR CLUTCH DISC 6. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 7. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Remove the forward clutch hub sub-assembly from the clutch drum. (b) Remove the 2 thrust needle roller bearings from the forward clutch hub. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 8. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY 9. REMOVE MULTIPLE DISC CLUTCH HUB (a) Remove the multiple disc clutch hub from the clutch drum. (b) Remove the No. 2 thrust bearing race and input shaft thrust bearing race rear from the multiple disc clutch hub. 10. REMOVE INPUT SHAFT ASSEMBLY (a) Remove the thrust needle roller bearing from the clutch drum. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (b) Remove the input shaft assembly from the clutch drum. 11. REMOVE INPUT SHAFT OIL SEAL RING (a) Remove the 3 oil seal rings from the input shaft. 12. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC (a) Using a screwdriver, remove the hole snap ring A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (b) Remove the 2 flanges, 6 discs and 5 plates from the input shaft. 13. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 14. REMOVE NO. 1 CLUTCH BALANCER (a) Place SST on the No. 1 clutch balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 09350-07070 (b) Remove the No. 1 clutch balancer and forward clutch return spring from the input shaft assembly. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (c) Remove the O-ring from the No. 1 clutch balancer. 15. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 16. REMOVE FORWARD CLUTCH PISTON (a) Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi) to the input shaft to remove the forward clutch piston. (b) Remove the 2 O-rings from the forward clutch piston. 17. REMOVE REVERSE CLUTCH FLANGE (a) Remove the reverse clutch flange from the clutch drum. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 18. REMOVE DIRECT CLUTCH DISK (a) Using a screwdriver, remove the 2 hole snap rings from the clutch drum. (b) Remove the reverse clutch flange, 6 plates and 5 discs from the clutch drum. 19. INSPECT DIRECT CLUTCH DISK 20. REMOVE NO. 3 CLUTCH BALANCER (a) Place SST on the No. 3 clutch balancer, and compress the return spring with a press. SST: 09387-00070 SST: 09350-30020 09350-07070 A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... 21. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Remove the reverse clutch return spring and O-ring from the reverse clutch piston. 22. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 23. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY (a) Remove the reverse clutch piston, sub-assembly from the clutch drum. (b) Remove the O-ring from the reverse clutch piston. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (c) Remove the O-ring from the clutch drum. 24. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY (a) Place SST on the direct clutch piston, and compress the return spring with a press. SST: 09320-89010 SST: 09350-30020 09350-07070 (b) Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum. (c) Remove the O-ring from the clutch drum. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: DI... (d) Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch piston. (e) Remove the 2 O-rings from the direct clutch piston. 25. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FB00RX Title: A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT REAR CLUTCH DISC (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 2. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing. Standard drum bushing: 35.812 to 35.837 mm (1.4099 to 1.4109 in.) Maximum drum bushing: 35.887 mm (1.4129 in.) If the inside diameter is greater than the maximum, replace the reverse clutch hub. 3. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the forward clutch hub bushing. Standard drum bushing: 26.037 to 26. 062 mm (1.0251 to 1.0261 in.) Maximum drum bushing: 26.112 mm (1.0280 in.) If the inside diameter is greater than the maximum, replace the forward clutch hub. 4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 5. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.053 in.) 6. INSPECT DIRECT CLUTCH DISK (a) Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage. NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes. 7. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 21.04 mm (0.828 in.) A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... 8. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard free length: 19.51 mm (0.768 in.) 9. INSPECT PACK CLEARANCE OF DIRECT CLUTCH (a) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average. Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) NOTICE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Flange moving distance A = 0.26 to 1.14 mm (0.010 to 0.045 in.) HINT: Pack clearance = Flange moving distance A - 0.05 mm (0.002 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: NO. THICKNESS NO. THICKNESS 0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.) 1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.) 2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.) A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... 3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.) 4 3.4 mm (0.134 in.) - - 10. INSPECT PACK CLEARANCE OF REVERSE CLUTCH (a) Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm 2, 57 psi) from the oil hole as shown in the illustration, and calculate the average. Pack clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.) NOTICE: Install a selective flange (3.3 mm (0.130 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Piston stroke A = 1.05 to 2.15 mm (0.041 to 0.085 in.) Flange moving distance B = 0.72 to 1.08 mm (0.029 to 0.043 in.) Pack clearance = Piston stroke A to Flange moving distance B to 0.06 mm (0.002 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... No. Thickness No. Thickness 0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.) 1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.) 2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.) 3 3.1 mm (0.122 in.) 9 3.7 mm (0.146 in.) 4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.) 5 3.3 mm (0.130 in.) - 11. INSPECT PACK CLEARANCE OF FORWARD CLUTCH (a) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at boths end across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average. Standard pack clearance: 0.6 to 0.9 mm (0.024 to 0.354 in.) NOTICE: Install a selective flange (3.4 mm (0.134 in.)) when measuring the moving distance (shaded area in the illustration.) HINT: Flange moving distance A = 0.26 to 1.36 mm (0.010 to 0.054 in.) HINT: Pack clearance = Flange moving distance A to 0.01 mm (0.0003 in.) (b) If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard. Standard flange thickness: NO. THICKNESS NO. THICKNESS 0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.) 1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.) 2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.) 3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.) 4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.) 5 3.5 mm (0.138 in.) - A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: IN... A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FE00RX Title: A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY (a) Coat 2 new O-rings with ATF, and install them in the direct clutch piston. (b) Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston. (c) Coat a new O-ring with ATF, and install them on the clutch drum sub-assembly. (d) Be careful not to damage the O-rings. Press in the direct clutch piston into the clutch drum with both hands. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (e) Place SST on the direct clutch piston, and compress the return spring with a press. SST: 09320-89010 SST: 09350-30020 09350-07070 (f) Install the snap ring with a snap ring expander. NOTICE: z z z Be sure the end gap of the snap ring is not aligned with the spring retainer claw. Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (g) Set the end gap of the snap ring in the piston as shown in the illustration. 2. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it on the clutch drum. (b) Coat a new O-ring with ATF, and install it on the reverse A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... clutch piston. (c) Be careful not to damage the O-ring. Press in the clutch drum sub-assembly into the reverse clutch piston with both hands. 3. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (a) Coat a new O-ring with ATF, and install it on the reverse clutch piston. (b) Install the reverse clutch return spring onto the reverse clutch piston. 4. INSTALL NO. 3 CLUTCH BALANCER (a) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press. SST: 09387-00070 SST: 09350-30020 09350-07070 A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the snap ring with a snap ring expander. (c) Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTICE: z z Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (d) Set the end gap of the snap ring in the piston as shown in the illustration. 5. INSTALL DIRECT CLUTCH DISK (a) Install the reverse clutch flange, 6 plates and 5 discs on the clutch drum. Install in order: P-P-D-P-D-P-D-P-D-P-D-P-D-F HINT: P = Plate, D = Disc, F = Flange (b) Using a screwdriver, install the 2 hole snap rings on the clutch drum. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... 6. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 7. INSTALL REVERSE CLUTCH FLANGE (a) Install the reverse clutch flange to the clutch drum. 8. INSTALL REVERSE CLUTCH REACTION SLEEVE (a) Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the reverse clutch hub. (b) Using a screwdriver, install the hole snap ring. 9. INSPECT PACK CLEARANCE OF REVERSE CLUTCH 10. REMOVE REVERSE CLUTCH REACTION SLEEVE A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Using a screwdriver, remove the snap ring from the clutch drum. (b) Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub. 11. INSTALL FORWARD CLUTCH PISTON (a) Coat 2 new O-rings with ATF, and install them on the No. 1 forward clutch piston. 12. INSTALL NO. 1 CLUTCH BALANCER (a) Coat a new O-ring with ATF and install it on the No. 1 clutch balancer. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the No. 1 clutch balancer and forward clutch return spring sub-assembly. NOTICE: Be careful not to damage the O-ring. (c) Place SST on the No. 1 clutch balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 09350-07070 (d) Install the snap ring with a snap ring expander. (e) Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTICE: z z Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed. Do not expand the snap ring excessively. (f) Set the end gap of the snap ring in the piston as shown in the illustration. 13. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly. Install in order: F- D - P - D - P - D - P - D - P - D - P - D - P - D - F HINT: P = Plate, D = Disc, F = Flange (b) Using a screwdriver, install the hole snap ring. 14. INSTALL INPUT SHAFT OIL SEAL RING (a) Coat the 3 oil seal rings with ATF. (b) Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove. NOTICE: Do not over-spread the ring ends. A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... HINT: After installing the oil seal rings, check that they rotate smoothly. 15. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 16. INSTALL INPUT SHAFT ASSEMBLY (a) Install the input shaft assembly to the clutch drum. (b) Install the thrust needle roller bearing to the clutch drum. Standard thrust needle roller bearing diameter: ITEM INSIDE OUTSIDE Thrust needle roller bearing 21.3 mm (0.839 in.) 41.1 mm (1.618 in.) 17. INSTALL MULTIPLE DISC CLUTCH HUB (a) Install the No. 2 thrust bearing race and input shaft thrust bearing race rear to the multiple disc clutch hub. Standard bearing and race diameter: ITEM INSIDE OUTSIDE No. 2 Thrust bearing race 38.4 mm (1.512 in.) 63.0 mm (2.480 in.) Input shaft bearing race rear 22.6 mm (0.890 in.) 60.0 mm (2.362 in.) A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (b) Install the multiple disc clutch hub to the clutch drum. 18. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY (a) Install the 2 thrust needle roller bearings to the forward clutch hub. Standard bearing and race diameter: ITEM INSIDE OUTSIDE Bearing A 42.5 mm (1.673 in.) 61.2 mm (2.409 in.) Bearing B 33.3 mm (1.311 in.) 56.6 mm (2.228 in.) (b) Install the forward clutch hub sub-assembly to the clutch drum. 19. INSTALL REAR CLUTCH DISC (a) Install the clutch cushion plate, reverse clutch flange, 4 plates and 5 discs to the reverse clutch hub. Install in order: D-P-D-P-D-P-D-P-D-F HINT: P = Plate, D = Disc, F = Flange 20. INSTALL REVERSE CLUTCH REACTION SLEEVE A750F AUTOMATIC TRANSMISSION: CLUTCH DRUM AND INPUT SHAFT ASSEMBLY: RE... (a) Install the reverse clutch reaction sleeve to the reverse clutch hub. 21. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY (a) Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates to the clutch drum. (b) Using a screwdriver, install the snap ring on the clutch drum and input shaft. A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: COMPONE... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLA004X Title: A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: COMPONE... A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: INSTALLA... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL9004X Title: A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL (a) Using SST and a hammer, carefully drive in a new oil seal in as far as will go. SST: 09316-60011 09316-00011 09316-00051 Oil seal depth from flat end: 5.4 to 5.8 mm (0.213 to 0.228 in.) (b) Coat the lip of the oil seal with MP grease. 2. INSTALL PROPELLER SHAFT ASSEMBLY 3. ADD AUTOMATIC TRANSMISSION FLUID HINT: 4. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: REMOVAL ... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLB004X Title: A750E AUTOMATIC TRANSMISSION: EXTENSION HOUSING REAR OIL SEAL: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE PROPELLER SHAFT ASSEMBLY 2. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug, gasket and drain ATF. (b) Install a new gasket and drain plug. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) 3. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL (a) Using SST, remove the oil seal. SST: 09308-00010 A750E AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F800SX Title: A750E AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F900SX Title: A750E AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE FRONT OIL PUMP BODY O-RING (a) Remove the O-ring from the oil pump assembly. 2. FIX OIL PUMP ASSEMBLY (a) Place the oil pump body on the torque converter clutch. 3. REMOVE CLUTCH DRUM OIL SEAL RING (a) Remove the 3 oil seal rings. 4. REMOVE STATOR SHAFT ASSEMBLY A750E AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) (a) Remove the 14 bolts, and then remove the stator shaft from the oil pump body. 5. REMOVE FRONT OIL PUMP BODY O-RING (a) Remove the O-ring from the oil pump body. (b) Remove the oil pump body from the torque converter clutch. 6. INSPECT FRONT OIL PUMP BODY SUB-ASSEMBLY 7. INSPECT STATOR SHAFT ASSEMBLY 8. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY 9. REMOVE FRONT OIL PUMP DRIVE GEAR 10. REMOVE FRONT OIL PUMP DRIVEN GEAR A750E AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) 11. REMOVE FRONT OIL PUMP OIL SEAL (a) Using a screwdriver, remove the oil seal. NOTICE: Be careful not to damage the bushing and oil pump body. A750E AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F700TX Title: A750E AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FRONT OIL PUMP BODY SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 38.188 mm (1.5035 in.) If the inside diameter is greater than the maximum, replace the oil pump body. 2. INSPECT STATOR SHAFT ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the stator shaft bushing. Maximum inside diameter: Front side 21.577 mm (0.8495 in.) Rear side 32.08 mm (1.2629 in.) If the inside diameter is grater than the maximum, replace the stator shaft. 3. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY (a) Push the driven gear to one side of the body. (b) Using a feeler gauge, measure the clearance. A750E AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) Standard body clearance: 0.10 to 0.17 mm (0.0039 to 0.0067 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance is greater than the maximum, replace the drive gear, driven gear or pump body. (c) Using a feeler gauge, measure the clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.070 to 0.150 mm (0.0028 to 0.0059 in.) Maximum tip clearance: 0.150 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the drive gear, driven gear or pump body. (d) Using a steel straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 to 0.05 mm (0.0008 to 0.002 in.) Maximum side clearance: 0.05 mm (0.002 in.) If the side clearance of both is gears greater than the maximum, replace the drive gear, driven gear or pump body. (e) There are 5 different thicknesses for the drive and driven gears. Standard drive and drive gears thickness: MARK THICKNESS 0 10.74 to 10.749 mm (0.4228 to 0.4232 in.) 1 10.75 to 10.759 mm (0.4232 to 0.4236 in.) 2 10.76 to 10.77 mm (0.4236 to 0.4240 in.) 3 10.771 to 10.78 mm (0.4241 to 0.4244 in.) 4 10.781 to 10.79 mm (0.4244 to 0.4248 in.) If the side clearance is greater than the maximum, replace the drive gear, driven gear or pump body. 4. INSPECT FRONT OIL PUMP DRIVE GEAR ROTATION A750E AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) (a) Make sure the drive gear rotates smoothly. (b) Remove the oil pump assembly from the torque converter. A750E AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FA00TX Title: A750E AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL FRONT OIL PUMP OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST: 09350-30020 09351-32140 HINT: The oil seal end should be flush with the outer edge of the pump body. (b) Coat the oil seal lip with MP grease. 2. FIX FRONT OIL PUMP BODY SUB-ASSEMBLY (a) Place the oil pump body on the torque converter clutch. 3. INSTALL FRONT OIL PUMP DRIVEN GEAR (a) Coat the driven gear with ATF. (b) Install the driven gear to the oil pump body. 4. INSTALL FRONT OIL PUMP DRIVE GEAR (a) Coat the drive gear with ATF. A750E AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) (b) Install the drive gear to the oil pump body. 5. INSTALL FRONT OIL PUMP BODY O-RING (a) Install a new O-ring to the oil pump body. 6. INSTALL STATOR SHAFT ASSEMBLY (a) Install the stator shaft with each bolt hole. (b) Install the 14 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 7. INSTALL CLUTCH DRUM OIL SEAL RING A750E AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) (a) Coat the 3 oil seal rings with ATF. (b) Squeeze the ends of the 3 oil seal rings together with the overlap distance 8 mm (0.314 in.) or less, and then install them to the starter shaft groove. NOTICE: Do not over-spread the ring ends. HINT: After installing the oil seal rings, check that they rotate smoothly. 8. INSPECT OIL PUMP DRIVE GEAR ROTATION 9. INSTALL FRONT OIL PUMP BODY O-RING (a) Install a new O-ring to the oil pump assembly. A750F AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F800RX Title: A750F AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: OIL PUMP: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F900RX Title: A750F AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE FRONT OIL PUMP BODY O-RING (a) Remove the O-ring from the oil pump assembly. 2. FIX OIL PUMP ASSEMBLY (a) Place the oil pump body on the torque converter clutch. 3. REMOVE CLUTCH DRUM OIL SEAL RING (a) Remove the 3 oil seal rings. 4. REMOVE STATOR SHAFT ASSEMBLY A750F AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) (a) Remove the 14 bolts, and then remove the stator shaft from the oil pump body. 5. REMOVE FRONT OIL PUMP BODY O-RING (a) Remove the O-ring from the oil pump body. (b) Remove the oil pump body from the torque converter clutch. 6. INSPECT FRONT OIL PUMP BODY SUB-ASSEMBLY 7. INSPECT STATOR SHAFT ASSEMBLY 8. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY 9. REMOVE FRONT OIL PUMP DRIVE GEAR 10. REMOVE FRONT OIL PUMP DRIVEN GEAR A750F AUTOMATIC TRANSMISSION: OIL PUMP: DISASSEMBLY (2007 4Runner) 11. REMOVE FRONT OIL PUMP OIL SEAL (a) Using a screwdriver, remove the oil seal. NOTICE: Be careful not to damage the bushing and oil pump body. A750F AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013F700SX Title: A750F AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT FRONT OIL PUMP BODY SUB-ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 38.188 mm (1.5035 in.) If the inside diameter is greater than the maximum, replace the oil pump body. 2. INSPECT STATOR SHAFT ASSEMBLY (a) Using a dial indicator, measure the inside diameter of the stator shaft bushing. Maximum inside diameter: Front side 21.577 mm (0.8495 in.) Rear side 32.08 mm (1.2629 in.) If the inside diameter is grater than the maximum, replace the stator shaft. 3. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY (a) Push the driven gear to one side of the body. (b) Using a feeler gauge, measure the clearance. A750F AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) Standard body clearance: 0.10 to 0.17 mm (0.0039 to 0.0067 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance is greater than the maximum, replace the drive gear, driven gear or pump body. (c) Using a feeler gauge, measure the clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.070 to 0.150 mm (0.0028 to 0.0059 in.) Maximum tip clearance: 0.150 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the drive gear, driven gear or pump body. (d) Using a steel straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 to 0.05 mm (0.0008 to 0.002 in.) Maximum side clearance: 0.05 mm (0.002 in.) If the side clearance of both is gears greater than the maximum, replace the drive gear, driven gear or pump body. (e) There are 5 different thicknesses for the drive and driven gears. Standard drive and drive gears thickness: MARK THICKNESS 0 10.74 to 10.749 mm (0.4228 to 0.4232 in.) 1 10.75 to 10.759 mm (0.4232 to 0.4236 in.) 2 10.76 to 10.77 mm (0.4236 to 0.4240 in.) 3 10.771 to 10.78 mm (0.4241 to 0.4244 in.) 4 10.781 to 10.79 mm (0.4244 to 0.4248 in.) If the side clearance is greater than the maximum, replace the drive gear, driven gear or pump body. 4. INSPECT FRONT OIL PUMP DRIVE GEAR ROTATION A750F AUTOMATIC TRANSMISSION: OIL PUMP: INSPECTION (2007 4Runner) (a) Make sure the drive gear rotates smoothly. (b) Remove the oil pump assembly from the torque converter. A750F AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FA00SX Title: A750F AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL FRONT OIL PUMP OIL SEAL (a) Using SST and a hammer, install a new oil seal. SST: 09350-30020 09351-32140 HINT: The oil seal end should be flush with the outer edge of the pump body. (b) Coat the oil seal lip with MP grease. 2. FIX FRONT OIL PUMP BODY SUB-ASSEMBLY (a) Place the oil pump body on the torque converter clutch. 3. INSTALL FRONT OIL PUMP DRIVEN GEAR (a) Coat the driven gear with ATF. (b) Install the driven gear to the oil pump body. 4. INSTALL FRONT OIL PUMP DRIVE GEAR (a) Coat the drive gear with ATF. A750F AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) (b) Install the drive gear to the oil pump body. 5. INSTALL FRONT OIL PUMP BODY O-RING (a) Install a new O-ring to the oil pump body. 6. INSTALL STATOR SHAFT ASSEMBLY (a) Install the stator shaft with each bolt hole. (b) Install the 14 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) 7. INSTALL CLUTCH DRUM OIL SEAL RING A750F AUTOMATIC TRANSMISSION: OIL PUMP: REASSEMBLY (2007 4Runner) (a) Coat the 3 oil seal rings with ATF. (b) Squeeze the ends of the 3 oil seal rings together with the overlap distance 8 mm (0.314 in.) or less, and then install them to the starter shaft groove. NOTICE: Do not over-spread the ring ends. HINT: After installing the oil seal rings, check that they rotate smoothly. 8. INSPECT OIL PUMP DRIVE GEAR ROTATION 9. INSTALL FRONT OIL PUMP BODY O-RING (a) Install a new O-ring to the oil pump assembly. A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010N800UX Title: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Apply the parking brake and turn the ignition switch ON. (b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P position and it does not start in other positions. (c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is set in R position and these do not function in other positions. If a failure is found, check the park/neutral position switch for continuity. 2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the park/neutral position switch bolt and move the shift lever to N. (b) Align the switch groove with the neutral basic line. (c) Hold the switch in position and tighten the bolt. Torque: 13 N·m (130 kgf·cm, 10 ft·lbf) A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONEN... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BKY009X Title: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONEN... A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION ... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BKX009X Title: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION ... Except 2 and L ↑ 10 kΩ or higher A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATI... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010N900VX Title: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch with the bolt. Torque: 13 N·m (130 kgf·cm, 10 ft·lbf) (b) Install a new lock washer and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf) (c) Bend the claws on the lock washer to stake the nut. (d) Adjust the park/neutral position switch . 2. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 4. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY HINT: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL (2... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010NC00UX Title: A750E AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Pry off the lock washer and remove the nut. (b) Remove the bolt and park/neutral position switch. A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMEN... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010N800TX Title: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Apply the parking brake and turn the ignition switch ON. (b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P position and it does not start in other positions. (c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is set in R position and these do not function in other positions. If a failure is found, check the park/neutral position switch for continuity. 2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Loosen the park/neutral position switch bolt and move the shift lever to N. (b) Align the switch groove with the neutral basic line. (c) Hold the switch in position and tighten the bolt. Torque: 13 N·m (130 kgf·cm, 10 ft·lbf) A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONEN... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BKY008X Title: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONEN... A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION ... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BKX008X Title: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Jack up the vehicle. (b) Disconnect the park/neutral position switch connector. (c) Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard resistance: SHIFT POSITION TESTER CONNECTION SPECIFIED CONDITION P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 1-2 Below 1 Ω Except R ↑ 10 kΩ or higher N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D and 4 2-7 Below 1 Ω Except D and 4 ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION ... Except 2 and L ↑ 10 kΩ or higher A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATI... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010N900UX Title: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Install the park/neutral position switch with the bolt. Torque: 13 N·m (130 kgf·cm, 10 ft·lbf) (b) Install a new lock washer and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf) (c) Bend the claws on the lock washer to stake the nut. (d) Adjust the park/neutral position switch . 2. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 4. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY HINT: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL (2... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM0000010NC00TX Title: A750F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE NO.1 ENGINE UNDER COVER SUB-ASSEMBLY 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY 3. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Pry off the lock washer and remove the nut. (b) Remove the bolt and park/neutral position switch. A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHM008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... ILLUSTRATION A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHO008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Remove the floor shift lever knob from the shift lever. 2. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (a) Release the 4 claws with a screwdriver and remove the floor shift position indicator housing sub-assembly and slide cover. 3. REMOVE LOWER POSITION INDICATOR HOUSING (a) Disconnect the 3 clamps of indicator lamp wire subassembly. (b) Release the 4 claws with a screwdriver and remove the lower position indicator housing. A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4R... 4. REMOVE SHIFT LOCK RELEASE BUTTON 5. REMOVE SHIFT LOCK RELEASE BUTTON COVER 6. REMOVE INDICATOR LAMP WIRE SUB-ASSEMBLY (a) Remove the indicator lamp wire sub-assembly. (b) Remove the bulb from the indicator lamp wire sub-assembly. 7. REMOVE SHIFT LOCK CONTROL COMPUTER SUB-ASSEMBLY (a) Remove the shift lever nut and shift lever lock pin. (b) Remove the shift lever guide housing. (c) Release the 2 claws with a screwdriver and remove the shift lock release link and spring. (d) Remove the 2 screws and the shift lock control computer. A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: INSTALLATION (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHK008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FLOOR SHIFT ASSEMBLY (a) Install the floor shift assembly with the 4 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (b) Connect the transmission control cable with the lock plate. (c) Connect the 2 clamps and 2 connectors. 2. ADJUST SHIFT LEVER POSITION HINT: 3. INSTALL REAR CONSOLE BOX ASSEMBLY 4. INSTALL NO.2 CONSOLE UPPER PANEL GARNISH 5. INSTALL NO.1 CONSOLE UPPER PANEL GARNISH 6. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY 7. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 8. INSPECT SHIFT LEVER POSITION HINT: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Ru... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHP008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL SHIFT LOCK CONTROL COMPUTER SUB-ASSEMBLY (a) Install the shift lock control computer with the 2 screws. (b) Install the spring and shift lock release link. (c) Install the shift lever guide housing. (d) Install the lever lock and shift lever nut. 2. INSTALL INDICATOR LAMP WIRE SUB-ASSEMBLY (a) Install the bulb to the indicator lamp wire sub-assembly. (b) Install the indicator lamp wire sub-assembly. 3. INSTALL SHIFT LOCK RELEASE BUTTON COVER 4. INSTALL SHIFT LOCK RELEASE BUTTON 5. INSTALL LOWER POSITION INDICATOR HOUSING A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Ru... (a) Install the lower position indicator housing. (b) Connect the 3 clamps of indicator lamp wire sub-assembly. 6. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (a) Install the slide cover and floor shift position indicator housing sub-assembly to the shift lever guide housing. HINT: Firmly make the claws fit. 7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (a) Install the floor shift lever knob to the shift lever. A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHN008X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY 3. REMOVE NO.1 CONSOLE UPPER PANEL GARNISH 4. REMOVE NO.2 CONSOLE UPPER PANEL GARNISH 5. REMOVE REAR CONSOLE BOX ASSEMBLY 6. REMOVE FLOOR SHIFT ASSEMBLY (a) Disconnect the 2 connectors and 2 clamps. (b) Remove the lock plate and disconnect the transmission control cable. (c) Remove the 4 bolts and floor shift assembly. A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Ru... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHJ007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHM007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... ILLUSTRATION A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: COMPONENTS (2007 4Ru... A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHO007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Remove the floor shift lever knob from the shift lever. 2. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (a) Release the 4 claws with a screwdriver and remove the floor shift position indicator housing sub-assembly and slide cover. 3. REMOVE LOWER POSITION INDICATOR HOUSING (a) Disconnect the 3 clamps of indicator lamp wire subassembly. (b) Release the 4 claws with a screwdriver and remove the lower position indicator housing. A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: DISASSEMBLY (2007 4R... 4. REMOVE SHIFT LOCK RELEASE BUTTON 5. REMOVE SHIFT LOCK RELEASE BUTTON COVER 6. REMOVE INDICATOR LAMP WIRE SUB-ASSEMBLY (a) Remove the indicator lamp wire sub-assembly. (b) Remove the bulb from the indicator lamp wire sub-assembly. 7. REMOVE SHIFT LOCK CONTROL COMPUTER SUB-ASSEMBLY (a) Remove the shift lever nut and shift lever lock pin. (b) Remove the shift lever guide housing. (c) Release the 2 claws with a screwdriver and remove the shift lock release link and spring. (d) Remove the 2 screws and the shift lock control computer. A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: INSTALLATION (2007 4R... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHK007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL FLOOR SHIFT ASSEMBLY (a) Install the floor shift assembly with the 4 bolts. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (b) Connect the transmission control cable with the lock plate. (c) Connect the 2 clamps and 2 connectors. 2. ADJUST SHIFT LEVER POSITION HINT: 3. INSTALL REAR CONSOLE BOX ASSEMBLY 4. INSTALL NO.2 CONSOLE UPPER PANEL GARNISH 5. INSTALL NO.1 CONSOLE UPPER PANEL GARNISH 6. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY 7. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 8. INSPECT SHIFT LEVER POSITION HINT: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Ru... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHP007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL SHIFT LOCK CONTROL COMPUTER SUB-ASSEMBLY (a) Install the shift lock control computer with the 2 screws. (b) Install the spring and shift lock release link. (c) Install the shift lever guide housing. (d) Install the lever lock and shift lever nut. 2. INSTALL INDICATOR LAMP WIRE SUB-ASSEMBLY (a) Install the bulb to the indicator lamp wire sub-assembly. (b) Install the indicator lamp wire sub-assembly. 3. INSTALL SHIFT LOCK RELEASE BUTTON COVER 4. INSTALL SHIFT LOCK RELEASE BUTTON 5. INSTALL LOWER POSITION INDICATOR HOUSING A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REASSEMBLY (2007 4Ru... (a) Install the lower position indicator housing. (b) Connect the 3 clamps of indicator lamp wire sub-assembly. 6. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (a) Install the slide cover and floor shift position indicator housing sub-assembly to the shift lever guide housing. HINT: Firmly make the claws fit. 7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (a) Install the floor shift lever knob to the shift lever. A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BHN007X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY 3. REMOVE NO.1 CONSOLE UPPER PANEL GARNISH 4. REMOVE NO.2 CONSOLE UPPER PANEL GARNISH 5. REMOVE REAR CONSOLE BOX ASSEMBLY 6. REMOVE FLOOR SHIFT ASSEMBLY (a) Disconnect the 2 connectors and 2 clamps. (b) Remove the lock plate and disconnect the transmission control cable. (c) Remove the 4 bolts and floor shift assembly. INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Vehicle Interior Section: Interior Panels/Trim Model Year: 2007 Model: 4Runner Doc ID: RM000002AUE005X Title: INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) REMOVAL 1. BOLT, SCREW AND NUT TABLE HINT: The bolts, screws and nuts, which are necessary for installation and removal of the instrument panel are shown in the illustration below and the text with alphabets. 2. DISCONNECT BATTERY NEGATIVE TERMINAL HINT: 3. REMOVE INSTRUMENT PANEL FINISH PLATE INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) (a) Remove the instrument panel finish plate. 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Remove the 2 bolts . (b) Disconnect the hood lock control cable assembly and fuel lid lock control cable sub-assembly. (c) Disengage the 4 clips. (d) Disconnect the connectors and remove the lower instrument panel finish panel sub-assembly. 5. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (a) Disengage the 5 clips and 2 claws, and remove the console upper rear panel, and then disconnect the connectors. 6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (a) Disengage the 6 clips and 2 claws, and then remove the upper console panel sub-assembly. INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) NOTICE: Be careful not to snap the claws during the operation. 7. REMOVE NO. 1 CONSOLE UPPER PANEL GARNISH (a) Disengage the clip. (b) Pull the No. 1 console upper panel garnish rearward to be removed. 8. REMOVE NO. 2 CONSOLE UPPER PANEL GARNISH 9. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (a) Remove the screw. (b) Disengage the 4 clips and remove the air conditioner, and then disconnect the connectors. INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) 10. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (a) Remove the 3 bolts . (b) Disengage the 8 clips and remove the center instrument cluster finish panel sub-assembly. 11. REMOVE RADIO RECEIVER ASSEMBLY (w/ Bracket) 12. REMOVE NO. 2 LOWER STEERING WHEEL COVER 13. REMOVE NO. 3 LOWER STEERING WHEEL COVER 14. REMOVE STEERING PAD 15. REMOVE STEERING WHEEL ASSEMBLY 16. REMOVE UPR STEERING COLUMN COVER 17. REMOVE TURN SIGNAL SWITCH ASSEMBLY (w/ Bracket) 18. REMOVE INSTRUMENT PANEL LOWER LH (a) Remove the 2 bolts . INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) (b) Disengage the 2 claws and remove the instrument panel lower LH. 19. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (a) Disengage the 7 clips. (b) Disconnect the connectors and remove the instrument cluster finish panel sub-assembly. 20. REMOVE COMBINATION METER ASSEMBLY 21. REMOVE REAR CONSOLE BOX ASSEMBLY (a) Disconnect the connectors. (b) Remove the 6 bolts and rear console box assembly. 22. REMOVE FRONT DOOR SCUFF PLATE RH 23. REMOVE COWL SIDE TRIM BOARD RH INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) (a) Remove the clip. (b) Disengage the 2 claws and remove the cowl side trim board RH. 24. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) Remove the screw . (b) Disengage the 3 clips and remove the No. 2 instrument panel under cover sub-assembly. 25. REMOVE GLOVE COMPARTMENT DOOR SUB-ASSEMBLY (a) Remove the screw and glove compartment door. (b) Deform the upper part of the glove compartment door to release the stoppers. (c) Pull the glove compartment door upward to remove it. 26. DISCONNECT PASSENGER AIRBAG CONNECTOR 27. REMOVE NO. 2 LOWER INSTRUMENT PANEL FINISH PANEL INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) (a) Remove the 4 screws . (b) Disengage the 2 claws and remove the instrument panel finish panel. 28. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Remove the screw . (b) Disengage the 2 clips and 2 claws, and then remove the No. 2 instrument panel register assembly. 29. REMOVE ASSIST GRIP SUB-ASSEMBLY 30. REMOVE FRONT PILLAR GARNISH LH (a) Using a screwdriver, remove the 2 assist grip plugs. HINT: Tape the screwdriver tip before use. (b) Remove the 2 bolts. (c) Using a screwdriver, disengage the claw. Remove the clip labeled A, clip labeled B and pillar garnish. 31. REMOVE FRONT PILLAR GARNISH RH INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) HINT: Use the same procedure described for the LH side. 32. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY (a) Remove the 9 bolts and nut . (b) Disconnect the connectors. (c) Remove the instrument panel safety pad sub-assembly. 33. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (a) Using a moulding remover, disengage the 4 clips and remove the No. 1 instrument panel speaker panel sub-assembly. 34. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY INSTRUMENT PANEL: INSTRUMENT PANEL SAFETY PAD: REMOVAL (2007 4Runner) (a) Remove the 2 screws and the front stereo component speaker assembly. 35. REMOVE NO. 1 INSTRUMENT PANEL PIN (a) Remove the screw and the No. 1 instrument panel pin. 36. REMOVE DEFROSTER NOZZLE ASSEMBLY (a) Remove the 2 screws and the defroster nozzle assembly. 37. REMOVE NO. 2 HEATER TO REGISTER DUCT (a) Remove the 5 screws and the No. 2 heater to register duct. 38. REMOVE NO. 1 METER HOOD RETAINER (a) Remove the screw and the No. 1 meter hood retainer. 39. REMOVE CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY (a) Remove the screw and the center instrument panel bracket sub-assembly. 40. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (a) Disconnect the connector. (b) Remove the automatic light control sensor. 41. REMOVE COOLER (SOLAR SENSOR) THERMISTOR (a) Disconnect the connector. (b) Remove the cooler (solar sensor) thermistor. 42. REMOVE NO. 2 INSTRUMENT PANEL WIRE 43. REMOVE ANTENNA CORD SUB-ASSEMBLY 44. REMOVE NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) 45. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH (a) Remove the 3 screws and the instrument cluster finish panel garnish. 46. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY 47. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY A750E AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLM007X Title: A750E AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT SHIFT LOCK OPERATION (a) Move the shift lever to the P position. (b) Turn the ignition switch to the LOCK position. (c) Check that the shift lever cannot be moved to any position other than P. (d) Turn the ignition switch to the on position, depress the brake pedal and check that the shift lever can be moved to another position. If operation can not be done as specified, inspect the shift lock control unit. 2. INSPECT SHIFT LOCK RELEASE BUTTON (a) Using a small screwdriver, remove the shift lock release cover. (b) When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position other than P. If operation can not be done as specified, check the shift lever assembly installation condition. 3. INSPECT KEY INTERLOCK OPERATION (a) Turn the ignition switch to the ON position. (b) Depress the brake pedal and move the shift lever to any position other than P. (c) Check that the ignition key cannot be turned to the LOCK position. (d) Move the shift lever to the P position, turn the ignition key to the LOCK position and check that the ignition key can be removed. If operation cannot be done as specified, inspect the shift lock control unit. 4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. Voltage: A750E AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (... TERMINAL MEASURING CONDITION VOLTAGE (V) 1 (ACC) - 3 Ignition switch ACC (E) 10 to 14 1 (ACC) - 3 Ignition switch OFF (E) Below 1 2 (STP) - 3 (E) Depress brake pedal 10 to 14 2 (STP) - 3 (E) Release brake pedal Below 1 1. Ignition switch ACC and shift lever P position Below 1 2. Ignition switch ACC and shift lever except P position 4 (KLS+) 3 (E) 7.5 to 11 3. Ignition switch ACC and shift lever except P position (After approx. 1 second) 6 to 9 5 (IG) - 3 (E) Ignition switch ON 10 to 14 5 (IG) - 3 (E) Ignition switch OFF Below 1 (b) Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. If operation cannot be done as specified, replace the shift lever assembly. Resistance: TERMINAL 1 (E) - Body ground 5. INSPECT KEY INTER LOCK SOLENOID MEASURING CONDITION Always SPECIFIED VALUE Below 1 Ω A750E AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (... (a) Disconnect the solenoid connector. (b) Connect KLS+ (4) terminal to the batteries' positive (+) terminal and KLS (3) terminal to the battery negative (-) terminal, and apply about 12 V between KLS+ - KLS- terminals. (c) Check that operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. A750F AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (2... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLM006X Title: A750F AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (2007 4Runner) ON-VEHICLE INSPECTION 1. INSPECT SHIFT LOCK OPERATION (a) Move the shift lever to the P position. (b) Turn the ignition switch to the LOCK position. (c) Check that the shift lever cannot be moved to any position other than P. (d) Turn the ignition switch to the on position, depress the brake pedal and check that the shift lever can be moved to another position. If operation can not be done as specified, inspect the shift lock control unit. 2. INSPECT SHIFT LOCK RELEASE BUTTON (a) Using a small screwdriver, remove the shift lock release cover. (b) When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position other than P. If operation can not be done as specified, check the shift lever assembly installation condition. 3. INSPECT KEY INTERLOCK OPERATION (a) Turn the ignition switch to the ON position. (b) Depress the brake pedal and move the shift lever to any position other than P. (c) Check that the ignition key cannot be turned to the LOCK position. (d) Move the shift lever to the P position, turn the ignition key to the LOCK position and check that the ignition key can be removed. If operation cannot be done as specified, inspect the shift lock control unit. 4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY (a) Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. Voltage: A750F AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (2... TERMINAL MEASURING CONDITION VOLTAGE (V) 1 (ACC) - 3 Ignition switch ACC (E) 10 to 14 1 (ACC) - 3 Ignition switch OFF (E) Below 1 2 (STP) - 3 (E) Depress brake pedal 10 to 14 2 (STP) - 3 (E) Release brake pedal Below 1 1. Ignition switch ACC and shift lever P position Below 1 2. Ignition switch ACC and shift lever except P position 4 (KLS+) 3 (E) 7.5 to 11 3. Ignition switch ACC and shift lever except P position (After approx. 1 second) 6 to 9 5 (IG) - 3 (E) Ignition switch ON 10 to 14 5 (IG) - 3 (E) Ignition switch OFF Below 1 (b) Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. If operation cannot be done as specified, replace the shift lever assembly. Resistance: TERMINAL 1 (E) - Body ground 5. INSPECT KEY INTER LOCK SOLENOID MEASURING CONDITION Always SPECIFIED VALUE Below 1 Ω A750F AUTOMATIC TRANSMISSION: SHIFT LOCK SYSTEM: ON-VEHICLE INSPECTION (2... (a) Disconnect the solenoid connector. (b) Connect KLS+ (4) terminal to the batteries' positive (+) terminal and KLS (3) terminal to the battery negative (-) terminal, and apply about 12 V between KLS+ - KLS- terminals. (c) Check that operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL3009X Title: A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL2009X Title: A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT SPEED SENSOR (NT SENSOR) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω 2. INSPECT SPEED SENSOR (SP2 SENSOR) (a) Disconnect the speed sensor connector from the transaxle. A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) (b) Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL1009X Title: A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL SPEED SENSOR (a) Coat a new O-ring with ATF. (b) Install the speed sensor with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (c) Connect the connector. A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL4009X Title: A750E AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE SPEED SENSOR (a) Disconnect the connector. (b) Remove the bolt and speed sensor. A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL3008X Title: A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL2008X Title: A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT SPEED SENSOR (NT SENSOR) (a) Disconnect the speed sensor connector from the transaxle. (b) Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω 2. INSPECT SPEED SENSOR (SP2 SENSOR) (a) Disconnect the speed sensor connector from the transaxle. A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION (2007 4Runner) (b) Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION SPECIFIED CONDITION 20°C (68°F) 1-2 560 to 680 Ω A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL1008X Title: A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL SPEED SENSOR (a) Coat a new O-ring with ATF. (b) Install the speed sensor with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (c) Connect the connector. A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL4008X Title: A750F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE SPEED SENSOR (a) Disconnect the connector. (b) Remove the bolt and speed sensor. A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLI008X Title: A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST: 09350-32014 09351-32020 (2) Press on the serrations of stater with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks up when turned counterclockwise. If necessary, clean the converter and retest the oneway clutch. Replace the converter if the one-way clutch still fails the test. (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. (See the sample.) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Replace the ATF in the torque converter clutch. A750E AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: z z Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts shall have the same length. (3) No missing spring washer. 2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Set up a dial indicator and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... Last Modified: 4-26-2007 1.6 G Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BLI007X Title: A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE: INSPECTION (2007 4Runner) INSPECTION 1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY (a) Inspect the one-way clutch. (1) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST: 09350-32014 09351-32020 (2) Press on the serrations of stater with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks up when turned counterclockwise. If necessary, clean the converter and retest the oneway clutch. Replace the converter if the one-way clutch still fails the test. (b) Determine the condition of the torque converter clutch assembly. (1) If the inspection result of the torque converter clutch assembly meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. (See the sample.) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. (c) Replace the ATF in the torque converter clutch. A750F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE... (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. (d) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: z z Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). (e) Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts shall have the same length. (3) No missing spring washer. 2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSEMBLY (a) Set up a dial indicator and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: ADJUSTMENT (... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL5007X Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: COMPONENTS ... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL7007X Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATIO... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL6007X Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the transmission control cable assembly with the nut. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (b) Install the transmission control cable bracket and lock plate. (c) Connect the transmission control cable with the 2 nuts to body. (d) Connect the transmission control cable with the 2 bolts to body. A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATIO... (e) Connect the transmission control cable with the lock plate to floor shift assembly. (f) Install the transmission control cable to floor shift assembly. 2. INSTALL REAR CONSOLE BOX ASSEMBLY 3. INSTALL NO.2 CONSOLE UPPER PANEL GARNISH 4. INSTALL NO.1 CONSOLE UPPER PANEL GARNISH 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY 6. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 7. INSPECT SHIFT LEVER POSITION HINT: 8. ADJUST SHIFT LEVER POSITION HINT: A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (200... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL8007X Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY 3. REMOVE NO.1 CONSOLE UPPER PANEL GARNISH 4. REMOVE NO.2 CONSOLE UPPER PANEL GARNISH 5. REMOVE REAR CONSOLE BOX ASSEMBLY 6. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Disconnect the transmission control cable assembly from shift lever assembly. (b) Remove the lock plate and disconnect the transmission control cable. (c) Remove the 2 bolts and disconnect the transmission control cable assembly from body. A750E AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (200... (d) Remove the 2 nuts and disconnect the transmission control cable assembly from body. (e) Remove the lock plate and transmission control cable bracket. (f) Remove the nut and transmission control cable assembly. 7. INSPECT SHIFT LEVER POSITION HINT: 8. ADJUST SHIFT LEVER POSITION HINT: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: ADJUSTMENT (... Last Modified: 4-26-2007 1.6 N Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL5006X Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: ADJUSTMENT (2007 4Runner) ADJUSTMENT 1. INSPECT SHIFT LEVER POSITION (a) When shifting from P to R position only with ignition switch ON and depress brake pedal, make sure that the shifting lever moves smoothly and can be moderately operated. (b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. 2. ADJUST SHIFT LEVER POSITION (a) Loosen the nut. (b) Push the control shaft fully rearward. (c) Return the control shaft lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the nut. Torque: 15.6 N·m (159 kgf·cm, 12 ft·lbf) A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: COMPONENTS ... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL7006X Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATION... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL6006X Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the transmission control cable assembly with the nut. Torque: 12 N·m (122 kgf·cm, 9 ft·lbf) (b) Install the transmission control cable bracket and lock plate. (c) Connect the transmission control cable with the 2 nuts to body. (d) Connect the transmission control cable with the 2 bolts to body. A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: INSTALLATION... (e) Connect the transmission control cable with the lock plate to floor shift assembly. (f) Install the transmission control cable to floor shift assembly. 2. INSTALL REAR CONSOLE BOX ASSEMBLY 3. INSTALL NO.2 CONSOLE UPPER PANEL GARNISH 4. INSTALL NO.1 CONSOLE UPPER PANEL GARNISH 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY 6. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 7. INSPECT SHIFT LEVER POSITION HINT: 8. ADJUST SHIFT LEVER POSITION HINT: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (200... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle Model Year: 2007 Model: 4Runner Doc ID: RM000002BL8006X Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (2007 4Runner) REMOVAL 1. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY 2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY 3. REMOVE NO.1 CONSOLE UPPER PANEL GARNISH 4. REMOVE NO.2 CONSOLE UPPER PANEL GARNISH 5. REMOVE REAR CONSOLE BOX ASSEMBLY 6. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (a) Disconnect the transmission control cable assembly from shift lever assembly. (b) Remove the lock plate and disconnect the transmission control cable. (c) Remove the 2 bolts and disconnect the transmission control cable assembly from body. A750F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE: REMOVAL (200... (d) Remove the 2 nuts and disconnect the transmission control cable assembly from body. (e) Remove the lock plate and transmission control cable bracket. (f) Remove the nut and transmission control cable assembly. 7. INSPECT SHIFT LEVER POSITION HINT: 8. ADJUST SHIFT LEVER POSITION HINT: A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM000002BKW009X Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runn... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013BZ00QX Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION WIRE (a) Install the transmission wire with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (b) Connect the transmission wire connector. 2. CONNECT TRANSMISSION WIRE (a) Connect the 7 connectors to the solenoid valves. (b) Install the clamp with the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 36 mm (1.42 in.) for bolt A 12 mm (0.47 in.) for bolt B (c) Connect the ATF temperature sensor. A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runn... 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Install a new O-ring and the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY HINT: Remove the gasket and be careful not to spill oil on the contacting surfaces of the transmission case and oil pan. (a) Install the oil pan with the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) 5. ADD AUTOMATIC TRANSMISSION FLUID HINT: 6. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013C100QX Title: A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Some fluid will remain in the oil pan. (a) Remove the 20 bolts. (b) Examine the particles in the pan. (1) Remove the magnets and use them to collect steel particles. Carefully inspect the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 4 bolts and oil strainer. A750E AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) NOTICE: Be careful as some fluid may leak out of the oil strainer. 4. SEPARATE TRANSMISSION WIRE (a) Remove the 2 bolt and clamp. (b) Disconnect the ATF temperature sensor. (c) Disconnect the 7 connectors from the solenoid valves. 5. REMOVE TRANSMISSION WIRE (a) Disconnect the transmission wire connector. (b) Remove the bolt and pull out the transmission wire. A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM000002BKW008X Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runn... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013BZ00PX Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION WIRE (a) Install the transmission wire with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) (b) Connect the transmission wire connector. 2. CONNECT TRANSMISSION WIRE (a) Connect the 7 connectors to the solenoid valves. (b) Install the clamp with the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 36 mm (1.42 in.) for bolt A 12 mm (0.47 in.) for bolt B (c) Connect the ATF temperature sensor. A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION (2007 4Runn... 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Install a new O-ring and the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY HINT: Remove the gasket and be careful not to spill oil on the contacting surfaces of the transmission case and oil pan. (a) Install the oil pan with the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) 5. ADD AUTOMATIC TRANSMISSION FLUID HINT: 6. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013C100PX Title: A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Some fluid will remain in the oil pan. (a) Remove the 20 bolts. (b) Examine the particles in the pan. (1) Remove the magnets and use them to collect steel particles. Carefully inspect the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY (a) Remove the 4 bolts and oil strainer. A750F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL (2007 4Runner) NOTICE: Be careful as some fluid may leak out of the oil strainer. 4. SEPARATE TRANSMISSION WIRE (a) Remove the 2 bolt and clamp. (b) Disconnect the ATF temperature sensor. (c) Disconnect the 7 connectors from the solenoid valves. 5. REMOVE TRANSMISSION WIRE (a) Disconnect the transmission wire connector. (b) Remove the bolt and pull out the transmission wire. A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FF00RX Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) ILLUSTRATION A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750E AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FG00RX Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts. (b) Remove the valve body. 2. REMOVE SHIFT SOLENOID VALVE SR (a) Remove the 2 bolts and shift solenoid valve SR. 3. REMOVE SHIFT SOLENOID VALVE SLU (a) Remove the bolt, 2 straight pins and solenoid lock plate. A750E AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) (b) Remove the shift solenoid valve SLU. 4. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. 5. REMOVE SHIFT SOLENOID VALVE SLT (a) Remove the bolt, 2 straight pins and solenoid lock plate. (b) Remove the shift solenoid valve SLT. 6. REMOVE SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. 7. REMOVE SHIFT SOLENOID VALVE S1 A750E AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) (a) Remove the bolt and shift solenoid valve S1. 8. REMOVE SHIFT SOLENOID VALVE S2 (a) Remove the bolt and shift solenoid valve S2. (b) Remove the O-ring from the shift solenoid valve S2. A750E AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FH00RX Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL SHIFT SOLENOID VALVE S2 (a) Install the O-ring to the shift solenoid valve S2. (b) Install the shift solenoid valve S2 with the bolt. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 2. INSTALL SHIFT SOLENOID VALVE S1 (a) Install the O-ring to the shift solenoid valve S1. (b) Install the shift solenoid valve S1 with the bolt. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 3. INSTALL SHIFT SOLENOID VALVE SL1 (a) Install the shift solenoid valve SL1. A750E AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) 4. INSTALL SHIFT SOLENOID VALVE SLT (a) Install the shift solenoid valve SLT. (b) Install the, 2 straight pins and solenoid lock plate with the bolt. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 5. INSTALL SHIFT SOLENOID VALVE SL2 (a) Install the shift solenoid valve SL2. 6. INSTALL SHIFT SOLENOID VALVE SLU (a) Install the shift solenoid valve SLU. A750E AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) (b) Install the bolt, 2 straight pins and solenoid lock plate. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 7. INSTALL SHIFT SOLENOID VALVE SR (a) Install the and shift solenoid valve SR with the 2 bolts. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 8. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Align the groove of the manual valve with the pin of the lever. (b) Install the 19 bolts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. A750E AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) Standard bolt length: 25 mm (0.98 in.) for bolt A 36 mm (1.42 in.) for bolt B A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FF00QX Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) ILLUSTRATION A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: VALVE BODY: COMPONENTS (2007 4Runner) A750F AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FG00QX Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) DISASSEMBLY 1. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts. (b) Remove the valve body. 2. REMOVE SHIFT SOLENOID VALVE SR (a) Remove the 2 bolts and shift solenoid valve SR. 3. REMOVE SHIFT SOLENOID VALVE SLU (a) Remove the bolt, 2 straight pins and solenoid lock plate. A750F AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) (b) Remove the shift solenoid valve SLU. 4. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the shift solenoid valve SL2. 5. REMOVE SHIFT SOLENOID VALVE SLT (a) Remove the bolt, 2 straight pins and solenoid lock plate. (b) Remove the shift solenoid valve SLT. 6. REMOVE SHIFT SOLENOID VALVE SL1 (a) Remove the shift solenoid valve SL1. 7. REMOVE SHIFT SOLENOID VALVE S1 A750F AUTOMATIC TRANSMISSION: VALVE BODY: DISASSEMBLY (2007 4Runner) (a) Remove the bolt and shift solenoid valve S1. 8. REMOVE SHIFT SOLENOID VALVE S2 (a) Remove the bolt and shift solenoid valve S2. (b) Remove the O-ring from the shift solenoid valve S2. A750F AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013FH00QX Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) REASSEMBLY 1. INSTALL SHIFT SOLENOID VALVE S2 (a) Install the O-ring to the shift solenoid valve S2. (b) Install the shift solenoid valve S2 with the bolt. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) 2. INSTALL SHIFT SOLENOID VALVE S1 (a) Install the O-ring to the shift solenoid valve S1. (b) Install the shift solenoid valve S1 with the bolt. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 3. INSTALL SHIFT SOLENOID VALVE SL1 (a) Install the shift solenoid valve SL1. A750F AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) 4. INSTALL SHIFT SOLENOID VALVE SLT (a) Install the shift solenoid valve SLT. (b) Install the, 2 straight pins and solenoid lock plate with the bolt. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 5. INSTALL SHIFT SOLENOID VALVE SL2 (a) Install the shift solenoid valve SL2. 6. INSTALL SHIFT SOLENOID VALVE SLU (a) Install the shift solenoid valve SLU. A750F AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) (b) Install the bolt, 2 straight pins and solenoid lock plate. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 7. INSTALL SHIFT SOLENOID VALVE SR (a) Install the and shift solenoid valve SR with the 2 bolts. Torque: 6.4 N·m (65 kgf·cm, 57 in·lbf) 8. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Align the groove of the manual valve with the pin of the lever. (b) Install the 19 bolts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. A750F AUTOMATIC TRANSMISSION: VALVE BODY: REASSEMBLY (2007 4Runner) Standard bolt length: 25 mm (0.98 in.) for bolt A 36 mm (1.42 in.) for bolt B A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4R... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM000002BKZ009X Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4R... A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013CK00QX Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Insert the pin of the lever into the hole of the manual valve. (b) Install 3 new drum seal gaskets onto the transmission case. (c) Install the 19 bolts. Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 36 mm (1.42 in.) for bolt A 25 mm (0.98 in.) for bolt B 2. CONNECT TRANSMISSION WIRE (a) Connect the 7 connectors to the solenoid valves. (b) Install the clamp with the 2 bolts. A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 12 mm (0.47 in.) for bolt A 36 mm (1.42 in.) for bolt B (c) Connect the ATF temperature sensor. Sensor wire harness: WIRE HARNESS COLOR for liner control Orange for oil temp. warning light Blue 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Install a new O-ring and the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY HINT: Remove the gasket and be careful not to spill oil on the contacting surfaces of the transmission case and oil pan. (a) Install the new gasket and the oil pan with the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... 5. ADD AUTOMATIC TRANSMISSION FLUID HINT: 6. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013CM00QX Title: A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 2. REMOVE TRANSMISSION OIL FILTER TUBE SUB-ASSEMBLY 3. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Some fluid will remain in the oil pan. (a) Remove the 20 bolts and oil pan. (b) Examine the particles in the oil pan. (1) Remove all the magnets and use them to collect steel particles. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 4. REMOVE VALVE BODY OIL STRAINER ASSEMBLY A750E AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) (a) Remove the 4 bolts and oil strainer. NOTICE: Be careful as some fluid may leak out of the oil strainer. 5. DISCONNECT TRANSMISSION WIRE (a) Remove the 2 bolts and clamp. (b) Disconnect the ATF temperature sensor. (c) Disconnect the 7 connectors from the solenoid valves. 6. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts and valve body. (b) Remove the 3 drum seal gaskets. A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4R... Last Modified: 4-26-2007 1.6 K Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM000002BKZ008X Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4Runner) COMPONENTS ILLUSTRATION A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS (2007 4R... A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013CK00PX Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4Runner) INSTALLATION 1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY (a) Insert the pin of the lever into the hole of the manual valve. (b) Install 3 new drum seal gaskets onto the transmission case. (c) Install the 19 bolts. Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 36 mm (1.42 in.) for bolt A 25 mm (0.98 in.) for bolt B 2. CONNECT TRANSMISSION WIRE (a) Connect the 7 connectors to the solenoid valves. (b) Install the clamp with the 2 bolts. A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Torque: 11 N·m (112 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Standard bolt length: 12 mm (0.47 in.) for bolt A 36 mm (1.42 in.) for bolt B (c) Connect the ATF temperature sensor. Sensor wire harness: WIRE HARNESS COLOR for liner control Orange for oil temp. warning light Blue 3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY (a) Install a new O-ring and the oil strainer with the 4 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY HINT: Remove the gasket and be careful not to spill oil on the contacting surfaces of the transmission case and oil pan. (a) Install the new gasket and the oil pan with the 20 bolts. Torque: 4.4 N·m (45 kgf·cm, 39 in·lbf) A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION (2007 4... 5. ADD AUTOMATIC TRANSMISSION FLUID HINT: 6. INSPECT AUTOMATIC TRANSMISSION FLUID HINT: A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) Last Modified: 4-26-2007 1.6 A Service Category: Drivetrain Section: Automatic Transmission/Transaxle: Unit Repair Model Year: 2007 Model: 4Runner Doc ID: RM0000013CM00PX Title: A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) REMOVAL 1. DRAIN AUTOMATIC TRANSMISSION FLUID (a) Remove the drain plug and gasket, and drain ATF. (b) Install a new gasket and the drain plug. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) 2. REMOVE TRANSMISSION OIL FILTER TUBE SUB-ASSEMBLY 3. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTICE: Some fluid will remain in the oil pan. (a) Remove the 20 bolts and oil pan. (b) Examine the particles in the oil pan. (1) Remove all the magnets and use them to collect steel particles. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bushing wear 4. REMOVE VALVE BODY OIL STRAINER ASSEMBLY A750F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL (2007 4Runner) (a) Remove the 4 bolts and oil strainer. NOTICE: Be careful as some fluid may leak out of the oil strainer. 5. DISCONNECT TRANSMISSION WIRE (a) Remove the 2 bolts and clamp. (b) Disconnect the ATF temperature sensor. (c) Disconnect the 7 connectors from the solenoid valves. 6. REMOVE TRANSMISSION VALVE BODY ASSEMBLY (a) Remove the 19 bolts and valve body. (b) Remove the 3 drum seal gaskets.